Center for Chemical Process Safety
Technical Steering Committee Meeting
Monday, October 1, 2001
The Westin Prince Hotel
8.00 am Jack Weaver called the meeting to order. Formatted
Jack introduced Scott Berger and each of the attendees introduced themselves. (see
attached list of attendees). Jack announced when and where the next meetings of the
Technical Steering would be.
List the meetings
Jack gave information on two new process safety books:
Layers of Protection Analysis (LOPA)
Jack asked for volunteers for two new projects:
Project Engineering Design, 2 Edition
8.20 am Scott Berger My thoughts on coming to CCPS
8.30 am Facility Siting presentations
Chuck Fryman, FMC
Tim Overton, Dow
Pete Lodal, Eastman
The group then divided into breakout sessions to discuss the facility siting issue.
The breakout sessions were led by:
John Murphy, Chemical Safety Board
John Herber, 3M
Myron Casada, ABS Consulting
The participants were asked to discuss the following questions:
What type of construction triggers a facility siting review?
What does a facility siting review cover?
Who leads a facility siting review? Which functions are represented?
Charts from breakout leaders (from John Davenport)
Before the presentations from the breakout session leaders, Jack Weaver
introduced Roland Anderson, Chemical Institute of Canada and Graham Creedy,
Canadian Chemical Producers Association. Both spoke briefly and welcomed the
participants to Toronto and emphasized the importance of the work that chemical
engineering societies are doing on process safety.
11 am Scott Berger Making CCPS more electronically accessible.
Scott distributed a survey and asked that it be returned to him by the end of the
day. He said the he would also be sending out an electronic version of the survey.
11.20 am Scott Berger Layers of Protection Analysis (LOPA).
The presentation was prepared by Art Dowell of Rohm and Haas, who was unable
to travel to Toronto because of company travel restrictions. Please note the
acronyms used in this presentation:
SIL Safety Integrity Level
IPL Independent Protection Layers
11.30 am Irv Rosenthal, US Chemical Safety Board
“Developing Metrics for Process Safety”
Dr. Rosenthal made the point that existing databases on chemical process accident
statistics do not provide enough information to draw useful, consistent
conclusions. Some possible approaches to improve the content of databases were
discussed. are not available from existing databases. The Marsh & McLennan
report on major accidents shows that accidents involving property damage have
been reduced but that accidents involving injury have increased. He asked if there
is a correlation between corporate culture (or profitability) and accident rates.
Following the presentation there were questions for clarification, discussion of
how CCPS might help, confidentiality, and the envisioned rulemaking process.
Comments from the audience:
Bob Perry, CCPS: Could this be a CCPS project Formatted: Bullets and Numbering
Jim Belke, USEPA: Would the new reporting requirements apply just to the
accident statistics? Yes, annual reporting of new accidents
Jack Weaver, CCPS: What about OSHA incidents?
Steve Arendt, ABS Consulting: How would people in the room use the new
information? Would affect the way public responds to incidents. In an
individual plant, most people would never see an incident.
Answer: The data would be useful for industry groups e.g. the Chlorine
Pat Ragan, Aventis Crop Science: Have seen presentations like this before. Formatted: Bullets and Numbering
No progress has been made.
Jan Windhorst, Nova Chemicals: Basic misunderstanding of adiabaticity.
Answer: Find facilities that have incidents, match with a control group that
has not has incidents. What is the difference between them? The new data
offers the opportunity to go further, similar to that used in disease
Kelvin Kwong, Solutia Inc: What about the reporting of annual material Formatted: Bullets and Numbering
usage? These data may be confidential.
Answer: An estimate of operating time may be OK, e.g. operating time by
Jack Weaver, CCPS: Can RMP*Info be used as a surrogate? What would be Formatted: Bullets and Numbering
missed if we used RMP*Info?
Answer: Some Section 112(r), paragraph 3 substances would not have to
Tim Overton, Dow Chemical: How would this change be implemented? Formatted: Bullets and Numbering
Answer: The Chemical Safety Board would have to get together with EPA
and OSHA and propose a joint rule making. At the moment the other CSB
Board members see an agenda crowded with other issues.
1.00 pm Planning Committee Report, Jack Weaver
The committee chair is Greg Keeports, Rohm and Haas. He was unable to attend
because of travel restrictions.
The projects presented were:
Project 0201 -- Transportation Risk Assessment
Project 0202 – Process Safety Issues for CAPs
Project 0203 – Safe Design and Operation of Process Vent and Emission Control
Project 0204 – Human Factors Considerations in Process Safety Management
Project 0205 – Applying Process Principles to other industries
Project 0206 – Retention of Corporate Knowledge During Organizational Change
Project 0207 – Maintenance and Mechanical Integrity Guidelines Book
Project 0211 – Site Security (protecting against terrorism)
Project 0213 – Extending the life and productivity of existing plants.
1.30 pm CCPS Project Reports
Lisa Bendixen, Arthur D. Little Inc. Inherent Safety and Pollution
John Bresland, CCPS for Russ Kahn, Syngenta Crop Protection. Project
121, Hazardous Particulate Solids Slides
John Davenport, CCPS Project 146 Guidelines for Fire Protection for
Chemical Processing Facilities Slides
John Davenport, CCPS Project 150 Guidelines for Facility Siting and
Brian Kelly, Syncrude Canada Ltd. Process Safety Incident Database
Scott Berger, Loss Prevention on CD-ROM, 2nd Edition
Steve Arendt, ABS Consulting Retaining Corporate Memory Slides
Jan Windhorst, Nova Chemicals Understanding Explosions Slides
2.45 pm Bob Perry, CCPS 2002 CCPS Conference
It will be held in Jacksonville, Florida from October 8 – 11, 2002.
Bob asked for suggestions for papers, sessions etc. for the 2002 Conference.
He also asked for volunteers for the Planning Committee.
2.55 pm Pete Lodal, Eastman Chemical Reactive Chemical Developments
Pete distributed copies of the “10 pager” on Reactive Material Hazards. He
saidThe document is a pamphlet that is intended to that it needs to be distributed
widely to raise awareness among those who don’t know if they have a problem
with reactive materials. It is can also be downloaded from available on the CCPS
web pagesite. The reactive chemistry training session, scheduled for Sunday,
September 30 in Toronto was cancelled because of a low projected attendance.
Pete asked for volunteers for CCPS Project 160, Reactive Chemical Hazards. The
focus of this project will be on the management of reactive chemical hazards.
He also reported that the OSHA Advanced Notice of Proposed Rulemaking on
reactive chemicals would not be published for several months. In the meantime
OSHA will be focusing on facilities that are having the most accidents.
3.10 pm Lisa Bendixen, Arthur D. Little Total Cost Accounting for Process
After Lisa’s presentation Jack Weaver pointed out that Total Cost Accounting ties
into the Business Case for Process Safety. He said that CCPS may be able to get
funding from the AIChE Foundation to extend this concept to process safety. Tim
Overton said that Dow has used this process and that CCPS should look at a
broader database e.g. from a major insurance company.
3.30 pm Group Sharing of Experiences
Tim Overton, Dow: OSHA and EPA are starting joints audits in Region 6 Formatted: Bullets and Numbering
Pat Ragan, Aventis Crop Science: More emphasis on plant security since
John Herber, 3M: his company is embarking on a 6-sigma project. Will be
looking for benchmarking partners.
John Murphy, USCSB: Public hearing on reactive chemical study early in
Kelvin Kwong, Solutia: his company is embarking is on a 2 year cost
reduction program. However, they will continue to support CCPS.
Jim Belke, USEPA: EPA is reviewing the list of RMP chemicals. No major
changes are expected. Reminded the attendees about the Spills Conference
in Baltimore on December 11 – 13.
Jack McCavit, Celanese Chemicals wants to improve its process safety and is
interested in benchmarking on the OSHA PSM program.
Brian Kelly, Syncrude Canada Ltd: Suggested a topic for a future meeting:
Interface management in plant operations. How do you transfer
Pete Lodal, Eastman Chemical: his company is splitting into two independent
companies – Voridian and Eastman Company.
John Davenport, CCPS: after the ammonium nitrate incident in Toulouse,
France, what will the impact be on the regulatory climate in Europe. The
incident is getting high-level political interest in Europe.
3.50 pm Plant Security
Jack Weaver introduced this session by stating comparing the climate in industry
regarding security today is similar to that the safety and security climate for
process safetytoday is similar to that after the Bhopal incident in 1985.
Kari Barrett, ACC, discussed ACC activities over the past two years regarding the
site security said that the chemical industry has been working on this issue for two
years. Site security is a management practice within the Responsible Care Process
Safety Code. September 11 accelerated this work and since September 11, there
have been lots of questions about site security.
ACC is preparing a guidance document on site security for plant managers and
they have asked member companies to appoint a security contact. There are also
working with SOCMA and the Chlorine Institute.
Richard Siegel, Foster Wheeler Environmental Corporation discussed a
November 16, 1990 presentation to SOCMA on site security by Kroll Schiff and
Angela DeConti, SOCMA, joined the meeting by telephone and discussed the
joint effort on site security among ACC, SOCMA and the Chlorine Institute.
An open discussion regarding site security followed. Sponsors with thoughts on
how CCPS can productively contribute to the site security discussion should
contact Jack Weaver or Scott Berger.
Open Discussion on Site Security:
Steve Arendt talked about the DOJ/Sandia Labs evaluation of site security. Formatted: Bullets and Numbering
Since September 11 there has been much more interest in this study. Steve
What can CCPS do in the short term?
What can CCPS do in the long term?
Whatever CCPS does, it needs to happen quickly because there are gaps in
Kari Barrett responded that the site security picture is not as bleak as Steve Formatted: Bullets and Numbering
Jack Weaver stated that historically, CCPS has been more involved in the
Richard Siegel said that industry needs to be pro-active in this matter.
Bob Ormsby said that some suspected terrorist activities involving Air
Products’ facilities had been reported to the FBI.
Jim Belke, EPA pointed out that the Fertilizer Institute should be included in
discussions on site security because of ammonium nitrate.
Tim Overton said that security is a high priority at Dow Chemical.
Actions: there are no short-term actions but CCPS is ready to work with ACC,
SOCMA etc. on this issue.
4.40 pm Bob Perry – ProSmart
Bob Perry, CCPS and David Campbell, Concord Associates presented a ProSmart
demonstration, followed by a group discussion.
The Technical Steering Committee meeting adjourned at 5.30 pm.