Books by CCPS (Center for Chemical Process Safety)

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.

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.

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.

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.

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.

This book provides designers and operators of chemical process facilities with a general philosophy and approach to safe automation, including independent layers of safety.

The 2nd edition provides an update of information since the publication of the first edition including best practices for managing process safety developed by industry as well as incorporate the additional process safety elements. In addition the book includes a focus on maintaining and improving a Process Safety Management (PSM) System.

An understanding of organizational change management (OCM) an often overlooked subject is essential for successful corporate decision making with little adverse effect on the health and safety of employees or the surrounding community.

This book helps advance process safety in a key area of interest. Currently, no literature exists which is solely dedicated to process safety for the bioprocessing industry. There are texts, guidelines, and standards on biosafety at the laboratory level and for industrial hygiene, but no guidelines for large-scale production facilities.

This guide provides an overview of methods for estimating the characteristics of vapor cloud explosions, flash fires, and boiling-liquid-expanding-vapor explosions (BLEVEs) for practicing engineers.

A comprehensive understanding of the potential dangers inherent in warehousing chemicals is the first step in managing the associated risks. Written by industry professionals for warehouse operators, designers, and all who are concerned with the safe warehousing of chemicals, this book offers a performance-based approach to such hazards as health effects, environmental pollution, fire, and explosion, and presents practical means to minimize the risk of these hazards to employees, the surrounding population, the environment, property, and business operations. These basic precepts can be used to evaluate the risks in initial or existing designs for warehousing facilities on a manufacturing site, for freestanding offsite buildings, and for strictly chemical or mixed-use storage. Each of the book's ten chapters has a list of references and suggestions for further reading. The numerous topics covered make this book invaluable for warehousing designers and operators.

Siting of permanent and temporary buildings in process areas requires careful consideration of potential effects of explosions and fires arising from accidental release of flammable materials.

This book discusses the fundamental skills, techniques, and tools of auditing, and the characteristics of a good process safety management system. A variety of approaches are given so the reader can select the best methodology for a given audit.