CCPS Projects | AIChE

Process Safety Incident Database (PSID)

Project Scope 

PSID Summary

PSID is an easily accessible, secure database that tracks process safety incidents with a focus on the lessons learned from the reports. It contains over 830 incident details. Currently, over 500 users from about 100 CCPS member companies have access to PSID. Participants use the database to pool and share process safety incident experience among participating companies so they can learn from the experiences of others without suffering the consequences of failures, while minimizing corporate liability. PSID contains incidents and near misses that did or could have resulted in fires, explosions, fatalities, multiple injuries, and significant release of hazardous materials. PSID supplements a company's internal incident database, improves hazard assessments, and facilitates due diligence activities.

PSID Steering Committee

The new PSID will be launched this year on a modern, state of the art software platform. We are now assembling a new PSID Steering committee. We need long-term commitments for this important work.  The updated platform will be fully configurable, easy to maintain, faster, reliable, and more efficient, thus enhancing user experience from data entry to reporting analytics and search functionality. Key content enhancements will include simplified incident types (fires, explosions, toxic releases, near misses) as well as lessons learned, root causes, emergency response, and references to key RBPS elements. Below are some of the responsibilities for the steering committee, including a pilot test of the new software platform.

  1. Program Development - Revise and update the program that manages PSID, which includes continuous improvement.
  2. Quality Control / Software Analysis – Help CCPS staff to maintain and provide continuous improvement to the database.
  3. PSID Advertising – Promote PSID and create incentives for incident input.
  4. Data Analysis – Evaluate data and create reports of general interest to PSID users.

The PSID committee is comprised of representatives from CCPS member companies. Any non-governmental or non-regulatory CCPS member company is eligible to join PSID. 

In 2020, building on the valuable benefit of this database, a subcommittee of volunteers from member companies completed an exercise to revise the functional specifications of PSID to include new, modern terms and categories. 

PSID Confidentiality

CCPS agrees to maintain the security and confidentiality of data submitted and to avoid disclosure of any information other than that agreed upon by the Participants or as required by law. Due to the confidentiality of the data, access for members must be approved by the member company’s PSID Administrator or by the PSID System Administrator. All participating companies should submit at least one incident per year to the database.

A number of special measures are in place to protect the confidentiality of data submitted by participants. Additionally, contracts between CCPS and any contractors hired to process confidential data will contain strict requirements for maintaining the security and confidentiality of the data. Information provided to the participants includes only sanitized and/or aggregated data for the entire database. Participating companies have the right to refrain from submitting any data that might become involved in litigation or may be sensitive for any other reason. 

CCPS will not voluntarily disclose the data to non-PSID members. In the event that any public body, government agency of any kind, or any third party seeks disclosure of confidential information contained in the PSID via legal means, CCPS will notify the participants of such demand, and give the participants an opportunity to defend all confidential information contained in the database, either in their own name or in CCPS’ name, from disclosure.

Register for PSID

PSID is an excellent platform for ‘Member Sharing’ and provides anonymity to those who wish to share incident data. Member companies who wish to enhance the breadth of knowledge in PSID can contact ccps_psid@aiche.org.

Accepting Volunteers 

Yes

Project Status 

On-going

Status Updated On 

July 19, 2021
Project 276: Guidelines/Essentials of Safe Work Practices

Project ID 

276

Project Scope 

The objective of Project 276 is to develop an integrated set of policies, procedures, permits, and other systems that are designed to manage risks associated with non-routine activities. Examples of these activities include performing hot work, opening process vessels or lines, and entering a confined space.

To date, a Safe Work Practice (SWP) document has been developed for hot work authorization, line breaking/isolation, lockout/tagout (control of energy hazards), and confined space entry.

Accepting Volunteers 

Yes

Project Status 

On-going

Status Updated On 

October 17, 2017

Leadership

 
Project 289: Golden Rules of Process Safety for Specific Technologies

Project ID 

289

Project Scope 

One of the most critical aspects of Process Safety is to know the hazards that one is dealing with, yet in too many incidents we realize that there was a knowledge gap in understanding the hazards. The goal of this project is to identify two to three technologies (e. g. FCC operations, Chlorine Chemistry, Nitration Chemistry, Peroxides, Combustible Dust, etc..) that have seen numerous incidents, have high hazards, and/or are highly utilized and Organize a team of process safety and process technology experts to develop a set of rules and tenants that serve the foundation for process safety.  

The rules and tenants are based on absolute statements to address the inherent hazards associated with the process technology (e.g. One should never mix A and B together, One should always check grounding connections, etc). The goal is to add to these initial technologies over time and develop an online library and also posters and other communication channels to communicate the message to a broad range of audiences (engineers, operations personnel, management).

This product will use technology as the foundation platform.

We are looking for expertise on: Ammonia, Hydrogen Sulfide, Ethylene Oxide, FCCU, Hydrotreating, and Alkylation

Accepting Volunteers 

Yes

Project Status 

On-time

Status Updated On 

July 31, 2020
Project 300: Book of Beacon

Project Scope 

This book will have consolidated publication of the Beacons published since the inception with added information about each of them.  This may include detailed explanation, lessons learned, similar incidents, what one can do if you are an engineer, manager or technical expert, applicable RBPS elements etc.

Accepting Volunteers 

Yes

Project Status 

On-time

Status Updated On 

July 31, 2020
Project 303: Guidelines for Chemical Reactivity Evaluation & Application to Process Design 2nd Ed.

Project Scope 

There are many new products and tools since the first edition was published in 1995.  This includes predicting hazards using thermodynamic calculations, Chemical Reactivity Worksheet(CRW), CHETAH, CAMEO etc. new calorimetry screening methods are now available.  New topics may include safe operating limit and storage condition assessments.  Several case studies are now available and will be added.

We are looking for R&D professionals, process development & reaction safety experts along with engineers & designers with chemical reactivity expertise.

Accepting Volunteers 

Yes

Project Status 

On-time

Status Updated On 

July 31, 2020
Project 289: Golden Rules of Process Safety for Specific Technologies

Project ID 

289

Project Scope 

One of the most critical aspects of Process Safety is to know the hazards that one is dealing with, yet in too many incidents we realize that there was a knowledge gap in understanding the hazards. The goal of this project is to identify two to three technologies (e. g. FCC operations, Chlorine Chemistry, Nitration Chemistry, Peroxides, Combustible Dust, etc..) that have seen numerous incidents, have high hazards, and/or are highly utilized and Organize a team of process safety and process technology experts to develop a set of rules and tenants that serve the foundation for process safety.  

The rules and tenants are based on absolute statements to address the inherent hazards associated with the process technology (e.g. One should never mix A and B together, One should always check grounding connections, etc). The goal is to add to these initial technologies over time and develop an online library and also posters and other communication channels to communicate the message to a broad range of audiences (engineers, operations personnel, management).

This product will use technology as the foundation platform.

We are looking for expertise on: Ammonia, Hydrogen Sulfide, Ethylene Oxide, FCCU, Hydrotreating, and Alkylation

Accepting Volunteers 

Yes

Project Status 

On-time

Status Updated On 

July 31, 2020
Project 291: Abnormal Situation Management

Project ID 

291

Project Scope 

Develop guidance for and a reference guide to techniques for Abnormal Situation Management (ASM).

This project would develop a guidebook, with references, for concepts, tools and techniques to identify, control and mitigate abnormal process safety conditions.

Accepting Volunteers 

No

Project Status 

On-time

Status Updated On 

May 25, 2018
Project 293: Guidelines for Documenting, Implementing and Maintaining Process Knowledge Management

Project Scope 

Developing, documenting, and maintaining process knowledge is one of two elements in the Risk Based Process Safety (RBPS) pillar of understanding hazards and risk. Developing a high level of Process Knowledge Management throughout the organization is key to operating a safe and profitable manufacturing facility in compliance with applicable regulations and near-by residential area inhabitants needs and expectations. The knowledge element of RBPS primarily focuses on information that can easily be recorded in documents, such as (1) written technical documents and specifications, (2) engineering drawings and calculations, (3) specifications for design, fabrication, and installation of process equipment, and (4) other written documents such as safety data sheets (SDSs). The knowledge element also involves work activities associated with compiling, cataloging, and making available a specific set of data that is normally recorded in paper or electronic format. The main product of the knowledge element is (1) accurate, complete, and up-to-date information to support process safety activities at each life cycle phase and (2) a system to store and retrieve this information. However, knowledge implies understanding, not simply compiling data. The book will focus on the need for, the importance of, and the use of that knowledge and understanding.

Accepting Volunteers 

No

Project Status 

On-going

Status Updated On 

July 31, 2019
Project 294: Managing Cybersecurity – A Risk Based Approach Building on the Process Safety Framework

Project Scope 

This project will produce a concept book that describes the case for the application of cyber security principals for process safety. Chemical manufacturing relies on a number of Safety, Controls, Alarms, and Interlocks (SCAI) to manage process hazards. A cyber-attack can compromise one or more of these protection layers causing an incident while simultaneously defeating protective and mitigative measures.

Accepting Volunteers 

No

Project Status 

On-going

Status Updated On 

April 5, 2021
Project 300: Book of Beacon

Project Scope 

This book will have consolidated publication of the Beacons published since the inception with added information about each of them.  This may include detailed explanation, lessons learned, similar incidents, what one can do if you are an engineer, manager or technical expert, applicable RBPS elements etc.

Accepting Volunteers 

Yes

Project Status 

On-time

Status Updated On 

July 31, 2020
Project 301: Interactive Online Process Safety Training Using Bow Tie Technique

Project Scope 

This is a regional project being executed in Brazil and rest of the Latin America.  The primary product will be in Portuguese and Spanish. We will use the game theory to develop tools for developing skills, drive innovation in Process Safety, motivating people to change behaviors, etc.

Accepting Volunteers 

No

Project Status 

On-time

Status Updated On 

July 31, 2020
Project 303: Guidelines for Chemical Reactivity Evaluation & Application to Process Design 2nd Ed.

Project Scope 

There are many new products and tools since the first edition was published in 1995.  This includes predicting hazards using thermodynamic calculations, Chemical Reactivity Worksheet(CRW), CHETAH, CAMEO etc. new calorimetry screening methods are now available.  New topics may include safe operating limit and storage condition assessments.  Several case studies are now available and will be added.

We are looking for R&D professionals, process development & reaction safety experts along with engineers & designers with chemical reactivity expertise.

Accepting Volunteers 

Yes

Project Status 

On-time

Status Updated On 

July 31, 2020
Process Safety Incident Database (PSID)

Project Scope 

PSID Summary

PSID is an easily accessible, secure database that tracks process safety incidents with a focus on the lessons learned from the reports. It contains over 830 incident details. Currently, over 500 users from about 100 CCPS member companies have access to PSID. Participants use the database to pool and share process safety incident experience among participating companies so they can learn from the experiences of others without suffering the consequences of failures, while minimizing corporate liability. PSID contains incidents and near misses that did or could have resulted in fires, explosions, fatalities, multiple injuries, and significant release of hazardous materials. PSID supplements a company's internal incident database, improves hazard assessments, and facilitates due diligence activities.

PSID Steering Committee

The new PSID will be launched this year on a modern, state of the art software platform. We are now assembling a new PSID Steering committee. We need long-term commitments for this important work.  The updated platform will be fully configurable, easy to maintain, faster, reliable, and more efficient, thus enhancing user experience from data entry to reporting analytics and search functionality. Key content enhancements will include simplified incident types (fires, explosions, toxic releases, near misses) as well as lessons learned, root causes, emergency response, and references to key RBPS elements. Below are some of the responsibilities for the steering committee, including a pilot test of the new software platform.

  1. Program Development - Revise and update the program that manages PSID, which includes continuous improvement.
  2. Quality Control / Software Analysis – Help CCPS staff to maintain and provide continuous improvement to the database.
  3. PSID Advertising – Promote PSID and create incentives for incident input.
  4. Data Analysis – Evaluate data and create reports of general interest to PSID users.

The PSID committee is comprised of representatives from CCPS member companies. Any non-governmental or non-regulatory CCPS member company is eligible to join PSID. 

In 2020, building on the valuable benefit of this database, a subcommittee of volunteers from member companies completed an exercise to revise the functional specifications of PSID to include new, modern terms and categories. 

PSID Confidentiality

CCPS agrees to maintain the security and confidentiality of data submitted and to avoid disclosure of any information other than that agreed upon by the Participants or as required by law. Due to the confidentiality of the data, access for members must be approved by the member company’s PSID Administrator or by the PSID System Administrator. All participating companies should submit at least one incident per year to the database.

A number of special measures are in place to protect the confidentiality of data submitted by participants. Additionally, contracts between CCPS and any contractors hired to process confidential data will contain strict requirements for maintaining the security and confidentiality of the data. Information provided to the participants includes only sanitized and/or aggregated data for the entire database. Participating companies have the right to refrain from submitting any data that might become involved in litigation or may be sensitive for any other reason. 

CCPS will not voluntarily disclose the data to non-PSID members. In the event that any public body, government agency of any kind, or any third party seeks disclosure of confidential information contained in the PSID via legal means, CCPS will notify the participants of such demand, and give the participants an opportunity to defend all confidential information contained in the database, either in their own name or in CCPS’ name, from disclosure.

Register for PSID

PSID is an excellent platform for ‘Member Sharing’ and provides anonymity to those who wish to share incident data. Member companies who wish to enhance the breadth of knowledge in PSID can contact ccps_psid@aiche.org.

Accepting Volunteers 

Yes

Project Status 

On-going

Status Updated On 

July 19, 2021
Project 244: Process Safety-Vision 2020

Project ID 

244

Project Scope 

Vision 20/20 is an effort to envision the unique characteristics that companies with great process process safety performance will have in the year 2020.  If those characteristics are identified, then companies can seek to meet those characteristics and organizations such as CCPS can further develop products to support the improvement. 

Accepting Volunteers 

No

Project Status 

On-going

Status Updated On 

January 17, 2017

Leadership

 
Project 251: Risk Based Process Safety in Pilot Plants and Laboratories

Project ID 

251

Project Scope 

This project will develop and publish a book providing advisory guidance on process safety for laboratories and pilot plants using as a basis the management system elements presented in the 2007 CCPS Guidelines for Risk Based Process Safety. The current version of NFPA 45 (2011) clearly draws a distinction between laboratories and pilot plants and focuses only on lab fire protection and provides no detailed guidance on many aspects of process safety. This book will pull together both literature information and company experience, including incident case study examples, to present management system processes and hazard controls practices appropriate for bench and small scale chemical operations.  Twenty four organizations are participating with 19 CCPS member companies, 4 SAChE university representatives and 1 DOE National Lab (chair of NFPA 45 committee).

Accepting Volunteers 

No

Project Status 

Late - In control

Status Updated On 

February 14, 2017

Leadership

 
Project 257: Translation of CCPS Books/Tools into Chinese

Project ID 

257

Project Scope 

Proposal: Process safety is emerging as a focus and competency in the Asia Pacific Region.  Industrial growth in this area has increased the need and desire to share information and lessons learned from companies and industries that have been involved from catastrophic incidents. Translation of CCPS Books into Mandarin will increase access to valuable information.
 
Benefits: expand CCPS’ global presence and share process safety information.

Accepting Volunteers 

No

Project Status 

On-time

Status Updated On 

April 25, 2017

Leadership

 
Project 260: Translation of CCPS Books into Spanish

Project ID 

260

Project Scope 

Proposal: Process safety is emerging as a focus and competency in the Latin America Region.  Industrial growth in this area has increased the need and desire to share information and lessons learned from companies and industries that have been involved from catastrophic incidents. Translation of CCPS Books into Spanish will increase access to valuable information.
 
Benefits: expand CCPS’ global presence and share process safety information.

Accepting Volunteers 

No

Project Status 

On-time

Status Updated On 

April 25, 2017

Leadership

 
Project 261: Translation of CCPS Books into Portuguese

Project ID 

261

Project Scope 

Proposal: Process safety is emerging as a focus and competency in the Brazil.  Industrial growth in this area has increased the need and desire to share information and lessons learned from companies and industries that have been involved from catastrophic incidents. Translation of CCPS Books into Portuguese will increase access to valuable information.
 
Benefits: expand CCPS’ global presence and share process safety information.

Accepting Volunteers 

No

Project Status 

On-time

Status Updated On 

April 25, 2017

Leadership

 
Project 270: Guidelines for Process Safety in Upstream Industry

Project ID 

270

Project Scope 

This project will include the development of a concept book as well as application(s) or tool(s) for the upstream oil and gas and the shale oil and gas industries. 

Accepting Volunteers 

No

Project Status 

On-time

Status Updated On 

February 14, 2017

Leadership

 
Project 276: Guidelines/Essentials of Safe Work Practices

Project ID 

276

Project Scope 

The objective of Project 276 is to develop an integrated set of policies, procedures, permits, and other systems that are designed to manage risks associated with non-routine activities. Examples of these activities include performing hot work, opening process vessels or lines, and entering a confined space.

To date, a Safe Work Practice (SWP) document has been developed for hot work authorization, line breaking/isolation, lockout/tagout (control of energy hazards), and confined space entry.

Accepting Volunteers 

Yes

Project Status 

On-going

Status Updated On 

October 17, 2017

Leadership

 
Project 281: Human Factors for Process Plant Operations: A Handbook

Project ID 

281

Project Scope 

This project will create a guideline that enables Process Safety professionals to build their understanding of human performance topics. This effort will also build on the highlight joint industry documents, tools, and educational offers. The project will expand on the Human Factors Methods for Improving Performance in the Process Industries book. 

Accepting Volunteers 

No

Project Status 

Late - In control

Status Updated On 

July 31, 2020
Project 283: Guidelines for Updating & Revalidating PHAs 2nd Ed.

Project ID 

283

Project Scope 

This project is an update on the 2001 book, Revalidating Process Hazard Analyses. This second edition will provide improved guidelines for identifying missing or undervalued elements of the prior PHA (such as facility siting, effective consideration of human factors, security, and other elements that were not in use at the time of the first edition’s composition).

The book will also guide those developing revalidation protocols to identify improvement opportunities with the use of today’s tools and techniques (e.g. LOPA and layers of protection, identification of passive vs. active, and preventive vs. mitigating safeguards). This edition will add references to already established CCPS tools and books.

Accepting Volunteers 

No

Project Status 

Late - In control

Status Updated On 

August 6, 2021

Leadership

 
Project 289: Golden Rules of Process Safety for Specific Technologies

Project ID 

289

Project Scope 

One of the most critical aspects of Process Safety is to know the hazards that one is dealing with, yet in too many incidents we realize that there was a knowledge gap in understanding the hazards. The goal of this project is to identify two to three technologies (e. g. FCC operations, Chlorine Chemistry, Nitration Chemistry, Peroxides, Combustible Dust, etc..) that have seen numerous incidents, have high hazards, and/or are highly utilized and Organize a team of process safety and process technology experts to develop a set of rules and tenants that serve the foundation for process safety.  

The rules and tenants are based on absolute statements to address the inherent hazards associated with the process technology (e.g. One should never mix A and B together, One should always check grounding connections, etc). The goal is to add to these initial technologies over time and develop an online library and also posters and other communication channels to communicate the message to a broad range of audiences (engineers, operations personnel, management).

This product will use technology as the foundation platform.

We are looking for expertise on: Ammonia, Hydrogen Sulfide, Ethylene Oxide, FCCU, Hydrotreating, and Alkylation

Accepting Volunteers 

Yes

Project Status 

On-time

Status Updated On 

July 31, 2020
Project 291: Abnormal Situation Management

Project ID 

291

Project Scope 

Develop guidance for and a reference guide to techniques for Abnormal Situation Management (ASM).

This project would develop a guidebook, with references, for concepts, tools and techniques to identify, control and mitigate abnormal process safety conditions.

Accepting Volunteers 

No

Project Status 

On-time

Status Updated On 

May 25, 2018
Project 292: Driving Continuous Process Safety Improvement from Investigated Incidents

Project ID 

292

Project Scope 

Over the years, the US Chemical Safety Board (CSB) has made numerous recommendations to various parties in an attempt to improve Process Safety performance and to ensure that catastrophic incidents are prevented.  This project will take a look at the best recommendations and learnings brought forward by the CSB and will provide content to help companies institutionalize these learnings within their own organizations. The CSB, through using actual incidents, often does a great job as to demonstrating why companies need to take action relative to certain hazards.  This project would then build from this starting point to outline how individual companies could then apply these recommendations within their own organizations:
 
What are the warning signs and metrics that might speak to a company at being at risk of a similar catastrophic event? What changes does a company need to make – where can they find best practices related to the situation, are there applicable regulations? How do they assess the risk and create the case for change, are there long-term engineering solutions, are there short-term administrative controls to consider? How can they evaluate the success of the changes they have made? Are there tools that should prevent these hazards from re-entering their organizations?
 
In addition to addressing a handful of key CSB recommendations, this publication through these examples, will also start to map out processes and approaches that would serve as models to be applied when looking at recommendations and learnings outside of the scope of this publication.  i.e. how do you take an outside learning and drive change within an organization.
 

Accepting Volunteers 

No

Project Status 

On-time

Status Updated On 

May 25, 2018
Project 293: Guidelines for Documenting, Implementing and Maintaining Process Knowledge Management

Project Scope 

Developing, documenting, and maintaining process knowledge is one of two elements in the Risk Based Process Safety (RBPS) pillar of understanding hazards and risk. Developing a high level of Process Knowledge Management throughout the organization is key to operating a safe and profitable manufacturing facility in compliance with applicable regulations and near-by residential area inhabitants needs and expectations. The knowledge element of RBPS primarily focuses on information that can easily be recorded in documents, such as (1) written technical documents and specifications, (2) engineering drawings and calculations, (3) specifications for design, fabrication, and installation of process equipment, and (4) other written documents such as safety data sheets (SDSs). The knowledge element also involves work activities associated with compiling, cataloging, and making available a specific set of data that is normally recorded in paper or electronic format. The main product of the knowledge element is (1) accurate, complete, and up-to-date information to support process safety activities at each life cycle phase and (2) a system to store and retrieve this information. However, knowledge implies understanding, not simply compiling data. The book will focus on the need for, the importance of, and the use of that knowledge and understanding.

Accepting Volunteers 

No

Project Status 

On-going

Status Updated On 

July 31, 2019
Project 294: Managing Cybersecurity – A Risk Based Approach Building on the Process Safety Framework

Project Scope 

This project will produce a concept book that describes the case for the application of cyber security principals for process safety. Chemical manufacturing relies on a number of Safety, Controls, Alarms, and Interlocks (SCAI) to manage process hazards. A cyber-attack can compromise one or more of these protection layers causing an incident while simultaneously defeating protective and mitigative measures.

Accepting Volunteers 

No

Project Status 

On-going

Status Updated On 

April 5, 2021
Project 299: Introduction to Process Safety for Undergraduates 2nd Ed.

Project Scope 

The contents will be restructured by adding focus on the needs of the target audience – the undergraduate students.  This will include more details on understanding hazards & risks, source models, inherently safer design etc.  The basic order of ‘what can go wrong, how bad can it be, how frequently would it occur and how to reduce the resulting risk.  The new edition of the book will be made more valuable to educators, by providing problem sets and lecture outlines for each chapter. 

We are looking for people with specific experience in delivering  undergraduate education in Process Safety. 

Accepting Volunteers 

No

Project Status 

On-time

Status Updated On 

July 31, 2020
Project 300: Book of Beacon

Project Scope 

This book will have consolidated publication of the Beacons published since the inception with added information about each of them.  This may include detailed explanation, lessons learned, similar incidents, what one can do if you are an engineer, manager or technical expert, applicable RBPS elements etc.

Accepting Volunteers 

Yes

Project Status 

On-time

Status Updated On 

July 31, 2020
Project 301: Interactive Online Process Safety Training Using Bow Tie Technique

Project Scope 

This is a regional project being executed in Brazil and rest of the Latin America.  The primary product will be in Portuguese and Spanish. We will use the game theory to develop tools for developing skills, drive innovation in Process Safety, motivating people to change behaviors, etc.

Accepting Volunteers 

No

Project Status 

On-time

Status Updated On 

July 31, 2020
Project 303: Guidelines for Chemical Reactivity Evaluation & Application to Process Design 2nd Ed.

Project Scope 

There are many new products and tools since the first edition was published in 1995.  This includes predicting hazards using thermodynamic calculations, Chemical Reactivity Worksheet(CRW), CHETAH, CAMEO etc. new calorimetry screening methods are now available.  New topics may include safe operating limit and storage condition assessments.  Several case studies are now available and will be added.

We are looking for R&D professionals, process development & reaction safety experts along with engineers & designers with chemical reactivity expertise.

Accepting Volunteers 

Yes

Project Status 

On-time

Status Updated On 

July 31, 2020