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CULT
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2011 Fundamentals for the Future

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 PROCESS SAFETY
REPORT 2011

CCPS MISSION STATEMENT

JUST AFTER MIDNIGHT on December 3, 1984, water contamination of
a tank of methyl isocyanate in Bhopal, India initiated a series of events
CONTENTS
that led to a catastrophic toxic release, killing more than 3,000 residents
and injuring over 100,000.
1 Management Report
In February of 1985, 17 chemical industry leaders asked the American
2 Operations Report Institute of Chemical Engineers (AIChE) to lead a collaborative effort to
eliminate catastrophic process incidents by:
3 Milestones of 2011
■ ADVANCING state-of-the-art process safety technology and
4 Projects and Events management practices
■ SERVING as the premier resource for information on process safety
7 CCPS Membership ■ FOSTERING knowledge of PS by engineers, students, and the public
■ PROMOTING process safety as a key industry value
10 Process Safety at a Glance
On March 23, 1985, AIChE formed the Center for Chemical Process Safety
12 CCPS Organization and by the end of 1985 had enlisted 39 charter member companies. CCPS
Structure and its member companies quickly published CCPS’ first book, Guidelines
for Hazard Evaluation Procedures, and by 1990 more than a dozen books
14 Project Committees had been published along with CCPS’ call to action publication, A
Challenge to Commitment. In these initial publications, CCPS first codified
20 CCPS Staff and 2011 the critical elements of process safety and provided key tools to manage,
Important Dates implement, and continually improve process safety programs. Focused
workshops and annual international conferences provided additional
22 Members opportunities for communal learning and formal discussion regarding
process safety.

Still following this approach 26 years later, CCPS continues to address the
most important process safety needs and encourage an overall culture of
process safety. Over 130 corporate members from around the world now
participate in CCPS, including most of the world’s leading chemical,
petroleum, and pharmaceutical companies. CCPS’ body of work reflects
the great strides made in the area of process safety. CCPS continues to
expand its catalog of over 100 books and products, build on its legacy of
25 successful international conferences, and cultivate its Safety and
Chemical Engineering Education (SAChE) university curriculum program.

CENTER FOR
CHEMICAL PROCESS SAFETY

3 Park Avenue
New York, New York 10016-5991 USA
Tel: (+1) 646.495.1371 Fax: (+1) 646.495.1504
www.ccpsonline.org
E-MAIL: [email protected]

AIChE is a 501 (c) (3) not-for-profit educational

organization. Annual member dues contributions
to CCPS may be tax-deductible. Consult a tax
advisor for further information.

©2011 AIChE 5575 • 01.11

MANAGEMENT
REPORT

26 YEARS AND COUNTING

Last summer I participated in a process safety workshop in India. One of the speakers
concluded his presentation by stressing, “You wouldn’t think about having a meal without rice,
so how could you think about having a plant without Risk Based Process Safety?”

My first thought upon hearing this impassioned conclusion was that CCPS’ efforts to globalize,
while re-energizing process safety improvement efforts via Guidelines for Risk Based Process
Safety (RBPS), were really paying off. An engineer, working in India and not previously
involved in CCPS activities had not only been implementing an RBPS program, but had also
personalized it in a way that would be meaningful in his culture.

However, as I took my Indian milk-tea and went to congratulate him on an

excellent presentation, a deeper realization dawned. This gentleman’s
actual message was, “Process safety is all about getting the basics right.”
In his culture, a meal without rice is not much of meal at all. Likewise, a
plant without process knowledge management, without hazard
identification and risk management, without management of change, or
without any other of the 20 RBPS Elements, well-executed, is that much
less of a plant.

CCPS projects tend to flow in cycles. High level concepts are followed by
technical breakthroughs, which are followed by detailed implementation
guidance. Guidance is followed by experience and improvement, which
is followed by implementation, and then the cycle repeats. As CCPS
approached its 25th anniversary, our focus was on high level concepts SCOTT BERGER
and technical breakthroughs such as globalization, RBPS, process safety CCPS Executive Director
metrics, risk criteria, inherently safer technology, and independent
protection layers. These new contributions are flowing through CCPS’
“Global Community Committed to Process Safety,” and we can expect their
positive impacts to be felt for years to come.

As CCPS ventures into its second 25 years, we now come to the implementation part of the
cycle, of focusing on the fundamentals, with projects on topics such as hazard identification,
conduct of operations, process safety for senior executives, and auditing. Some of these
topics are less exciting than those resulting in breakthroughs. However, they require our
focused attention, because our workers are counting on getting every element of RBPS
correct so they can come home and put rice on the table.

I’d like to thank the hundreds of dedicated volunteers who contributed their expertise and
passion for process safety to CCPS’ efforts in 2010. I am also grateful to CCPS’ 130+ members
for maintaining their loyal support through the past two years, despite recent economic
pressures. You are all living proof that process safety is fundamental.

A D VA N C I N G P R O C E S S S A F E T Y G L O B A L LY 1
 OPERATIONS
REPORT

Focusing on CCPS’ Operating Fundamentals to Help our

Members Focus on Their RBPS Fundamentals
CCPS projects, meetings, and educational efforts support member and broader industry efforts to focus
on the fundamentals of Risk Based Process Safety. What steps has CCPS taken to integrate this goal
into our operations?

Maintaining the unique and distinctive CCPS activities, alongside CCPS’s rapid growth, have required more
robust membership support processes and the establishment of a more comprehensive development system.

To help accomplish this, Lauren Horowitz joined the CCPS staff in 2010 to lead this effort. Lauren, an
experienced non-profit professional, has been upgrading our databases and increasing our membership
support and communication process, as well as improving CCPS communications and development
strategies regarding the mission and value of CCPS.

Along with growth, has come an increased focus for process safety in undergraduate education, which
has placed greater demands on our educational capabilities. To help energize this dimension, Louisa
Nara joined CCPS in 2010, as Technical Director. Louisa oversaw the successful launch of our Process
Safety Boot Camp course, as well as our first e-learning effort Process Safety for Biofuel Plants, and will
continue to support an expanded educational portfolio. Louisa replaces Paul Butler, who retired in early
2010. We thank Paul for his service, both as CCPS Technical Manager for 2 years and as TSC
representative for Buckman Laboratories for many years before that.

Roxy Schneider has also shifted to provide greater support for e-learning activities, including the
Biofuels course, several new CCPS e-learning projects and the SAChE undergrad education initiative
which we are ramping up (see “Value of Process Safety in Undergraduate Education,” page 6).

Internationally, Pronob Mukherjee launched a successful first CCPS India regional meeting. We look
forward to working with our Asian members to hold increasingly frequent regional meetings in India,
Southeast Asia/Australia, and China.

Continued growth and technological changes in the coming years will have a positive effect on the
growth of CCPS. In order to best serve our mission and our members, the fundamentals that built and
drive CCPS will remain the back bone of CCPS as we continue to evolve organizationally. Please let us
know how we’re doing, and how we can improve.

ADVANCING PROCESS SAFETY

During 2010, CCPS continued to add to its large body of process safety knowledge that now includes over
100 books, web tools, software and other products. We completed the following projects in the past year:

■ “A Practical Approach to Hazard Identification for Operations and Maintenance Workers”

■ “Guidelines for Acquisition Evaluation and Post Merger Integration”
■ “Guidelines for Vapor Cloud Explosion, Pressure Vessel Burst, BLEVE and
Flash Fire Hazards, 2nd Edition”
■ “Guidelines for Process Safety in Bioprocess Manufacturing Facilities”
■ “Guidelines for Auditing PSM Systems, 2nd Edition”
■ “Guidelines for Conduct of Operations”

2 2011 CCPS PROCESS SAFETY REPORT

MILESTONES
OF 2010

SAFETY IN UNDERGRADUATE EDUCATION: SACHE MILESTONES

In 2010, CCPS’ Safety in Chemical Engineering Education
(SAChE) program grew dramatically. The SAChE Certificate
program, which creates online tools that allow students to
interactively self-teach process safety material, added a new
module on Dust Explosion Control bringing the total to six
available modules. The number of certificates issued to students
through the program has doubled this year, with over 3,000
certificates issued in 2010 alone. In addition to the new online resources it created, SAChE also ran a
successful Faculty Workshop sponsored by ExxonMobil. Over 20 professors from around the country
attended the workshop in ExxonMobil’s Baytown, TX facility where they spent three days learning about
various topics in process safety from industry experts.

CCPS REGIONAL MEETINGS

The first CCPS India Regional Meeting was held in Mumbai,
India on August 19, 2010. Reliance Industries, Ltd. hosted the
meeting, with their President of Group Manufacturing Services,
V. V. Surya Rau, SHE Head and CCPS Advisory Board
representative Dr. Prasad Tipnis, and TSC representative Ravi
Ramaswamy making presentations. Scott Berger, Executive
Director, CCPS, and Pronob Mukherjee, CCPS Asia-Pacific
Regional Manager, introduced the participants to CCPS and
its work and discussed CCPS projects, training and regional
activities. TSC representative Yogesh Joshi of Hikal Ltd. also
presented. S. Ganeshan, TSC representative of Toyo
Engineering, India shared his experiences of his participation
as a TSC representative. CCPS thanks Reliance Industries Ltd,
for their kind gesture in hosting the meeting. Most importantly, the meeting led to a clear desire for more,
in-depth meetings and the need for an “India organizing committee.”

DEFINING “INHERENTLY SAFER

TECHNOLOGY”
From its origins, CCPS has espoused inherently safer design CHINA SAWS MEETING
as a useful risk management tool, supplementing other risk
CCPS staff and member companies
management tools for designing safe plants. But what is
made presentations relating to
inherently safer design, and how does it differ from
Process Safety Management of
“inherently safer technology (IST)” which has recently been
Hazardous Chemicals at the 5th
highly debated as a regulatory mechanism? Trevor Kletz,
China International Forum on Work
who first coined the term, defined it in terms of a series of
examples and CCPS expanded on these examples, but until Safety (September 2010, Beijing,
2010, no formal definition existed. In the absence of a China), hosted by the State
definition, it was difficult to have an educated public Administration on Worker Safety.
discourse about IST. To advance this discourse, the US
Department of Homeland Security’s Chemical Security
Analysis Center asked CCPS to create a technically sound
and scientifically based definition of Inherently Safer
Technology. To see the full definition please visit,
www.aiche.org/ccps/ist.

Kenan Stevick — Dow

A D VA N C I N G P R O C E S S S A F E T Y G L O B A L LY 3
 PROJECTS
AND EVENTS

Coming Soon
■ Executive Seminars for Process Safety: The issue of executive oversight of process safety
programs has been thrust into the forefront by recent US Chemical Safety Board reports of
significant investigations. Industry executives around the world are requesting information
regarding their role in process safety management. A video of respected industry executives
will explain the importance of process safety in the operation of their facilities and the
commitment it takes to establish and instill a robust process safety culture.

■ Guidelines for Conduct of Operations: The new Conduct of Operations book will outline the
operational discipline needed to execute process safety system requirements correctly –
every time – to avoid incidents and injuries and to achieve high levels of safe performance.
This book does not focus on basic operations and maintenance elements, such as procedures,
training, safe work practices, asset integrity, management of change, and pre-startup safety
review, but rather a management system to help ensure the effectiveness of these and other
PSM systems. It will provide specific guidance on how an effective system can be established
and implemented.

■ Guidelines for Pressure Relief and Effluent Handling, 2nd Edition: Pressure relief systems
have always been important components in the design of safety systems for chemical plants
and refineries. In recent years however, with concern for possible human health effects and
environmental harm, the chemical and petroleum industries have devoted increased attention
to reducing the discharge of hazardous materials from emergency relief devices. This book
was prepared in recognition of the need for guidance in designing emergency relief systems to
minimize or contain the discharge of potentially harmful materials. This second edition book
provides significantly updated content and improved readability.

■ Independent Layers of Protection:

This publication will be a companion
book to the CCPS Layers of Protection
Analysis (LOPA) concept book and
Guidelines for Safe and Reliable
Instrumented Protective Systems.
It will provide process automation
engineers, process engineers, facility
operators, and safety professionals
with the appropriate treatment and
requirements applicable to equipment
design, administrative procedures, or
other “credits” that are treated as an
independent protection layer from a
Layer of Protection Analysis (LOPA)
perspective.

Ongoing Projects
■ Conditional Modifiers and Enabling Events: A short publication is planned, which will provide
information and considerations on developing and using conditional modifiers. It will also provide
similar information on applying enabling event values to hazard analyses.

■ Guidelines for Engineering Design for Process Safety, 2nd Edition: These Guidelines will create
a single, comprehensive reference for engineering design topics as they relate to process safety.
They will provide plant design engineers, facility operators, and safety professionals with key
information on selected topics of interest, many of which are dealt with in other CCPS publications.
The publication will also provide an extensive bibliography to related publications and topic-specific
information, as well as the key information on failure modes and potential design solutions from the
1998 book Guidelines for Design Solutions for Process Failures.

4 2011 CCPS PROCESS SAFETY REPORT

■ Guidelines for Evaluating Process Plant Buildings for External Fires, Explosions, and Toxic
Releases, 2nd Edition: OSHA and the CSB both emphasize the importance of facility siting.
The second edition of this book will address lessons learned from BP Texas City and other recent
incidents on the issue of facility siting, including that of portable buildings. The second edition also
incorporates recent developments relating to facility siting, such as API Recommended Practices
752 and 753, and additional technology developments in the chemical industry.

■ Guidelines for Implementing Process Safety Management Systems, 2nd Edition: The second
edition is an update to the original process safety management system implementation guideline
that recognizes that most companies now have some form of process safety management system,
but a number of companies, especially smaller companies, need a roadmap of how to efficiently and
effectively upgrade their systems.

■ Guidelines for Organizational Change Management:

Many companies continue to struggle with effective implementation of Management of Organizational
Change. This project will culminate in a short book that addresses these issues and will help
companies bring their MOOC systems to the same degree of maturity as other process safety
management systems.

■ Guidelines for Process Safety Knowledge and Expertise: This project will present the framework
of process safety knowledge and expertise versus the desired competency level in a “super-matrix”
format. The guidelines will target multiple audiences, ranging from front-line chemical operators,
mechanics and instrument technicians through senior management, including financial and
business executives. Gaps between existing and desired training levels can then be identified, and
potential remedies suggested. Customization for a specific company will be possible.

■ Hazard Identification for Operators and Maintenance: A CCPS Training Module: Frequently,
front line personnel are not made aware of the full extent of process safety hazards present in their
work environments. This project will determine an optimal format for visual training and produce
DVD/web training to enhance awareness and identification of process safety hazards by front line
personnel. The training sessions are based on the CCPS publication A Practical Approach to Hazard
Identification to strengthen awareness of process safety hazards in front line personnel.

■ Likelihood of Ignition of Released Flammables: This book will be the culmination of a research
project to collect and evaluate the experiences and methodologies of operating companies
on the topic of ignition of released flammables as well as additional published information. This
information is being consolidated to form the foundation for technically calculating
the likelihood/probability that a release
of a flammable material will ignite. With
this capability, industry can better define
risk-based equations and make better
technology-based decisions. This may
be most useful in the task of siting, as it
relates to the protection of people in
buildings. It may also be a valuable tool
for CPQRA and LOPA studies.

A D VA N C I N G P R O C E S S S A F E T Y G L O B A L LY 5
 PROJECTS
AND EVENTS

■ Process Safety Benchmarking:

This study is a first-of-a-kind approach to
benchmarking process safety, which
allows participating companies to
understand the effectiveness of their
process safety management systems
compared to other participating peer
companies. The benchmarks are
conducted on a site basis and look at six
key elements of the CCPS Guideline on
Risk Based Process Safety. The formal
evaluation program began in the fall of
Process Safety Benchmarking Example Results
2010 with about 15 sites participating in
the first round. Results will be provided to the participants in early 2011. A second round of
benchmarking with these elements is planned for 2011 as well as consideration of the remaining Risk
Based Process Safety elements. Interested parties should contact the CCPS office at: [email protected].

■ Process Safety for Front Line Supervisors:

While “top-down” emphasis on process safety and other safety programs is necessary, the
daily “enforcement” is at the operator/technician and supervisor levels. This project will
increase the understanding and buy-in at the front-line supervisory level through better
understanding of PSM, its benefits, and the interactions of the various elements.

■ Recognizing Catastrophic Incident Warning Signs in the Process Industries:

Warning signs or problems are often present prior to many potentially serious process
incidents, but often not recognized in time to provide an appropriate response. This project
has developed guidance for recognizing and responding to early warning signs to avoid
process incidents and injuries. Key areas examined are: Leadership, Discipline and
Organizational Culture; Training and Competency; Process Safety Information; Procedures;
Asset Integrity; Analysis of Risk and Managing Change; Information Learned from Audits;
Lessons Learned from Experience; and Physical Warning Signs.

2011 CCPS Projects

The following projects have been selected by the Technical Steering Committee to begin in early 2011.
Additional projects will be started later in 2011. Contact CCPS for more information, or to volunteer.

Implementing New Process Safety Curriculum Requirements

In 2009, the US Chemical Safety Board recommended that AIChE/CCPS and the Accreditation
Board of Engineering Technology (ABET) revise undergraduate curriculum requirements to include
addressing process hazards. Because CCPS already provides many SAChE curriculum modules and
certificates to universities, the requirement should not be onerous. In fact, these new requirements
can also enhance the overall education experience. The new CCPS initiative, Value of Process
Safety in Undergraduate Education, is aimed at encouraging universities to view process safety as
a core competency, an opportunity to enhance learning and analytical skills, and improve overall
campus safety culture. This project will also provide guidance on how to meet the new ABET
requirement using SAChE and other process safety resources.
To further support the new ABET requirements, CCPS has launched a new project “Student
Handbook for Process Safety.” This project will include the development and evaluation of tools for
application of process safety principles throughout the standard chemical engineering curriculum
in addition to, or as an alternative to, adding a new specific process safety course.
To help with this effort, contact Roxy Schneider at: [email protected].

6 2011 CCPS PROCESS SAFETY REPORT

 Process Safety for the Biofuels Industry:
Free e-learning course now available on-line."Process
Safety Management for the Biofuel Industry" is an
awareness-training course developed by CCPS under a
“Susan Harwood Grant” from OSHA. Its intent is to
increase process safety awareness for employees of com-
panies covered by the Occupation Safety and Health Act,
but is available for all. This e-learning course is available
at no cost through September 30, 2011. Contact Louisa
Nara ([email protected]) for more information or go to
http://www.aiche.org/CCPS/Education/biofuels.aspx
to begin your course.

■ Linking Human Factors and Process Safety Culture:

The objective of this project is to capture industry best practices and deliver practical
guidelines linking Human Factors with Process Safety Culture. The ultimate goal being to drive
down the number/rate of human-error related incidents. In addition, these guidelines can be
used in the development of job aids, procedures, task management tools and other front-line
assistance to reduce human error rate, or provide sufficient opportunities to recover from
human error before escalation of consequences.

■ Share Your Process Safety Moments with Others:

Sharing lessons learned is one of the most powerful
and effective ways of learning from our past and
preventing an undesirable reoccurrence. To facilitate
that sharing, CCPS is creating a library of short
PowerPoint presentations, video clips, podcasts, etc.
that can be used by member companies to impart
knowledge on a broad scale. Join in the sharing to
achieve our ultimate goal of incident prevention.
Send your Process Safety Moments to Dennis
Hendershot at: [email protected].

Those who cannot remember

the past are condemned to
repeat it. – George Santayana

A D VA N C I N G P R O C E S S S A F E T Y G L O B A L LY 7
 CCPS
MEMBERSHIP

Additional Opportunities for CCPS Members

■ New Online Library Offer to CCPS Members Only CCPS has worked with its online publisher
Knovel to create a new offer only for CCPS Members: the CCPS+ Library. The new CCPS+ Library
includes all CCPS titles as well as many other useful process safety resources at a significantly
reduced price. Subscribing to the CCPS library allows any employee from your company to access
these resources from anywhere in the world. To learn more, contact Roxy Schneider at:
[email protected]. The standard CCPS collection will also continue to be available to members and
non-members who wish to access CCPS books as part of a broader Knovel subscription.

■ CCPS Conference The 7th Global Congress on Process Safety will take place on March 13-16,
2011 in Chicago, IL, USA. Focusing on Inherently Safer Design, the 2011 conference will feature
over 100 top quality papers and 40 posters from respected process safety experts around
the world. Attended the GCPS in the past? Think it’s a great way to network and learn from
experts in the field? Then try volunteering on the conference planning team to get even
more from your participation. The “Bring a Young Colleague” program in which GCPS
attendees are encouraged to bring a colleague under the age of 35 for half price, continues to
be a great success. Review the conference website for more information www.aiche.org/gcps.

The 3rd CCPS Latin American Conference is set to take place in Buenos Aires, Argentina on
August 8-10, 2011. This conference is looking to build on momentum from the successful 2010
conference in which over 400 attendees gathered to discuss both global and local process
safety issues. Encourage your colleagues in the region to attend and learn from the experts!

Impart 25 Years of Process Safety Experience to Chemical

Engineering Staff in 4 Days

Process Safety Boot Camp was developed by

CCPS to train engineers who need to move
beyond an understanding of personnel safety
and learn the basics of process safety
management. It follows the twenty elements
of the Risk Based Process Safety model and
aligns with other valuable references.
Experienced CCPS staff consultants, lead the
four-day intensive course. To bring additional relevance to the subject
matter, company liaisons facilitate the process by reinforcing key
messages from management and by discussing specific case histories
as appropriate. In 2010, CCPS conducted six Boot Camps in North
America and one in India. If you would like to schedule a Process Safety
Boot Camp at your facility, contact Louisa Nara at: [email protected].

8 2011 CCPS PROCESS SAFETY REPORT

Leveraging Your Company’s CCPS Membership
■ Technical Steering Committee
Technical Steering Committee (TSC) meetings are a great to network with and learn from your process
safety peers as they share their experiences and lessons learned. TSC meetings feature presentations on
useful and applicable new developments in process safety technology and management. These meeting
are a great way to learn from the experts and benchmark with your peers. Make sure someone from your
company attends the next meeting. For more information contact Lauren Horowitz at: [email protected].

■ Join a Project Subcommittee

From Engineering Design to Organization Change
Management there is bound to be a CCPS project on a
topic that you work with everyday. If you join a CCPS
subcommittee, you will have the opportunity to share
your knowledge and help shape industry best practices.
More importantly, while working with your fellow sub-
committee members on books and other projects you
are bound to increase both your breadth and depth of
knowledge in the subject. Join a CCPS subcommittee
because as the saying goes “if you really want to learn
something, write a book about it.” To volunteer contact
Lauren Horowitz at: [email protected].

CCPS membership
“provides an avenue
for process safety
engineers to collabo-
rate on the most press-
■ CCPS Conferences
ing Process Safety
The record setting 6th Global Congress on issues. Participation in
Process Safety (GCPS) took place on March the Technical Steering
21-23 in San Antonio, Texas with almost 600 Committee meetings
global process safety leaders and experts provides additional insight to key issues, a forum
from around the world! for networking with peers, and opportunity to
vote on priorities for project funding. In addition,
The 2nd CCPS Latin American Conference CCPS has created training such as ‘Process
took place in São Paulo, Brazil on June 21-23. Safety Boot Camp’ to teach new engineers about
The conference was held in conjunction with process safety utilizing industry events and
instructor experience to emphasize key elements.
ABIQUIM’s Responsible Care conference
Participating with CCPS can be a rewarding and
and had over 400 attendees for its technical
essential aspect of Process Safety improvement.”
sessions and networking events. ——Joe Allaben
Director, Process Risk Management
Flint Hills Resources

A D VA N C I N G P R O C E S S S A F E T Y G L O B A L LY 9
 PROCESS SAFETY
AT A GLANCE

PROCESS SAFETY AT A CCPS MANAGEMENT

GLANCE USER KEY
RESOURCE TOOLS
Identify your area of resource needs
via the 20 CCPS Elements of Process
Safety chart in the center of the page. GUIDELINES (G/L) FOR RISK BASED
PROCESS SAFETY
CCPS Management Resource
Tools are in the left chart and are
color keyed by safety category. UNDERSTAND HAZARDS AND RISK
Select any of the identified
20 CCPS Elements of Process Safety Evaluating Process Safety in the Chemical Industry: A
categories, from the center chart, User’s Guide to Quantitative Risk Analysis
and use the color key to get you to
G/L for Developing Quantitative Safety Risk Criteria
the appropriate management tools
for your safety needs. G/L for Chemical Process Quantitative Risk Analysis,
2nd Ed.
CCPS Technical Resource Tools
G/L for Chemical Transportation Safety, Security, and
are in the chart on the right, by Risk Management
category. Select any of the identified
20 CCPS Elements of Process Safety G/L for Hazard Evaluation Procedures, 3rd Ed.
categories, from the center chart, Layer of Protection Analysis
and use the category identifiers to
get you to the appropriate technical G/L for Process Safety Documentation
tool category for your safety needs. G/L for Process Safety in Outsource Manufacturing Operations
A Practical Approach to Hazard Identification

MANAGE RISK
G/L for Acquisition Evaluation and Post Merger
Integration
G/L for Management of Change for Process Safety
G/L for Mechanical Integrity Systems
G/L for Technical Planning for On-Site Emergencies
G/L for Performing Effective Pre-Startup Safety Reviews
G/L for Conduct of Operations for Process Safety

LEARN FROM EXPERIENCE

CCPS Process Safety Metrics Online Reporting Application
G/L for Auditing Process Safety Management Systems,
2nd Ed.
G/L for Investigating Chemical Process Incidents, 2nd Ed.
G/L for Process Safety Metrics
Incidents that Define Process Safety
Process Safety Incident Database
Revalidating Process Hazard Analysis
CCPS Process Safety Benchmarking Program

10 2011 CCPS PROCESS SAFETY REPORT

20 CCPS ELEMENTS OF CCPS TECHNICAL
PROCESS SAFETY RESOURCE TOOLS
PROCESS SAFETY CULTURE
● Deflagration and Detonation
Flame Arrestors
STANDARDS, CODES, REGULATIONS,
● G/L for Pressure Relief and
AND LAWS VENTING AND
Effluent Handling Systems
EMERGENCY ● Emergency Relief Systems
PROCESS SAFETY COMPETENCY RELIEF Design Using DIERS Technology

WORKFORCE INVOLVEMENT ■ Essential Practices for Managing

Chemical Reactivity Hazards
STAKEHOLDER OUTREACH ■ G/L for Reactivity Evaluation
CHEMICAL and Application to Process Design
REACTIVITY ■ G/L for Safe Storage and
PROCESS KNOWLEDGE MANAGEMENT Handling of Reactive Materials
HAZARDS
■ G/L for Process Safety in Batch
HAZARD IDENTIFICATION AND Reaction Systems
RISK ANALYSIS

■ Continuous Monitoring for

OPERATING PROCEDURES Hazardous Material Releases
■ G/L for Engineering Design for
SAFE WORK PRACTICES Process Safety
■ G/L for Evaluating Process
Plant Buildings for External
ASSET INTEGRITY AND RELIABILITY Explosions and Fires
■ Human Factors: Methods for
CONTRACTOR MANAGEMENT Improving Performance in the
Process Industries
■ G/L for Safe Handling of
TRAINING AND PERFORMANCE SAFE DESIGN Powders and Bulk Solids
ASSURANCE ■ G/L for Safe Design and
Operation of Process Vents and
Emission Control Systems
MANAGEMENT OF CHANGE
■ Making EHS an Integral Part of
Process Design
OPERATIONAL READINESS ■ G/L for Safe and Reliable
Instrumented Protective Systems
■ Inherently Safer Design, 2nd Ed.
CONDUCT OF OPERATIONS ■ G/L for Process Safety in
Bioprocess Manufacturing Facilities
EMERGENCY MANAGEMENT

■ G/L for Consequence Analysis

INCIDENT INVESTIGATION
of Chemical Releases
■ G/L for Evaluating the
MEASUREMENT AND METRICS Characteristics of Vapor Cloud
Explosions, Flash Fires, and
AUDITING
CONSEQUENCE BLEVEs, 2nd Edition
MODELING ■ Understanding Explosions
■ Wind Flow and Vapor Cloud
MANAGEMENT REVIEW AND CONTINUOUS Dispersion at Industrial and
IMPROVEMENT Urban Sites

A D VA N C I N G P R O C E S S S A F E T Y G L O B A L LY 11
 ORGANIZATIONAL
STRUCTURE

CCPS ACTIVITIES are monitored and directed by a Managing Board, an

Advisory Board, and a Technical Steering Committee. Additionally, MANAGING BOARD
members of the Technical Steering Committee and other member
June Wispelwey
company representatives serve on subcommittees that oversee CCPS AIChE Executive Director, Chair
projects.
Scott Berger
The Managing Board includes members of the Executive Committee and CCPS Executive Director

Board of Directors of AIChE, as well as the CCPS Director. It is chaired by Maria Burka
the Executive Director of AIChE and oversees CCPS fiscal and AIChE President
management operations. The Advisory Board brings together senior
David Rosenthal
executive representatives of member companies to review CCPS’ mission
AIChE President Elect
and strategies, support its initiatives, and provide guidance on CCPS
projects. Hank Kohlbrand
AIChE Past President
The Technical Steering Committee (TSC), CCPS’ primary operating group,
Andre Da Costa
provides technical direction to CCPS activities and selects its projects. AIChE Treasurer
TSC members serve voluntarily on CCPS project subcommittees and
provide the technical expertise evident in CCPS publications. All member Kim Ogden
AIChE Secretary
companies have one voting representative on the Technical Steering
Committee. Monty Alger
AIChE Director
The Planning Committee is responsible for monitoring process safety
Tom Connelly
needs and trends of industry, Affiliates of the CCPS Global Community, AIChE Director
and other stakeholders in order to supply the TSC with a portfolio of
projects and other activities to consider. The Planning Committee also Kate Ziemer
AIChE Director
coordinates with the affiliates of the CCPS Global Community to leverage
projects, training, and other efforts.

CCPS ORGANIZATIONAL
CCPS
STRUCTURE
Managing Board

CCPS
Advisory Board

Special Projects:
Technical Steering
• SACHE
Committee • PERD
• PSID

Standing
Voted Project Subcommittees: Regional Networks:
Subcommittees • Planning • CCPS China Section
• ˜ 20 • External • Future Networks
• PS Beacon

12 2011 CCPS PROCESS SAFETY REPORT

■ ADVISORY BOARD ■ PROJECT PLANNING
COMMITTEE
Scott Berger Anne O’Neal
AIChE Chevron Corporation Peter Lodal (Chair)
Executive Director, CCPS Global Manager Eastman Chemical Company
Operational Excellence
Per Bagge Angelo Kathy Anderson
Maersk Oil Thomas Polton Vertellus Specialties, Inc
Group Vice President Pfizer, Inc.
Scott Berger
Senior Director, EHS-Health & Safety
Betty Hawk CCPS
3M Company Ed Quick
Eric Freiburger
General Manager Celanese Corporation
Praxair, Inc.
Global EHS Director
Linda Hicks
Cheryl Grounds
Vertellus Inc. Ron Rife
BP
VP Corporate Technology and ExxonMobil Corporation
Manufacturing Process Safety Manager Ken Harrington
ChevronPhillips Chemical Company
Craig Huffman Scott Sharp
International Specialty Products, Inc. ChevronPhillips Chemical Company Shakeel Kadri
Vice President, Engineering Vice President, EHS Air Products and Chemicals, Inc.

Jenne Johns Maureen Song Chai Kee Neil Maxson

BP PETRONAS Bayer MaterialScience
Vice President Safety and Risk General Manager, Group HSE Jack McCavit
Strategy CCPS Emeritus
Kou Jianchao
SINOPEC Karen Tancredi Louisa Nara
Deputy Director, DuPont Company CCPS
Safety and Environment Bureau Global Technology Manager -
Cathy Pincus
Robert Kelley Environmental and Process Safety
ExxonMobil Corporation
Formosa Plastics Corporation (USA) Don Taylor
Vice President of Environment, The Dow Chemical Company
Roxy Schneider
Safety and Communication CCPS
Vice President of Manufacturing
Steve Kemp Jatin Shah
Prasad Tipnis
Occidental Chemical Corporation BakerRisk
Reliance Industries, Ltd.
Vice President, Health, Environment Senior Vice President, Kenan Stevick
and Safety Chief Centre for HSE Excellence The Dow Chemical Company
Danny Kite June Wispelwey Karen Tancredi
Total AIChE DuPont Company
General Manager, HSE Executive Director Gavin Towler
Karen Klimas John Wnek UOP (Honeywell)
Merck & Company, Inc. Degussa Corporation John Venitz
Vice President of Safety & Vice President, Environment, Pfizer, Inc.
Environment Safety and Health
Scott Wallace
John Licata
Olin Corporation
Syngenta Crop Protection
Head, Health Safety,
Environment and Safety
Patrick Louglin
Air Products and Chemicals, Inc.
Vice President, Environment, Health,
Safety and Quality
Craig Matthiessen
US EPA/OEM
Division Director
Emer Obroin
Monsanto Company
Vice President, EH&S

A D VA N C I N G P R O C E S S S A F E T Y G L O B A L LY 13
 PROJECT
COMMITTEES

■ PROCESS EQUIPMENT ■ PROCESS SAFETY BEACON/PROCESS ■ PROCESS SAFETY

RELIABILITY DATABASE SAFETY MOMENTS INCIDENT DATABASE
(PERD) (PSID)
John George King Bill Marshall
Dave Belonger (Chair) Eli Lilly and Company Adrian Sepeda
CCPS Staff Consultant Dow Corning CCPS Staff Consultant
Michael Marshall
Kumar Bhimavarapu Dennis Hendershot OSHA Laurie Brown
FM Global CCPS Staff Consultant Eastman Chemical Company
Jack McCavit
David Dylis Yasser Ahmed CCPS Emeritus C. Curtis Clements
Alion Science Gulf Petrochemical DuPont Company
Georges Melhem
Bill Goble Industries Corp.
IoMosaic Corporation Lisa Faris
Exida Mushtaque Ahmed William Olsen Bayer MaterialScience
Randy Keenan Syncrude Canada, Ltd
Merck & Company, Inc.
David Guss
Savanna River Nuclear Solutions Kathy Anderson Jeff Philiph Nexen, Inc.
Luis Eduardo Niño Vertellus Specialties, Inc. Monsanto Company
TMC Innovations Inc.
Sazali Kassim
Jabar Busari Petronas
Ravi Ramaswamy
Dean Salvador Petronas
Reliance Industries, Ltd Manny Marta
Chevron Corporation Americo Diniz
Roy Sanders NOVA Chemicals Corp.
Steven Shaw Braskem
PPG Industries, Inc.
DNV Steve Marwitz
Larry Duvall (Retired)
Formosa Plastics Corporation
Bob Stack Celanese Chemicals
Nick Sands
The Dow Chemical Company Jeff Fox Mikelle Moore
DuPont Company
Buckman North America
Angela Summers Dow Corning
Sara Saxena
SIS-TECH Solution, LLC Frederic Gil BP
Albert Ness
BP The Dow Chemical Company
Hal Thomas Adrian Sepeda
Air Products and Chemicals, Inc. Aaron Gordon CCPS Emeritus
Karen Paulk
(Retired) Nexen, Inc. ConocoPhillips
Jatin Shah
Stanley Urbanik John Herber BakerRisk
Jeff Philiph
DuPont CCPS Emeritus Monsanto Company
G. Smith
Daniel Horowitz Process Improvement
Qi Li
US Chemical Safety Board SINOPEC
Institute
Shakeel Kadri Mike Smith Rajendra Raghuwanshi
Air Products and Reliance Industries, Ltd.
Shell Downstream
Chemicals, Inc. Bill Ralph
Kenan Stevick
Paul Kaufman The Dow Chemical BP
BP Company Joseph Saverino
Morris Kho Kee Wee John Stoney Air Products and Chemicals, Inc.
Petronas BP Ronald G. Schaffhauser
Mike Korst Dave Thaman PPG Industries, Inc.
LyondellBasell PPG Industries, Inc. Clark Shepard
Dave Krabacher Nico Versloot ExxonMobil
Cognis TNO
S. L. Sreedhar
Allen Lasater Jan Windhorst Santos, Ltd.
Koch Industries, Inc. CCPS Emeritus
Gary Weimer
Antonio Ribeiro Dawn Wurst Suncor Energy
Lauzana Koch Industries, Inc.
Peter Williams
Petrobras
Syncrude Canada, Ltd.
Larry LeMesurier
Syncrude Canada, Ltd Johnny Wright
BP
Marc Levin
Shell Downstream David Zhang
Husky Energy

14 2011 CCPS PROCESS SAFETY REPORT

■ GUIDELINES FOR ■ INDEPENDENT PROTECTION LAYERS ■ PROCESS SAFETY
PRESSURE RELIEF CULTURE, ENHANCED
AND EFFLUENT Wayne Chastain Kelly Keim EDITION
HANDLING, 2ND (Chair) ExxonMobil
EDITION Eastman Chemical
Kevin L. Klein Shakeel Kadri (Chair)
Company Air Products and Chemicals, Inc.
Celanese Chemicals
Robert D'Alesandro (Chair) John Murphy Bill Marshall Greg Keeports
Evonik
CCPS Staff Consultant CCPS Staff Consultant
Eli Lilly and Company
Harold Fisher (Chair)
Joe Allaben Steve Arendt
DIERS Steven Meszaros
Koch Industries, Inc. ABS Group, Inc.
Hari Attal Pfizer
Steve Arendt Mindy Bergman
BP Henry Ozog Texas A&M University
ABS Group, Inc.
Wayne Chastain IoMosaic Corporation
John Baik Jeffry Castillo
Eastman Chemical Company John Remy
BP Monsanto Company
Ron Darby Lyondell Basell
Matt Bennett Diane Chadwick-Jones
Texas A&M University Angela Summers BP
BP
Dilip Das SIS-Tech Solutions
Cho Nai Cheung
Bayer CropScience Kumar Bhimavarapu Hal Thomas (retired) Contra Costa County Health
FM Global Research
Warren Greenfield Air Products and Services
International Specialty Jim Curtis Chemicals, Inc. Glenn Crowe
Products, Inc. Celanese Chemicals Potash Corp.
Stanley Urbanik
John Hause Dale Dressel DuPont Company F. Russ Davis
PROSAF Inc. Solutia Inc. Solutia, Inc.
Tim Wagner
Alan Keiter Jeff Fox The Dow Chemical S. Ditchburn
IoMosaic Corporation Dow Corning Company Nexen, Inc.
Shah Khajeh Najafi Randy Freeman Scott Wallace Robert Fischer
Safer Systems CCPS Emeritus Olin Corporation Total
George King Richard Griffin
Bob Gale Robert Wasileski
Dow Corning ChevronPhillips Chemical Company
Emerson Process NOVA Chemicals Corp
Steve Kostos Management Dennis Hendershot
Paula Wiley
Bayer Technology Services CCPS Emeritus
Art Jensen ChevronPhillips Chemical
Jim Lay Sunoco, Inc. Company Lou Higgins
Chemical Safety Board Rhodia, Inc.
Kathleen A. Kas
Marc Levin The Dow Chemical Tom Janicik
Shell Company Covidien
Roy Lucas Dave Jones
Lummus Technology, a CB&I Co. Chevron Corporation
Michael Maness Steve Marwitz
Eastman Chemical Company Formosa Plastics Corporation
Georges Melhem Jack McCavit
IoMosaic Corporation CCPS Emeritus
Dean Miller Al Mok
Fike Corp. Suncor Energy
Jim Peterson Tim Overton
Koch Industries, Inc. BP
Peter Ralbovsky Stephanie Payne
NETZSCH Instruments North Texas A&M University
America, LLC
Maria Cristina D. Reis
Aubrey Shackelford
Petrobras
Lloyd's Register
Mike Snarkard Karen Tancredi
DuPont Company
AcuTech Consulting
Gary Van Sciver Nico Versloot
TNO
The Dow Chemical Company
Linda Young Full project descriptions can be found on pages 4-6
Shell

A D VA N C I N G P R O C E S S S A F E T Y G L O B A L LY 15
 PROJECT
COMMITTEES

■ GUIDELINES FOR ■ BENCHMARKING PROCESS SAFETY ■ EXECUTIVE

EVALUATING PROCESS MANAGEMENT SYSTEMS PROCESS SAFETY
AND PLANT BUILDINGS SEMINARS
FOR EXTERNAL Jim Muoio (Chair) Bill Marshall
EXPLOSIONS AND LyondellBasell Eli Lilly and Company David Cummings
FIRES, 2ND EDITION Jack McCavit Niel Maxson (Co-Chair)
CCPS Staff Consultant Bayer MaterialScience DuPont Company
Wayne Garland (Chair) Joe Allaben Russ Medhora Linda Hicks (Co-Chair)
Eastman Chemical Company Vertellus Specialties, Inc.
Koch Industries, Inc. Lloyd’s Register
Adrian Sepeda Steve Arendt Georges Melhem Bob Perry
CCPS Staff Consultant CCPS Staff Consultant
ABS Group, Inc. IoMosaic Corporation
John Alderman Don Connolley David A. Moore Steve Arendt
AON Energy Risk Engineering BP AcuTech Consulting ABS Group, Inc.
Quentin Baker Glenn Crowe Robert J. Mussat Iclal Atay
BakerRisk Potash Corp. MeadWestvaco New Jersey DEP
Larry Bowler David Cummings Dave Nixon William Bridges
SABIC Innovative Plastics DuPont Company Syncrude Canada, Ltd. Process Improvement Institute
Chris Buchwald Ruskin Damani Tim Overton Henry Brinker
ExxonMobil Reliance Industries, Ltd. BP Monsanto Company
Kieran Glynn Americo Diniz Robert Pappas Michael P Broadribb
BP Braskem MeadWestvaco BakerRisk
Chris Gyasi Jeff Fox Dow Karen Paulk Eric Freiburger
LANXESS Corporation Corning ConocoPhillips Praxair
Ralph Hodges Mark Guindon Mick Pelupessy David Guss
Bayer MaterialScience Suncor Energy Celanese Chemicals Nexen, Inc.
Phillip Partridge David Guss Cathy Pincus John Herber
The Dow Chemical Company Nexen, Inc. ExxonMobil CCPS Emeritus
Glen Peters Kenneth Harrington Shannon Ross Shakeel Kadri
Air Products and Chemicals, Inc. ChevronPhillips Chemical Covidien Air Products and Chemicals, Inc.
Robin Pitblado Company
Sheri Sammons Brian Kelly
DNV Shakeel Kadri TPC CCPS Emeritus
Thomas Scherpa Air Products and Chemicals,
Randy Sawyer Bill Marshall
DuPont Company Inc.
Contra Costa County Health Eli Lilly and Company
Jan Ketchum Services
Georges Melhem
TPC
Gustavo Sliva IoMosaic Corporation
Shah Khajeh Najafi AE Solutions
Steven Meszaros
Safer Systems
Kenan Stevick Pfizer
George King The Dow Chemical Company
Mikelle Moore
Dow Corning
Angela Summers Buckman North America
Mitch Krutilek SIS-Tech Solutions
Jim Muoio
ChevronPhillips Chemical
Chris Urwin Lyondell Basell
Company
DNV
Pat Ragan
Milton Carneiro Nico Versloot Bayer CropScience
Lacerda Filho TNO
Filho Petrobras Adrian Sepeda
Antoinette Wenzel CCPS Emeritus
Mark Leigh Sunoco, Inc.
ConocoPhillips Terry Welch
Peter Williams BP
Syncrude Canada, Ltd.

16 2011 CCPS PROCESS SAFETY REPORT

■ LIKELIHOOD OF ■ GUIDELINES ENGINEERING DESIGN FOR ■ RECOGNIZING
IGNITION PROCESS SAFETY, 2ND EDITION INCIDENT WARNING
SIGNS
Bob Stack (Chair) Peter Lodal (Chair) Mikelle Moore
The Dow Chemical Company Eastman Chemical Company Buckman North America Bobby Fischer (Chair)
Adrian Sepeda Dave Belonger Mike Moosemiller Total
CCPS Staff Consultant CCPS Staff Consultant BakerRisk Brian Kelly
Zaheer Ahmed Trey Morrison CCPS Staff Consultant
John Baik
Baker Petrolite Exponent, Inc. Steve Arendt
BP
Gill Aigman Perry Morse ABS Group Inc.
Quentin Baker
Honeywell, Inc. DuPont Company Todd Aukerman
BakerRisk
Donnie Carter Keith Pace LANXESS Corporation
Larry Britton
BP Praxair Joyce Becker
Consultant
Edward Mark Davis Jack Philley BP
Mervyn Carneiro
Eli Lilly and Company Baker Petrolite Scott Berger
Eli Lilly and Company
Edward Dyke Ravi Ramaswamy AIChE/CCPS
Wayne Chastain
Merck & Company, Inc. Reliance Industries, Ltd. Larry Bowler
Eastman Chemical Company
Brad Fong Ron Riselle SABIC Innovative Plastics
Trond Elvehoy
3M Company Nexen, Inc. Michael Boyd
DNV
Jeff Fox Sheri Sammons Husky Energy
Jeff Fox
Dow Corning TPC Owen Chappel
Dow Corning
Eric Freiburger Narayanan Sankaran BP
Randy Hawkins
Praxair UOP LLC Jeff Fox
AON Energy Risk Engineering
Dr. S. Ganeshan Kevin Shaughnessy Dow Corning
Georges Melhem
Toyo Engineering India, Ltd. The Dow Chemical Company Christy Franklyn
IoMosaic Corporation
Bala Chaitanya Varma Gill SigmonSyncrude AON Energy Risk Engineering
Mike Moosemiller
Gottimukkala Honeywell, Inc. John Herber
BakerRisk
Lummus Technology, CCPS Emeritus
Russell Ogle Jim Slaugh
a CB&I Co.
Exponent, Inc. LyondellBasell James Klein
Dave Krabacher DuPont Company
Brad Otis Gary Solak
Cognis
Shell Bayer MaterialScience David Lewis
Darrin Miletello Occidental Chemical
Jack Reisdorf Angela Summers
Bayer CropScience Corporation
Fluor Enterprises SIS-Tech Solutions
Jon Mock Kevin MacDougall
James E. Salter Brooke Vickery
ConocoPhillips Husky Energy
Chevron Corporation Koch Industries, Inc.
Scott Wallace William Douglas Morrison
Vincent Van Brunt
Olin Corporation Nexen Inc.
University of South Carolina
John Murphy
Nico Versloot CCPS Emeritus
TNO
Charles Pacella
Daniel Wozniak BakerRisk
Abbott Laboratories
Ron Rhodes
Total
Fred Simmons
Savannah River Nuclear
Solutions
Jim Slaugh
LyondellBasell
Marise Textor
TPC
Full project descriptions can be found on pages 4-6

A D VA N C I N G P R O C E S S S A F E T Y G L O B A L LY 17
 PROJECT
COMMITTEES

■ HAZARD ■ PS FOR FRONTLINE ■ GUIDELINES FOR ■ GUIDELINES FOR

IDENTIFICATION FOR SUPERVISORS IMPLEMENTING ORGANIZATIONAL
OPERATORS AND PROCESS SAFETY CHANGE
MAINTENANCE: A John Herber MANAGEMENT MANAGEMENT
CCPS TRAINING DVD CCPS Staff Consultant SYSTEMS, 2ND EDITION
John Wincek (Chair)
William Bridges Dan Sliva Croda
Debra McDaniel (Co-Chair) Process Improvement
Koch Industires, Inc. CCPS Staff Consultant
Institute Dave Belonger
Murray Callbeck (Co-Chair) Abdul Aldeeb CCPS Staff Consultant
Jonas Duarte
Husky Engergy Siemens Energy, Inc.
Chemtura Mohamed Fazaly
Roxy Schneider Kenneth Harrington John Alderman Mohamad Ali
CCPS Staff AON Energy Risk Engineering Petronas
BakerRisk
Jon Bernardi Steve Arendt Andréia Virginia Pepe
Don Hess
The Lubrizol Corporation ABS Group, Inc. Ambrozin
3M Company
Monsanto Company
Servet Disha Joe Chandler
Shah Khajeh Najafi
DuPont Company Koch Industries, Inc. Habib Amin
Safer Systems
Robert Fischer Contra Costa County Health
Brian Kelly Donald K. Lorenzo
Total Services
CCPS Staff Consultant ABS Group, Inc.
Dennis Hickman Steve Arendt
Karen McGregor Bill Marshall
Koch Industries, Inc. ABS Group, Inc
Ascend Performance Materials Eli Lilly and Company
Shah Khajeh Najafi Michael P. Broadribb
Robert J. Mussat Niel Maxson
Safer Systems BakerRisk
MeadWestvaco Bayer MaterialScience
Niel Maxson Joe Chandler
Jack Philley Karen McGregor
Bayer MaterialScience Koch Industries, Inc.
Baker Petrolite Ascend Performance Materials
Georges Melhem Rich Craig
Maria Cristina D. Reis Jim Muoio
IoMosaic Corporation Praxair
Petrobras LyondellBasell
Darrin Miletello Glenn Crowe
K.N. Sen Robert Pappas
Bayer CropScience Potash Corp.
Larsen and Toubro Limited MeadWestvaco
Sara J Perrin Jonas Duarte
Luiz Claudio Silva Adriano Reis
MeadWestvaco Chemtura
Petrobras Monsanto Company
Kenneth Harrington
Mark Foutenot Sheri Sammons ChevronPhillips Chemical
Ascend Performance Materials TPC Company
Kief Hess Brandon Sproles Don Lanier
Chemtura ChevronPhillips Chemical Bayer MaterialScience
Company
James P. Miller
Karen Tancredi ConocoPhillips
DuPont Company
Cathy Pincus
Kristie Terpening ExxonMobil
BP
Francis Schultz
John Traynor SABIC Innovative Plastics
Evonik
Dave Thaman
PPG Industries, Inc.
Rachel Vincze
Suncor Energy

18 2011 CCPS PROCESS SAFETY REPORT

■ CONDITIONAL MODIFIER & ■ GUIDELINES FOR ■ GUIDELINES
ENABLING EVENTS PROCESS SAFETY FOR MECHANICAL
KNOWLEDGE AND INTEGRITY
EXPERTISE
Wayne Chastain (Chair) Kieran Glynn Louisa Nara
Eastman Chemical Company BP Dave Belonger CCPS Staff
John Murphy Kenneth Harrington CCPS Staff Consultant Michael P. Broadribb
(CCPS Staff Consultant) ChevronPhillips Chemical BakerRisk
John Alderman
Company
Kathy Anderson AON Energy Risk Engineering F. Russ Davis
Vertellus Specialties, Inc. Randy Hawkins Solutia Inc.
Jeff Fox
AON Energy Risk Engineering
John Baik Dow Corning Georges Melhem
BP David Kahn IoMosaic Corporation
Shah Khajeh Najafi
AcuTech Consulting
Larry Bowler Safer Systems Jeff Philiph
SABIC Innovative Plastics Kimberly Mullins Monsanto Company
Nico Versloot
Praxair
William Bridges TNO Bob Ricker
Process Improvement Institute Robin Pitblado Larry Westrum Baker Petrolite
DNV
Martyn Brown Boulder Scientific Company Nico Versloot
Huntsman Corporations Jack Reisdorf TNO
Francois Joseph
Fluor Enterprises
Mervyn Carneiro BP Tom Wash
Eli Lilly and Company Kathy Shell 3M Company
AE Solutions
Andrew Carpenter
Exponent, Inc. Bob Stack
The Dow Chemical Company
F. Russ Davis ■ STUDENT HANDBOOK
Solutia, Inc. Angela Summers FOR PROCESS SAFETY ■ GUIDELINES FOR
SIS-Tech Solutions
Chris Devlin SAFE AUTOMATION,
Dave Thompson Roxy Schneider
Celanese Chemicals 2ND EDITION
Koch Industries, Inc. CCPS Staff
Thomas Dileo
Albemarle Stanley Urbanik Iclal Atay Dan Sliva
DuPont Company New Jersey DEP CCPS Staff Consultant
Jeff Fox
Dow Corning Vincent Van Brunt Dan Crowl John Alderman
University of South Carolina Michigan Technical University AON Energy Risk Engineering
Randy Freeman
CCPS Emeritus Nico Versloot Jerry Forest John Campbell
TNO Celanese Chemicals Conoco
Eric Frieberger
Praxair Robert Wasileski Jeff Fox
Rick Dunn
NOVA Chemicals Corp Dow Corning
Wayne Garland DuPont Company
Eastman Chemical Company Bill Marshall
Neil Maxson
Eli Lilly and Company
Bayer MaterialScience
Jack Philley
Baker Petrolite
Russell Ogle
Exponent, Inc.
Scott Wallace
Olin Corporation
Peter Stickles
IoMosaic Corporation
Angela Summers
SIS-Tech Solutions

Full project descriptions can be found on pages 4-6

A D VA N C I N G P R O C E S S S A F E T Y G L O B A L LY 19
 STAFF

CCPS STAFF
Scott Berger, Executive Director, joined has a BA from University of Hartford and MA in
CCPS in 2001 after 5 years at Owens International Affairs from The New School University.
Corning, where he held a range of
Environment, Health, and Safety (EHS) Pronob Mukherjee, joined CCPS as Asia
assignments including Director of EHS Strategic Pacific Regional Manager in 2009 and
Management. Scott also worked for 18 years at Rohm manages the CCPS office in Mumbai.
and Haas Company in R&D, engineering, and EHS. Pronob has more than 25 years of experi-
Scott received his BS and MS from the Massachusetts ence in process safety. He has worked for both chemi-
Institute of Technology. cal manufacturing companies as well as loss
prevention associations in India. Pronob received his
Louisa Nara, Technical Director joined BSChE from National Institute of Technology, Durgapur.
CCPS in 2010 after 15 years at Bayer, most
recently as Director of Risk Management, Roxy Schneider, Project Engineer, joined
NAFTA. Louisa has over 30 years of domes- CCPS in 2008. Roxy is responsible for
tic and international experience in the chemical, petro- the Global Congress on Process Safety
chemical, pharmaceutical and food industries. Louisa and other CCPS conferences, SAChE, and
holds a BS in Chemical Engineering from West Virginia e-leaning oriented projects. Roxy holds a BS in
University, a MS in Environmental Engineering from Chemical Engineering from Princeton University.
Villanova University and is a Certified Compliance and
Ethics Professional (CCEP).
CCPS CHINA SECTION
Prof. Zhao Dongfeng has worked in the
Lauren Horowitz, came to CCPS in 2010 in
China University of Petroleum since 1992.
the role of Sponsor Relations, Lauren has
He is now the Director of the CCPS
responsibility for sponsor development
China Section.
and operations within CCPS. Lauren comes
to us with several years of non-profit experience and

2011 Important Dates

EVENT DATE
Technical Steering Committee Web Meeting January 20, 10:00 AM EST
7th Global Conference on Process Safety March 13 - March 16
CCPS Advisory Board Meeting, Chicago March 13
CCPS Managing Board Meeting, Chicago March 13
Technical Steering Committee Meeting, Chicago March 17
Technical Steering Committee Web Meeting June 16, 10:00 AM EDT
Technical Steering Committee Web Meeting September 13, 10:00 AM ED

Technical Steering Committee Meeting, Phoenix, AZ November 9 - 10

CCPS China Section Training September

3rd Latin American Conference, Buenos Aires August 8-10
CCPS India Regional Meeting, Hyderabad, India May 16

For more details e-mail [email protected]

20 2011 CCPS PROCESS SAFETY REPORT

CCPS STAFF CONSULTANTS
Don Abrahamson has over forty years of Brian Kelly joined CCPS in 2005 as a staff consultant
experience in operations and engineering roles after 34 years of service with Imperial Oil and
to draw from: process safety management, Syncrude Canada Ltd. He held a number of senior
operations management, process safety positions in engineering, operations, risk manage-
engineering, technical management, quality assurance mentand process safety. Brian received his BASc and MASc degrees in
management, process development and research. He recently chemical engineering from the University of Ottawa (Canada).
retired from Celanese as the Global Process Safety Manager.
Jack McCavit retired from Celanese Chemical
David J. Belonger came to CCPS in 1996 as staff Company after 35 years with experience in operations
consultant for PERD. Dave is a graduate chemical management and practical application of process
engineer from the University of Wisconsin. He safety management systems. Jack served as the BP
spent most of his career in various assignments Baker Panel’s technical project manager. He graduated from Texas
with Rohm and Haas Company, including Corporate Safety Tech University with a BS in chemical engineering.
Director and Plant Manager.
John Murphy retired from the U.S. Chemical Safety
Jim Conner has 34 years of experience in and Hazard Investigation Board where he served as
chemical process engineering, chemical lead investigator. John also retired from Dow Chemical
manufacturing operations, and R&D across Company where he was a leader in process safety. He
operations in Asia, Europe, Middle East, and North has a BS in Chemical Engineering from Tufts University and an MBA
America. Prior to his recent retirement from Celanese Ltd, he from Central Michigan University.
served as Vice President, Global Operations and Technology for
both domestic and international operations and R&D facilities. Robert W. Ormsby joined CCPS as a staff consultant
Jim has both a BS Chemical Engineering and Masters in 2003 after 27 years of service with Air Products and
Environmental Engineering from Rice University. Chemicals, Inc. Bob served as Global Manager of
Process Safety. Bob has a BS in chemical engineering
Dennis Hendershot retired in 2005 as Senior Hazard from Penn State University and an MS from Lehigh University.
Analysis Fellow at Rohm and Haas Company after 35
years of service. Dennis has dedicated most of his Bob G. Perry retired as Managing Director of AIChE
career to process safety and risk management, and in 1997. Previously, Bob had a 37-year career with
is one of the world’s foremost champions of inherently safer Union Carbide, retiring in 1993 as Vice President of
design. Dennis has a BS in chemical engineering from Lehigh Manufacturing and Engineering. Bob is a BS chemical
University and an MBA from the University of Pennsylvania. engineering graduate of the University of Texas.

John Herber joined CCPS in 2009 after a 33-year Adrian L. Sepeda joined CCPS in early 2002 as a
career with 3M Company that included positions in staff consultant after 33 years of service with
process and project engineering, production Occidental Chemical Corp. During those years, he
operations and corporate safety. John developed held positions in a variety of technical and
programs for improving PSM systems across 3M’s operations, management positions, retiring as the Director of HES Risk
including metrics, policy and implementation guidance. John has Management. Adrian holds a BS in mechanical engineering from
a BS in Chemical Engineering from Purdue University. Lamar University.

Greg Keeports joined CCPS in early 2008 after Daniel E. Sliva joined CCPS after he retired from GE,
retiring from Rohm and Haas Company where he where he held a variety of positions over his 30-year
held positions including Global Technical Manager career. Dan received his BS and PhD in chemical
for Agricultural Chemicals and Director of Risk engineering from Rensselaer Polytechnic Institute and
Management Services. He has over 38 years experience in the an MS in chemical engineering from the University of Rochester.
chemical industry. Greg earned BS and MS degrees in chemical
engineering from Penn State and University of Pennsylvania, CCPS wishes to thank John Davenport, Walt Frank and Joe Louvar as
respectively; he also completed the Wharton Business they complete their staff
Management program at Penn. consulting assignments
and for dedicated years
at CCPS.

A D VA N C I N G P R O C E S S S A F E T Y G L O B A L LY 21
2011 WORLDWIDE CCPS MEMBERS
STRENGTHEN YOUR CORPORATE PROCESS SAFETY CULTURE
CONTRIBUTE TO THE OVERALL SAFETY OF THE INDUSTRY
3M COMPANY KRATON POLYMERS
ABBOTT LABORATORIES LANXESS CORPORATION
ABS GROUP, INC. LARSEN AND TOUBRO LIMITED
ACUTECH CONSULTING LLOYD'S REGISTER
AE SOLUTIONS THE LUBRIZOL CORPORATION
AIR PRODUCTS AND CHEMICALS, INC. LUMMUS TECHNOLOGY, A CB&I CO.
AKZO NOBEL CHEMICALS, INC. LYONDELL BASELL
ALBEMARLE MAERSK OIL
AMGEN MARSULEX, INC.
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ARKEMA MITSUBISHI CHEMICAL CORPORATION
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BAKERRISK NAGARJUNA FERTILIZERS AND CHEMICALS LIMITED
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BOULDER SCIENTIFIC COMPANY NOVA CHEMICALS CORP.
BP OCCIDENTAL CHEMICAL CORPORATION
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BUCKMAN NORTH AMERICA PAN AMERICAN ENERGY, LLC
CARGILL PETROBRAS
CELANESE CHEMICALS PETROCHEMCIAL CORPORATION OF SINGAPORE
CF INDUSTRIES PETRONAS
CHARTIS PFIZER, INC.
CHEMTURA PIDILITE INDUSTRIES LIMITED
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CONTRA COSTA COUNTY HEALTH SERVICES RELIANCE INDUSTRIES, LTD.
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DUPONT COMPANY SIEMENS ENERGY, INC.
EASTMAN CHEMICAL COMPANY SINOPEC
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ELI LILLY AND COMPANY SISTEMAS DACS SA
EMERSON PROCESS MANAGEMENT SOLUTIA, INC.
EVONIK SRF LIMITED
EXPONENT, INC. STARR TECHNICAL RISKS AGENCY, INC.
EXXONMOBIL SUNCOR ENERGY
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FM GLOBAL RESEARCH SYNCRUDE CANADA, LTD.
FORMOSA PLASTICS CORPORATION SYNGENTA CROP PROTECTION
GENENTECH TALISMAN ENERGY
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HUSKY ENERGY TPC
INTERNATIONAL SPECIALTY PRODUCTS, INC. US EPA/OEM
INVENSYS PROCESS SYSTEMS VERTELLUS SPECIALTIES, INC.
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KBR ENERGY AND CHEMICALS WOODSIDE
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