Japan Process Safety

Symposium
Umesh Dhake
Regional Manager-Asia Pacific & Middle East
Center for Chemical Process Safety
4th December 2018
Okayama Convention Center, Japan

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 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.
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“The Global Community Committed to Process Safety”
 CCPS Vision

“To protect people, property and the environment

by 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.”

“The Global Community Committed to Process Safety”

 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
 Leading Process Safety
since 1985
Creating Industry-wide
CCPS Certified Tools, Programs and
CCPSC Creating Books Guidelines
and Publications
Sharing Best Practices

Educating Educators

Process
Safety
Beacon Conducting Global Conferences
and Training
“The Global Community Committed to Process Safety”
 Responsible
Collaboration
Organization
Energy Institute [EI]
Society of Petroleum Engineers [SPE]
American Chemical Council [ACC]
Japan Society for Safety Engineering [JSSE]
European Process Safety Center [EPSC]
EPSC + Dow Chemicals
IChemE, MKO, EPSC and WPLP
Singapore Chemical Industry Council
PERTAMINA University [Indonesia]
Universiti Teknologi Petronas [UTP]
University [Malaysia]
OSHA
Chemical Safety Board [CSB]
Collaborating activity
Bow Tie Guideline Book
Process Safety for Upstream Guideline Book
Enhancing Process Safety effort
4th Global Summit, Okayama, Japan
Europe PS + Big Data Conference, Frankfurt
RAST [Risk Analysis Screening Tool]
2017 WCCE-10 Barcelona PSM Track
MOU signed; 6th Global Summit [2019]
MOU signed
2nd Global Summit
CCPS Risk Based Process Safety elements as best
practices reference on the OSHA Web Tool
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
- Undergraduate Process Safety Learning Initiative [UPSLI]
- CCPS Credentialing [CCPSC]
- CCPS Vision 20/20

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The Global Community Committed to Process Safety
 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

$15
MM
Goal

$10.5 MM*
(as of
MAJOR CONTRIBUTORS: 5/18)
/18)
5/18)

Partners - $100,000-$249,000
Albemarle FMC
Archer Daniels Midland Co. Mitsui & Co. (U.S.A.), Inc. $7.3 MM
Cabot Corporation Olin (Towards
Covestro LLC PolyOne UPSLI )
Evonik Wacker Chemical Corporation
ExxonMobil Corporation

Supporters - $50,000 - $99,999

Air Liquide Intercontinental Terminal Doing a World of Good
Arkema Inc LANXESS Campaign -- Funds
Bouchard Transportation Novus International, Inc.
Cargill Praxair Raised
Honeywell Trinseo
* Does not include $1MM
in unrecorded pledges
For a complete list of donors, visit www.DoingaWorldofGood.org
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

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

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“The Global Community Committed to Process Safety”
 How CCPSC Works

Decision to Awarding Conduct as

apply credential certificants

Maintaining
Application Scoring
credential

Application
Testing
Review

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“The Global Community Committed to Process Safety”
 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

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“The Global Community Committed to Process Safety”
 CCPS Process Safety Vision 20/20

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 Vision 20/20 Assessment Tool

• CCPS Vision 20/20 with Industry
Benchmark_ 2015 GCPS
CCPS Tools
- Process Safety Incident Database (PSID)
- LOPA Database
- Chemical Reactivity Worksheet (CRW v4.0)
- Risk Analysis Screening Tool (RAST)
- Safe Work Practices (SWP)

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The Global Community Committed to Process Safety
 Process Safety Incident Database (PSID)

• 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

“The Global Community Committed to Process Safety”

 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

 Guidelines / Essential of Safe Work Practices

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

Fundamental Intent An integrated set of policies, procedures, permits, and other systems that are designed to
Potential Hazards manage risks associated with non-routine activities such as performing hot work, opening
process vessels or lines, or entering a confined space.
Incidents
Control Hazards & Protect Personnel Control Special Hazards
Effective Practices 1. Hot work authorization 14. Radiation source handling (e.g., mechanical
2. Line breaking / isolation (and opening and integrity inspection)
Reference Materials blinding of process equipment) 15. Electrical safe work
Workflows 3. Lockout / tagout (and control of energy
hazards) Impairment of Safety Systems
Call to Action 4. Confined space entry 16. Fire system impairment
5. Access to process areas by unauthorized 17. Temporary isolation of relief devices
Common Practices personnel 18. Temporary bypassing or jumpering of
6. Access to hazardous areas during interlocks
normal/routine operation
7. Roof access permits (vents, PSV’s, etc.)
Others
8. Elevated work and fall protection
19. Sampling
20. Shutdown / Safing equipment and processes
Protect Against Mishaps and Secondary 21. Water pressure and blasting
Effects 22. Equipment identification
9. Excavation in or around process areas 23. Equipment filling and mixing
10. Operation of vehicles in process areas 24. Field review of permits (vs. “armchair”
11. Lifting and hoisting over process permitting)
equipment 25. Permits for simultaneous operations
12. Use of other heavy construction equipment (SIMOPS)
in or around process areas 26. Scaffolding permits
13. Hot tapping lines and equipment 27. Temporary buildings and/or structures
28. Extending permits over shifts/days
29. Temporary repairs / leak sealing and
clamping
 Guidelines / Essential of Safe Work Practices
Line Break LOTO Confined Space Hot Work Excavation Lifting
Fundamental Intent
Potential Hazards
Incidents
Effective Practices
Reference Materials
Fundamental Intent define
the fundamental intent of the safe work
Workflows practice, the purpose it can serve, and
the benefits intended to provide. Draw
Call to Action veterans back-to-basics and provide a
Common Practices solid foundation for those in the
developmental stages of their program.
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
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.
Hot Tap Work at Height Temp. Bypass Scaffolding
Potential Hazards
identify 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.
Effective Practices – provide
information and details regarding effective
practices developed and implemented
within industry to strengthen safe work
practices and minimize related issues.
Workflows– Example of a typical
workflow for managing hot work on the
plant
Questions?

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The Global Community Committed to Process Safety