2018 AIChE Spring Meeting & 14th GCPS Short Courses
- S1: Introduction to CCPS Safe Automation of Chemical Process
- S2:Investigating Incidents and Near Misses
- S3: Layer of Protection Analysis
- S4: Understanding Human Factors
- S5: Dust Explosion Dynamics
- S6: Pressure Relief System Awareness Training
- S7: Inherently Safer Design
- S8: Best Practices in PHA Facilitation
Short Courses Schedule: April 22,2018 9:00AM -5:00PM*
You can register for any of these short courses by selecting the course title during the 2018 AIChE Spring Meeting and 14th GCPS online registration process or call customer service at 1800.242.4363
S1: Introduction to CCPS Safe Automation of Chemical Process
Location: Marriott, Bahamas
Price: $600
Instructors: Angela Summers and Eloise Roche
Book:Guidelines for Safe Automation 2nd Edition
Guidelines for Safe Automation of Chemical Processes was first published in October 1993 to provide designers and operators of chemical process facilities with a general philosophy and approach to safe automation, including independent layers of safety controls, alarms, and interlocks (SCAI). Automation technology has evolved rapidly in the intervening decades. The second edition has transformed the original through the incorporation of current concepts in reliable and safe control system design.
Agenda:
This course will cover highlights of the updated book material, including the following topics:
- Safe Automation Lifecycle Process
- Designing Automation for Reliable Control (e.g., inherently safer practices)
- Control System Hardware Selection (e.g., instrumentation, logic solvers, auxiliaries)
- Alarm and Instrument Justification and Alarm Management
- Designing Automation for Functional Safety
- Designing Automation for Cyber Security
- Safe Automation Management Systems
S2: Investigating Incidents and Near Misses
Location: Marriott, Aruba
Price: $600
Instructors: Trey Morrison and Brenton Cox;
Book: Guidelines for Investigating Chemical Process Incidents
A principal goal of process safety professionals everywhere is to prevent chemical process incidents from occurring. However, even the most risk averse organizations experience learning opportunities. Through the scientific investigation of incidents and near misses, a company can take advantage of these opportunities and acquire the knowledge necessary to avoid repeating past mistakes. Effectively sharing lessons learned may also reduce the frequency of similar incidents across the Chemical Process Industry.
This course will follow the incident investigation techniques set forth in CCPS’ Guidelines for Investigating Chemical Process Incidents, while incorporating information from other industry guidance documents. Each aspect of incident investigation will be illustrated with case studies pulled from real incidents and near misses. The course will incorporate brief team-based workshops to provide attendees with hands-on experience in applying investigation principles.
The curriculum will proceed chronologically through an investigation, first discussing the initial response to an incident or near miss. Then the course will cover the assembly of an investigation team, which can span from two engineers to a multidisciplinary team of experts. The team picks up where the initial response left off, preserving and collecting forensic evidence, witness statements, and process information. Then the data is analyzed in an attempt to determine the direct and root causes of the incident or near miss. Last but not least, the findings of the investigation are documented and shared.
Agenda:
- Introduction
- Learning from Engineering Disasters
- Documentation and Sharing of the Lessons Learned
- Effective Communication of Findings
- Developing Effective Recommendation Incident Investigation
- Incident Investigation
- Initial Response
- Assembling a Team
- Basic Investigation Techniques
- Collecting and Preserving Forensic Evidence
- Direct and Root Cause Determination
- Structured Techniques for Cause Determination
- Causal Factors & Root Causes
- Human Factors
- Case Studies in Applying Structured Techniques
S3: Layer of Protection Analysis
Location: Marriott, Grand Cayman
Price: $500
Instructor: Arthur M. Dowell, III
Book: No Book
Are proposed or existing combinations of safeguards enough to prevent an accident or mitigate the consequences? Do you perceive that doing a fully quantitative risk assessment (QRA) would be over-working the problem? Then Layer of Protection Analysis (LOPA) is the new tool you need to learn. LOPA combines both qualitative and quantitative elements of hazard evaluation and risk assessment to analyze and judge the adequacy of existing or proposed safeguards against process deviations and accident scenarios. A key to the success of LOPA is its rules for judging if protection layers are truly independent. Because of these rules, LOPA helps the analysts make consistent judgments of if the risk of scenarios are “as low as reasonably practical (ALARP)”. This “How To” course is taught by one of the principal authors of the AIChE/CCPS book, Layer of Protection Analysis (2001). The course will also bring you up-to-date on changes from the newly released Guidelines for Initiating Events and Independent Protection Layers, CCPS/AIChE.
Agenda:
Introduction to LOPA
- Learning objectives and goals of using the LOPA technique
- What is LOPA? How is LOPA applied? Definitions? When is LOPA used?
Developing LOPA Scenarios
- Selecting candidate scenarios from brainstorming hazard evaluations
- Scenarios from design questions and from incidents
Estimating the Consequence of the Scenario
- Using a look-up table of consequence; Developing a consequence look-up table for your company; Alternative methods for estimating consequences
- Workshop 1: Estimating the consequence of a scenario (part of a continuing example)
Estimating the Likelihood of the Selected Initiating Event
- Using a look-up table of initiating event categories and frequencies
- How to develop an initiating event look-up table for your company
- Addressing enabling conditions and time-dependent initiating events
- Workshop 1: Estimating the frequency of an initiating event of a scenario (part of a continuing example)
Estimating the Probability of Failure of Independent Protection Layers
- Definitions, rules, and exceptions for giving credit for an independent protection layer (IPL); Using a look-up table of IPL categories and probability of failure on demand (PFOD); How to develop an IPL look-up table
- Workshop 1: Deciding which safeguards are valid IPLs and estimating the PFOD of the valid IPLs (part of a continuing example)
Calculating the Risk
- Using a standardized LOPA worksheet; Rules for calculating risk for an individual scenario (LOPA); Rules for summing risk of related scenarios
- Workshop 1: Calculating the risk of a LOPA scenario (part of a continuing example)
Judging the Risk
- Examples of risk tolerance criteria from the industry
- Development and implementation of a company risk tolerance criteria
- Workshop 1: Judging the risk of a LOPA scenario (cont. example)
Special Applications of LOPA
- Using LOPA for facility siting questions; Selecting the SIL for an interlock
S4: Understanding Human Factors
Location: Marriott, Puerto Rico
Price: $500
Instructors: William G. Bridges
Book: No Book
Human error is widely acknowledged as the major cause of quality, production, and safety risks in many industries. This course explains the underlying reasons why humans make mistakes and how you can prevent these mistakes with engineering solutions and with administrative solutions. Although it is unlikely that human error will ever be completely prevented, there is growing recognition that many human performance problems stem from a failure within organizations to develop an effective policy for managing human reliability.
The course will provide hands-on experience of practical error reduction techniques, using real-life case studies. You will also gain an understanding of the underlying causes of human error and how to reduce its occurrence by changing the culture of the organization and changing the design of the processes. Workshops are used throughout the course to illustrate concepts and to demonstrate human error analysis applications.
Agenda:
Introduction to Human Error
- Learning objectives and goals of human error prevention
- What is human error and human error analysis?
Understanding Human Error:
- Errors and their relationship to loss events
- Which is most important: Management system deficiencies or personal behavior?
- Types of human error
- Workshop: Classifying Human Errors
- Modeling human behavior (an example of a simple model that works is used throughout the course)
- Elements associated with understanding and controlling human error
- Workshop: Relating Human Error to Human Factor Influences
HUMAN FACTORS and How to Optimize These
- Information Presentation Rules (procedures, trainers, communication, signs, etc.)
- Process/Operation/Workplace Design Rules
- Other General Rules
- Exercises
Overview of Techniques for Predicting and Analyzing Human Error
- Checklist Analysis: For situational and for management system related errors
- Guideword-based analysis (HAZOP, Job Hazard Analysis, etc.)
- Quantitative Human Reliability Analysis
- Workshop: Using Simple Technique for Predicting and Analyzing Human Errors
Behavior/Habits
- What controls human behavior (T-H-O theory and analysis)
- Implementation strategies for controlling undesired behaviors
S5: Dust Explosion Dynamics
Location: Marriott, St. Thomas
Price: $600
Instructors: Russ Ogle
Book: Dust Explosion Dynamics, Butterworth-Heinemann (2016)
The purpose of this short course is to reveal the combustion science behind combustible dust hazards. Numerous examples will be presented from case studies to illustrate the application of dust explosion dynamics to dust hazard analysis.
AGENDA
1. Introduction to combustible dust hazards
2. The key physical properties of combustible dust
3. Thermodynamics of dust combustion
4. Transport phenomena for dust combustion
5. Smoldering phenomena
6. Dust particle combustion models
7. Unconfined dust flame propagation
8. Confined unsteady dust flame propagation (deflagrations)
9. Dust flame acceleration effects (shock waves, detonations, and pressure piling)
10. Applications of dust explosion dynamics to dust hazard analysis
S6: Pressure Relief System Awareness Training
Location: Marriott, West Indies
Price: $500
Instructors: Rahul Raman
Book: No Book
This is a comprehensive one day awareness course for Pressure Relief System. It highlights the impetus of having a Pressure Safety Review Program, details the minimum mandatory requirements, and a workflow to keep Process Safety Information evergreen. Comprehend the definition of Pressure Relief terminology, detail the workings of pressure relief devices along with their advantages and disadvantages, and understanding the codes and standards of the protected vessel. Participants will engage in a workshop to size and select a commercially available relief device. The target audience of the training is staff engineers and managers who would like to have an awareness or refresher course.
AGENDA
I. Impetus for having a Pressure Safety Design Review Program
- Overpressure accidents
- Audit findings / ERS design deficiencies OSHA 1910.119 & Citations (ERS Inspection Record Retention)
- ERS Design being performed by untrained engineers
II. Pressure Safety Requirements
a. Workflow
- Detailed pressure safety review / contingency analysis
- Necessary Information / Data gathering
- Necessary participants
- How to facilitate the review and perform overpressure analysis
- Design & assembling an ERS package
- Review & approval of ERS package
b. Properly documented ERS design packages
c. Understanding Codes of Construction
d. Relief device working
- PSV – Conventional & Bellows
- PSV-Trim type
- Pilot Operated Valve
- Non-reclosing device (Rupture Disk & Buckling Pin)
- Weighted Pallet Device / Conservation Vents
III. Pressure Safety terminology
a. Definition of terms & Formulae
- MAWP, Accumulation, Overpressure
- Stagnation Pressure
- Other important terms
- Liquid capacity calculation
- Vapor capacity calculation
b. Simple Design Cases
- Instrument failure
- Thermal Expansion
- Pump Overpressure
- In-breathing / Out-breathing
- Other contingencies
c. External Fire
- Effects of vessel, geometry, and location
- Effects of credit or environmental factors
- Effects of code of construction
- Effects of vessel outage
- Effects of flow regime
d. Workshop: Sizing and Selection of Relief Device
IV. Advanced ERS Concepts – Knowing when to seek assistance!
a. Effluent handling & treatment
b. Reactive systems
c. Reaction data example
V. Relief Device Installation
a. Best installation practices
b. Stability of a relief valve
c. Installation of a relief valve
d. Installation of a combination device
e. Installation of weighted pallet devices for low pressure tanks
VI. Closing Remarks
a. More trues stories of overpressure incidents
b. Emphasis on doing the right thing!
S7: Inherently Safer Design
Location: Marriott, Key Biscayne
Price: $500
Instructor: Sonny Sachdeva and Brian Fagala
Book: No Book
Many catastrophic incidents such as Methyl Isocyanate release in Bhopal, Bayer CropScience pesticide waste tank explosion, Chevron Richmond Refinery fire, Tesoro Refinery explosion and fire, have highlighted the importance of implementing principles of Inherently Safer Design (ISD). ISD means eliminating or removing the hazard, wherever possible, instead of managing or controlling it. The underlying philosophy of ISD is to avoid or reduce the hazard upfront, early in the design, rather than dealing with it at a later stage in the lifecycle.
The primary objective of the Inherently Safer Design Training course is to:
- Provide an overview of the elements of inherent safety to managers, supervisors, frontline operators, engineers and maintenance personnel.
- Highlight the differences between a traditional design and ISD.
- Provide an understanding of how to implement ISD principles, where ISD fits best in the design life cycle, and how to measure it.
- Explain the latest changes being proposed and their status in the rule making process to better equip facility staff and management for the upcoming change.
- Share industry best practices and lessons learned based on real-life accident case histories (e.g., Bhopal India, Bayer CropScience pesticide waste tank explosion, Chevron Richmond Refinery fire, Tesoro Refinery explosion and fire, etc.).
AGENDA
- Introduction
- History and Philosophy of ISD
- What is Inherently Safer Design?
- Traditional Design versus ISD
- Risk Reduction Strategies
- Principals of Inherently Safer Design
- Minimize
- Moderate
- Substitute
- Simplify
- Industry Examples of each principle
- Inherent Safety in the Design Life Cycle
- How to measure Inherent Safety
- ISD indices
- Limitations of Indices
- Incorporating ISD in Process Safety Management
- Introduction to EPA’s new proposed rule on Safer Technology and Alternative Analysis (STAA)
- Inherently Safer Design Conflicts
- Challenges to application of ISD Approaches
- Case Studies
S8: Best Practices in PHA Facilitation
Location: Marriott, Kay Largo
Price: $500
Instructor: Robert J. Weber and Aaran E. Green
Book: No Book
The objective of this course is to provide a better understanding of the importance of certain aspects of Process Hazard Analysis (PHA) facilitation and the best practices that should be used during a PHA study. Using these best practices will reduce time, confusion and increase the quality of the PHA. This course will also highlight the “dos and don’ts” in a PHA study.
In addition to classroom training, participants will form study teams and take turns leading the team in performing a PHA study using practical exercises based on actual real-life examples. These exercises are overseen by an expert Instructor who will give feedback on performance.
AGENDA
- PHA Regulatory Requirements
- Choosing the Appropriate PHA Methodology
- “What-If” Studies
- “What-If”/Checklist Studies
- Hazard & Operability Studies (HAZOP)
- Fault Tree Analysis (FTA)
- Failure Modes and Effects Analysis (FMEA)
- Other Methods
- Understanding the Importance of Intent, Parameters and Deviations
- Understanding the Importance of Type of Process (Batch, Continuous, Procedural, Control Systems), Modes of Operation (start-up, shutdown, maintenance, normal), Life-cycle of process (conceptual, design, commissioning, operation or decommissioning)
- Understanding the Importance of PHA Study, Purpose and Objectives
- Understanding the Importance of Team Members, Roles and Responsibilities, Management of PHA studies/Quality Control in PHA studies
- Understanding the Importance of Node Selection
- Understanding the importance of proper PHA documentation and reporting
- Understanding the Importance of Global issues, Facility Siting and Human Factors
- Understanding the importance of proper Risk Ranking
- Managing the follow-up of PHA results
- Software demonstration and mock facilitation