This book is one in a series of process safety guidelines and concept books published by the Center for Chemical Process Safety (CCPS). Please go to www.wiley.com/go/ccps for a full list of titles in this series.
It is sincerely hoped that the information presented in this document will lead to an even more impressive process safety record for industry; however, neither the American Institute of Chemical Engineers, its consultants, CCPS Technical Steering Committee and Subcommittee members, their employers, their employers officers and directors, nor BakerRisk® and its employees warrant or represent, expressly or by implication, the correctness or accuracy of the content of the information presented in this document. As between (1) American Institute of Chemical Engineers, its consultants, CCPS Technical Steering Committee and Subcommittee members, their employers, their employers officers and directors, and BakerRisk® and its employees, and (2) the user of this document, the user accepts any legal liability or responsibility whatsoever for the consequence of its use or misuse.
This edition first published 2019
© 2019 the American Institute of Chemical Engineers
A Joint Publication of the American Institute of Chemical Engineers and John Wiley & Sons, Inc.
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Library of Congress Cataloging-in-Publication Data is available
Hardback ISBN 9781118795071
Cover Images: Silhouette, oil refinery © iStock.com/manyx31; Stainless stell © Creativ Studio Heinemann/Getty Images, Inc.; Dow Chemical Operations, Stade, Germany / Courtesy of The Dow Chemical Company
This Glossary contains the terms specific to this Guideline and process safety related terms from the CCPS Process Safety Glossary. The specific CCPS process safety related terms in this Guideline are current at the time of publication; please access the CCPS website for potential updates to the CCPS Glossary.
The Chemical Center for Process Safety (CCPS) thanks all of the members of the Guidelines for Integrating Process Safety into Engineering Projects Subcommittee for providing technical guidance in the preparation of this book. CCPS also expresses its appreciation to the members of the Technical Steering Committee for their advice and support.
The chairman of the Subcommittee was Eric Freiburger of Praxair. The CCPS staff consultant was David Belonger. Acknowledgement is also given to John Herber, who was the CCPS staff consultant at the beginning of this project.
The Subcommittee had the following key contributing members:
| Ignacio Jose Alonso | Consejo de Seguridad de Procesos |
| Christopher Buehler | Exponent |
| Donnie Carter | Retired (formerly BP) |
| Robert Dayton | Chevron |
| Dr. S. Ganeshan | Adjunct Professor of Chemical Engineering, |
| Bombay | |
| Andrew Goddard | Arkema |
| Anil Gokhale | CCPS |
| Emmanuelle Hagey | Nova Chemicals, Inc. |
| Kevin Watson | Chevron |
The following members also supported this project: Susan Bayley (Linde); Jack Brennan (BASF); Phil Bridger (Nexen); Jessica Chen (Diageo); Sean Classen (Shell); Jonas Duarte (LANXESS, formerly DuPont and Chemtura); Marisa Pierce (DNV); and Robert Wasileski (formerly NOVA Chemicals).
AIChE and CCPS wishes to acknowledge the many contributions of the BakerRisk® staff members who contributed to this edition, especially the principal author Michael Broadribb and his colleagues who contributed to portions of this manuscript: Joe Zanoni (FEL2) and Chuck Peterson (Commissioning /startup). Editing assistance from Moira Woodhouse, BakerRisk®, is gratefully acknowledged, as well.
Before publication, all CCPS books are subjected to a thorough peer review process. CCPS gratefully acknowledges the thoughtful comments and suggestions of the peer reviewers. Their work enhanced the accuracy and clarity of these guidelines.
Peer Reviewers:
| Anne Bertelsmann | Marathon Petroleum |
| Denise Chastain-Knight | Exida |
| Marlon Harding | Merck |
| Patti Jones | Praxair |
| Pamela Nelson | Solvay |
| John Remy | LyondellBasell |
| Steven Thomas | Chevron |
The following files are available to purchasers of Guidelines for Integrating Process Safety into Engineering Projects. They are accessible from the AIChE/CCPS website below using the password P250-files.
www.aiche.org/ccps/publications/EngineeringProjects
Typical Process Safety Studies Over Project Life Cycle
Project Process Safety Plan
Typical Hazard & Risk Register
Safety Checklist for Process Plants
Example of Site-Specific Decommissioning Checklist / Questionnaire
Typical Project Documentation
Stage Gate Review Protocol for Process Safety
The American Institute of Chemical Engineers (AIChE) has been closely involved with process safety, environmental and loss control issues in the chemical, petrochemical and allied industries for more than four decades. Through its strong ties with process designers, constructors, operators, safety professionals, and members of academia, AIChE has enhanced communications and fostered continuous improvement between these groups. AIChE publications and symposia have become information resources for those devoted to process safety, environmental protection and loss prevention.
AIChE created the Center for Chemical Process Safety (CCPS) in 1985 soon after the major industrial disasters in Mexico City, Mexico, and Bhopal, India in 1984. The CCPS is chartered to develop and disseminate technical information for use in the prevention of accidents. The CCPS is supported by more than 200 industry sponsors who provide the necessary funding and professional guidance to its technical steering committees. The major product of CCPS activities has been a series of guidelines to assist those implementing various elements of the Risk Based Process Safety (RBPS) approach. This book is part of that series.
Process safety should be a major consideration during the development of engineering projects within the chemical, petroleum and associated industries. Whether the project is a major capital project or a modification governed by management of change, incorporating process safety activities throughout the project life cycle will reduce risks and help prevent and mitigate incidents. In particular, the adoption of process safety early in the project life cycle can achieve levels of inherent safety that becomes more difficult and expensive in later design development. The CCPS Technical Steering Committee initiated the creation of this guideline to assist companies in integrating process safety into engineering projects.
This guideline book addresses process safety activities that are appropriate for a range of engineering projects, although not all activities will applicable to a specific project. It is not the intent of this guideline book to explain methodologies for the activities as these are covered in other CCPS publications. The guideline book also provides an introduction to project terminology so that process safety engineers and others can articulate the recommended process safety activities in a language that project management teams can understand.