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A pre-startup safety review (PSSR) is the methodical analysis of a facility or operating unit to ensure no hazardous situations occur before operating a facility or plant. This book guides readers to integrate the PSSR throughout the project or turnaround phases of plant operations, with a verification check at the traditional PSSR step.

Management of Change (MOC) is a process for evaluating and controlling adjustments to facility design, operations, organization, or activities-prior to implementation-to make certain that no new hazards are introduced and that the risk of existing hazards to employees, the public, or the environment is not unknowingly increased.

This book contains comprehensive information and methodologies for preparing process equipment for maintenance and, ultimately, return to service. Specifically, this book addresses two phases of equipment handovers, providing information and tools to help personnel at manufacturing sites reduce their risks. The first phase is isolating and preparing equipment for maintenance. The second phase is returning the equipment back to service, applying specified operational readiness plans in addition to a traditional pre-startup safety review (PSSR). Topics include understanding the unique types of hazards personnel might be exposed to, planning for and executing decontamination and de-energization plans, and safely recommissioning the equipment for its return to service. Case studies, examples, and incident investigation discussions provide the reader with invaluable practical learnings that, when applied, help reduce the likelihood of another similar operational incident from occurring at their facility. Topics include understanding the unique types of hazards personnel might be exposed to, planning for and executing decontamination and de-energization plans, and safely recommissioning the equipment for its return to service. Case studies, examples, and incident investigation discussions provide the reader with invaluable practical learnings that, when applied, help reduce the likelihood of another similar operational incident from occurring at their facility.This book contains comprehensive information and methodologies for preparing process equipment for maintenance and, ultimately, return to service. Specifically, this book addresses two phases of equipment handovers, providing information and tools to help personnel at manufacturing sites reduce their risks. The first phase is isolating and preparing equipment for maintenance. The second phase is returning the equipment back to service, applying specified operational readiness plans in addition to a traditional pre-startup safety review (PSSR). Topics include understanding the unique types of hazards personnel might be exposed to, planning for and executing decontamination and de-energization plans, and safely recommissioning the equipment for its return to service. Case studies, examples, and incident investigation discussions provide the reader with invaluable practical learnings that, when applied, help reduce the likelihood of another similar operational incident from occurring at their facility.

The book discusses why management of abnormal situations is important to process safety. The book provides guidance on practical steps to avoid or mitigate an accident or incident before it escalates into a more dangerous and costly issues which can include downtime, lost production, equipment damage, injuries, and external/ environmental damage. Through the use of case studies the book illustrates the impact these deviant occurrences can have on operating facilities.Management principles that can be established before an issue occurs are presented while case studies are used to illustrate the impact that an abnormal situation can have on an operating facility. The impact of plant design are detailed, with separate focus points on new plant design and retrofits to existing plants. A section on writing plant procedures and plant policies so that they incorporate the principles of managing abnormal situations is also included.Training content is provided on how to manage deviant situations, with guidance on presenting the information to specific target populations, such as front-line operators, operations managers, plant engineers, and process safety engineers. Readers are also shown tools that are currently available for recognizing and responding to abnormal situations, and actions that process safety engineers can use during Hazard Identification and Risk Analysis (HIRA).

The chemical process industry is a rich target for cyber attackers who are intent on causing harm. Current risk management techniques are based on the premise that events are initiated by a single failure and the succeeding sequence of events is predictable. A cyberattack on the Safety, Controls, Alarms, and Interlocks (SCAI) undermines this basic assumption. Each facility should have a Cybersecurity Policy, Implementation Plan and Threat Response Plan in place. The response plan should address how to bring the process to a safe state when controls and safety systems are compromised. The emergency response plan should be updated to reflect different actions that may be appropriate in a sabotage situation. IT professionals, even those working at chemical facilities are primarily focused on the risk to business systems. This book contains guidelines for companies on how to improve their process safety performance by applying Risk Based Process Safety (RBPS) concepts and techniques to the problem of cybersecurity.

Process Safety for EngineersFamiliarizes an engineer new to process safety with the concept of process safety managementIn this significantly revised second edition of Process Safety for Engineers: An Introduction, CCPS delivers a comprehensive book showing how Process Safety concepts are used to reduce operational risks. Students, new engineers, and others new to process safety will benefit from this book.In this updated edition, each chapter begins with a detailed incident case study, provides steps that help address issues, and contains problem sets which can be assigned to students.The second edition covers:* Process Safety: including an overview of CCPS' Risk Based Process Safety* Hazards: specifically fire and explosion, reactive chemical, and toxicity* Design considerations for hazard control: including Hazard Identification and Risk Analysis* Management of operational risk: including management of changeIn addition, the book presents how Process Safety performance is monitored and sustained. The associated online resources are linked to the latest online CCPS resources and lectures.

The book makes the case for process safety and provides a brief overviews of the upstream industry and of CCPS Risk Based Process Safety. The majority of the book focuses on the concepts of implementing process safety in wells, onshore, offshore, and projects. Topics include Overview of Upstream Operations; Overview of Risk Based Process Safety (RBPS); Application of RBPS in Drilling, Completions, Work-Overs & Interventions, Application of RBPS in Onshore Production, Application of RBPS in Offshore Production, Application of RBPS to Engineering Design, Installation, and Construction, Future Developments in the Field

GUIDELINES FOR REVALIDATING A PROCESS HAZARD ANALYSISThis book is derived from the experience of many companies in the chemical and hydrocarbon processing industries, and presents demonstrated, concise, and common sense approaches for a resource-effective revalidation of process hazard analyses (PHAs). It includes flowcharts, checklists, and worksheets that provide invaluable assistance to the revalidation process.The new edition, now as a guideline, provides a compete and thorough update of the first book and will provide much needed and requested guidance on PHA Revalidations including evaluating Prior PHA Studies, Identifying an Appropriate Revalidation Methodology, Preparing and Conducting the Revalidation Study Sessions, and Documenting the Revalidation Study.

Human Factors Handbook for Process Plant OperationsProvides clear and simple instructions for integrating Human Factors principles and practices in the design of processes and work tasksHuman Factors, the science of interaction between humans and other elements of a system, draws from disciplines such as psychology, ergonomics, anthropometrics, and physiology to understand how and why people behave and perform as they do--and how best to support them in performing tasks. The goals of the Human Factors approach are to improve human reliability, minimize the risk from human error, and optimize the working environment, human wellbeing, and overall system performance.Human Factors Handbook for Process Plant Operations guides supervisors, managers, and engineers on incorporating Human Factors principles and practices into plant maintenance and operations. With thorough and accessible coverage of all Human Factors topics of relevance to process industries, this easy-to-use handbook uses real-world anecdotes and case studies to demonstrate effective training and learning, task planning, communications, emergency response, risk and error management, and more. Throughout the text, the authors offer valuable insights into why people make mistakes while providing advice on how to help workers perform their process operational tasks successfully.* Explains all essential Human Factors concepts and knowledge with clear descriptions and illustrative examples* Offers actionable advice and models of good practice that can be applied to design, process operations, start-ups and shut-downs, and maintenance* Addresses job aids, equipment design, competence, task support, non-technical skills, working with contractors, and managing change* Discusses how lack of Human Factors considerations during the engineering design phase can adversely affect safety and performance* Describes how to use indicators to both recognize and learn from human error and performance issuesWritten by highly experienced operating and maintenance personnel, Human Factors Handbook for Process Plant Operations is an indispensable resource for everyone involved with defining, planning, training, and managing process operations, maintenance, and emergency response in the food, pharmaceutical, chemical, petroleum, and refining industries.The missions of both the CCPS and EI include developing and disseminating knowledge, skills and good practices to protect people, the environment, and property by bringing the best knowledge and practices to industry, academia, governments and the public around the world through collective wisdom, tools, training and expertise. The CCPS, an industrial technology alliance of the American Institute of Chemical Engineers (AIChE), has been at the forefront of documenting and sharing important process safety risk assessment methodologies for more than 35 years and has published over 100 books in its process safety guidelines and process safety concept book series. The EI's Technical Work Program addresses the depth and breadth of the energy sector from fuels and fuels distribution to health and safety, sustainability and the environment. The EI program provides cost-effective, value-adding knowledge on key current and future international issues affecting those in the energy sector.

New perspectives on how to successfully drive changes in companies' process safety management systemsSimply learning from process safety incidents has proven to be insufficient to drive performance improvements. To truly change, organizations must seek out & embed learnings in their programs & systems. This book picks up from previous CCPS books, Incidents That Define Process Safety and Investigating Process Safety Incidents.This important book:* Offers guidelines for improving process safety performance by embedding the lessons learned from publicly available investigations* Recommends a continuous improvement learning model focused on organizational learning* Provides examples for using the model's techniques to drive ­continuous improvementsContains an index of more than 400 investigated incidents and introduces the concept of Drilldown to help find lessons that might not have been mentioned before.Written for safety professionals and process safety consultants, Driving Continuous Process Safety Improvement from Investigated Incidents is a hands-on guide for adopting a model for successfully driving the learnings from process safety incident investigations.

The definitive leadership guide on safe practices The release of chemicals and other hazardous materials pose significant, potentially catastrophic threats worldwide. An alarming number of such events, all of which are preventable, occur too often. Reducing the frequency of serious incidents is a fundamental responsibility of leadership at all levels, from frontline managers and supervisors to C-suite executives and the board of directors as well. Process Safety Leadership from the Boardroom to the Frontline is a practical, authoritative guide that clearly demonstrates how to create a viable culture of safety within an organization, implement and maintain disciplined management systems, and address the risks of process safety deficiencies. The most important factor in any management system is leadership. For chemical process safety management, effective and informed leadership provides direction, reinforces commitment, and drives responsibility. Written by experts from the Center for Chemical Process Safety, the world's largest provider of engineering curriculum materials for process safety, this pragmatic book contains the critical information and guidelines required to lead and manage process safety. Detailed yet accessible chapters examine topics such as strengthening management system accountability, driving operation within constraints, ensuring corporate memory, verifying execution, and more. Designed to be frequently used, shared, and discussed by leadership teams throughout an organization, this indispensable resource: Demonstrates the many ways process safety benefits an organization, based on benchmarking and broad industrial experience Develops skills and expands knowledge needed to drive consistent, reliable process safety performance Describes essential behaviors and actions for leaders to drive excellence in process safety cultures and disciplined management systems Helps establish risk criteria and safeguards for companies Presents new and previously unpublished experiences, approaches, and thinking Written for executives, plant leaders, functional managers, frontline supervisors and also individual contributors, Process Safety Leadership from the Boardroom to the Frontline provides a much-needed guide for instituting safe practices within a company.

AN ESSENTIAL GUIDE FOR RECOGNIZING AND RESPONDING TO NORMALIZATION OF DEVIANCE TO HELP ORGANIZATIONS IMPROVE THEIR PROCESS SAFETY PERFORMANCE This book provides an introduction to and offers approaches for finding and addressing normalization of deviation both in operational and organizational activities. It addresses the initial and long-term effects of normalization of deviations as seen in reduced efficiencies, reduced product quality, extended batch run time, and near miss process safety incidents which can lead to loss of containment of hazardous materials and energies. Recognizing and Responding to Normalization of Deviance addresses how to recognize and respond to the normalization of deviation that can, and almost certainly will, occur in any ongoing operations that involves humans. The book's primary focus is on reducing the incidence of normalization of deviation and the associated increased risk exposure due to its effects when operating chemical or petrochemical manufacturing facilities. It contains an introduction to the concept and offers approaches for finding and addressing normalization of deviation when it presents itself in both operational and organizational activities. Contains guidance to assist facilities in recognizing and addressing the phenomenon of normalization of deviation Provides techniques for addressing normalized deviations and techniques to eliminate waste in all manufacturing processes Describes methods for identifying normalized deviation as well as where to find deviations Includes techniques to reduce operational normalization of deviance and to reduce organizational normalization of deviance Aimed at process safety professionals and consultants applying process safety risk reduction efforts in manufacturing areas, Recognizing and Responding to Normalization of Devianceis an important book for any organization that has seen its process safety performance deteriorate over time. The Center for Chemical Process Safety (CCPS) was founded in 1985 to develop technology and management practices that mitigate or eliminate chemical and petrochemical industry process safety incidents. Since that time, CCPS has published more than 100 books and held dozens of international conferences, each representing the most advanced thinking in process safety. CCPS is supported by the contributions and voluntary participation of more than 200 companies globally. CCPS is also the world's largest provider of undergraduate engineering curriculum materials through its Safety and Chemical Engineering Education (SAChE) program, with more than 160 universities around the world participating.

Prevent operational incidents and reduce risks with an essential CCPS guideYou can help your company reduce its operating risks by learning how to effectively manage transient operations and avoid major incidents. Startups and shutdowns, known as transient operations, can be high-risk periods for manufacturing facilities. Guidelines for Process Safety During Transient Operations offers useful guidance in preparing for the safe startup and shutdown of chemical processes. With an understanding of the risks involved, you can work proactively to prevent fatalities, serious injuries, reduced productivity, and costly damage.This essential guide for plants provides clear examples of how to anticipate and avoid major issues. The book examines safe shutdown procedures in the event of an emergency. You will also gain direction on how to resume operations safely after an unexpected shutdown. The book supports anyone tasked with regulating and overseeing chemical plants and procedures, whether you are an engineer, manager, or government professional.* Minimize operating risks through the effective management of transient operations* Establish safe start-up and shutdown procedures for chemical processes* Be ready to safely shut down processes in the event of an emergency* Learn from real world examples of start-up or shutdown incidents* Review procedures and engineering controls that help prevent or reduce the effects of incidents involving transient operationsGuidelines for Process Safety comes to you from The Center for Chemical Process Safety (CCPS), which offers advanced thinking in the critical area of process safety. The organization develops technology and management practices for companies seeking to reduce hazards within the chemical and petrochemical industries.

Since the publication of the second edition several United States jurisdictions have mandated consideration of inherently safer design for certain facilities. Notable examples are the inherently safer technology (IST) review requirement in the New Jersey Toxic Chemical Prevention Act (TCPA), and the Inherently Safer Systems Analysis (ISSA) required by the Contra Costa County (California) Industrial Safety Ordinance. More recently, similar requirements have been proposed at the U.S. Federal level in the pending EPA Risk Management Plan (RMP) revisions. Since the concept of inherently safer design applies globally, with its origins in the United Kingdom, the book will apply globally.The new edition builds on the same philosophy as the first two editions, but further clarifies the concept with recent research, practitioner observations, added examples and industry methods, and discussions of security and regulatory issues. Inherently Safer Chemical Processes presents a holistic approach to making the development, manufacture, and use of chemicals safer. The main goal of this book is to help guide the future state of chemical process evolution by illustrating and emphasizing the merits of integrating inherently safer design process-related research, development, and design into a comprehensive process that balances safety, capital, and environmental concerns throughout the life cycle of the process.It discusses strategies of how to: substitute more benign chemicals at the development stage, minimize risk in the transportation of chemicals, use safer processing methods at the manufacturing stage, and decommission a manufacturing plant so that what is left behind does not endanger the public or environment.

AN AUTHORITATIVE GUIDE THAT EXPLAINS THE EFFECTIVENESS AND IMPLEMENTATION OF BOW TIE ANALYSIS, A QUALITATIVE RISK ASSESSMENT AND BARRIER MANAGEMENT METHODOLOGY From a collaborative effort of the Center for Chemical Process Safety (CCPS) and the Energy Institute (EI) comes an invaluable book that puts the focus on a specific qualitative risk management methodology - bow tie barrier analysis. The book contains practical advice for conducting an effective bow tie analysis and offers guidance for creating bow tie diagrams for process safety and risk management. Bow Ties in Risk Management clearly shows how bow tie analysis and diagrams fit into an overall process safety and risk management framework. Implementing the methods outlined in this book will improve the quality of bow tie analysis and bow tie diagrams across an organization and the industry. This important guide: Explains the proven concept of bow tie barrier analysis for the preventing and mitigation of incident pathways, especially related to major accidents Shows how to avoid common pitfalls and is filled with real-world examples Explains the practical application of the bow tie method throughout an organization Reveals how to treat human and organizational factors in a sound and practical manner Includes additional material available online Although this book is written primarily for anyone involved with or responsible for managing process safety risks, this book is applicable to anyone using bow tie risk management practices in other safety and environmental or Enterprise Risk Management applications. It is designed for a wide audience, from beginners with little to no background in barrier management, to experienced professionals who may already be familiar with bow ties, their elements, the methodology, and their relation to risk management. The missions of both the CCPS and EI include developing and disseminating knowledge, skills, and good practices to protect people, property and the environment by bringing the best knowledge and practices to industry, academia, governments and the public around the world through collective wisdom, tools, training and expertise. The CCPS has been at the forefront of documenting and sharing important process safety risk assessment methodologies for more than 30 years. The EI's Technical Work Program addresses the depth and breadth of the energy sector, from fuels and fuels distribution to health and safety, sustainability and the environment. The EI program provides cost-effective, value-adding knowledge on key current and future international issues affecting those in the energy sector.

This book provides a comprehensive treatment of investing chemical processing incidents. It presents on-the-job information, techniques, and examples that support successful investigations. Issues related to identification and classification of incidents (including near misses), notifications and initial response, assignment of an investigation team, preservation and control of an incident scene, collecting and documenting evidence, interviewing witnesses, determining what happened, identifying root causes, developing recommendations, effectively implementing recommendation, communicating investigation findings, and improving the investigation process are addressed in the third edition. While the focus of the book is investigating process safety incidents the methodologies, tools, and techniques described can also be applied when investigating other types of events such as reliability, quality, occupational health, and safety incidents.

Examines the concept of aging process facilities and infrastructure in high hazard industries and highlights options for dealing with the problem while addressing safety issuesThis book explores the many ways in which process facilities, equipment, and infrastructure might deteriorate upon continuous exposure to operating and climatic conditions. It covers the functional and physical failure modes for various categories of equipment and discusses the many warning signs of deterioration. Dealing with Aging Process Facilities and Infrastructure also explains how to deal with equipment that may not be safe to operate. The book describes a risk-based strategy in which plant leaders and supervisors can make more informed decisions on aging situations and then communicate them to upper management effectively. Additionally, it discusses the dismantling and safe removal of facilities that are approaching their intended lifecycle or have passed it altogether.Filled with numerous case studies featuring photographs to illustrate the positive and negative experiences of others who have dealt with aging facilities, Dealing with Aging Process Facilities and Infrastructure covers the causes of equipment failures due to aging and their consequences; plant management commitment and responsibility; inspection and maintenance practices for managing life cycle; specific aging asset integrity management practices; and more.* Describes symptoms and causal mechanisms of aging in various categories of process equipment* Presents key considerations for making informed risk-based decisions regarding the repair or replacement of aging process facilities and infrastructure* Discusses practices for managing process facility and infrastructure life cycle* Includes examples and case histories of failures related to agingDealing with Aging Process Facilities and Infrastructure is an important book for industrial practitioners who are often faced with the challenge of managing process facilities and infrastructure as they approach the end of their useful lifecycle.

Providing in-depth guidance on how to design and rate emergency pressure relief systems, Guidelines for Pressure Relief and Effluent Handling Systems incorporates the current best designs from the Design Institute for Emergency Relief Systems as well as American Petroleum Institute (API) standards.

This book provides an overview for understanding an organization s working culture and provides guidance on why a good culture is essential for safe, cost-effective, and high quality operations.

This book describes how to conduct Process Hazard Assessments (PHAs) for processes handling combustible solids. The book explains how to do a dust hazard assessment by using either an approach based on compliance with existing consensus standards, or by using a risk based approach.

This book is an update and expansion of topics covered in Guidelines for Mechanical Integrity Systems (2006). The new book is consistent with Risk-Based Process Safety and Life Cycle approaches and includes details on failure modes and mechanisms. Also, example testing an inspection programs is included for various types of equipment and systems. Guidance and examples are provided for selecting and maintaining critical safety systems.

This book provides guidance on what can be done from a management systems perspective to identify hazards and manage risks of loss of containment events in chemical laboratories and pilot plants.

There is much industry guidance on implementing engineering projects and a similar amount of guidance on Process Safety Management (PSM). However, there is a gap in transferring the key deliverables from the engineering group to the operations group, where PSM is implemented. This book provides the engineering and process safety deliverables for each project phase along with the impacts to the project budget, timeline and the safety and operability of the delivered equipment.

This book combines the synergies between performance improvement systems to help ensure safe and reliable operations, streamline procedures and cross-system auditing, and supporting regulatory and corporate compliance requirements.

This book presents a guidance on a large range of decision aids for risk analysts and decision makers in industry so that vital decisions can be made in a more consistent, logical, and rigorous manner. It provide good industry practices on how risk decision making is conducted in the chemical industry from many risk information sources as well as all the elements that need to be addressed to ensure good decisions are being made. Topics Include: Identifying Risk Decisions, A Risk Decision Strategy for Process Safety, Case Studies in Risk Decision Making Failures, Guidance on Selecting Decision Aids, Templates for Decision Making in Risk-Based Process Safety, Understanding Process Hazards & Worst Possible Consequences, Management of Change as an Exercise in Risk Identification, Inherently Safer Design as an Exercise in Risk Tradeoff Analysis, Using LOPA and Risk Matrices in Risk Decisions, Using CPQRA and Safety Risk Criteria in Risk Decisions, Group Decision Making, Avoiding Decision Traps, Documentation of Process Safety Risk Decisions

This Guideline presents the framework of process safety knowledge and expertise versus the desired competency level in a super-matrix format, vertically and diagonally.

Complemented by an estimating tool spreadsheet based on a fixed set of chemicals to assist in risk estimations, Probability of Ignition of a Released Flammable Mass converts a "best guess" to a calculated value based on available information and current technology.

Over the years, companies have developed independent systems for managing process safety, environment, health, safety, and quality. Many aspects of these management systems are similar. Integrating EHS management systems can yield economies and improved system effectiveness. This book explains how integration reduces cost of delivery through a reduction in the number of management program steps and avoidance of redundancy; how it results in more effective programs, since the best practices can be combined into a single process; and how this integration brings a faster, and more cost effective response to new demands.