Process Safety beacon is published by CCPS every month. Center for Chemical Process Safety (CCPS) is the Global community for providing Safety needs for all chemical, Petroleum and Pharmaceutical Industries which is a part of American Institute of Chemical Engineers (AICHE) .SACHE is a program established by CCPS called Safety and Chemical Engineering Education. It was initiated in the year 1992.
Process Safety Beacon – Messages for Manufacturing Personnel
Process Safety Beacon is an Industrial Safety tool for conveying One Page Safety message for manufacturing personnel every month. First Edition was published in 2001. And now it is available in about 30 Languages including Indian Languages like Tamil, Telugu & Hindi. This regional language support will help the industry personnel to train the contract labor also. Process safety beacon analyses industrial safety issues in detail to avoid the accidents to happen again.
Every Process safety beacon analyses the safety incident for 5 W’s.
Who is it about?
What happened?
When did it take place?
Where did it take place?
Why did it happen?
The Industrial accidents are analyzed for the root causes and gives solutions for the manufacturing personnel to avert such incidents in future. Every issue comes with a solution – What you can do? It is really a worth tip to have and follow in carrying out the jobs safely in any Industry.
Download Process Safety Beacon
All the issues of Process Safety beacon are available online in PDF formats for free. You can use it for educating your Industry personnel to make them sound in Process Safety. Archives can be accessed here. The back issues from year 2001 till 2022 are available for download.
Website
http://www.sache.org/beacon/products.asp
| S No | Month | Year | Topic | Download Link |
|---|---|---|---|---|
| 260 | 06 | 2023 | Sense of vulnerability – a very important safety component | Download here |
| 259 | 05 | 2023 | Wrong material + Wrong tank = Trouble | Download here |
| 258 | 04 | 2023 | Lifting Hazards | Download here |
| 257 | 03 | 2023 | Toxic Gases | Download here |
| 256 | 02 | 2023 | People are a critical part of safe operations | Download here |
| 255 | 01 | 2023 | Effects from changes may take years to appear | Download here |
| 254 | 12 | 2022 | Take safety home for the holidays | Download here |
| 253 | 11 | 2022 | Idle Does Not Mean Safe | Download here |
| 252 | 10 | 2022 | Communication – the heart of safe operations | Download here |
| 251 | 09 | 2022 | Lightning Strikes – YIKES!! | Download here |
| 250 | 08 | 2022 | What’s an Acceptable LEL Detector Reading? | Download here |
| 249 | 07 | 2022 | Manage Temporary Changes – Including Clamps! | Download here |
| 248 | 06 | 2022 | Some mistakes take time to become incidents | Download here |
| 247 | 05 | 2022 | “ What happens if ?” An important question for hazard reviews | Download here |
| 246 | 04 | 2022 | Process Safety lessons from a ship fire | Download here |
| 245 | 03 | 2022 | Hot Work is more than Welding, Burning & Grinding | Download here |
| 244 | 02 | 2022 | Piping Dead Legs – Another hazard in plain sight! | Download here |
| 243 | 01 | 2022 | The drawing and procedures were missing some things | Download here |
| 242 | 12 | 2021 | Situational Awareness: A key to avoiding errors | Download here |
| 241 | 11 | 2021 | Happy 20th Anniversary - Process Safety Beacon | Download here |
| 240 | 10 | 2021 | How do you know your safety devices are working? | Download here |
| 239 | 09 | 2021 | Does your nose really know? Probably not! | Download here |
| 238 | 08 | 2021 | Explosion of a tank containing “mostly water” | Download here |
| 237 | 07 | 2021 | Cyber security and chemical operations | Download here |
| 236 | 06 | 2021 | Combustible dust hazards are everywhere! | Download here |
| 235 | 05 | 2021 | Valve position errors can cause serious incidents | Download here |
| 234 | 04 | 2021 | Recent nitrogen fatalities are a vivid reminder | Download here |
| 233 | 03 | 2021 | Do not allow your relief device vents to be a hazard | Download here |
| 232 | 02 | 2021 | Static discharges are frequent ignition sources | Download here |
| 231 | 01 | 2021 | Material Identification - The first link in the process safety system | Download here |
| 230 | 12 | 2020 | Reactive Chemistry Incidents Can Happen Anywhere! | Download here |
| 229 | 11 | 2020 | Not all vibrations in process equipment are good vibrations | Download here |
| 228 | 10 | 2020 | Hazardous Chemicals Hidden in Plain Sight | Download here |
| 227 | 09 | 2020 | Hand Sanitizer Hazards at Home and Work | Download here |
| 226 | 08 | 2020 | Where to Check the LFL Before Hot Work? | Download here |
| 225 | 07 | 2020 | Process interruptions: a threat to process safety | Download here |
| 224 | 06 | 2020 | Can a “fail open” valve fail closed? | Download here |
| 223 | 05 | 2020 | Permitted Work – a special cause | Download here |
| 222 | 04 | 2020 | A Hidden Chain of Hazards | Download here |
| 221 | 03 | 2020 | Vacuum Trucks can Catch Fire and Explode! | Download here |
| 220 | 02 | 2020 | A Small Word with a lot of Power - ASK!! | Download here |
| 219 | 01 | 2020 | Housekeeping is more than "pretty" - its about safety | Download here |
| 218 | 12 | 2019 | Well-Identified Flying Objects | Download here |
| 217 | 11 | 2019 | What Does That Button Do? | Download here |
| 216 | 10 | 2019 | Sluggish control systems – a warning sign | Download here |
| 215 | 09 | 2019 | Plugged line & equipment – More than a nuisance | Download here |
| 214 | 08 | 2019 | Hidden Hazards! | Download here |
| 213 | 07 | 2019 | Small leak leads to catastrophic failure | Download here |
| 212 | 06 | 2019 | Corrosion under insulation | Download here |
| 211 | 05 | 2019 | Surrounded by warning signs? | Download here |
| 210 | 04 | 2019 | What if that wrong instrument reading is correct? | Download here |
| 209 | 03 | 2019 | Undetected Ball Valve Failure | Download here |
| 208 | 02 | 2019 | Critical safeguards must be kept functional! | Download here |
| 207 | 01 | 2019 | Process Safety Stories | Download here |
| 206 | 12 | 2018 | Common Cause Failures | Download here |
| 205 | 11 | 2018 | Accumulation of small changes leads to an explosion | Download here |
| 204 | 10 | 2018 | Hazardous Energy! | Download here |
| 203 | 09 | 2018 | What if your process is acting differently? | Download here |
| 202 | 08 | 2018 | What if your agitator fails? | Download here |
| 201 | 07 | 2018 | Can overcooling a reactor cause a runaway reaction? | Download here |
| 200 | 06 | 2018 | Safe Work Permits – Understand the Scope of Work | Download here |
| 199 | 05 | 2018 | Aging Process Facilities and Infrastructure | Download here |
| 198 | 04 | 2018 | Maintain a Sense of Vulnerability | Download here |
| 197 | 03 | 2018 | Reporting and Investigating Near Misses | Download here |
| 196 | 02 | 2018 | Runaway Reactions Caused by Contamination | Download here |
| 195 | 01 | 2018 | Could your plant be impacted by a natural disaster? | Download here |
| 194 | 12 | 2017 | Liquefied Gases | Download here |
| 193 | 11 | 2017 | Purged Enclosures in Hazardous Areas | Download here |
| 192 | 10 | 2017 | Are your alarms alarming? | Download here |
| 191 | 09 | 2017 | Haste Makes Waste! | Download here |
| 190 | 08 | 2017 | Vulnerable Piping | Download here |
| 189 | 07 | 2017 | Management of Change | Download here |
| 188 | 06 | 2017 | Incident Investigation of a Steam Pipe Failure | Download here |
| 187 | 05 | 2017 | Corroded Tanks | Download here |
| 186 | 04 | 2017 | Are you sure that vessel is empty? | Download here |
| 185 | 03 | 2017 | …but the temperature was below the flash point! | Download here |
| 184 | 02 | 2017 | Mixing Incompatible Materials in Storage Tanks | Download here |
| 183 | 01 | 2017 | Hazards of High Oxygen Concentration | Download here |
| 182 | 12 | 2016 | Ignition Sources – Once More | Download here |
| 181 | 11 | 2016 | 15 Years of the Process Safety Beacon! | Download here |
| 180 | 10 | 2016 | Process safety in the laboratory | Download here |
| 179 | 09 | 2016 | Can you recognize a change? | Download here |
| 178 | 08 | 2016 | A little static can cause a big fire! | Download here |
| 177 | 07 | 2016 | Understanding chemical compatibility | Download here |
| 176 | 06 | 2016 | Dangerous chemical reactions at home! | Download here |
| 175 | 05 | 2016 | More repeat incidents! | Download here |
| 174 | 04 | 2016 | Plugged flame arrestor causes explosion! | Download here |
| 173 | 03 | 2016 | Safety Device or Control Device? | Download here |
| 172 | 02 | 2016 | Still Overflowing Tanks! | Download here |
| 171 | 01 | 2016 | Hydrate Hazards | Download here |
| 170 | 12 | 2015 | Stop! Look! Listen! | Download here |
| 169 | 11 | 2015 | Wrong hose causes ammonia leak | Download here |
| 168 | 10 | 2015 | Water, water, everywhere... | Download here |
| 167 | 09 | 2015 | Unloading and Loading Hazardous Materials | Download here |
| 166 | 08 | 2015 | Operational Readiness | Download here |
| 165 | 07 | 2015 | Know when to leave! | Download here |
| 164 | 06 | 2015 | Conduct of Operations | Download here |
| 163 | 05 | 2015 | Mechanical Integrity | Download here |
| 162 | 04 | 2015 | Safe Work Practices | Download here |
| 161 | 03 | 2015 | Details Matter in Process Safety! | Download here |
| 160 | 02 | 2015 | Who are all these people? | Download here |
| 159 | 01 | 2015 | What is the Process Risk? | Download here |
| 158 | 12 | 2014 | Bhopal – The Worst Industrial Disaster in History | Download here |
| 157 | 11 | 2014 | Thirty Years Ago – An LPG Tragedy | Download here |
| 156 | 10 | 2014 | Dust Explosions - Clean up this Hazard! | Download here |
| 155 | 09 | 2014 | What is your role in Hazard Identification and Risk Analysis? | Download here |
| 154 | 08 | 2014 | Ignition Sources | Download here |
| 153 | 07 | 2014 | Persistence – Good or Bad? | Download here |
| 152 | 06 | 2014 | A Safety Device Gone Wrong! | Download here |
| 151 | 05 | 2014 | Major Spills and Environmental Incidents | Download here |
| 150 | 04 | 2014 | How do you measure process safety performance? | Download here |
| 149 | 03 | 2014 | Don’t forget about occupational safety! | Download here |
| 148 | 02 | 2014 | Are we reliving past incidents? | Download here |
| 147 | 01 | 2014 | Corrosion Under Insulation | Download here |
| 146 | 12 | 2013 | Hazards of strong oxidizers | Download here |
| 145 | 11 | 2013 | Holiday Operations | Download here |
| 144 | 10 | 2013 | Electrical Equipment in Hazardous Areas | Download here |
| 143 | 09 | 2013 | Air Power! | Download here |
| 142 | 08 | 2013 | Can a Water Pump Explode? | Download here |
| 141 | 07 | 2013 | Remembering Piper Alpha | Download here |
| 140 | 06 | 2013 | Why Can't I Open That Valve? | Download here |
| 139 | 05 | 2013 | Pressure relief valve bonnets - to plug or not to plug? | Download here |
| 138 | 04 | 2013 | Have you heard a pressure relief valve chatter? | Download here |
| 137 | 03 | 2013 | Are your signs and labels confusing? | Download here |
| 136 | 02 | 2013 | What is supporting your equipment? | Download here |
| 135 | 01 | 2013 | Some Answers to the November 2012 Beacon “Find the Problem” Contest | Download here |
| 134 | 12 | 2012 | Good Housekeeping for Safety! | Download here |
| 133 | 11 | 2012 | Can you find the safety problem? | Download here |
| 132 | 10 | 2012 | Manage Temporary Changes! | Download here |
| 131 | 09 | 2012 | What can I do? I'm just the operator! | Download here |
| 130 | 08 | 2012 | Hot work Hazards | Download here |
| 129 | 07 | 2012 | Emergency Preparation – The Titanic Disaster | Download here |
| 128 | 06 | 2012 | Nitrogen - Hazard and Safeguard | Download here |
| 127 | 05 | 2012 | Mechanical Integrity of Tubing | Download here |
| 126 | 04 | 2012 | What if you unload the wrong material into a tank? | Download here |
| 125 | 03 | 2012 | Double Block and Bleed | Download here |
| 124 | 02 | 2012 | Mechanical Integrity – The Bolts Are Too Short! | Download here |
| 123 | 01 | 2012 | What happens when the lights go out? | Download here |
| 122 | 12 | 2011 | Caps and Plugs - One Day You Will Miss Them! | Download here |
| 121 | 11 | 2011 | One Incident – Three Beacons! | Download here |
| 120 | 10 | 2011 | Hose Hazards! | Download here |
| 119 | 09 | 2011 | Hazards from Abandoned Equipment | Download here |
| 118 | 08 | 2011 | Flammable Vapor Release Hazards in Congested Areas | Download here |
| 117 | 07 | 2011 | Shift Work | Download here |
| 116 | 06 | 2011 | Are you prepared for a natural disaster? | Download here |
| 115 | 05 | 2011 | Flammable material release inside building causes explosion! | Download here |
| 114 | 04 | 2011 | Don 't let a small leak become a big leak! | Download here |
| 113 | 03 | 2011 | Bad things can come in small packages! | Download here |
| 112 | 02 | 2011 | Understand the Reactivity of Your Heat Transfer Fluid! | Download here |
| 111 | 01 | 2011 | Vapor Cloud Explosions | Download here |
| 110 | 12 | 2010 | Are You Ready for Winter? | Download here |
| 109 | 11 | 2010 | Two valve actuator rupture incidents! | Download here |
| 108 | 10 | 2010 | Hazardous Material Storage and Shipment | Download here |
| 107 | 09 | 2010 | Has anybody seen our process safety information (PSI)? | Download here |
| 106 | 08 | 2010 | Early lessons from a tragedy | Download here |
| 105 | 07 | 2010 | Passive Safety Equipment | Download here |
| 104 | 06 | 2010 | Containment Dikes and Pads | Download here |
| 103 | 05 | 2010 | Fireproofing Structural Supports | Download here |
| 102 | 04 | 2010 | Fire Protection - Long Bolt Flangeless Valves | Download here |
| 101 | 03 | 2010 | Facility Siting | Download here |
| 100 | 02 | 2010 | Lest We Forget! | Download here |
| 099 | 01 | 2010 | Corrosion and Erosion | Download here |
| 098 | 12 | 2009 | The Bhopal Tragedy – 25 Years Ago | Download here |
| 097 | 11 | 2009 | BLEVE! | Download here |
| 096 | 10 | 2009 | Overflow + Ignition = Tank Farm Fire! (Part 2) | Download here |
| 095 | 09 | 2009 | Overflow + Ignition = Tank Farm Fire! (Part 1) | Download here |
| 094 | 08 | 2009 | Never underestimate the hazard! | Download here |
| 093 | 07 | 2009 | What is a Safety Instrumented System? | Download here |
| 092 | 06 | 2009 | Don’t forget safety in a difficult economy! | Download here |
| 091 | 05 | 2009 | Mechanical integrity | Download here |
| 090 | 04 | 2009 | Be Prepared! | Download here |
| 089 | 03 | 2009 | Fatality caused by unloading the wrong chemical into a storage tank! | Download here |
| 088 | 02 | 2009 | More lessons from fire while filling containers | Download here |
| 087 | 01 | 2009 | Fire while filling portable container! | Download here |
| 086 | 12 | 2008 | Static Electric Discharge Causes Fire | Download here |
| 085 | 11 | 2008 | Laboratory Refrigerator Explosions – Electrical Classification | Download here |
| 084 | 10 | 2008 | Ice ruptures unused pipe and causes fire! | Download here |
| 083 | 09 | 2008 | Plant Security | Download here |
| 082 | 08 | 2008 | Measuring process safety performance | Download here |
| 081 | 07 | 2008 | What is process safety? | Download here |
| 080 | 06 | 2008 | Halon cylinder becomes rocket! | Download here |
| 079 | 05 | 2008 | Is sugar an explosion hazard? | Download here |
| 078 | 04 | 2008 | Gasoline pipeline damaged by construction causes fire | Download here |
| 077 | 03 | 2008 | Do your shutoff systems actually work? | Download here |
| 076 | 02 | 2008 | How Can You Use “The Beacon”? | Download here |
| 075 | 01 | 2008 | 2007 Beacon Review – Remember the Lessons Learned! | Download here |
| 074 | 12 | 2007 | Oil Tank Fire Caused by Static Discharge | Download here |
| 073 | 11 | 2007 | Cold Embrittlement and Thermal Stress | Download here |
| 072 | 10 | 2007 | We Have Liftoff! | Download here |
| 071 | 09 | 2007 | Hot Work Permits | Download here |
| 070 | 08 | 2007 | Hazards of Temporary Confined Spaces | Download here |
| 069 | 07 | 2007 | Fire Caused by Hose Repaired with Duct Tape! | Download here |
| 068 | 06 | 2007 | Process Safety Culture | Download here |
| 067 | 05 | 2007 | The Great Boston Molasses Flood of 1919 | Download here |
| 066 | 04 | 2007 | Mr. Potato Head Is Down! | Download here |
| 065 | 03 | 2007 | Instrumentation - Can you be fooled by it? | Download here |
| 064 | 02 | 2007 | Vacuum hazards - collapsed tanks | Download here |
| 063 | 01 | 2007 | 2006 Beacon Review - Remember the lessons learned | Download here |
| 062 | 12 | 2006 | Liquified gas cylinder failure | Download here |
| 061 | 11 | 2006 | Hazards of relief devices in series | Download here |
| 060 | 10 | 2006 | Do you store cylinders properly? | Download here |
| 059 | 09 | 2006 | Overfilling Tanks - What happened? | Download here |
| 058 | 08 | 2006 | Static electricity | Download here |
| 057 | 07 | 2006 | Do you have storage pallets that look like this? | Download here |
| 056 | 06 | 2006 | Is this valve open, or closed? | Download here |
| 055 | 05 | 2006 | Dust explosion hazards | Download here |
| 054 | 04 | 2006 | Mechanical integrity | Download here |
| 053 | 03 | 2006 | Pressure relief systems - do you see any hazards here? | Download here |
| 052 | 02 | 2006 | 2005 Beacon Review | Download here |
| 051 | 01 | 2006 | Time sensitive chemicals | Download here |
| 050 | 12 | 2005 | Startup hazards | Download here |
| 049 | 11 | 2005 | Hurricane Katrina - Emergency response and recovery | Download here |
| 048 | 10 | 2005 | Gas leak destroys plant | Download here |
| 047 | 09 | 2005 | September 11, 2001 - Never to be Forgotten! | Download here |
| 046 | 08 | 2005 | Toxic reaction in sewer is fatal | Download here |
| 045 | 07 | 2005 | Piper Alpha Oil Platform Destroyed | Download here |
| 044 | 06 | 2005 | Too many start-stop switches | Download here |
| 043 | 05 | 2005 | Storage area completely destroyed | Download here |
| 042 | 04 | 2005 | Pressure explosion results | Download here |
| 041 | 03 | 2005 | Tower top rockets off | Download here |
| 040 | 02 | 2005 | Insulation does not prevent corrosion | Download here |
| 039 | 01 | 2005 | 2004 in review - remember the lessons learned | Download here |
| 038 | 12 | 2004 | Bhopal - a tragic event | Download here |
| 037 | 11 | 2004 | Unapproved procedure change = fire | Download here |
| 036 | 10 | 2004 | Available when needed? | Download here |
| 035 | 09 | 2004 | Overflow + Ignition Source = Tank Farm Fire | Download here |
| 034 | 08 | 2004 | Chlorine transfer hose failure | Download here |
| 033 | 07 | 2004 | Misalignment + Corrosion = Failure! | Download here |
| 032 | 06 | 2004 | Flixborough - 30 years ago | Download here |
| 031 | 05 | 2004 | Start your hot work safely | Download here |
| 030 | 04 | 2004 | Do you see the hazard? | Download here |
| 029 | 03 | 2004 | The electricity just went off | Download here |
| 028 | 02 | 2004 | Flammable gas in enclosed space = BOOM! | Download here |
| 027 | 01 | 2004 | Avoid improper fuel to air mixtures | Download here |
| 026 | 12 | 2003 | Trees, trees, confusing trees | Download here |
| 025 | 11 | 2003 | But the pressure rating was OK! | Download here |
| 024 | 10 | 2003 | Don't pop your top | Download here |
| 023 | 09 | 2003 | Dust did this! | Download here |
| 022 | 08 | 2003 | Simply mixing chemicals | Download here |
| 021 | 07 | 2003 | Static Electricity + Flammables + Air = ?? | Download here |
| 020 | 06 | 2003 | Interlocked for a reason | Download here |
| 019 | 05 | 2003 | A good idea could turn bad | Download here |
| 018 | 04 | 2003 | What? No spark? | Download here |
| 017 | 03 | 2003 | Reactive Chemistry - Not always when or where you want it | Download here |
| 016 | 02 | 2003 | How Well Are You Trained to Respond to Fires? | Download here |
| 015 | 01 | 2003 | Check the clearance | Download here |
| 014 | 12 | 2002 | Security – It’s everybody’s Job | Download here |
| 013 | 11 | 2002 | What has your steam up? | Download here |
| 012 | 10 | 2002 | It’s a bird, it’s a plane, it’s A PUMP! | Download here |
| 011 | 09 | 2002 | In Remembrance of September 11th, 2001 | Download here |
| 010 | 08 | 2002 | Faster than a speeding bullet | Download here |
| 009 | 07 | 2002 | The seal that didn't perform | Download here |
| 008 | 06 | 2002 | Don't get your pipes in a twist | Download here |
| 007 | 05 | 2002 | And he blew the house down | Download here |
| 006 | 04 | 2002 | The cylinder that got away | Download here |
| 005 | 03 | 2002 | Layers of Protection | Download here |
| 004 | 02 | 2002 | Vacuum is a powerful force! | Download here |
| 003 | 01 | 2002 | Explosions | Download here |
| 002 | 12 | 2001 | Snow and Ice Hazards – they can cause more than slips and falls! | Download here |
| 001 | 11 | 2001 | Trace quantities of flammables can cause an event like this! | Download here |
The EPSC Learning Sheets are meant to stimulate discussion on important process safety topics at operational sites, to improve competency & awareness in a pleasant format.
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Related Books:
Buy What Went Wrong?: Case Studies of Process Plant Disasters By Kletz from Flipkart.com
Buy Process Safety and Loss Prevention By Mohanad El-harbawi from Flipkart.com
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