Process Safety


Process Safety Boot Camp

Face-to-Face Course
Offered 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.

Guidelines for Process Safety Metrics

October, 2009
Process safety metrics is a topic of frequent conversation within chemical industry associations. Guidelines for Process Safety Metrics provides basic information on process safety performance indicators, including a comprehensive list of metrics for measuring performance and examples as to how...

Practical Compliance with the EPA Risk Management Program: A CCPS Concept Book

July, 2009
At last, smaller chemical processing operations have truly easy access to process safety and risk management programs tailored to meet their needs. Written as a "how to" book with checklists, it offers sufficient information for managers of facilities with small chemical operations to implement a...

Incidents That Define Process Safety

March, 2008
Incidents That Define Process Safety describes approximately fifty incidents that have had a significant impact on the chemical and refining industries' approaches to modern process safety. Events are described in detail so readers get a fundamental understanding of the root causes, the...

Safe Design and Operation of Process Vents and Emission Control Systems

March, 2006
Process vent header collection systems are subject to continually varying compositions and flow rates and thus present significant challenges for safe design. Due to increasingly demanding safety, health, environmental, and property protection requirements, today's industrial designers are faced...

Layer of Protection Analysis: Simplified Process Risk Assessment

October, 2001
Layer of protection analysis (LOPA) is a recently developed, simplified method of risk assessment that provides the much-needed middle ground between a qualitative process hazard analysis and a traditional, expensive quantitative risk analysis. Beginning with an identified accident scenario, LOPA...

Guidelines for Chemical Process Quantitative Risk Analysis, 2nd Edition

October, 1999
Chemical process quantitative risk analysis (CPQRA) as applied to the CPI was first fully described in the first edition of this CCPS Guidelines book. This second edition is packed with information reflecting advances in this evolving methodology, and includes worked examples on a CD-ROM. CPQRA is...

Avoiding Static Ignition Hazards in Chemical Operations

September, 1999
Written by Laurence Britton, who has over 20 years' experience in the fields of static ignition and process fire and explosion hazards research, this resource addresses an area not extensively covered in process safety standards or literature: understanding and reducing potential hazards associated...

Estimating the Flammable Mass of a Vapor Cloud

July, 1999
This CCPS Concept book shows designers and operators of chemical facilities how to realistically estimate the flammable mass in a cloud of accidentally released material that is capable of igniting. It provides information on industry experience with flammable vapor clouds, basic concepts of fires...

Guidelines for Pressure Relief and Effluent Handling Systems

March, 1998
Current industry, government and public emphasis on containment of hazardous materials makes it essential for each plant to reduce and control accidental releases to the atmosphere. Guidelines for Pressure Relief and Effluent Handling Systems meets the need for information on selecting and sizing...

Electrostatic Ignitions of Fires and Explosions

July, 1997
Tom Pratt, a long-time process safety practitioner and lecturer in electrostatic safety, wrote this book to educate industry in the basics of electrostatics. It offers a selected collection of information designed to give readers the tools they need to examine the hazard potential of common...

Guidelines for Safe Storage and Handling of Reactive Materials

September, 1995
With new and growing interest in dealing with the hazards of reactive chemicals, this book offers guidelines that can significantly reduce the risk or mitigate the severity of accidents associated with storing and handling reactive materials. Necessary elements of a reliable system to prevent...

Guidelines for Consequence Analysis of Chemical Releases

March, 1995
This Guidelines book provides technical information on how to conduct a consequence analysis to satisfy your company's needs and the EPA rules. It covers quantifying the size of a release, dispersion of vapor clouds to an endpoint concentration, outcomes for various types of explosions and fires,...

Is Your Hot Work Safety Zone Actually Safe?

Delmar Morrison, Ryan J. Hart, P.E., Eric Peterson, Morgan Reed
Hot work safety zone boundaries are often based on fixed criteria, which fail to take into account changing conditions at the worksite and undetected gas leaks.


eLearning (online) Course


eLearning (online) Course
当使用潜在的危险物质时,有正确合适的工具来处理它们是很重要的。本入门课程回顾了学生需要熟悉的工具,以识别、最小化和管理过程中的危险。学生将仔细探索“本质上更安全的设计”的含义,并学习了解后果和风险。此外,本课程通过引入事故起因和事故案例,与实际生产相结合。 了解有关SAChE文凭课程的更多信息。

SAChE® Certificate Program - Fire Hazards

eLearning (online) Course
Uncontrolled fire can have devastating consequences in an industrial setting. Thus, anyone working in a process industry should be aware of potential...

Process Safety Beacon: Share Stories to Communicate Safety

Process Safety Beacon
Story telling has been recognized for centuries as an effective way to impact the brain and the heart, as well as to preserve history. While fairy tales have proven to be useful tools for teaching children life lessons, stories can also be used to...

SAChE® Certificate Program - Source Models

eLearning (online) Course
When working in chemical plants, failures of equipment will result in releases of toxic, flammable and explosive materials. This course introduces...

Process Safety Beacon: Be Alert for Common-Cause Failures

Process Safety Beacon
Hartsfield-Jackson Atlanta International Airport is the busiest airport in the world, serving an average of 275,000 passengers each day). At about 1 pm on Sunday, Dec. 18, 2017, a fire disabled the airport’s main power supply, as well as the backup...

November 2018 CEP Preview

This issue, essentials of job hazard analysis, a special section on energy-efficient manufacturing, including a 10-step process for energy analysis, and much more.

Essentials of Job Hazard Analysis

Back To Basics
Fatima Ibrahim, Jeremy Lebowitz, P.E.
Job hazard analyses require employees and employers to think critically about the dangers of a work environment and prepare operators for the unexpected.

Process Safety Beacon: Several Small Changes Can Add Up to a Big Problem

Process Safety Beacon
A 70-m 3 (18,500-U.S. gal) fixed-roof acrylic acid (AA) tank exploded, causing a fire at an industrial site in Himeji, Japan, in September 2012, destroying the tank and damaging nearby facilities ( Image 1 and Image 2 ). A firefighter was killed and...

Spotlight on Safety: Abnormal Situation Management

Spotlight on Safety
Louisa Nara
Hazard analyses prevent incidents before they happen and incident investigations prevent incidents from reoccurring, but what about at the onset of an incident? When you detect something abnormal but do not have time to analyze the situation,...

1987 Celanese Pampa Butane Vapor Cloud Explosion

Conference Presentation
AIChE Spring Meeting and Global Congress on Process Safety
April 28, 2015
On Saturday November 14, 1987, the presenter personally witnessed a catastrophic vapor cloud explosion at the Celanese Chemicals facility in Pampa,...

Process Safety Beacon: Energy Is Hazardous, Too

Process Safety Beacon
The left engine of a commercial airliner flying from New York City to Dallas failed on April 17, 2018 over eastern Pennsylvania. Fragments of the engine inlet and cowling ( Image 1 ) struck the wing ( Image 2 ) and fuselage, causing significant...

Process Safety Management for Bioethanol

eLearning (online) Course
Process safety management is different in the biodiesel industry. Gain tools, techniques and regulatory guidance tailored to your unique needs.

HAZOP Studies

eLearning (online) Course
Need to plan and execute a HAZOP Study team review? This course covers the concepts and techniques you’ll need.

Layer of Protection Analysis (LOPA)

eLearning (online) Course
LOPA is the methodology used by process organizations worldwide for risk analysis. Learn the basic LOPA approach to selecting and analyzing potential...

Process Safety Management Overview

eLearning (online) Course
Explore the whys and hows of process safety. A great introduction for new hires and refresher for seasoned engineers.

Process Safety Beacon: Speak Up If You Notice Operational Abnormalities

Process Safety Beacon
The August 2018 Beacon described an incident involving a runaway reaction in a batch reactor that occurred because of agitator failure. During normal operation, the reactor needed cooling to maintain the required temperature. However, the batch...

Use Scare Tactics to Communicate Major Incidents

Renato Prestes, TJ Larkin
Communication that frightens employees triggers more behavior changes than similar messages without the scare factor. Including a fear appeal makes it much less likely that process safety incidents will be repeated.

BASF Hosts First Faculty Workshop on Process Safety

As a Founders’ Circle member of our Doing a World of Good campaign, BASF recently hosted their first process safety workshop to better educate faculty and provide an in-depth look at the importance of process safety education for undergraduates.


July, 2018


September, 2017


June, 2015

Process Safety Beacon: What If Your Agitator Fails?

Process Safety Beacon
What if Your Agitator Fails? A German manufacturer employed a process that reacted o -chloronitrobenzene with caustic soda dissolved in methanol in a 36-m 3 (9,500-gal) batch reactor to produce o -nitroanisol. The reaction is exothermic, and the...

Spotlight on Safety: The Three-Legged Stool of PSM

Spotlight on Safety
John Herber
During a session I was instructing on risk-based process safety, one of the company process safety leaders presented a simple process safety model: If you design it right, operate it correctly, and maintain it properly, the process should operate...

Process Safety Beacon: Excess Cooling Can Cause a Runaway Reaction

Process Safety Beacon
A process at a British dye factory required addition of nitrosyl sulfuric acid (NSA) to a 600-gal (~2.3-m 3 ) batch reactor containing an amine and sulfuric acid at 30–40°C. The manual feed to the reactor typically took about five hours to complete...


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