Japan Process Safety Symposium

Umesh DhakeRegional Manager-Asia Pacific & Middle East

Center for Chemical Process Safety

4th December 2018 Okayama Convention Center, Japan

1

About CCPS

• Formed on 23 March 1985

• Not for profit organization; part of AICHE

• Corporate supported – over 210 members

• 40% of members outside of USA

• Global scope and mission; Focus: preventing process incidents: fires, explosions, and toxic releases

• Petroleum production, refining, chemicals, pharma, chemical users

• Headquarter is in New York City, with offices in Frankfurt, Mumbai, Singapore, Ningbo [China] and Houston.

2“The Global Community Committed to Process Safety”

“The Global Community Committed to Process Safety”

“To protect people, property and the environmentby bringing the best process safety knowledge and

practices to industry, academia, the governments and the public around the world through collective wisdom,

tools, training and expertise.”

CCPS Vision

CCPS Mission

Eliminate catastrophic process incidents globally by:

• Advancing global PS technologies, culture, and management practices

• Establishing Process Safety as foundation for responsible operation

• Serving as premier worldwide resource of Process Safety

• Fostering knowledge and understanding of Process Safety

• Promoting Process Safety as key societal value and expectation

“The Global Community Committed to Process Safety”

210 Global Corporate Members!

Representing 36 Countries

Creating Books and Publications

Conducting Global Conferences and Training

Creating Industry-wideTools, Programs and

Guidelines

Sharing Best Practices

ProcessSafety Beacon

Leading Process Safety since 1985

“The Global Community Committed to Process Safety”

CCPS CertifiedCCPSC

Educating Educators

Responsible Collaboration

Organization Collaborating activityEnergy Institute [EI] Bow Tie Guideline BookSociety of Petroleum Engineers [SPE] Process Safety for Upstream Guideline BookAmerican Chemical Council [ACC] Enhancing Process Safety effortJapan Society for Safety Engineering [JSSE] 4th Global Summit, Okayama, JapanEuropean Process Safety Center [EPSC] Europe PS + Big Data Conference, FrankfurtEPSC + Dow Chemicals RAST [Risk Analysis Screening Tool]IChemE, MKO, EPSC and WPLP 2017 WCCE-10 Barcelona PSM TrackSingapore Chemical Industry Council MOU signed; 6th Global Summit [2019]PERTAMINA University [Indonesia] MOU signedUniversiti Teknologi Petronas [UTP] University [Malaysia]

2nd Global Summit

OSHA CCPS Risk Based Process Safety elements as best practices reference on the OSHA Web Tool

Chemical Safety Board [CSB] Potential CCPS-CSB collaboration on developing video modules using CCPS content

CCPS Engagement Framework

CCPS Engagement Framework

“The Global Community Committed to Process Safety”

CCPS Key Initiatives

12The Global Community Committed to Process Safety

- Undergraduate Process Safety Learning Initiative [UPSLI]- CCPS Credentialing [CCPSC]- CCPS Vision 20/20

Undergraduate Process Safety Learning Initiative [UPSLI]

VISION“To accelerate process safety education and better prepare graduates for the workforce”

SAChE

Faculty Workshops

Student Outreach & Bootcamps

The ultimate goal is to have 100% of graduating bachelor-degree chemical engineers to be trained and knowledgeable about process safety

Safety and Chemical Engineering Education (SAChE) – Overall Curriculum

www.aiche.org/sache

Fundraising

MAJOR CONTRIBUTORS:Partners - $100,000-$249,000Albemarle FMCArcher Daniels Midland Co. Mitsui & Co. (U.S.A.), Inc.Cabot Corporation OlinCovestro LLC PolyOneEvonik Wacker Chemical Corporation ExxonMobil Corporation

Supporters - $50,000 - $99,999Air Liquide Intercontinental Terminal Arkema Inc LANXESSBouchard Transportation Novus International, Inc.Cargill PraxairHoneywell Trinseo

For a complete list of donors, visit www.DoingaWorldofGood.org

Doing a World of GoodCampaign -- Funds

Raised

$10.5 MM*(as of 5/18)

$15 MM

Goal

$7.3 MM (Towards

UPSLI )

* Does not include $1MM in unrecorded pledges

5/18)5555555555//////////111888888))))))))))))))))/18)//1188))

$7.3 MM (Towards

UPSLI )

CCPS Credentialing - CCPSC

What is CCPSC

• Uniform and Consistent basis for assessing the Body of Knowledge in Process Safety

• Criteria: Range, Rigor, References• Range: Breadth of experience• Rigor: Depth of hands on experience• References: Recognition by peers and colleagues

• Risk Based Process Safety (RBPS) at the core

“The Global Community Committed to Process Safety”

More at: www.aiche.org/ccps-certified18

How CCPSC Works

“The Global Community Committed to Process Safety”

Decision to apply

Application

ApplicationReview

Testing

Scoring

Awarding credential

Conduct as certificants

Maintaining credential

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How it Works

• Examination - Typically 2 or 3 times a year– 4 hours, continuous, open book, individualized

• Conducted Online• Multiple Choice questions

– 120 questions covering the 20 elements of RBPS

• Essay questions– Descriptive answers required for situation analysis

• Examination is in English– Careful consideration is given to avoid confusion for applicants whose

first language is not English

“The Global Community Committed to Process Safety”20

CCPS Process Safety Vision 20/20

• CCPS Vision 20/20 Assessment Tool• CCPS Vision 20/20 with Industry

Benchmark_ 2015 GCPS

Five Industry tenets:• A Committed Culture• Vibrant Management Systems• Disciplined Adherence to Standards• Intentional Competency Development• Enhanced Applications of Lessons Learned

Four societal Themes:• Enhanced Stakeholder Knowledge• Responsible Collaboration• Harmonization of Standards• Meticulous Verification

CCPS Tools

22The Global Community Committed to Process Safety

- Process Safety Incident Database (PSID)- LOPA Database- Chemical Reactivity Worksheet (CRW v4.0)- Risk Analysis Screening Tool (RAST)- Safe Work Practices (SWP)

“The Global Community Committed to Process Safety”

• More than 800 incidents and lessons learned.• Also known as “Lessons-Learned Database”• Collection of learning's from incidents and near-misses.• Useful for hazard analysis, incident investigation, process

design, and training• It is CCPS expectation that all member companies,

participating in the PSID, will be able to submit one incident on a yearly basis, as a minimum, to this database.

• Access to PSID is free to CCPS member companies.• For more information, please contact ccps_psid@aiche.org

Process Safety Incident Database (PSID)

Ever Green LOPA Database

• LOPA Database is being developed to keep practitioners apprised of new developments, new data, and other changes in the field.

Database have various LOPA Components:– Initiating Events (23 IEs)– Independent Layer of Protection (49 IPLs)– Conditional Modifier (11 CMs)– Enabling Conditions (Seasonal Risk, Process state Risk, Campaigning Enabling

Conditions)

• Access to LOPA database is free to CCPS member companies. (https://www.aiche.org/ccps/resources/tools/lopa)

Chemical Reactivity Worksheet 4.0

• The Chemical Reactivity Worksheet (CRW) is a free software program

• CRW can use to find out about the chemical reactivity of thousands of common hazardous chemicals, compatibility of absorbents, and suitability of materials of construction in chemical processes.

• Access to CRW is free to all companies https://www.aiche.org/ccps/resources/chemical-reactivity-worksheet-40

“The Global Community Committed to Process Safety” 25

Chemical Reactivity Worksheet 4.0

“The Global Community Committed to Process Safety” 26

Risk Analysis Screening Tool (RAST)

• The RAST software and its associated CHEF documentation were developed through the collaborative efforts of volunteers from member companies of the Center for Chemical Process Safety (CCPS) and the European Process Safety Centre (EPSC).

• Special appreciation is extended to The Dow Chemical Company for donating RAST/CHEF for global use and for providing the resources to help modify the software and documentation such that companies can tailor the RAST software to meet their company-specific risk tolerance levels.

• It is sincerely hoped that companies using RAST and CHEF during their hazards evaluations and risks assessments will be able to improve their process safety performance.

“The Global Community Committed to Process Safety” 27

Safe Work Practices

• Work place fatalities and injuries continue to occur with hot work incidents, nitrogen asphyxiations, confined space, line opening and other activities because of unsafe work practices.

• This tool is designed to reach, and provide value to, a very broad audience including operations, maintenance and engineering personnel in the process industries (Chemical, petrochemical, electronics, natural gas and others).

• In addition to appealing to larger, more established member companies, this information has been tailored to also reach both large and small, domestic and international.

• SWPs are freely available to all companies https://www.aiche.org/ccps/resources/tools/safe-work-practices

“The Global Community Committed to Process Safety” 28

Home Page Line BreakLOTO Confined Space Excavation Lifting Hot Tap Work at Height Temp. Bypass Scaffolding

Fundamental Intent

Potential Hazards

Incidents

Effective Practices

Reference Materials

Workflows

Call to Action

Guidelines / Essential of Safe Work Practices

Common Practices

Control Hazards & Protect Personnel1. Hot work authorization2. Line breaking / isolation (and opening and

blinding of process equipment)3. Lockout / tagout (and control of energy

hazards)4. Confined space entry5. Access to process areas by unauthorized

personnel6. Access to hazardous areas during

normal/routine operation7. Roof access permits (vents, PSV’s, etc.)8. Elevated work and fall protection

Protect Against Mishaps and Secondary Effects9. Excavation in or around process areas10. Operation of vehicles in process areas11. Lifting and hoisting over process

equipment12. Use of other heavy construction equipment

in or around process areas13. Hot tapping lines and equipment

Control Special Hazards14. Radiation source handling (e.g., mechanical

integrity inspection)15. Electrical safe work

Impairment of Safety Systems16. Fire system impairment17. Temporary isolation of relief devices18. Temporary bypassing or jumpering of

interlocks

Others 19. Sampling20. Shutdown / Safing equipment and processes21. Water pressure and blasting22. Equipment identification23. Equipment filling and mixing24. Field review of permits (vs. “armchair”

permitting)25. Permits for simultaneous operations

(SIMOPS)26. Scaffolding permits27. Temporary buildings and/or structures28. Extending permits over shifts/days29. Temporary repairs / leak sealing and

clamping

An integrated set of policies, procedures, permits, and other systems that are designed to manage risks associated with non-routine activities such as performing hot work, opening process vessels or lines, or entering a confined space.

Hot work authorization

Hot WorkLine Break LOTO Confined Space Excavation Lifting Hot Tap Work at Height Temp. Bypass Scaffolding

Fundamental Intent

Potential Hazards

Incidents

Effective Practices

Reference Materials

Workflows

Call to Action

Fundamental Intent define the fundamental intent of the safe work practice, the purpose it can serve, and the benefits intended to provide. Draw veterans back-to-basics and provide a solid foundation for those in the developmental stages of their program.

Potential Hazardsidentify potential hazards that exist with

performing work related to the safe work practice. Enable users to understand potential pitfalls and challenges so that pertinent incidents and effective practices may be better appreciated and understood.

Incidents – provide a listing of incidents that have identified root and contributing causes associated to each safe work practice. Briefly describe the incident and provide detailed insight into the safe work practice issues

Effective Practices – provide information and details regarding effective practices developed and implemented within industry to strengthen safe work practices and minimize related issues.

Reference Materials – provide a listing of related materials and information sources that readers can refer to in order to gain further information and insight into intent, incidents, and effective practices.

Workflows– Example of a typical workflow for managing hot work on the plant

Guidelines / Essential of Safe Work Practices

Common Practices

Potential Hazards

Questions?

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