Process Safety Boot Camp | AIChE

Process Safety Boot Camp

Process Safety Boot Camp is CCPS’ flagship course based on CCPS’ Risk Based Process Safety (RBPS) Management approach, featured in the CCPS book Guidelines for Risk Based Process Safety. The Boot Camp covers the fundamental concepts of process safety, why effective process safety management systems are needed, and why process safety is important as an operating principle, not just as a regulatory requirement. The four pillars and twenty elements that define the RBPS approach are examined, which address design, construction, operations, and maintenance of an industrial process. Participants from the chemical, oil and gas, pharmaceutical, foods, metals, mining and other industries will gain the knowledge to improve process safety management practices and build and operate more effective process safety management systems that will fit your company’s needs and resources.   

Compliance is not enough. CCPS’ RBPS Approach exceeds regulatory requirements and focuses on the risk that is associated with each operation in order to, protect people, property, and the environment.

This highly interactive, fast-paced course is taught by two process safety experts, each with 25+ years’ experience.  Lecture, videos, case studies, discussion, and breakout sessions are featured. An incident (or example) is included with most elements to emphasize the importance of that element and the potential consequences of lacking or inadequate definition or implementation. For selected elements, a workshop, exercise, or discussion follows for participants to analyze the concepts presented and participate in group discussions to facilitate information sharing, understanding, and application of the materials.  

Pillars and Elements include:



1.   Commit to process safety

  • Process Safety Culture
  • Compliance with Standards
  • Process Safety Competency
  • Workforce Involvement
  • Stakeholder Outreach

2.   Understand hazards and risk

  • Process Knowledge Management
  • Hazard Identification and Risk Analysis

 3.   Manage risk

  • Operating Procedures
  • Safe Work Practices
  • Asset Integrity and Reliability
  • Contractor Management
  • Training and Performance Assurance
  • Management of Change
  • Operational Readiness
  • Conduct of Operations
  • Emergency Management

  4.   Learn from experience

  • Incident Investigation
  • Measurement and Metrics
  • Auditing
  • Management Review and Continuous Improvement

View a timed course outline and learning outcomes in the tabs below.

See Process Safety Boot Camp in the News!

Interested in taking this course outside of North America?

Please register for the Foundations of Process Safety course.

This course will be taught by one of the instructors listed below.

Learning Outcomes:

  • Understand the four pillars and 20 different elements of risk based process safety.

  • Understand the different types of process hazard analysis techniques including an introduction to HAZOP.

  • Describe how process safety management should be used in coordination with process design and plant operations.

  • Understand OSHA's and the EPA's regulations impact on process safety.

  • Explain the importance of inherently safer processes during plant design along with risk analysis and management.

  • Analyze the concept of layers of protection to prevent and/or mitigate loss of containment events.

  • Discuss the principles of Risk Analysis and Risk Management.

 



 

Who Should Attend:

Technical staff in the process industries, pipeline industries, utility companies, and engineering service companies who need to move beyond an understanding of personal safety and learn the basics of Process Safety and Process Safety Management, including:

  • Chemical Engineers
  • Process Design Engineers
  • Manufacturing Engineers
  • Chemists
  • Mechanical and Reliability Engineers
  • Instrumentation/Automation Engineers
  • Shift Supervisors
  • Lead Operators
  • EHS Specialists
  • Managers who wish to gain a more comprehensive understanding of best risk based management system practices

Day One

7:30 – 8:00

Registration

8:00 – 8:15

Welcoming Remarks

8:15 – 11:30

  • Introduction to Process Safety
  • Key Concepts and Anatomy of an Incident
  • Loss of Containment (and Prevention/Mitigation)

11:30 – 12:30

Lunch Break

12:30 – 5:00

  • Management Systems for Process Safety – a Risk-Based Approach

FI​RST FOUNDATION BLOCK – COMMIT TO PROCESS SAFETY

  • Element 1: Process Safety Culture
  • Element 2: Compliance with Standards
  • Element 3: Process Safety Competency
  • Element 4: Workforce Involvement
  • Element 5: Stakeholder Outreach

Day Two

8:00 – 11:30

FIRST FOUNDATION BLOCK--COMMIT TO PROCESS SAFETY (continued) 

  • Human Factors 
  • Element 6: Process Safety Knowledge Management
    • Inherent Hazards of Chemicals
    • Flammability & Combustibility
    • Chemical Reactivity Hazards
    • Toxicity
    • Corrosivity

11:30 – 12:30

Lunch Break

12:30 – 5:00

  • Element 6: Process Safety Knowledge Management (continued)
    • Process Plant Design Considerations
    • Inherently Safer Design Concepts
    • Layout & Spacing
    • Overpressure & Vacuum
    • Fire Prevention & Mitigation
    • Hazardous Area Classification
    • Static Electricity, Grounding, Bonding, and Inerting
    • Flame & Detonation Arrest
    • Fireproofing, Firewalls, and Emergency Isolation

SECOND FOUNDATION BLOCK – UNDERSTANDING HAZARDS & RISKS 

  • Element 7: Hazard Identification and Risk Analysis (HIRA) 
    • Hazard Identification

Day Three

8:00 – 11:30

  • Element 7: Hazard Identification and Risk Analysis (HIRA) (continued)
    • Analyzing Potential Consequences & Impacts
    • Estimating Probability
    • Risk Analysis, Risk Assessment, and Risk Tolerance

THIRD FOUNDATION BLOCK – MANAGE RISK

  • Element 8: Operating Procedures

11:30 – 12:30

Lunch Break

12:30 – 5:00

  • Element 9: Safe Work Practices
  • Element 10: Asset Integrity and Reliability
  • Element 11: Contractor Management
  • Element 12. Training and Performance Assurance

Day Four

8:00 – 11:30

THIRD FOUNDATION BLOCK—MANAGE RISK (continued)

  • Element 13: Management of Change
  • Element 14 Operational Readiness
  • Element 15: Conduct of Operations
  • Element 16: Emergency Management

11:30 – 12:30

Lunch Break

12:30 – 5:00

FOURTH FOUNDATION BLOCK—LEARN FROM EXPERIENCE

  • Element 17: Incident Investigation
  • Element 18: Measures and Metrics
  • Element 19: Auditing
  • Element 20: Management Reviews and Continuous Improvement

Please email questions to academy@aiche.org .

Login Times Before Virtual Class Sessions Begin:

  • Day 1:  Login at 9:00 AM Eastern time zone USA for testing connection and short review of features of virtual classroom controls/features before class start at 9:15 AM Eastern time
  • Days 2 through 5:  Login at 9:10 AM Eastern time zone USA to verify or resolve any connection issues before class start at 9:15 AM Eastern time.

Virtual Classroom Schedule:

  • Daily Class Starting Time-- 9:15  AM Eastern Time USA class each session
  • 10-minute break typically between 10:30 and 11:00 AM Eastern time zone USA
  • 30-minute break from ~ noon to 12:30 PM Eastern time zone USA
  • Two 10-minute breaks in afternoon
  • Daily Class Ending Time-- 5:30 PM Eastern time zone USA class for Days 1 through 4 and by ~ 4PM on Day 5

Note: Sessions 1 through 5 focus on the first two Foundation Stones of RBPS:

  • Commit to Process Safety (Elements 1-5)--Culture, Compliance with Standards, Competencies,  Workforce Involvement & Stakeholder Outreach

Understanding Hazards and Risk (Elements 6-7)—Process Knowledge Management & Hazard Identification & Risk Analysis (HIRA)

Session Agenda Topics
1
  • Course Overview-Purpose/Objectives/Format/Key Themes
  • Overview of the RBPS Mgt. System 4 Foundation Stones and 20 Elements

COMMIT TO PROCESS SAFETY

  • Competencies (Element 3): Purpose/Scope/Principles
  • Basic Process Safety Concepts
    • Primary Loss of Containment (LOC) & Common Causes
    • Possible Knock-on Effects after LOC

Session 1 Quiz

2
  • Basic Process Safety Concepts (continued)
    • Incident Sequence
    • Need for Multiple Layers of Protection & Types of Barriers/Safeguards
    • Basic Process Control System and Safety Instrumented Systems

UNDERSTAND HAZARDS AND RISK

  • Process Knowledge Management Overview (Element 6): Purpose/Scope/Principles
  • Hazard Identification & Risk Analysis (HIRA) Overview (Element 7):
    • Basic Risk Concepts
    • Risk Assessment/Analysis Overview
    • Risk Matrices and Risk Tolerance Criteria
  • Basic Process Safety Concepts (continued)
    • Inherently Safer Design Concepts & Practices

Session 2 Quiz

3
  • HIRA (Element 7-continued):
    • HIRA Methods/Tools for Hazard ID

COMMIT TO PROCESS SAFETY (continued)

  • Compliance with Standards (Element 2): Purpose/Scope/Principles

UNDERSTAND HAZARDS AND RISK (continued)

  • Basic Process Safety Concepts (completed)
    • Understand Safeguards for Overpressure / Vacuum Protection
    • Process Hazard Analysis exercise
  • HIRA (Element 7-continued)
    • Design Engineers’ Responsibilities & Use of HIRA Methods Throughout Process Lifecycle

Session 3 Quiz

4

COMMIT TO PROCESS SAFETY

  • Culture (Element 1): Importance & Key Principles

Two Process Safety Culture Moments

  • Workforce Involvement (Element 4): Purpose/Scope/Principles

Two Process Safety Culture Moments

  • Stakeholder Outreach (Element 5): Purpose/Scope/Principles

Understand Hazards & Risk (Elements 6 & 7 continued):

  • Know Flammability & Combustion Characteristics of Materials

A Process Safety Culture Moment

Understand Hazards & Risk (Elements 6 & 7 continued):

  • Quantitative Consequence Analysis (focused on fires & explosions)

Session 4 Quiz

5

Understand Hazards & Risk (Elements 6 & 7 continued):

  • Integrated Strategies for Fire / Explosion Prevention & Mitigation
  • Asphyxiant Gas Use Hazards

A Process Safety Culture Moment

Understand Hazards & Risk (Elements 6 & 7 continued):

  • Know Chemical Reactivity Hazards
  • Know Toxicity of Materials

A Process Safety Culture Moment

Understand Hazards & Risk (Elements 6 & 7 continued):

  • Quantitative Probability & Risk Analysis

Session 5 Quiz

 

Note: Sessions 6 through 8 focus on Human Factors and the last two Foundation Stones of RBPS:

  • MANAGE RISK (Elements 8 - 16)—Operating Procedures, Safe Work Practices, Asset Integrity & Reliability, Contractor Management, Training & Performance Assurance, Management of Change, Operational Readiness, Conduct of Operations, & Emergency Mgt.

LEARN FROM EXPERIENCE (Element 17 -20)—Incident Investigation, Measurement & Metrics, Auditing & Management Review & Continuous Improvement

6

Understand Hazards and Risk  (Elements 6 & 7 completed):

  • Know Corrosivity of Materials (Also Know Degradation Mechanisms for Non-Metallic Materials!)
  • Human Factors / Human Error

A Process Safety Culture Moment

MANAGE RISK

  • Operating Procedures (Element 8):  Purpose/Scope/Principles
  • Safe Work Practices (Element 9): Purpose/Scope/Principles
  • Asset Integrity & Reliability (Element 10): Purpose/Scope/Principles
  • Contractor Management (Element 11): Purpose/Scope/Principles

Session 6 Quiz

7

MANAGE RISK (continued)

  • Training & Performance Assurance (Element 12): Purpose/Scope/Principles
  • Management of Change (Element 13): Purpose/Scope/Principles
  • Operational Readiness (Element 14): Purpose/Scope/Principles

A Process Safety Culture Moment

MANAGE RISK (continued)

  • Emergency Management (Element 16): Purpose/Scope/Principles

LEARN FROM EXPERIENCE

  • Incident Investigation (Element 17): Purpose/Scope/Principles

Session 7 Quiz

8

LEARN FROM EXPERIENCE (continued)

  • Measurement & Metrics (Element 18): Purpose/Scope/Principles

A Process Safety Culture Moment

LEARN FROM EXPERIENCE (completed)

  • Audits (Element 19): Purpose/Scope/Principles
  • Management Review & Continuous Improvement (Element 20): Purpose/Scope/Principles

MANAGE RISK (completed)

  • Conduct of Operations (Element 15)

CAPSTONE GROUP EXERCISE

Session 8 Quiz

Course Closing Comments and Online Course Evaluation by Attendees

Day One

7:30 – 8:00

Registration

8:00 – 8:15

Welcoming Remarks

8:15 – 11:30

  • Introduction to Process Safety
  • Key Concepts and Anatomy of an Incident
  • Loss of Containment (and Prevention/Mitigation)

11:30 – 12:30

Lunch Break

12:30 – 5:00

  • Management Systems for Process Safety – a Risk-Based Approach

FI​RST FOUNDATION BLOCK – COMMIT TO PROCESS SAFETY

  • Element 1: Process Safety Culture
  • Element 2: Compliance with Standards
  • Element 3: Process Safety Competency
  • Element 4: Workforce Involvement
  • Element 5: Stakeholder Outreach

Day Two

8:00 – 11:30

FIRST FOUNDATION BLOCK--COMMIT TO PROCESS SAFETY (continued) 

  • Human Factors 
  • Element 6: Process Safety Knowledge Management
    • Inherent Hazards of Chemicals
    • Flammability & Combustibility
    • Chemical Reactivity Hazards
    • Toxicity
    • Corrosivity

11:30 – 12:30

Lunch Break

12:30 – 5:00

  • Element 6: Process Safety Knowledge Management (continued)
    • Process Plant Design Considerations
    • Inherently Safer Design Concepts
    • Layout & Spacing
    • Overpressure & Vacuum
    • Fire Prevention & Mitigation
    • Hazardous Area Classification
    • Static Electricity, Grounding, Bonding, and Inerting
    • Flame & Detonation Arrest
    • Fireproofing, Firewalls, and Emergency Isolation

SECOND FOUNDATION BLOCK – UNDERSTANDING HAZARDS & RISKS 

  • Element 7: Hazard Identification and Risk Analysis (HIRA) 
    • Hazard Identification

Day Three

8:00 – 11:30

  • Element 7: Hazard Identification and Risk Analysis (HIRA) (continued)
    • Analyzing Potential Consequences & Impacts
    • Estimating Probability
    • Risk Analysis, Risk Assessment, and Risk Tolerance

THIRD FOUNDATION BLOCK – MANAGE RISK

  • Element 8: Operating Procedures

11:30 – 12:30

Lunch Break

12:30 – 5:00

  • Element 9: Safe Work Practices
  • Element 10: Asset Integrity and Reliability
  • Element 11: Contractor Management
  • Element 12. Training and Performance Assurance

Day Four

8:00 – 11:30

THIRD FOUNDATION BLOCK—MANAGE RISK (continued)

  • Element 13: Management of Change
  • Element 14 Operational Readiness
  • Element 15: Conduct of Operations
  • Element 16: Emergency Management

11:30 – 12:30

Lunch Break

12:30 – 5:00

FOURTH FOUNDATION BLOCK—LEARN FROM EXPERIENCE

  • Element 17: Incident Investigation
  • Element 18: Measures and Metrics
  • Element 19: Auditing
  • Element 20: Management Reviews and Continuous Improvement

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  • Course ID:
    CH900
  • Source:
    CCPS - Center for Chemical Process Safety
  • Language:
    English
  • Skill Level:
    Basic
  • Duration:
    4 days
  • CEUs:
    3.20
  • PDHs:
    32.00
  • Accrediting Agencies:
    Florida
    New Jersey
    New York
    RCEP