Process Safety Boot Camp Face-to-Face CourseOffered in North America, this intensive and highly interactive 4-day course trains chemical engineers in the fundamentals of Process Safety. Taught...
Center for Chemical Process Safety (CCPS) CCPS was established in 1985 to focus on engineering and management practices that can prevent and mitigate catastrophic accidents involving release of hazardous materials. CCPS is supported by sponsors in the chemical and hydrocarbon process industries and active worldwide via conferences, books, databases, education, research, and more.
2nd CCPS Global Summit on Process Safety November 3-5, 2015Hotel Istana, Kuala Lumpur, MalaysiaThe 1st Global Summit on Process Safety held in Mumbai on December 2014 was a great success. The theme of the conference is based on Vision 2020, developed by the Center for Chemical Process Safety and is supported by the Universiti Teknologi PETRONAS (UTP).
Guidelines for Preventing Human Error in Process Safety August, 2004Almost all the major accident investigations--Texas City, Piper Alpha, the Phillips 66 explosion, Feyzin, Mexico City--show human error as the principal cause, either in design, operations, maintenance, or the management of safety. This book provides practical advice that can substantially reduce...
Guidelines for Facility Siting and Layout August, 2003A resource for individuals responsible for siting decisions, this guidelines book covers siting and layout of process plants, including both new and expanding facilities. This book provides comprehensive guidelines in selecting a site, recognizing and assessing long-term risks, and the optimal lay...
Understanding Explosions July, 2003There are many different types of explosions, each with its own complex mechanism. Understanding explosions is important in preventing them. This reference provides valuable information on explosions for everyone involved in the operation, design, maintenance, and management of chemical processes,...
Essential Practices for Managing Chemical Reactivity Hazards March, 2003In its recent investigation of chemical reactivity accidents, the US Chemical Safety Board noted a gap in technical guidance and regulatory coverage. This volume closes the gap in technical guidance, helping small and large companies alike identify, address, and manage chemical reactivity hazards...
Guidelines for Investigating Chemical Process Incidents, 2nd Edition March, 2003This book provides a valuable reference tool for technical and management personnel who lead or are a part of incident investigation teams. This second edition focuses on investigating process-related incidents with real or potential catastrophic consequences. It presents on-the-job information,...
Deflagration and Detonation Flame Arresters May, 2002Designed for chemical engineers and other technical personnel involved in the design, operation, and maintenance of facilities and equipment where deflagration and detonation flame arresters (DDFAs) may be required, this book fosters effective application and operation of DDFAs through treatment of...
Wind Flow and Vapor Cloud Dispersion at Industrial and Urban Sites April, 2002A key component of risk reduction is reducing the potential consequences that could result from toxic or flammable releases. The science of vapor cloud dispersion has advanced significantly in recent years, but one of the long-standing challenges has been in accounting for dispersion around...
Making EHS an Integral Part of Process Design June, 2001This book presents an approach—termed MERITT (Maximizing EHS Returns by Integrating Tools and Talents)—for enhancing process development through better integration of environmental, health, and safety evaluations. It draws upon critical components of inherent safety, pollution prevention, green...
Revalidating Process Hazard Analyses February, 2001The foundation of any successful process safety program is a current set of process hazard analyses (PHAs) for each of its processes. Revalidating PHAs to keep them up to date and applicable is a must. This book is derived from the experience of many companies in the chemical and hydrocarbon...
Guidelines for Process Safety in Outsourced Manufacturing Operations September, 2000In today’s competitive economy, companies often augment in-house production by outsourcing chemical reaction processes and distillation, drying, formulating, blending, and packaging operations. While most of these tolling, or contracted manufacturing services, proceed without incident, recent major...
Evaluating Process Safety in the Chemical Industry: A User's Guide to Quantitative Risk Analysis June, 2000Quantitative Risk Analysis is a powerful tool used to help manage risk and improve safety. When used appropriately, it provides a rational basis for evaluating process safety and comparing alternative safety improvements. This guide, an update of an earlier American Chemistry Council (ACC)...
Guidelines for Process Safety in Batch Reaction Systems September, 1999Batch reaction systems pose unique challenges to process safety managers because they do not operate in a steady state. The sequence of processing steps, and frequent start-ups and shutdowns, increase the possibility of human errors and equipment failures. And, since batch plants are often designed...
Guidelines for Design Solutions for Process Equipment Failures August, 1998While there is no "perfect" solution or absolute zero risk, engineering design can significantly reduce risk potential in the CPI. In Guidelines for Design Solutions to Process Equipment Failures, industry experts offer their broad experience in identifying numerous solutions to the more common...
Guidelines for Improving Plant Reliability Through Data Collection and Analysis June, 1998Written by reliability data experts, the book gives plant managers and supervisors the guidance they need to collect, and use with confidence, process equipment reliability data for risk-based decisions. Focusing on the process industries, it provides the protocol and techniques to collect and...
Guidelines for Safe Warehousing of Chemicals June, 1998A comprehensive understanding of the potential dangers inherent in warehousing chemicals is the first step in managing the associated risks. Written by industry professionals for warehouse operators, designers, and all who are concerned with the safe warehousing of chemicals, this book offers a...
Guidelines for Postrelease Mitigation Technology in the Chemical Process Industry December, 1996This book puts together a body of very recent information never before presented in one volume on the design of post-release mitigation systems. The development of a fundamental knowledge base on post-release mitigation systems, through testing and data correlation, is very new. While further...
Guidelines for Use of Vapor Cloud Dispersion Models, 2nd Edition December, 1996The second edition of this essential reference updates and combines two earlier titles to capture the many technological advances for predicting the "footprint" of a vapor cloud release. Cited by EPA in its 1996 document, "Off-Site Consequence Analysis Guidance," the aim of the book is to encourage...
Contractor and Client Relations to Assure Process Safety December, 1996Written and edited by engineering contractors and industry project/maintenance managers as an easy-to-use guide for other industry professionals, this book identifies important process safety issues in the contractor-client relationship,which are not addressed by other groups and publications...
Guidelines for Evaluating Process Plant Buildings for External Explosions and Fires September, 1996Dedicated to the Memory and Spirit of Donald F. Othmer Though there are many industry practices for building design and siting, they do not always apply to all sectors of the industry, or ensure consistent levels of safety. This practical book, written by the same author as API Recommended Practice...
Guidelines for Writing Effective Operating and Maintenance Procedures May, 1996The EPA investigation of a 1994 chemical plant tragedy concluded that "the explosion resulted from a lack of written safe operating procedures…" While good written procedures can't guarantee zero accidents, they can reduce the number of accidents caused by human error. This new book shows how to...
Understanding Atmospheric Dispersion of Accidental Releases December, 1995A brief introduction to a complex topic, giving a description of the processes involved in an accidental or emergency release and the resulting downwind transport and dilution of gases, vapors, and aerosols.
Guidelines for Technical Planning for On-Site Emergencies June, 1995Prevention, preparedness, response and recovery--the key components of emergency planning--form the major sections of this work. The book first describes PSM (Process Safety Management) as the key to prevention, then goes on to consider the main features of a preparedness program, including...
Guidelines for Process Safety Documentation April, 1995The process industry has developed integrated process safety management programs to reduce or eliminate incidents and major consequences, such as injury, loss of life, property damage, environmental harm, and business interruption. Good documentation practices are a crucial part of retaining past...
Guidelines for Chemical Reactivity Evaluation and Application to Process Design April, 1995Drawn from international sources, this book provides principles and strategies for the evaluation of chemical reactions, and for using this information in process design and management. A useful resource for engineers who design, start-up, operate, and manage chemical and petrochemical plants, the...
Guidelines for Process Safety Fundamentals in General Plant Operations April, 1995At last, a book that covers safety procedures and standards with information that is rarely available outside of proprietary materials. A comprehensive source for basic and essential operations and procedures in use in any facility, the book offers chemical operators and first line supervisors...
Guidelines for Safe Process Operations and Maintenance March, 1995First-line managers have to maintain the integrity of facilities, control manufacturing processes, and handle unusual or emergency situations, as well as respond to the pressures of production demand. On a daily basis, they are closest to the operating personnel who may be injured by a process...
Tools for Making Acute Risk Decisions with Chemical Process Safety Applications August, 1994The complexity of today's risk decisions is well known. Beyond cost and risk there are many other factors contributing to these decisions, including type of risk (such as human injury or fatality), the economic impact on the local community, profitability, availability of capital, alternatives for...
Guidelines for Implementing Process Safety Management Systems April, 1994The causes of catastrophic accidents in the process industries, now recognized as complex and interrelated, need to be matched by multi-faceted technical management systems. These principles apply to companies of any size and to a full range of industries beyond the chemical industry, such as pulp...
Guidelines for Safe Automation of Chemical Processes October, 1993Increased automation reduces the potential for operator error, but introduces the possibility of new types of errors in design and maintenance. This book provides designers and operators of chemical process facilities with a general philosophy and approach to safe automation, including independent...
Guidelines for Process Equipment Reliability Data, with Data Tables February, 1989The book supplements Guidelines for Chemical Process Quantitative Risk Analysis by providing the failure rate data needed to perform a chemical process quantitative risk analysis.
Guidelines for Vapor Release Mitigation April, 1988Guidelines for Vapor Release Mitigation is a survey of current industrial practice for controlling accidental releases of hazardous vapors and preventing their escape from the source area.
CEP: Process Safety Beacon - Why Can't I Open that Valve? June2013Process Safety BeaconIn April 2004, an explosion and fire at a polyvinyl chloride (PVC) plant killed five people and severely injured three others. The explosion and fire destroyed most of the reactor building and an adjacent warehouse. Because smoke from the fire drifted...
CEP: Process Safety Beacon- Pressure-Relief Valve Bonnets — To Plug or Not To Plug? May2013Process Safety BeaconUnderstand what kind of pressure-relief valves you have in your plant, and know what you must do to ensure that they work properly.
CEP: Process Safety Beacon - Have You Heard a Pressure-Relief Valve Chatter? April2013Process Safety BeaconChattering is the rapid opening and closing of a pressure-relief valve. The resulting vibration may cause misalignment, valve seat damage, and, if prolonged, mechanical failure of valve internals and associated piping. Some causes of chattering...
CEP: Process Safety Beacon - Are Your Signs and Labels Confusing? March2013Process Safety BeaconLack of labeling can be a safety problem, and poor or confusing labels or information signs can be even worse.
Improve Safety by Improving Human Performance August2006SafetyDonald K. LorenzoFollow these guidelines to identify situations in which human errors are likely to occur and to correct potential problems early enough to avoid adverse consequences.
CEP: Process Safety Beacon - What is Supporting Your Equipment? February2013Process Safety BeaconPipes and equipment that are not properly supported will be subject to stress, vibration, or other problems, This can cause leaks, or even a complete collapse of piping or equipment. But, problems with inadequate support of piping and other...
CEP: Process Safety Beacon - Mechanical Integrity of Tubing May2012Process Safety BeaconProper installation, maintenance, and inspection of metal tubing is important in preventing fires and toxic material releases in process plants. Do not forget about tubing just because it is usually small. Even a small leak can cause a fire that can...
Product Digest - Safety Equipment May2012Product DigestCheck out warning devices for hazardous areas and high-visibility work vests that reduce static electricity.
Beware of the Dangers of Cold Traps February2013SafetyJames R. RiskoCold traps — steam traps that no longer drain condensate — are often ignored in lieu of less-critical leaking traps, until a catastrophic event, such as a plant shutdown or personal injury, occurs. Use historical data to accurately estimate the annual cost of these cold traps to justify their swift repair.
Process Safety and Risk Management of Chemical Parks Report This document is also available in Chinese
Process Safety and Risk Management of Chemical Parks Report-Chinese This document is also available in English.
CEP: Process Safety Beacon -Some Answers to the November 2012 Beacon Find-the-Problem Contest January2013Process Safety Beacon
Special Section: Energy - Expanding the Shale Gas Infrastructure August2012Special SectionJesse F. GoellnerDevelopment of U.S. shale gas resources will require expansion of infrastructure assets ranging from roads and rails to pipelines and seaports to power-generation plants and ethane crackers, and more.
Reshaping Process Safety Regulations March2002SafetyWalter L. FrankChanges to OSHA's PSM rule and EPA's RMP programs are underway, due to pressures from various groups and the need for greater security.
Developing Safety Standard for Pilot Plants October2006SafetyRichard P. PalluziSafety standards can significantly improve pilot plant safety and increase efficiency. This article addresses many of the issues involved in developing, deploying and using such standards.
Six Steps to Effectively Update and Revalidate PHAs January2001SafetyDavid K. Whittle, Kevin SmithProcess hazard analyses must be revamped — or redone from scratch — every five years by law. Following the guidance given here will facilitate this effort.
CEP: Process Safety Beacon - Good Housekeeping for Safety December2012Process Safety BeaconA fire started in a fiber trash drum in a process building. The drum contained solder flux and paste, welding debris, general trash, and oil-soaked rags. It had not been emptied for a long time. The ignition source may have been hot welding debris...
Before OSHA Comes Knocking ... March2009SafetyDaniel SteinwayThe OSHA Process Safety Management National Emphasis Program will soon apply to the chemical industry, targeting compliance with safety standards associated with chemical hazards.
CEP: Commentary - Working Together to Put CFATS Back on Track November2012CommentaryBill AllmondMore than five years ago, Congress enacted the most robust and comprehensive chemical security regulatory program to date. The regulation — the Chemical Facility Anti-Terrorism Standards (CFATS) — protects facilities against attack without impairing...
CEP: Process Safety Beacon - Can You Find the Safety Problem? November2012Process Safety BeaconWe are finishing our celebration of 10 years of the Process Safety Beacon with a “Find-the-Problem” contest.
CEP: Spotlight on Safety - LOPA — A Valuable Risk-Reduction Tool November2012Spotlight on SafetyJohn F. Murphy, P.E.Layer of protection analysis (LOPA) is a simplified process risk-assessment technique that uses order-of-magnitude estimates for initiating events, consequence severity, and likelihood of failure of independent protection layers (IPLs) to approximate the risk of a scenario. It is generally used after a process hazard analysis (PHA) team has identified a hazard scenario that requires further analysis to ensure the adequacy of the safeguards that exist or are being proposed.
Use a Comprehensive Database to Better Manage Process Safety August2001SafetyBrian D. KellyFind out if your database is large enough to be meaningful and whether it is being used to its fullest extent.
CEP: Process Safety Beacon - Double Block and Bleed March2012Process Safety BeaconThe December 2011 Beacon described an incident where a missing plug on a vent line resulted in a flammable material leak that caught fire, causing a fatality. That incident reminded us of the importance of caps and plugs on process vent lines and...
CEP: Process Safety Beacon - Manage Temporary Changes October2012Process Safety BeaconA filter on the suction of a pump frequently plugged. Because of this, the pressure needed to be monitored, both in the field and at the control panel. To minimize installation time for a pressure transmitter, it was decided to install a tap on the...
Implement an Operational Discipline Program to Improve Plant Process Safety June2011SafetyJames A. Klein, Bruce K. VaughenBuilt on a solid foundation of leadership support and employee involvement, an operational discipline program can help to prevent serious incidents and injuries, and improve overall site safety and business performance.
CEP: Spotlight on Safety - Management of Change: It's Not Just for Work, but for Your Private Life as Well August2012Spotlight on SafetyAdrian L. Sepeda, P.E.
Handle Corrosive Acids and Caustics Safely September2012SafetyRichard W. Prugh, P.E., CSPUnderstand the corrosivity hazards of acids and caustics, and follow these guidelines to manage those hazards through inherently safer design, engineering and administrative controls, and personal protective equipment.
CEP: Process Safety Beacon - What Can I do? I’m Just the Operator. September2012Process Safety BeaconA frequent comment from workers is, “What can I do to improve the safety of our processes? I am just the operator (or technician, mechanic, etc.). I just turn valves, operate the equipment, take samples, turn wrenches, adjust the equipment.” It is...
Guidelines for Auditing Process Safety Management Systems, 2nd Edition February, 2011This book discusses the fundamental skills, techniques, and tools of auditing, and the characteristics of a good process safety management system. A variety of approaches are given so the reader can select the best methodology for a given audit. This book updates the original CCPS Auditing...
CEP: Spotlight on Safety - Process Safety Education: Meeting the New ABET Requirments April2012Spotlight on Safety
CEP: Process Safety Beacon - Hot Work Hazards August2012Process Safety BeaconA contract welder and a foreman were repairing an agitator support on top of an atmospheric-pressure storage tank. The tank contained a polyvinyl fluoride slurry with a flammable concentration if vinyl fluoride in the vapor space. An explosion...
CEP: Process Safety Beacon - What If You Unload the Wrong Material into a Tank? April2012Process Safety Beacon
CEP: Process Safety Beacon - Overflow + Ignition = Tank Farm Fire (Part 2) October2009SafetyProcess Safety Beacon
It's Time to Consider Human Factors in Alarm Management November2002InstrumentationIan NimmoImplement these procedures to consider human factors, not simply human error, in control-room architecture and reduce the chance for incidents in the plant.
Controlling Risk During Major Capital Projects April2009SafetyWilliam BridgesThink of process safety management (PSM) as a project deliverable, and follow these best practices for scheduling and performing process hazard analyses (PHAs) and completing other PSM requirements during key phases of a major project.
Preventing Dust Explosions: Are You Doing Enough? March2008News FeatureIssue Date: March 2008Experts agree that greater vigilance is needed to snuff out the ever-present risk at facilities handling powdered materials.