History of Process Safety andHistory of Process Safety andLoss Prevention in the AmericanLoss Prevention in the AmericanInstitute of Chemical EngineersInstitute of Chemical Engineers

D. C. Hendershot (speaker)D. C. Hendershot (speaker)T. A. T. A. VentroneVentrone, R. F. Schwab, R. W. , R. F. Schwab, R. W. OrmsbyOrmsby,,

J. A. Davenport, W. J. BradfordJ. A. Davenport, W. J. Bradford

American Chemical SocietyAmerican Chemical SocietyNational MeetingNational Meeting

August 28 August 28 –– September 1, 2005 September 1, 2005Washington, DCWashington, DC

Chemical Safety Past and Future, 1900 to 2015Chemical Safety Past and Future, 1900 to 2015CHAS 0011CHAS 0011

Safety and engineeringSafety and engineering

νν A long historyA long historyνν Safety has always been an integral part ofSafety has always been an integral part of

all engineering, including chemicalall engineering, including chemicalengineeringengineering

νν Increasing societal expectations andIncreasing societal expectations andhigher standardshigher standards

An early exampleAn early example

““... an alteration which I think will... an alteration which I think willconsiderably reduce the quantity ofconsiderably reduce the quantity ofmachinery as well as the liability tomachinery as well as the liability tomismanagement mismanagement …… in their present in their presentcomplicated state they cannot becomplicated state they cannot bemanaged by managed by ‘‘foolsfools’’, therefore they must, therefore they mustundergo some alteration or amendment.undergo some alteration or amendment.””

- 1828, Robert Stevenson pioneering railway engineer, discussing- 1828, Robert Stevenson pioneering railway engineer, discussingmodifications in the design of the newly developed steammodifications in the design of the newly developed steam

locomotivelocomotive

What is What is ““Process SafetyProcess Safety””

νν Process safety considers those aspects ofProcess safety considers those aspects ofsafety related to the chemical and physicalsafety related to the chemical and physicalprocessing of materials processing of materials –– generally fire, generally fire,explosion, reactivity, and toxicity hazards.explosion, reactivity, and toxicity hazards.

νν The safety problems in the pictures areThe safety problems in the pictures areimportant, but they are not really important, but they are not really ““processprocesssafetysafety”” problems problems

Some chemical engineering historySome chemical engineering history

νν 1635 1635 –– John Winthrop, Jr. opens the first John Winthrop, Jr. opens the firstchemical plant what would become the Unitedchemical plant what would become the UnitedStates, in Boston to manufacture saltpeterStates, in Boston to manufacture saltpeter

νν 1802 - E.I. 1802 - E.I. du du Pont bought a site on thePont bought a site on theBrandywine River in Delaware for a powder millBrandywine River in Delaware for a powder millfor $6,740for $6,740–– Inherent safety featuresInherent safety features–– Safety rules in writing and widely circulated by 1811Safety rules in writing and widely circulated by 1811

Transcontinental Railroad Transcontinental Railroad –– late 1860s late 1860s

νν Central Pacific Railroad Central Pacific Railroad –– Sierra Nevada mountain Sierra Nevada mountaincuts and tunnels through hard granite required highcuts and tunnels through hard granite required highpower explosives such as nitroglycerine, traditionalpower explosives such as nitroglycerine, traditionalblack powder was inadequateblack powder was inadequate

νν Several incidents in storage and transportationSeveral incidents in storage and transportationνν In-situ manufacture of nitroglycerine at theIn-situ manufacture of nitroglycerine at the

construction site by an English chemist, Jamesconstruction site by an English chemist, JamesHowdenHowden–– Minimize the quantity of hazardous material to what wasMinimize the quantity of hazardous material to what was

immediately neededimmediately needed–– Substitute Substitute ““in-situin-situ”” production for transport production for transport

A better solutionA better solution

νν 1867 - Alfred Nobel discovers that the1867 - Alfred Nobel discovers that thestability of nitroglycerine is greatlystability of nitroglycerine is greatlyenhanced by absorbing it on an inertenhanced by absorbing it on an inertcarrier (dynamite)carrier (dynamite)

Chemical engineering historyChemical engineering history

νν Claimants to being Claimants to being ““the first chemicalthe first chemicalengineerengineer””–– George E. Davis, Manchester, EnglandGeorge E. Davis, Manchester, England–– Albin Albin Haller, Nancy, FranceHaller, Nancy, France–– Lewis Mills Norton, MIT, USALewis Mills Norton, MIT, USA–– Fritz Fritz HaberHaber, Germany, Germany

The first chemical engineeringThe first chemical engineeringuniversity programsuniversity programs

νν Davis, Manchester, England, 1887 Davis, Manchester, England, 1887 –– first firstformal class lectures (series of 12)formal class lectures (series of 12)

νν Norton, MIT, 1888 Norton, MIT, 1888 –– ““Course XCourse X”” –– first 4 first 4year degree programyear degree program

νν University of Pennsylvania University of Pennsylvania –– 1892 1892νν Tulane University Tulane University –– 1894 1894νν My alma mater, Lehigh University, beganMy alma mater, Lehigh University, began

granting chemical engineering degrees ingranting chemical engineering degrees in19021902

American Institute of ChemicalAmerican Institute of ChemicalEngineersEngineers

νν Founded in June 1908 in PhiladelphiaFounded in June 1908 in Philadelphiaνν ACS was ~30 years old and had ~ 5000ACS was ~30 years old and had ~ 5000

membersmembersνν ACS formed Division of IndustrialACS formed Division of Industrial

Chemistry and Chemical EngineeringChemistry and Chemical Engineeringνν Initial rivalry, evolved into cooperationInitial rivalry, evolved into cooperation

and recognition of synergismand recognition of synergismνν Safety recognized as critical, but noSafety recognized as critical, but no

separate organization within separate organization within AIChE AIChE initiallyinitially

Safety in Air, Ammonia andSafety in Air, Ammonia andRelated FacilitiesRelated Facilities

νν Series of incidents and problems in ammoniaSeries of incidents and problems in ammoniaplants and low temperature air separationplants and low temperature air separationplants in early 1950splants in early 1950s

νν Chemical Engineering ProgressChemical Engineering Progress article in article inNovember 1956 on November 1956 on ““Safe Design and OperationSafe Design and Operationof Low Temperature Air Separation Plantsof Low Temperature Air Separation Plants””invited interested people to discuss subject atinvited interested people to discuss subject atDecember December AIChE AIChE meeting in Bostonmeeting in Boston

νν Over 100 people turned up, had to move to aOver 100 people turned up, had to move to abigger roombigger room

Safety in Ammonia and RelatedSafety in Ammonia and RelatedFacilitiesFacilities

νν Agreed to organize symposium forAgreed to organize symposium forSeptember 1957 September 1957 AIChE AIChE Meeting inMeeting inBaltimore Baltimore –– Norton Walton of Atlantic Norton Walton of AtlanticRefining was a key organizerRefining was a key organizer

νν The 50The 50thth Safety in Ammonia Plants and Safety in Ammonia Plants andRelated Facilities Symposium will be heldRelated Facilities Symposium will be heldSeptember 25-29, 2005 in TorontoSeptember 25-29, 2005 in Toronto

Loss Prevention SymposiumLoss Prevention Symposium

νν In early 1960s, a series of large fires andIn early 1960s, a series of large fires andexplosions occurred in oil andexplosions occurred in oil andpetrochemical plantspetrochemical plants

νν Symposium on Loss Prevention in theSymposium on Loss Prevention in theChemical Industry organized by RussellChemical Industry organized by RussellMiller (Monsanto) and William DoyleMiller (Monsanto) and William Doyle(Factory Insurance Association)(Factory Insurance Association)

νν AIChE AIChE National Meeting, Houston, 1967National Meeting, Houston, 1967

The first LPS paper - 1967The first LPS paper - 1967

Case Study of IncidentInvolving Acetylenic Alcohol

Fred Lorentz

Hoffman-Laroche

The responseThe response““The first meeting was held at the old convention center inThe first meeting was held at the old convention center in

HoustonHouston……the separating walls for the meeting roomsthe separating walls for the meeting roomsseemed to be paper thin. The acoustics were not tooseemed to be paper thin. The acoustics were not toogood and the air conditioning miserable. That couldgood and the air conditioning miserable. That couldhave killed the whole idea right then, but the agendahave killed the whole idea right then, but the agendawas filled with great topics by terrific speakers. Thewas filled with great topics by terrific speakers. Theaudience must have been mesmerized, probably withaudience must have been mesmerized, probably withthe thought that we have to continue these meetings.the thought that we have to continue these meetings.Here we are some 38 years laterHere we are some 38 years later…”…”

Ted Ted VentroneVentroneFounding editor of Founding editor of Process Safety ProgressProcess Safety Progress

Attendee at the first Loss Prevention SymposiumAttendee at the first Loss Prevention Symposium

Loss Prevention SymposiumLoss Prevention Symposium

νν The 40The 40thth Annual Loss Prevention Annual Loss PreventionSymposium will be held as a part of theSymposium will be held as a part of the22ndnd Annual World Congress on Process Annual World Congress on ProcessSafety in April 2006 in OrlandoSafety in April 2006 in Orlando

AIChE AIChE Safety and Health DivisionSafety and Health Division

νν Formed in 1979Formed in 1979νν Assumed responsibility for programming inAssumed responsibility for programming in

process safety areas (ammonia safety and lossprocess safety areas (ammonia safety and lossprevention)prevention)

νν Currently ~ 1000 members out of an Currently ~ 1000 members out of an AIChEAIChEmembership of about 35,000membership of about 35,000

νν Large fraction of membership have a primaryLarge fraction of membership have a primaryjob function in research, process developmentjob function in research, process developmentand design, and plant operationsand design, and plant operations

Sharing informationSharing information

νν For many years, LPS Proceedings published in aFor many years, LPS Proceedings published in ahigh quality, glossy booklet formathigh quality, glossy booklet format

νν In early 1980s, economic constraints forcedIn early 1980s, economic constraints forcedAIChE AIChE to stop publication of full proceedings ofto stop publication of full proceedings ofLoss Prevention SymposiaLoss Prevention Symposia

νν In 1982, In 1982, AIChE AIChE and the Safety and Healthand the Safety and HealthDivision sponsored publication of the journalDivision sponsored publication of the journalPlant/Operations ProgressPlant/Operations Progress (subsequently (subsequentlychanged to changed to Process Safety Progress) Process Safety Progress) to publishto publishthe best of the Loss Prevention papers, andthe best of the Loss Prevention papers, andpapers from other sourcespapers from other sources

Process Safety ProgressProcess Safety Progress

νν Now published byNow published byWiley for Wiley for AIChE AIChE andandthe Safety and Healththe Safety and HealthDivisionDivision

νν Entire contents forEntire contents forVolumes 1-24 areVolumes 1-24 areavailable on line fromavailable on line fromthe Wiley web sitethe Wiley web site

AIChEAIChE Safety and Health Division Safety and Health Division

νν Publishing economics permitted resumption ofPublishing economics permitted resumption ofLoss Prevention Proceedings in 1990sLoss Prevention Proceedings in 1990s

νν Thanks to John Davenport of Industrial RiskThanks to John Davenport of Industrial RiskInsurers, ALL papers presented at all LossInsurers, ALL papers presented at all LossPrevention Symposia, including the years whenPrevention Symposia, including the years whenno formal proceedings book was published,no formal proceedings book was published,were preservedwere preserved

νν ~ 1998 the Division approved a project to~ 1998 the Division approved a project todigitize all Loss Prevention Symposium papersdigitize all Loss Prevention Symposium papers

LPS/CCPS CDLPS/CCPS CD

νν All papers presented atAll papers presented atLoss PreventionLoss PreventionSymposium and CCPSSymposium and CCPSConferences throughConferences through20032003

νν Currently being updatedCurrently being updatedto include 2004-2005to include 2004-2005

νν Full text searchableFull text searchable

Design Institute for EmergencyDesign Institute for EmergencyRelief Systems (DIERS)Relief Systems (DIERS)

νν Formed as an Formed as an AIChEAIChE industry alliance in early 1976 by industry alliance in early 1976 by29 companies to develop methods for design of29 companies to develop methods for design ofemergency relief systems for runaway reactionsemergency relief systems for runaway reactions

νν Initial project complete in 1985, developedInitial project complete in 1985, developedmathematical modeling tools and analytical equipmentmathematical modeling tools and analytical equipment(Vent Sizing Package [VSP] calorimeter)(Vent Sizing Package [VSP] calorimeter)

νν Continues to promote technology development andContinues to promote technology development andsharing as DIERS Users Groupsharing as DIERS Users Group

νν Periodic technical meetings and symposiaPeriodic technical meetings and symposia–– AIChEAIChE National Meeting, October 30 National Meeting, October 30 –– November 4, 2005 in November 4, 2005 in

CincinnatiCincinnati

Center for Chemical Process SafetyCenter for Chemical Process Safety

νν Bhopal Bhopal –– December 1984 December 1984νν In response, In response, AIChE AIChE formed CCPS asformed CCPS as

an industry alliance to promotean industry alliance to promoteprocess safetyprocess safety

νν Technical focus Technical focus –– not intended to not intended topromote policies or regulationspromote policies or regulations

νν Initially, 13 corporate sponsorsInitially, 13 corporate sponsors

The first CCPS productThe first CCPS product

νν Sold over 2000 copiesSold over 2000 copiesin first year (1985)in first year (1985)

νν Second edition withSecond edition withsignificantly expandedsignificantly expandedcontent in 1992,content in 1992,continues to be acontinues to be aprimary referenceprimary reference

νν Proposal for 3Proposal for 3rdrd edition editionin next couple of yearsin next couple of years

CCPS TodayCCPS Today

νν Over 80 sponsorsOver 80 sponsorsνν Over 70 publications and software products related toOver 70 publications and software products related to

process safetyprocess safety–– For example, process safety management, risk assessment,For example, process safety management, risk assessment,

vapor cloud dispersion, reactivity hazards, incidentvapor cloud dispersion, reactivity hazards, incidentinvestigation, batch processing, inherently safer design, etc.investigation, batch processing, inherently safer design, etc.

–– Available on line by subscription through Available on line by subscription through Knovel Knovel Corp.Corp.

νν Sponsors SACHE (Safety and Chemical EngineeringSponsors SACHE (Safety and Chemical EngineeringEducation) to promote process safety content inEducation) to promote process safety content inchemical engineering university curriculachemical engineering university curricula

νν 20 annual international conferences 20 annual international conferences –– all content all contentavailable on Loss Prevention/CCPS Conference CDavailable on Loss Prevention/CCPS Conference CD

CCPS Collaborative ActivitiesCCPS Collaborative Activitiesνν Security Vulnerability Analysis (SVA) Security Vulnerability Analysis (SVA) –– developed developed

guidelines and made available on line at no charge,guidelines and made available on line at no charge,close collaboration with DHS, ACC, SOCMA, API, ASME,close collaboration with DHS, ACC, SOCMA, API, ASME,others.others.

νν Reactive Chemistry hazards Reactive Chemistry hazards –– Developed Developed ““EssentialEssentialPractices for Managing Chemical Reactivity HazardsPractices for Managing Chemical Reactivity Hazards””available for on line viewing with sponsorship by OSHA,available for on line viewing with sponsorship by OSHA,EPA, SOCMA, ACC, and EPA, SOCMA, ACC, and KnovelKnovel Corporation Corporation

νν Process Safety Beacon Process Safety Beacon –– monthly safety messages monthly safety messagesaimed at operating personnel, distributed electronicallyaimed at operating personnel, distributed electronicallyfree of chargefree of charge

νν Safety Alerts Safety Alerts –– available for free download from CCPS available for free download from CCPSweb siteweb site

νν Reactivity Management Roundtable Reactivity Management Roundtable –– collaboration with collaboration withEPA and OSHA to share information on reactiveEPA and OSHA to share information on reactivechemistry hazard managementchemistry hazard management

Process Plant Safety SymposiumProcess Plant Safety Symposium

νν First held in 1992 as a local event by the SouthFirst held in 1992 as a local event by the SouthTexas Section of Texas Section of AIChEAIChE in Houston in Houston

νν Participation from all over the US, and evenParticipation from all over the US, and evenoverseasoverseas

νν Focus more on practical, Focus more on practical, ““hands onhands on”” safety safetyinformation for chemists and engineers involvedinformation for chemists and engineers involvedin day to day operation of plantsin day to day operation of plants

νν Enthusiastic response, sessions had to beEnthusiastic response, sessions had to berepeated because rooms filled to capacityrepeated because rooms filled to capacity

Process Plant Safety SymposiumProcess Plant Safety Symposium

νν Continued to be held every two years, atContinued to be held every two years, atfirst by South Texas Section,first by South Texas Section,subsequently sponsored by subsequently sponsored by AIChE AIChE SafetySafetyand Health Divisionand Health Division

νν Now part of Global Congress on ProcessNow part of Global Congress on ProcessSafety, along with Loss PreventionSafety, along with Loss PreventionSymposium and CCPS Annual ConferenceSymposium and CCPS Annual Conference

Global Congress on Process SafetyGlobal Congress on Process Safety

νν First held in April 2005 in Atlanta at First held in April 2005 in Atlanta at AIChEAIChESpring National MeetingSpring National Meeting–– Loss Prevention SymposiumLoss Prevention Symposium–– CCPS Annual ConferenceCCPS Annual Conference–– Process Plant Safety SymposiumProcess Plant Safety Symposium

νν Nearly 100 technical papers covering allNearly 100 technical papers covering allaspects of process safety over a threeaspects of process safety over a threeday period, mostly in 3 parallel sessionsday period, mostly in 3 parallel sessionson specific topicson specific topics

Future plansFuture plans

νν 22ndnd Global Congress in April 2006 in Global Congress in April 2006 inOrlando, FLOrlando, FL

νν As a result of attendee feedback, ProcessAs a result of attendee feedback, ProcessPlant Safety Symposium frequencyPlant Safety Symposium frequencyincreased to annual from every two yearsincreased to annual from every two years

What next What next –– future challenges future challenges

νν Globalization of the chemical industryGlobalization of the chemical industry–– Establishing safety culture in developing countriesEstablishing safety culture in developing countries

νν Continued economic pressures Continued economic pressures –– need to do need to domore with less resourcesmore with less resources

νν Maintaining a good process safety culture andMaintaining a good process safety culture andmanagement system at a time of frequentmanagement system at a time of frequentmergers, acquisitions, divestitures, and othermergers, acquisitions, divestitures, and otherbusiness environment changesbusiness environment changes

νν Chemical process safety in industries other thanChemical process safety in industries other thanthe traditional Chemical Process Industrythe traditional Chemical Process Industry(biotechnology, electronics, food,(biotechnology, electronics, food,pharmaceuticals, etc.)pharmaceuticals, etc.)

What next What next –– future challenges future challenges

νν ComplacencyComplacency–– Do some people think that process safety is aDo some people think that process safety is a

problem which has been solved?problem which has been solved?–– Will good experience threaten the programs that areWill good experience threaten the programs that are

responsible for that good experience?responsible for that good experience?

νν Education and awareness in broad industryEducation and awareness in broad industrycommunitycommunity–– Walt Howard (Monsanto) 1984 paper inWalt Howard (Monsanto) 1984 paper in

Plant/Operations Progress Plant/Operations Progress ““We We AinAin’’t Farmint Farmin’’ As GoodAs GoodAs We Know HowAs We Know How””

–– Examples Examples –– reactivity hazards, dust explosions reactivity hazards, dust explosions

New problems, or modern versionsNew problems, or modern versionsof the same old problems?of the same old problems?