CCPS Projects | AIChE

Project 313: RBPS Implementation Guide

Project Scope 

We are seeking Risk Based Process Safety (RBPS) success stories to be incorporated into the RBPS Implementation Guide. Please use the template provided to submit a success story and email your completed form to RBPS-Stpry@aiche.org. All submitted stories will be reviewed by the project chairs and you will be contacted to ensure you agree with the final contents to be included.  

RBPS Story Template

Since Guidelines for Risk-Based Process Safety was first published in 2007 it has served as the reference for theory and concepts related to Risk Based Process Safety (RBPS). The purpose of Guidelines for Risk-Based Process Safety is to help organizations design and implement more effective process safety management systems by providing methods and ideas on how to (1) design a process safety management system, (2) correct a deficient process safety management system, or (3) improve process safety management practices. A risk-based approach reduces the potential for assigning an undue number of resources to manage lower-risk activities, thereby freeing up resources for tasks that address higher-risk activities. The theoretical groundwork developed in Guidelines for Risk-Based Process Safety serves as the basis for the Risk-Based Process Safety Implementation Guide.

The Implementation Guide will

  • Provide real-world practices that have been developed by CCPS member companies as effective applications for risk management.
  • Complement Guidelines for Risk-Based Process Safety with success stories from CCPS Member companies, providing practical insights into strategies and practices that have proven effective when applying the RBPS Elements.
  • Provide examples of systems and programs that have been deployed and helped prevent incidents from happening, for each of the Elements and Pillars. These are proven examples of management systems and processes that have improved the effectiveness of process safety at companies and throughout industry. This reference will provide organizations with easy access to these best practices so they can incorporate or adapt based on their site or company needs. Each example will present the issue, provide details on the solutions that were implemented, discuss the resources required, highlight challenges to implementation, and show how those challenges were overcome. These examples will help us meet our collective goal of “A World without Process Safety IncidentsTM.”

This book will differ from many CCPS books, in that it will showcase and highlight success stories that can be replicated, rather than sharing information and learnings from incidents to prevent further incidents from occurring. The Implementation Guide will focus on positive outcomes achieved by the implementation of process safety programs related to the Elements and Pillars of RBPS.

This book will seek to provide the answer to one question – “What went right?” 

Accepting Volunteers 

Yes

Project Status 

On-going

Status Updated On 

March 11, 2024
Project 321: Spinoffs and Carveouts

Project Scope 

The 2010 book on mergers and acquisitions did not fully cover Spinoffs and Carveouts of business divisions into separate new entities. The Process Safety knowledge does not transfer easily in this situation. The product of this project is likely to be a focused Monograph, but may morph into a book volume if necessary. Note: Carve out leads to new owners whereas spinoff is legal divestiture but same owners or stockholders. Volunteer ask: Process safety strength, having first-hand experience in either of the two types of divestitures in focus. 

Accepting Volunteers 

Yes

Project Status 

On-time

Status Updated On 

October 27, 2023
Project 323: Contract Manufacturing

Project Scope 

This practice is common in many industries such as Food, Pharmaceuticals, Fine Chemicals, etc.  During a recent incident investigation, the US Chemical Safety Board reviewed the available literature around the world and did not find sufficient up to date guidance on this topic of Contract or Toll manufacturing. We will be updating the 2000 book with a focused monograph that will at a minimum address the deficiencies in the literature identified by CSB.  We will also review the latest best practices and include them in the guidance.  Volunteer ask: Process safety strength, with contract manufacturing knowledge and experience.

Accepting Volunteers 

Yes

Project Status 

On-time

Status Updated On 

October 27, 2023
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 710 member-submitted incident details. 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 Steering Committee

The new PSID has been launched on a modern, state of the art software platform.  The updated platform is fully configurable, easy to maintain, faster, reliable, and efficient, thus enhancing user experience from data entry to reporting analytics and search functionality. There are many attributes to search from, including incident types (fires, explosions, toxic releases, near misses) as well as lessons learned, root causes, emergency response, and references to key RBPS elements.

The PSID Steering Committee meets monthly in order to provide continuous improvement to the database. Below are some of the responsibilities for the Steering Committee.

  1. Software Analysis – Help CCPS staff to maintain and provide continuous improvement to the database.
  2. Promote PSID and create incentives for incident input.
  3. Data Analysis – Evaluate data 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. 

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. All participating companies should submit at least one incident per year to the database.

Confidentiality and security are maintained through a robust software system and workflow process.

The information contained in PSID, and all output from this system, are available to participating CCPS member company employees strictly for their internal use. It shall not be released to, or discussed with others, without the written approval of CCPS.

It is sincerely hoped that the information presented in this database will lead to an even more impressive safety record for the entire industry. However, neither the American Institute of Chemical Engineers, its consultants, CCPS Technical Steering Committee and Subcommittee members, their employers, their employers' officers and directors, warrant or represent, expressly or by implication, the correctness or accuracy of the content of the information presented in this database. As between (1) American Institute of Chemical Engineers, its consultants, CCPS Technical Steering Committee and Subcommittee members, their employers, their employers' officers and directors, (2) the user of this database, the user accepts any legal liability or responsibility whatsoever for the consequence of its use or misuse.

Access the New Database

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 

No

Project Status 

On-going

Status Updated On 

January 25, 2023
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

AMS Committee ID 

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

AMS Committee ID 

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

AMS Committee ID 

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

AMS Committee ID 

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

AMS Committee ID 

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 

No

Project Status 

On-going

Status Updated On 

October 17, 2017

AMS Committee ID 

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 

No

Project Status 

On-time

Status Updated On 

July 31, 2020
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 

No

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 

No

Project Status 

On-time

Status Updated On 

July 31, 2020
Project 313: RBPS Implementation Guide

Project Scope 

We are seeking Risk Based Process Safety (RBPS) success stories to be incorporated into the RBPS Implementation Guide. Please use the template provided to submit a success story and email your completed form to RBPS-Stpry@aiche.org. All submitted stories will be reviewed by the project chairs and you will be contacted to ensure you agree with the final contents to be included.  

RBPS Story Template

Since Guidelines for Risk-Based Process Safety was first published in 2007 it has served as the reference for theory and concepts related to Risk Based Process Safety (RBPS). The purpose of Guidelines for Risk-Based Process Safety is to help organizations design and implement more effective process safety management systems by providing methods and ideas on how to (1) design a process safety management system, (2) correct a deficient process safety management system, or (3) improve process safety management practices. A risk-based approach reduces the potential for assigning an undue number of resources to manage lower-risk activities, thereby freeing up resources for tasks that address higher-risk activities. The theoretical groundwork developed in Guidelines for Risk-Based Process Safety serves as the basis for the Risk-Based Process Safety Implementation Guide.

The Implementation Guide will

  • Provide real-world practices that have been developed by CCPS member companies as effective applications for risk management.
  • Complement Guidelines for Risk-Based Process Safety with success stories from CCPS Member companies, providing practical insights into strategies and practices that have proven effective when applying the RBPS Elements.
  • Provide examples of systems and programs that have been deployed and helped prevent incidents from happening, for each of the Elements and Pillars. These are proven examples of management systems and processes that have improved the effectiveness of process safety at companies and throughout industry. This reference will provide organizations with easy access to these best practices so they can incorporate or adapt based on their site or company needs. Each example will present the issue, provide details on the solutions that were implemented, discuss the resources required, highlight challenges to implementation, and show how those challenges were overcome. These examples will help us meet our collective goal of “A World without Process Safety IncidentsTM.”

This book will differ from many CCPS books, in that it will showcase and highlight success stories that can be replicated, rather than sharing information and learnings from incidents to prevent further incidents from occurring. The Implementation Guide will focus on positive outcomes achieved by the implementation of process safety programs related to the Elements and Pillars of RBPS.

This book will seek to provide the answer to one question – “What went right?” 

Accepting Volunteers 

Yes

Project Status 

On-going

Status Updated On 

March 11, 2024
Project 321: Spinoffs and Carveouts

Project Scope 

The 2010 book on mergers and acquisitions did not fully cover Spinoffs and Carveouts of business divisions into separate new entities. The Process Safety knowledge does not transfer easily in this situation. The product of this project is likely to be a focused Monograph, but may morph into a book volume if necessary. Note: Carve out leads to new owners whereas spinoff is legal divestiture but same owners or stockholders. Volunteer ask: Process safety strength, having first-hand experience in either of the two types of divestitures in focus. 

Accepting Volunteers 

Yes

Project Status 

On-time

Status Updated On 

October 27, 2023
Project 323: Contract Manufacturing

Project Scope 

This practice is common in many industries such as Food, Pharmaceuticals, Fine Chemicals, etc.  During a recent incident investigation, the US Chemical Safety Board reviewed the available literature around the world and did not find sufficient up to date guidance on this topic of Contract or Toll manufacturing. We will be updating the 2000 book with a focused monograph that will at a minimum address the deficiencies in the literature identified by CSB.  We will also review the latest best practices and include them in the guidance.  Volunteer ask: Process safety strength, with contract manufacturing knowledge and experience.

Accepting Volunteers 

Yes

Project Status 

On-time

Status Updated On 

October 27, 2023