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Guidelines for Investigating Chemical Process Incidents
2nd Edition

The Center for Chemical Process Safety compiled a team of incident investigation experts from a wide-ranging cross section of the chemical and refining industry to produce this second edition of the already popular guideline. This edition provides updated information on many facets of the investigative process as well as additional details on important considerations such as human factors, forensics, legalities surrounding incident investigation, and near miss reporting.

Whether investigating a minor personnel safety incident, a near-miss, or a major catastrophe, the CCPS team produced what turned out to be a definitive training manual for any investigation team member. One European peer reviewer opened his review comments with this quote ”An impressively comprehensive book which I'll recommend to HSE training managers to include as a reference work for our training course on major incident investigation.”

Extensive examples and investigation aids are provided, including many customizable forms on the accompanying CD-ROM.

Topics include:

• Designing an Incident Investigation Management System
• An Overview of Incident Causation Theories
• An Overview of Incident Investigation Tools and Methodologies
• Reporting and Investigating Near Misses
• The Impact of Human Factors
• Building and Leading an Investigation Team
• Gathering and Analyzing Evidence
• Determining Root Causes — Structured Approaches
• Developing Effective Recommendations
• Communication Issues and Preparing the Final Report
• Considering Legal Issues
• Implementing the Team's Recommendations
• Seeking Continuous Improvement for Your System
• Lessons Learned

This book is also available from John Wiley & Sons, Inc.

 

The Business Case
for Process Safety

AEI was selected to work with an AIChE CCPS team to determine what separates the top-tier companies in the chemical processing industry from the rest. One essential characteristic each displays is that they have adopted a rigorous philosophy regarding process safety. This summary of a recent industry-wide study identifies four ways that your business will benefit from implementing a robust process safety program. Process safety is an essential part of achieving manufacturing excellence and increasing shareholder value.

Two Qualitative Benefits
Corporate Responsibility — Process safety is the embodiment of corporate responsibility and accountability. It helps your company display these characteristics through its actions. The heart of process safety lies in consistently planning to do the right things, then doing them right – consistently. Corporate responsibility leads to the second benefit…

Business Flexibility — Corporate responsibility as demonstrated in your process safety management program leads to a greater range of business flexibility. When you openly display responsibility through implementing an effective process safety program, your company can achieve greater freedom and self-determination.

Two Quantitative Benefits
Risk Reduction — Process safety provides unparalleled loss avoidance capability. A healthy process safety program significantly reduces the risk of catastrophic events and helps prevent the likelihood of human injury, environmental damage, and associated costs that arise from incidents. Although the essence of process safety focuses on preventing catastrophic incidents, the number of less severe incidents is also reduced.

Sustained Value — Process safety relates directly to enhanced shareholder value. When properly implemented, it helps ensure reliable processes that can produce high quality products, on time, and at lower cost. This increases shareholder value. Be an ambassador for process safety and share this brochure with your customers and suppliers, your local chamber of commerce, trade organizations, and new managers in your own company.

Download The Business Case for Process Safety.

 

Guidelines for Process Safety in Outsourced Manufacturing Operations

In today's competitive economy, companies use a wide variety of commercial arrangements to augment in-house production. This includes outsourcing chemical reaction processes, distillation, drying, formulating, blending and packaging products. While most of these tolling or contracted manufacturing services proceed without incident, recent major accidents have pointed to weaknesses in some tolling arrangements. Some shortcomings were lack of effective communication, inadequate outsourcing procedures, incomplete technology transfer, improper use of equipment, and lack of effective management oversight.

This CCPS guideline addresses a multi-faceted approach to improved process safety in contracted manufacturing. One unique aspect of this text is that it clearly shows the relationship between process safety, environmental responsibility and product quality insupporting overall business excellence. It provides the reader with proven procedures to:

• Identify and assess the capabilities and adequacy of potential toll manufacturers,
• Develop contractual agreements which properly address legal obligations and responsibilities for process safety, health, environment and product quality issues,
• Resolve responsibility for using process safety techniques such as process hazard analysis, managing process changes, developing safe operating procedures, training operators in the procedures, and complying with applicable regulations,
• Oversee the pre-startup, startup and tolling operation phases,
• Conduct audits of the toller's operational management systems,
• Review audit results and recommendations from incident investigations, and
• Close out the outsourcing agreement and facility operations.

Checklists and examples are used throughout. They help make this book a valuable learning tool and reference for companies conducting or considering outsourcing manufacturing. It is available through AIChE publications at www.aiche.org or by calling 1-800-242-4363.

This important work focuses on helping both tollers (companies that perform chemical related services for a fee) and the companies that contract their services to develop and implement a management system aimed at improving process safety and environmental compliance while also improving quality and efficiency.

 

CCPS Guidelines for Writing Effective Operating and Maintenance Procedures

The American Institute of Chemical Engineers (AIChE) selected R.J. Walter as the lead author and lecturer for their continuing education series course on the Center for Chemical Process Safety text, Guidelines for Writing Effective Operating and Maintenance Procedures, regarded as the definitive text on operating and maintenance procedures for the chemical processing industries. Mr. Walter was project manager for its development.

Available by phone at: 1-800-242-4363

or online at www.aiche.org

 

Practical Compliance with the EPA Risk Management Program

This book is intended to guide companies using a step-by-step approach toward compliance with the recent EPA Risk Management Program rule. It focuses on developing an overall understanding of the rule and a ready implementation plan for using the tools provided by EPA to make complying and registering easier.

Part of the CCPS Concept Series by AIChE Publications

This book is also available from John Wiley & Sons, Inc.

 

Local Emergency Planning Committee Guidebook
Understanding the EPA Risk Management Program Rule

A companion to the previous title, this book explains the rule in a way that helps local emergency planning committees (LEPCs) in playing their part in Risk management. It leads them to develop knowledge of what is expected of them in regard to EPA RMP and how they can use the information made available through EPA to make their communities safer in the event of a chemical release. This book provides LEPCs with the basic parts of the RMP rule and a series of activities that will help make them a more effective response organization for their community.

Part of the CCPS Concept Series by AIChE Publications

This book is also available from John Wiley & Sons, Inc.

 

Chemical Engineering Progress Magazine

Mr. Walter was lead author for the article "Write Better Procedures for Process Safety Management" in the September 1996 issue of Chemical Engineering Progress magazine. This was an in-depth study of a seven-step process designed to help chemical and manufacturing plants meet OSHA PSM and EPA RMP requirements. The method basically involves developing a high-quality procedure program, ensuring that it is user-friendly, while documenting all required activities. This article explores the advantages of employing an electronic document-management system and how it can assist in keeping procedures current and easily accessible. He also frequently contributes book reviews for CEP.

"Write Better Procedures for Process Safety Management"

To order reprints of this article, contact AEI

Phone:301-865-0015

or via email at rjwalter@antientropics.com

 

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