Process Safety

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Process Safety Boot Camp

Public (classroom) 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.

Portfolio Risk Management for Process Safety

Conference Presentation
AIChE Spring Meeting and Global Congress on Process Safety
Monday, March 14, 2011 - 8:00pm
A majority of PSM tools and risk methodologies are focused on risks at individual sites or process units. For example, PHA risk ranking matrices are...

Can Functional Testing Be Replaced by Inspection After Demands?

Conference Presentation
AIChE Spring Meeting and Global Congress on Process Safety
Monday, March 14, 2011 - 8:00pm
Safety instrumented systems are used to reduce the risk of major accidents in the process industry. To claim a certain risk reduction from such...

Ignition of Dust Layers by Mechanical Sparks

Conference Presentation
AIChE Spring Meeting and Global Congress on Process Safety
Monday, March 14, 2011 - 8:00pm
Dust explosions represent a considerable safety risk in process industry. Statistical records of dust explosions show that 32.7 % of these explosions...

Inherently Safer Design – Not Only about Reducing Consequences!

Conference Presentation
AIChE Spring Meeting and Global Congress on Process Safety
Monday, March 14, 2011 - 8:00pm
Process risk is a function of both the likelihood of occurance of an incident, and of the consequences of the incident. There is a common perception...

A Work Process for Revalidating LOPAs and Other Risk Analyses

Conference Presentation
AIChE Spring Meeting and Global Congress on Process Safety
Monday, March 14, 2011 - 8:00pm
The Chemical Process Industry (CPI) has long recognized the necessity of periodically revalidating Process Hazard Analyses (PHAs), such as Hazard and...

Systematic Workforce Involvement In Process Safety

Conference Presentation
AIChE Spring Meeting and Global Congress on Process Safety
Monday, March 14, 2011 - 8:00pm
Workforce involvement is an essential element of effective process safety management. This paper will describe proven methods of workforce...

PSM Auditing Dilemmas

Conference Presentation
AIChE Spring Meeting and Global Congress on Process Safety
Sunday, March 13, 2011 - 8:00pm
In most PSM audits, the audit team will face one or more situations that represent a dilemma. These dilemmas usually require the individual auditor...

OSHA Refinery and Chemical NEP Findings

Conference Presentation
AIChE Spring Meeting and Global Congress on Process Safety
Tuesday, March 23, 2010 - 8:00pm
Since 2007, OSHA has initiated two major National Emphasis Programs (NEPs) in process safety. The Petroleum Refinery Process Safety Management NEP (...

How to Evaluate Process Safety Culture

Conference Presentation
AIChE Spring Meeting and Global Congress on Process Safety
Monday, March 22, 2010 - 8:00pm
At first glance it may seem that organizational culture is subjective and therefore difficult to measure. Indeed, even the definition of culture...

Lessons Learned from Real World Application of the Bow-Tie Method

Conference Presentation
AIChE Spring Meeting and Global Congress on Process Safety
Monday, March 22, 2010 - 8:00pm
The benefits of using bow-tie diagrams for risk management have been realized by organizations world-wide. They provide a readily understandable...

Fire Study of Melting Fiberglass Using FLUENT CFD Software

Conference Presentation
AIChE Spring Meeting and Global Congress on Process Safety
Sunday, March 21, 2010 - 8:00pm
Thermal insulation is used in chemical plants primarily as a tool to prevent energy loss. However, if installed properly, an added benefit is that of...

Case Histories and Lessons Learned

Conference Presentation
AIChE Spring Meeting and Global Congress on Process Safety
Wednesday, April 29, 2009 - 9:30am
Reviews of process safety incidents and near misses provide valuable learning opportunities. Papers dealing with incidents, near misses, and the...

Fire, Explosion, & Quantitative Analysis

Conference Presentation
AIChE Spring Meeting and Global Congress on Process Safety
Tuesday, April 28, 2009 - 11:30am
Fires and explosions result in the largest losses in process safety accidents. The increased sensitivity by industry, regulatory, and public sectors...

Process Safety - From the Top-Down and Bottom-up

Conference Presentation
AIChE Spring Meeting and Global Congress on Process Safety
Tuesday, April 28, 2009 - 9:30am
The theme of this session is implementing Process Safety systems from two different perspectives: (1) what Senior Management needs from process...

Implementing PSM Globally

Conference Presentation
AIChE Spring Meeting and Global Congress on Process Safety
Monday, April 27, 2009 - 9:30am
In the last several years there have been numerous changes in technical and analytical methods, process safety management systems, regulations,...

Applications of Lopa (Layer Of Protection Analysis)

Conference Presentation
AIChE Spring Meeting and Global Congress on Process Safety
Monday, April 27, 2009 - 6:00am
Layer of Protection Analysis (LOPA) continues to be a powerful and popular tool for assessing risk. This session presents papers focusing on applied...

A Century of Process Safety: Process Safety at OSHA

Conference Presentation
AIChE Annual Meeting
Monday, November 17, 2008 - 12:00pm-12:30pm
This presentation will provide a brief history of OSHA's efforts in process safety management. It will include discussion of the PSM standard and...

Process Safety Beacon: Hydrate Hazards

January
2016
Process Safety Beacon
Water can be a hazard in process plants. When water is mixed with some materials, typically gases but also liquids, it can form a crystaline, ice-like solid. This solid is called a hydrate. When a hydrate forms, it can plug piping, instrument connections, valves, and other equipment, which causes process upsets that may be hazardous. Hydrogen sulfide, acetylene, methyl mercaptan, chlorine, vinyl fluoride, carbon dioxide, ethylene, methane, ethane, natural gas, and other hydrocarbon gases can form hydrates.

Process Safety Beacon: Overflowing Tanks

February
2016
Process Safety Beacon
Although the operations in your storage tank farm may not seem to be very complex, they may actually be more complicated than you think. There may be many interconnections between tanks. You may have to put material in tanks that are already...

Process Safety Beacon: Safety Devices Used as Control Devices

March
2016
Process Safety Beacon
A volunteer at a vintage railroad tourist attraction describes how he prepares a steam locomotive for operation by building up the fire to warm the firebox and increasing the boiler pressure. He explains that he knows that the locomotive is ready...

Spotlight on Safety: Process Safety Begins in the School Laboratory

February
2016
Spotlight on Safety
Louisa Nara
Resources — money, personnel, raw materials, etc. — are finite, and it is vital we value and protect them. Perhaps our most precious resource is the youth who are poised to pursue careers in chemical engineering, where they will take up the mantle...

过程安全事故解析

September, 2015
全书主要介绍化工过程安全管理知识,并基于对50余个过程安全事故案例的深入解析,详细介绍过程安全事故发生的机理、结果、教训及预防事故的经验,以帮助化工领域相关管理人员和操作人员提高安全意识和技能,促进安全生产的实现。

事例に学ぶ化学プロセス安全 Beacon の教訓と事故防止の知恵

March, 2015
本書は、米国CCPS(AIChE)が毎月発行する、実際に起こった事故や不安全状態を取り上げて化学プロセス安全上の鍵となる教訓などをまとめたProcess Safety Beacon(2006年4月~2014年1月号)の和訳、およびその事例についての解説を一冊に収載したものである。

Cybersecurity for Executives: A Practical Guide

June, 2014
This essential cybersecurity text for executives in all sectors and at all levels provides practical advice that equips executives with the knowledge they need to make the right cybersecurity decisions. In plain language, you’ll learn how to recognize and act on threats to you and your business, along with how to act decisively to mitigate and recover from cyber incidents.

Characterize Reactive Chemicals with Calorimetry

July
2013
Safety
Dr. Daniel A. Crowl, Jason Keith
In designing and operating chemical manufacturing processes, the reactivity of chemicals must be identified to avoid hazards. Calorimetry experiments combined with analytical methods provide a straightforward technique to identify these reactions...

CEP: Spotlight on Safety - Verify, then Act

May
2015
Spotlight on Safety
Louisa Nara
Verify-then-act is a practice and mindset that all engineers and personnel in the chemical process industries (CPI) should adopt. Mixing the wrong chemicals, setting temperatures or pressures outside of safe operating limits, or performing a step out of sequence can result in a range of consequences, from a bad batch or loss of production to a catastrophic incident. However, simply verifying before acting can reduce the risk of these penalties and save time, money, and lives.

Improve Process Safety with Near-Miss Analysis

May
2013
On The Horizon
Ulku Oktem, Ankur Pariyani, Dr. Warren Seider, Masoud Soroush
Valuable information about unsafe conditions resides in the large alarm databases of distributed control systems and emergency shutdown systems. This overlooked and underutilized information can be analyzed to identify process near-misses and determine the probability of serious accidents.

Design an Inherently Safer Plant

January
2012
Special Section
Steven T. Maher, P.E., Kristin D. Norton, P.E., Senem Surmeli
Continue to search for ways to build safety into your process — from conceptual through detailed design, to procurement and construction, and even into operation.

A Root-Cause Approach to PSM Audits

October
2013
Safety
David Heller, David Kahn
Tracing audit findings back to the management system that allowed the failure to occur is an effective way to uncover deficiencies in an organization’s process safety management system. Follow the guidance provided in this article to apply root-cause-based auditing to your facility.

CEP: Spotlight on Safety - Discover Your Personal Process Safety Culture

February
2014
Spotlight on Safety
John Herber
Culture can be defined as a collective group of shared beliefs and values that shape how we act. We think of culture as it relates to the actions and reactions of a group, company, or society. However, it can also characterize an individual — what influences how you make day-to-day decisions or handle various situations. Personal process safety culture can be assessed by observing someone’s (yours or another person’s) response to situations involving a safety violation.

Process Safety: How are you Doing?

May
2008
Safety
Scott Berger, Tim Overton and Scott Berger
Use these metrics to benchmark your company's process safety performance, and to set a course toward continual improvement.

Assess Hazards with Process Flow Failure Modes Analysis

March
2013
Safety
Rosalynn MacGregor
Process flow failure modes (PFFM) analysis is an intuitive, process-flow-directed way to identify potentially hazardous scenarios. Learn how to apply this technique to your process hazard reviews.

Maintain Accurate Process Safety Information

April
2014
Back To Basics
Sandipan Laskar
Accurate process safety information is the cornerstone of effective process safety management. Follow this three-phase approach to create and maintain an effective PSI program.

Navigating NFPA Codes and Standards

May
2012
Safety
Jeremy Lebowitz
Follow the recommendations and how-to Guidance provided by the National Fire Protection Association to safeguard against fires and explosions.

Minimize Electrostatic Hazards During Process Operations

June
2013
Safety
Vahid Ebadat, Ph.D.
Understand the electrostatic hazards of your process so you can limit the accumulation of charge and prevent static discharge in flammable atmospheres. Select the appropriate combination of electrostatic mitigation measures to ensure safety from electrostatic ignition hazards.

Is Your Dust Collection System An Explosion Hazard?

October
2003
Safety
Vahid Ebadat, Ph.D.
The prevalence of dust explosions in dust collection units may be due to the fact that the hazards posed by the powders handled are not fully understood or that explosion preventive and protective control measures are insufficient or absent. This...

Managing Dust Explosion Hazards

August
2009
Safety
Vahid Ebadat, Ph.D.
Companies that handle powders or other particulate solids need to be aware of the potential for fire and explosions, and follow industry best practices, codes and standards to manage the risk.

CEP: Spotlight on Safety - Be Prepared, Be Safe, and Have Fun

August
2014
Spotlight on Safety
Louisa Nara
One of my favorite warm weather activities is kayaking. The river provides a respite away from crowds and electronic distractions. Daily stressors are erased by the warm sun, a light breeze, and the sound of water lapping at my boat. A recent weekend with great weather afforded the perfect opportunity to go out on the river with my husband. Earlier that week, severe storms blew through the area with significant rainfall and flash flooding. This increased the volume of water in the river, so conditions would be perfect for a fast and exciting ride. It also called for a more-mindful approach to safety hazards, like swift currents and debris in the water.

CEP: Spotlight on Safety - Sensing Safety

August
2015
Spotlight on Safety
Louisa Nara
Most of us are fortunate enough to have five working senses — sight, hearing, touch, smell, and taste. We use these personal, internal feedback loops to perceive and understand our surroundings, which makes our senses some of our most valuable and essential safety equipment. Before the advent of optical, vibrational, and auditory sensors, the chemical process industries (CPI) depended on sensory perception to identify operational upsets or changes. Although sensing equipment is now ubiquitous in CPI facilities, we must also use our senses to collect critical safety data, rather than blindly relying on equipment to signal unsafe conditions.

Streamline Your Process Hazard Analysis

January
2013
Safety
Molly R. Myers, Judy Perry
A little creativity during preparation — developing checklists, grouping similar processes, pre-populating worksheets, and considering possible deviations and safeguards before meeting face to face — goes a long way toward improving the efficiency and effectiveness of your PHA efforts.

OSHA's New Chemical NEP: How to Make the Grade and Earn Extra Credit

October
2012
Safety
Heather Forgione, Henry Ozog
The Occupational Safety and Health Administration evaluates chemical facilities’ process safety management systems through a new national emphasis program. Follow these tips to reduce your risk of receiving citations, streamline the inspection process, and pave the way for future excellence.

Process Safety Beacon: Stop! Look! Listen!

December
2015
Process Safety Beacon
Railroad crossings that are not protected by gates or warning lights typically include signs to alert you of the potential for danger. Versions of the sign all have one thing in common — the reminder to stop, look, and listen. Only after stopping...

Select the Best Model for Two-Phase Relief Sizing

May
2001
Safety
Ronald Darby, Ron Darby, Paul R. Meiller, & Jarad R. Stockton
A variety of methods exist for sizing valves, but not all give the best predictions for certain conditions. RonDarby-PaulR.Meiller-JaradR.Stockton-

Avoid Chemical Reactivity Incidents in Warehouses

February
2008
Safety
Scott Berger, Peter Lodal, J. Wayne Chastain, William W. Doerr, Scott Berger and Peter N. Lodal
Use this approach for the initial evaluation of potential reactivity hazards in storage applications.

Use Hydrogen Safely

July
2013
Safety
David Farese, Svetlana Ivanova
Understand the potential dangers associated with handling and storing hydrogen, and take the appropriate precautions to mitigate the risks.

Take the FUN Out of Process Safety

February
2014
Safety
Peter Lodal
Process safety can be approached in many different ways. This article provides an unconventional way of looking at process safety that ties together wide-ranging ideas from seemingly disparate fields.

CEP: Spotlight on Safety - Personal Growth and Lessons Learned from Two Global Tragedies

November
2014
Spotlight on Safety
Louisa Nara
The 30-year anniversaries of two events of significance to the chemical engineering profession, particularly the process safety community, occur in November and December — the PEMEX disaster outside of Mexico City, Mexico, and the Union Carbide Corp. tragedy in Bhopal, India. These two incidents, two-and-a-half weeks apart, molded my professional career and ultimately motivated me to work for the Center for Chemical Process Safety (CCPS) at AIChE, where our mission is to prevent such tragedies from occurring.

Sizing Pressure-Relief Devices

October
2013
Back To Basics
Dr. Daniel A. Crowl, Scott A. Tipler
Although relief devices may never be activated, they must be designed and sized to function correctly every time they are necessary. This article provides an introduction to sizing pressure-relief devices for liquid and vapor service.

AIChE Journal Highlight: A Sustainable Approach to Process Safety

November
2015
Journal Highlight
Process safety engineering involves the use of fundamental engineering knowledge (e.g., thermodynamics, fluid dynamics, and kinetics) to develop and apply measures to prevent, mitigate, and respond to catastrophic incidents. The objective of this...

Spotlight on Safety: Enable Employee Growth and Success

November
2015
Spotlight on Safety
Albert Ness
On a recent talk radio program, Zeynep Ton, the author of the book The Good Jobs Strategy, discussed the defining factors of a good job — fair wages, predictable schedules, and opportunities for growth and success. The last element — opportunities...

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