Professional Documents
Culture Documents
2 0 0 7
PROCESS SAFETY REPORT
Process Safety
Report 2007
CENTER FOR
CHEMICAL PROCESS SAFETY
3 Park Avenue
New York, New York 10016-5991 USA
Tel: 212.591.7319 Fax: 212.591.8883 AIChE is a 501 (c) (3) not-for-profit educational organization.
www.ccpsonline.org Annual member dues contributions to CCPS may be tax-deductible.
E-MAIL: ccps@aiche.org Consult a tax advisor for further information.
In the last few years, though, CCPS leaders have recognized that CCPS
must become more than a US-based organization serving the world;
it must be a global organization.
Scott Berger
CCPS Director
The globalization of CCPS began in 2004 with the publication of the
Process Safety Beacon in numerous languages. In 2006, CCPS made its
global presence physical, running programs and events in Mumbai, In the last few years,
India and Qingdao, China, including training. We are expanding our
activities in China and India to include additional membership and proj-
CCPS leaders have
ect activities, and we continue to seek partners to help CCPS and our recognized that CCPS
process safety culture take root in other regions of the world.
must become more
While the world of CCPS expands, we face new challenges in the field than a US-based
of process safety. The rapid expansion in the pharmaceutical industry,
particularly in biopharmaceuticals, is adding a new dimension to organization serving
process safety, demonstrated by the recent doubling of the number of
pharmaceutical company members of CCPS. While most traditional
the world; it must be a
process safety fundamentals apply, we expect to see our pharmaceuti- global organization.
cal members spawn new and interesting projects in the coming years.
Smaller companies, whether in the US or abroad, present a significant need for additional process safety
resources. CCPS continues to support process safety in smaller companies through its Occupational
Safety & Health Administration (OSHA) Alliance on chemical reactivity hazard management, on-going
recruiting efforts, and participation in meetings of key state chemical industry trade organizations.
In 2006, CCPS also established an online process safety community to facilitate member-to-member
interaction and to put the CCPS experience on our members’ desktops. This new technology, featuring
blogging, bulletin boards, news feeds, and other important tools, will bridge global time zones and make
it easier than ever for smaller companies to participate in CCPS. CCPS sponsors also believe this
investment will engage the increasing number of younger chemical engineers who are assuming
process safety responsibilities.
We thank you for your continued dedication to process safety and for your support of CCPS.
In 2007, CCPS will continue to make process safety resources available online. Our goal is to establish
a single, interactive website that incorporates the full CCPS library and that serves the industry
for most, if not all, process safety needs. The CCPS Web Community can be accessed by going to
www.ccpsonline.org and logging in with your company information.
We invite all employees of CCPS member companies to become active in CCPS and welcome the
opportunity to discuss ways you might become involved.
If your company is not a CCPS member, we encourage you to consider membership. CCPS members
and volunteers are the key to our success.
■ LANGUAGES AVAILABLE:
Arabic, Dutch, English, French, German, Gujarati, Hebrew, Hindi, Italian, Japanese, Korean,
Mandarin, Portuguese, Spanish, Swedish, Thai
■ Guidelines for Management of Change for Process Safety: CCPS has updated guidance
on this cornerstone principle of process safety. Including case studies and real-life examples plus
CD-based support tools, this new book details the methods for measuring, auditing, and improving
the efficiency and effectiveness of process safety.
■ Guidelines for Safe and Reliable Instrumented Protective Systems: This detailed
implementation guide for IEC 61508, IEC 61511, and ISA-84 standards explains the decision-making
and work processes for the management and implementation of instrumented protective systems
(IPS) throughout a project’s life.
■ Process Safety and Risk Management of Chemical Parks: This report, developed in
collaboration with the European Process Safety Centre (EPSC), addresses the challenges inherent
to manufacturing locations where multiple companies operate on sites that were once owned by a
single company. In such situations, disputes over ownership of issues may interfere with resolution,
while cross-company impacts may be missed. The report may be downloaded from either the
EPSC or CCPS website.
■ Guidelines for Performing Effective Pre-Startup Safety Reviews: Start-up remains one of the
highest-risk phases of plant operation. A well-executed pre-startup safety review is critical to maintaining
safety during this period. This new publication will guide engineers through the pre-startup review
process, complete with customizable checklists.
■ Incidents that Define Process Safety: It is critical that the next generation of engineers under-
stands both the “how” and the “why” of process safety. This new publication will use historical
accounts to illustrate critically important aspects of process safety.
■ Guidelines for Hazard Evaluation Procedures, 3rd Edition: This update of the CCPS classic will
showcase lessons learned since the 2nd edition was published in 1992, including new hazard evaluation
procedures and a refinement of the detailed PHA checklists included in the previous two editions.
The 2007 SACHE workshop will again be hosted by Rohm and Haas, Arkema,
and Chilworth Technology.
NEW PROJECTS
CCPS has begun its third decade with new projects that build on its legacy of thoughtful, pacesetting guidelines.
CCPS also continues to apply practical experience to improve and expand many of its signature works.
■ Guidelines for Developing Risk Tolerance Criteria: This project is establishing quantitative safety
risk criteria. The book will show how to develop criteria reflecting company-specific operating needs,
while maintaining consistency with industry-wide practices.
■ Guidelines for Evaluating the Characteristics of Vapor Cloud Explosions,
Flash Fires, and BLEVES, 2nd edition: This project is an update to the classic 1994 CCPS book.
The new edition will include many new technologies and approaches proven over the past 12 years.
■ Guidelines for Pressure Relief and Effluent Handling Systems, 2nd edition: This update is
being written in conjunction with the Design Institute for Emergency Relief Systems (DIERS) and will
include new data gained since original publication.
■ Guidelines for Process Safety Metrics: The
objective of this project is to work with a broad range 2007 INTERNATIONAL
of domestic and international organizations to develop CONFERENCE
a small, common set of process safety metrics to The 22nd CCPS International Conference,
improve monitoring and communication of the success April 23–25, in Houston, Texas, will again be a
and progress of process safety initiatives. cornerstone of the Global Congress on Process
■ Tools to Enhance Hazard Identification: This Safety. The theme of this year’s conference is
project will provide guidance to enhance awareness Case Histories: Advancing Process Safety through
and identification of process safety hazards by front Design and Operations. Sessions will include:
line personnel. The tool will address the general con-
■ Risk Based Process Safety and Risk Tolerance
cept of process safety hazard identification as well as
Criteria
provide for ongoing activity to target awareness in
■ Process Safety Management Systems
more focused areas of process safety.
■ Inherent Safety
■ Non-SIS Independent Protection Layers: This ■ Standards, Codes, and Regulations, and
publication will be a companion to both the CCPS Criteria for Retroactive Implementation
Layers of Protection Analysis (LOPA) concept book ■ Reliability and Process Safety including
and Guidelines for Safe and Reliable Instrumented Mechanical Integrity, Risk-Based Process
Protective Systems. It will address issues such as how Safety and Turnaround Considerations
to ensure the effectiveness and maintain reliability for
Running in conjunction with the AIChE Spring
administrative controls or “inherently safer, passive”
Meeting, the CCPS program will include strong
concepts.
technical papers addressing issues related to
■ Guidelines for Auditing Process Safety design and operations and will explore the most
Management Systems, 2nd edition: This update of current thinking and approaches as demonstrated
the 1992 CCPS book will update the fundamental skills, through case histories and lessons learned.
techniques, and tools of auditing, including integration
into risk-based process safety. For more information on the CCPS Conference,
please go to www.aiche.org/ccps and select
We invite new participants and peer reviewers to join Conferences.
these projects, as well as new projects we launch in 2007.
■ Standards, Codes, (o) Compliance audits .58 Compliance audits Process Safety Management
COMMIT TO
■ Workforce (c) Employee participation .83 Employee participation Process Safety Management
Involvement
■ Process Knowledge (d) Process safety .48 Safety information Process Safety Management
UNDERSTAND
Management information
■ Hazard Identification (e) Process hazard .67 Process hazard Hazard Analysis, Risk Analysis
and Risk Analysis analysis analysis and Reliability; Consequence
Modeling; Chemical Reactivity
Hazards
■ Operating Procedures (f) Operating procedures .52 Operating procedures Process Safety in Operations
.69 Operating procedures
■ Safe Work Practices (k) Hot work permit .85 Hot work permit Process Safety in Operations;
Safe Design; Venting and
Emergency Relief
■ Asset Integrity and (j) Mechanical integrity .73 Mechanical integrity Process Safety in Operations
Reliability
MANAGE RISK
■ Incident Investigation (m) Incident investigation .60 Incident investigation Process Safety Management
.81 Incident investigation
LEARN FROM
EXPERIENCE
■ Auditing (o) Compliance audits .58 Compliance audits Process Safety Management
.79 Compliance audits
.220 Audits
HAZARD ANALYSIS,
CONSEQUENCE CHEMICAL VENTING AND
RISK ANALYSIS, AND
MODELING REACTIVITY HAZARDS EMERGENCY RELIEF
RELIABILITY
Member representatives may serve on project subcommittees to develop content and attend Technical
Steering Committee meetings in which they can participate in project selection, help define areas of
study, and provide overall technical guidance to CCPS activities. CCPS participants join a network of
peers with whom they can confidentially discuss safety concerns and benchmarking programs.
C MANAGE RISK
■ Operating Procedures
■ Safe Work Practices
■ Asset Integrity and Reliability
■ Contractor Management
■ Training and Performance Assurance
■ Management of Change
■ Operational Readiness D LEARN FROM EXPERIENCE
■ Conduct of Operations
■ Incident Investigation
■ Emergency Management
■ Measurement and Metrics
■ Auditing
■ Management Review and
Continuous Improvement
To see how CCPS products can assist you in addressing these process safety elements,
please see www.aiche.org/ccps/resources.
Members of CCPS include major petroleum, chemical and pharmaceutical companies, as well as other
manufacturers and users of chemicals, engineering contractors, safety consultants, insurance firms and
government agencies. In recent years, CCPS membership has grown to include manufacturers based
outside North America, as well as small specialty manufacturers.
I M P O R TA N T DAT E S F O R 2 0 0 7
EVENT D AT E
David Rosenthal
Rohm and Haas
AIChE Treasurer
John Chen
Lehigh University
AIChE Past President
Amos Avidan
Bechtel
AIChE Director
Deborah Grubbe
BP
AIChE Director
Liese Dallbauman
Pepsico-Qtg
AIChE Director
J. Reed Welker
University of Arkansas
Ronald J. Willey
Northeastern University
Bob Johnson
Unwin Company
Steve Marwitz
Formosa Plastics Corp. (USA)
■ TRANSPORTATION RISK AND SECURITY Michael Moriarty
AKZO Nobel Chemicals, Inc.
This subcommittee is writing a book to provide introductory trans-
port risk considerations for process engineers when determining via- Lisa Morrison
BP
bility of project. The project includes providing guidance on route
selection, equipment factors and materials that may affect public risk Cedric Pereira
as well as guidance on transportation security risk issues and indus- BP
try practices to mitigate them. For more information, contact Brian Glen Peters
Kelly at kellybd@telus.net. Air Products & Chemicals, Inc.
Mike Green
BP
This committee is responsible for the Beacon, a monthly one-page This subcommittee is developing
process safety newsletter for plant operators. For more information, CCPS content and resources in
contact Dennis Hendershot at ccps_beacon@aiche.org. a fully searchable, topic driven
online format. This project also
John Herber (Co-Chair) Jack McCavit includes a process safety blog
3M Company CCPS Emeritus
and bulletin board through
George King (Co-Chair) Bill Olsen which CCPS members can
The Dow Chemical Company Merck & Company, Inc.
interact and have technical
Don Abrahamson Cathy Pincus discussions in real time.
Occidental Chemical Corporation ExxonMobil For more information on this
Dave Cummings Mike Rogers project, contact Robert Coulter
DuPont Company Syncrude Canada, Ltd. at robert@rbcoulter.com.
Frederic Gil Roy Sanders
BP PPG Industries, Inc. Christie Arseneau (Chair)
PPG Industries
Daniel Horowitz Adrian Sepeda
US Chemical Safety Board CCPS/AIChE Don Abrahamson
Henry Ingram John Stoney Occidental Chemical Corporation
Shell Chemical Company Rhodia, Inc. Steve Arendt
Dave Krabacher Tony Thompson ABS Group, Inc
Cognis CCPS Emeritus
Susan Cowher
David Leggett Dan Wiff International Specialty Products
Baker Engineering and Risk Nova Chemical Ltd.
Consultants Chris Devlin
Nico Versloot Celanese
Bill Marshall TNO Initiative for Industrial Safety
Eli Lilly and Company John Herber
3M Company
Mike Marshall
OSHA Greg Keeports
Rohm and Haas Company
Americo Neto
■ INCIDENTS THAT DEFINE PROCESS SAFETY Braskem
Tim Overton
This project is using actual incidents to describe how the various The Dow Chemical Company
components of process safety came into being and to underscore
Karen Person
why they are important. For more information, contact Bob Perry at CCPS/AIChE
BobGPerry@comcast.net.
Pat Ragan
Albert Ness (Chair) Dave Jones Bayer Crop Science
Rohm & Haas Company Chevron Jatin Shah
Habib Amin Christy Franklyn Baker Engineering and Risk
Contra Costa County Health Services Risk Reliability and Safety Consultants
Engineering
Mike Broadribb Steve Sigmon
BP Jack McCavit Honeywell, Inc.
CCPS Emeritus
Paul Butler Karen Tancredi
Buckman Laboratories Jim Slaugh DuPont Company
Basell
Sergio Castro
Servatis Steve Smolen
Solutia, Inc.
Robert Dupree
Basell Nico Versloot
TNO Initiative for Industrial Safety
Dan Isaacson
The Lubrizol Corporation
Bob Lenahan
Bayer Materials Science
Dave Moore
Acutech Consulting
Michael Moriarty
AKZO Nobel Chemicals, Inc.
John Murphy
CCPS Emeritus
Narayanan Sankaran
UOP
John Stoney
Rhodia
Angela Summers
SIS-Tech
Tim Wagner
Scott Berger and Simon The Dow Chemical Company
Xu welcome Mu Shanjun
Joe Wilson
and Li Qi of Sinopec to
Syngenta
their first Technical
Steering Committee
meeting.