Chemical Engineering Site

Safety Beacon – Chemical Process Safety Tool

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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 NoMonthYearTopicDownload Link
260062023Sense of vulnerability – a very important safety componentDownload here
259052023Wrong material + Wrong tank = TroubleDownload here
258042023 Lifting HazardsDownload here
257032023Toxic GasesDownload here
256022023People are a critical part of safe operations Download here
255012023Effects from changes may take years to appearDownload here
254122022Take safety home for the holidaysDownload here
253112022Idle Does Not Mean SafeDownload here
252102022Communication – the heart of safe operationsDownload here
251092022Lightning Strikes – YIKES!!Download here
250082022What’s an Acceptable LEL Detector Reading?Download here
249072022Manage Temporary Changes – Including Clamps!Download here
248062022Some mistakes take time to become incidentsDownload here
247052022“ What happens if ?” An important question for hazard reviewsDownload here
246042022Process Safety lessons from a ship fireDownload here
245032022Hot Work is more than Welding, Burning & GrindingDownload here
244022022 Piping Dead Legs – Another hazard in plain sight!Download here
243012022The drawing and procedures were missing some thingsDownload here
242122021Situational Awareness: A key to avoiding errorsDownload here
241112021Happy 20th Anniversary - Process Safety BeaconDownload here
240102021How do you know your safety devices are working?Download here
239092021Does your nose really know? Probably not!Download here
238082021Explosion of a tank containing “mostly water”Download here
237072021Cyber security and chemical operationsDownload here
236062021Combustible dust hazards are everywhere!Download here
235052021Valve position errors can cause serious incidentsDownload here
234042021Recent nitrogen fatalities are a vivid reminderDownload here
233032021Do not allow your relief device vents to be a hazardDownload here
232022021Static discharges are frequent ignition sourcesDownload here
231012021Material Identification - The first link in the process safety systemDownload here
230122020Reactive Chemistry Incidents Can Happen Anywhere!Download here
229112020Not all vibrations in process equipment are good vibrationsDownload here
228102020Hazardous Chemicals Hidden in Plain SightDownload here
227092020Hand Sanitizer Hazards at Home and WorkDownload here
226082020Where to Check the LFL Before Hot Work?Download here
225072020Process interruptions: a threat to process safety Download here
224062020Can a “fail open” valve fail closed? Download here
223052020Permitted Work – a special causeDownload here
222042020A Hidden Chain of HazardsDownload here
221032020Vacuum Trucks can Catch Fire and Explode!Download here
220022020A Small Word with a lot of Power - ASK!!Download here
219012020Housekeeping is more than "pretty" - its about safetyDownload here
218122019Well-Identified Flying ObjectsDownload here
217112019What Does That Button Do?Download here
216102019Sluggish control systems – a warning signDownload here
215092019Plugged line & equipment – More than a nuisanceDownload here
214082019Hidden Hazards!Download here
213072019Small leak leads to catastrophic failureDownload here
212062019Corrosion under insulationDownload here
211052019Surrounded by warning signs?Download here
210042019What if that wrong instrument reading is correct?Download here
209032019Undetected Ball Valve FailureDownload here
208022019Critical safeguards must be kept functional!Download here
207012019Process Safety StoriesDownload here
206122018Common Cause FailuresDownload here
205112018Accumulation of small changes leads to an explosionDownload here
204102018Hazardous Energy!Download here
203092018What if your process is acting differently?Download here
202082018What if your agitator fails?Download here
201072018Can overcooling a reactor cause a runaway reaction?Download here
200062018 Safe Work Permits – Understand the Scope of WorkDownload here
199052018Aging Process Facilities and InfrastructureDownload here
198042018Maintain a Sense of VulnerabilityDownload here
197032018Reporting and Investigating Near MissesDownload here
196022018Runaway Reactions Caused by ContaminationDownload here
195012018Could your plant be impacted by a natural disaster?Download here
194122017Liquefied GasesDownload here
193112017Purged Enclosures in Hazardous AreasDownload here
192102017Are your alarms alarming?Download here
191092017Haste Makes Waste!
Download here
190082017Vulnerable Piping
Download here
189072017Management of ChangeDownload here
188062017Incident Investigation of a Steam Pipe FailureDownload here
187052017Corroded TanksDownload here
186042017Are you sure that vessel is empty?Download here
185032017…but the temperature was below the flash point!Download here
184022017Mixing Incompatible Materials in Storage TanksDownload here
183012017Hazards of High Oxygen ConcentrationDownload here
182122016Ignition Sources – Once MoreDownload here
18111201615 Years of the Process Safety Beacon!Download here
180102016Process safety in the laboratoryDownload here
179092016Can you recognize a change?Download here
178082016A little static can cause a big fire!Download here
177072016Understanding chemical compatibilityDownload here
176062016Dangerous chemical reactions at home!Download here
175052016More repeat incidents!Download here
174042016Plugged flame arrestor causes explosion!Download here
173032016Safety Device or Control Device?Download here
172022016Still Overflowing Tanks!Download here
171012016Hydrate HazardsDownload here
170122015Stop! Look! Listen!Download here
169112015Wrong hose causes ammonia leakDownload here
168102015Water, water, everywhere...Download here
167092015Unloading and Loading Hazardous MaterialsDownload here
166082015Operational ReadinessDownload here
165072015Know when to leave!Download here
164062015Conduct of OperationsDownload here
163052015Mechanical IntegrityDownload here
162042015Safe Work PracticesDownload here
161032015Details Matter in Process Safety!Download here
160022015Who are all these people?Download here
159012015What is the Process Risk?Download here
158122014Bhopal – The Worst Industrial Disaster in HistoryDownload here
157112014Thirty Years Ago – An LPG TragedyDownload here
156102014Dust Explosions - Clean up this Hazard!Download here
155092014What is your role in Hazard Identification and Risk Analysis?Download here
154082014Ignition SourcesDownload here
153072014Persistence – Good or Bad?Download here
152062014A Safety Device Gone Wrong!Download here
151052014Major Spills and Environmental IncidentsDownload here
150042014How do you measure process safety performance?Download here
149032014Don’t forget about occupational safety!Download here
148022014Are we reliving past incidents?Download here
147012014Corrosion Under InsulationDownload here
146122013Hazards of strong oxidizersDownload here
145112013Holiday OperationsDownload here
144102013Electrical Equipment in Hazardous AreasDownload here
143092013Air Power!Download here
142082013Can a Water Pump Explode?Download here
141072013Remembering Piper AlphaDownload here
140062013Why Can't I Open That Valve?Download here
139052013Pressure relief valve bonnets - to plug or not to plug?Download here
138042013Have you heard a pressure relief valve chatter?Download here
137032013Are your signs and labels confusing?Download here
136022013What is supporting your equipment?Download here
135012013Some Answers to the November 2012 Beacon “Find the Problem” ContestDownload here
134122012Good Housekeeping for Safety!Download here
133112012Can you find the safety problem?Download here
132102012Manage Temporary Changes!Download here
131092012What can I do? I'm just the operator!Download here
130082012Hot work HazardsDownload here
129072012Emergency Preparation – The Titanic DisasterDownload here
128062012Nitrogen - Hazard and SafeguardDownload here
127052012Mechanical Integrity of TubingDownload here
126042012What if you unload the wrong material into a tank?Download here
125032012Double Block and BleedDownload here
124022012Mechanical Integrity – The Bolts Are Too Short!Download here
123012012What happens when the lights go out?Download here
122122011Caps and Plugs - One Day You Will Miss Them!Download here
121112011One Incident – Three Beacons!Download here
120102011Hose Hazards!Download here
119092011Hazards from Abandoned EquipmentDownload here
118082011Flammable Vapor Release Hazards in Congested AreasDownload here
117072011Shift WorkDownload here
116062011Are you prepared for a natural disaster?Download here
115052011Flammable material release inside building causes explosion!Download here
114042011Don 't let a small leak become a big leak!Download here
113032011Bad things can come in small packages!Download here
112022011Understand the Reactivity of Your Heat Transfer Fluid!Download here
111012011Vapor Cloud ExplosionsDownload here
110122010Are You Ready for Winter?Download here
109112010Two valve actuator rupture incidents!Download here
108102010 Hazardous Material Storage and ShipmentDownload here
107092010Has anybody seen our process safety information (PSI)?Download here
106082010Early lessons from a tragedyDownload here
105072010Passive Safety EquipmentDownload here
104062010Containment Dikes and PadsDownload here
103052010Fireproofing Structural SupportsDownload here
102042010Fire Protection - Long Bolt Flangeless ValvesDownload here
101032010Facility SitingDownload here
100022010Lest We Forget!Download here
099012010Corrosion and ErosionDownload here
098122009The Bhopal Tragedy – 25 Years AgoDownload here
097112009 BLEVE!Download here
096102009Overflow + Ignition = Tank Farm Fire! (Part 2)Download here
095092009Overflow + Ignition = Tank Farm Fire! (Part 1)Download here
094082009Never underestimate the hazard!Download here
093072009What is a Safety Instrumented System?Download here
092062009Don’t forget safety in a difficult economy!Download here
091052009Mechanical integrityDownload here
090042009Be Prepared!Download here
089032009Fatality caused by unloading the wrong chemical into a storage tank!Download here
088022009More lessons from fire while filling containersDownload here
087012009Fire while filling portable container!Download here
086122008Static Electric Discharge Causes FireDownload here
085112008Laboratory Refrigerator Explosions – Electrical ClassificationDownload here
084102008Ice ruptures unused pipe and causes fire!Download here
083092008Plant SecurityDownload here
082082008Measuring process safety performanceDownload here
081072008What is process safety?Download here
080062008Halon cylinder becomes rocket!Download here
079052008Is sugar an explosion hazard?Download here
078042008Gasoline pipeline damaged by construction causes fireDownload here
077032008Do your shutoff systems actually work?Download here
076022008How Can You Use “The Beacon”?Download here
0750120082007 Beacon Review – Remember the Lessons Learned!Download here
074122007Oil Tank Fire Caused by Static DischargeDownload here
073112007Cold Embrittlement and Thermal StressDownload here
072102007We Have Liftoff!Download here
071092007Hot Work PermitsDownload here
070082007Hazards of Temporary Confined SpacesDownload here
069072007Fire Caused by Hose Repaired with Duct Tape!Download here
068062007Process Safety CultureDownload here
067052007The Great Boston Molasses Flood of 1919Download here
066042007Mr. Potato Head Is Down!Download here
065032007Instrumentation - Can you be fooled by it?Download here
064022007Vacuum hazards - collapsed tanksDownload here
0630120072006 Beacon Review - Remember the lessons learnedDownload here
062122006Liquified gas cylinder failureDownload here
061112006Hazards of relief devices in seriesDownload here
060102006Do you store cylinders properly?Download here
059092006Overfilling Tanks - What happened?Download here
058082006Static electricityDownload here
057072006Do you have storage pallets that look like this?Download here
056062006Is this valve open, or closed?Download here
055052006Dust explosion hazardsDownload here
054042006Mechanical integrityDownload here
053032006Pressure relief systems - do you see any hazards here?Download here
0520220062005 Beacon ReviewDownload here
051012006Time sensitive chemicalsDownload here
050122005Startup hazardsDownload here
049112005Hurricane Katrina - Emergency response and recoveryDownload here
048102005Gas leak destroys plantDownload here
047092005September 11, 2001 - Never to be Forgotten!Download here
046082005Toxic reaction in sewer is fatalDownload here
045072005Piper Alpha Oil Platform DestroyedDownload here
044062005Too many start-stop switchesDownload here
043052005Storage area completely destroyedDownload here
042042005Pressure explosion resultsDownload here
041032005Tower top rockets offDownload here
040022005Insulation does not prevent corrosionDownload here
0390120052004 in review - remember the lessons learnedDownload here
038122004Bhopal - a tragic eventDownload here
037112004Unapproved procedure change = fireDownload here
036102004Available when needed?Download here
035092004Overflow + Ignition Source = Tank Farm FireDownload here
034082004Chlorine transfer hose failureDownload here
033072004Misalignment + Corrosion = Failure!Download here
032062004Flixborough - 30 years agoDownload here
031052004Start your hot work safelyDownload here
030042004Do you see the hazard?Download here
029032004The electricity just went offDownload here
028022004Flammable gas in enclosed space = BOOM!Download here
027012004Avoid improper fuel to air mixturesDownload here
026122003Trees, trees, confusing treesDownload here
025112003But the pressure rating was OK!Download here
024102003Don't pop your topDownload here
023092003Dust did this!Download here
022082003Simply mixing chemicalsDownload here
021072003Static Electricity + Flammables + Air = ??Download here
020062003Interlocked for a reasonDownload here
019052003A good idea could turn badDownload here
018042003What? No spark?
Download here
017032003Reactive Chemistry - Not always when or where you want itDownload here
016022003How Well Are You Trained to Respond to Fires?Download here
015012003Check the clearanceDownload here
014122002Security – It’s everybody’s JobDownload here
013112002What has your steam up?Download here
012102002It’s a bird, it’s a plane, it’s A PUMP!Download here
011092002In Remembrance of September 11th, 2001Download here
010082002Faster than a speeding bulletDownload here
009072002The seal that didn't performDownload here
008062002Don't get your pipes in a twistDownload here
007052002And he blew the house downDownload here
006042002The cylinder that got awayDownload here
005032002Layers of ProtectionDownload here
004022002Vacuum is a powerful force!Download here
003012002ExplosionsDownload here
002122001Snow and Ice Hazards – they can cause more than slips and falls!Download here
001112001Trace 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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