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AIChE CCPSC Exam Syllabus Topics:

SectionWeightObjectives
Topic 1: Measurement, Audit, and Continuous Improvement15%- Audit and Assessment
  • 1. Compliance verification
    • 2. System effectiveness evaluation
      - Performance Indicators
      • 1. Data collection and reporting
        • 2. Leading and lagging metrics
          Topic 2: Hazard Identification and Risk Analysis25%- Risk Evaluation and Control
          • 1. Inherent safety, prevention, mitigation
            • 2. Risk criteria and prioritization
              - Hazard Assessment Methods
              • 1. HAZOP, What-If, Checklist
                • 2. FMEA, LOPA, Quantitative Risk Analysis
                  Topic 3: Incident Investigation and Learning15%- Learning and Improvement
                  • 1. Knowledge sharing and prevention
                    • 2. Corrective actions implementation
                      - Investigation Methodology
                      • 1. Evidence collection and analysis
                        • 2. Root cause analysis
                          Topic 4: Risk Based Process Safety (RBPS) Fundamentals15%- Process Safety Culture
                          • 1. Compliance and standards
                            • 2. Workforce engagement
                              • 3. Leadership and commitment
                                - Process Safety Competency
                                • 1. Competency verification
                                  • 2. Training and development
                                    • 3. Knowledge and skills requirements
                                      Topic 5: Process Safety Management Systems30%- Asset Integrity and Reliability
                                      • 1. Maintenance, inspection, testing
                                        • 2. Equipment quality assurance
                                          - Management of Change
                                          • 1. Technical and administrative review
                                            • 2. Risk assessment for changes
                                              - Process Knowledge Management
                                              • 1. Documentation, P&IDs, design basis
                                                • 2. Data management and integrity
                                                  - Operating Procedures and Safe Work Practices
                                                  • 1. Procedure development and maintenance
                                                    • 2. Permit systems, lockout/tagout

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                                                      AIChE CCPS Process Safety Professional Certification Sample Questions (Q59-Q64):

                                                      NEW QUESTION # 59
                                                      An organization with strong Conduct of Operations is able to minimize: (select all that apply)

                                                      Answer: A,C,E

                                                      Explanation:
                                                      The correct answers are A, C, and D because strong Conduct of Operations (CoO) ensures disciplined, consistent, and well-understood operational practices, which directly reduce errors and unsafe behaviors.
                                                      Option A (misunderstanding of expectations) is minimized because CoO emphasizes clear communication, defined roles, and standardized procedures , ensuring that operators understand exactly what is expected of them.
                                                      Option C (normalization of deviation) is also minimized. One of the key goals of CoO is to prevent gradual acceptance of unsafe practices. By enforcing strict adherence to procedures and promoting a questioning attitude, organizations avoid drifting away from safe operating limits.
                                                      Option D (frequency of process safety incidents) is reduced because consistent and disciplined operations lower the likelihood of human error, procedural violations, and unsafe conditions , all of which are major contributors to incidents.
                                                      Option B is incorrect because CoO does not aim to reduce training frequency; in fact, it may reinforce the need for ongoing training . Option E is also incorrect because audits are a management system requirement and are not reduced by CoO.
                                                      CCPS highlights that strong Conduct of Operations promotes operational discipline, reliability, and safety , directly improving process safety performance.


                                                      NEW QUESTION # 60

                                                      During a field inspection of the process piping in a production unit, a section of piping is identified as containing a dead leg in which stagnant liquid is trapped. It is determined that this dead leg branch line is used very infrequently. Assume that the plant is in a location where winter temperatures drop below 20°F (-7°C) and summer temperatures can exceed 90°F (32°C). Which of the following are valid process safety reasons to remove the line? (Select all that apply)

                                                      Answer: A,D

                                                      Explanation:
                                                      The correct answers are B and D because they directly relate to process safety risks associated with mechanical integrity and loss of containment .
                                                      Option B is correct because stagnant liquid in a dead leg can freeze in cold temperatures , especially below 20°
                                                      F. When water or process liquid freezes, it expands, which can lead to pipe rupture or cracking , creating a potential loss of containment scenario. This is a well-recognized hazard in cold climates and is specifically addressed in CCPS guidance on mechanical integrity and design for environmental conditions.
                                                      Option D is also correct because stagnant fluids promote localized corrosion mechanisms , such as pitting or microbiologically influenced corrosion (MIC). Dead legs are particularly vulnerable because there is little or no flow , allowing corrosive species to concentrate and degrade the pipe wall over time.
                                                      Option A is not a process safety reason-it is an economic consideration. Option C relates to occupational safety (trip hazard) , not process safety.
                                                      CCPS emphasizes eliminating dead legs where possible because they are common sources of corrosion, blockage, and integrity failure , all of which can lead to hazardous releases.


                                                      NEW QUESTION # 61
                                                      Which of the following is generally a disadvantage of a rupture disc vs a relief valve?

                                                      Answer: D

                                                      Explanation:
                                                      The correct answer is C because rupture discs are generally more fragile and susceptible to damage during installation and handling compared to relief valves, which is a recognized disadvantage in CCPS guidance on pressure relief systems within Mechanical Integrity.
                                                      Rupture discs are thin membranes designed to burst at a specific pressure. Because of their delicate construction, improper installation (e.g., incorrect torque, misalignment, or physical handling damage) can alter their burst pressure or cause premature failure. This sensitivity requires strict installation procedures, trained personnel, and careful inspection practices.
                                                      Option A is actually an advantage of rupture discs. They provide tight sealing with zero leakage , preventing fugitive emissions and eliminating simmering that can occur in relief valves.
                                                      Option B is also an advantage. Rupture discs respond very rapidly to sudden pressure spikes , making them suitable for scenarios like deflagrations or tube ruptures.
                                                      Option D is generally considered an advantage as well, since rupture discs can be made from corrosion- resistant materials or coated, often at lower cost than equivalent corrosion-resistant relief valves.
                                                      CCPS emphasizes selecting pressure relief devices based on service conditions, reliability, response characteristics, and maintenance considerations, including installation sensitivity.


                                                      NEW QUESTION # 62
                                                      Which of the following changes require a Management of Organizational Change (MOOC) Review? (Select all that apply.)

                                                      Answer: A,C,D

                                                      Explanation:
                                                      The correct answers are B, C, and E because these represent organizational changes that can significantly impact process safety risk , and therefore require a Management of Organizational Change (MOOC) review as defined by CCPS under the RBPS framework.
                                                      MOOC focuses on evaluating how changes in staffing, structure, roles, responsibilities, or working conditions may affect hazard control, decision-making, supervision, and operational reliability.
                                                      B (Replacing maintenance with contractors) introduces risks related to competency, training, communication, and familiarity with site hazards , which are critical CCPS concerns.
                                                      C (Reducing number of operators) directly affects workload, fatigue, ability to respond to abnormal situations, and supervision , all of which are key human factor risks.
                                                      E (Changing shift length from 8 to 12 hours) impacts fatigue, alertness, and human performance reliability , which CCPS identifies as major contributors to incidents.
                                                      The incorrect options are less impactful:
                                                      A (moving operator within same unit) does not significantly change organizational risk if competency remains equivalent.
                                                      D (office to cubicle relocation) has negligible effect on process safety.
                                                      CCPS emphasizes that organizational changes must be treated with the same rigor as technical changes , because many major incidents have been linked to staffing reductions, contractor use, and fatigue-related performance degradation.


                                                      NEW QUESTION # 63
                                                      A process calls for the addition of a reactant over a certain period of time. The flow controller on the reactant' s feed line was out of calibration and reduced the flow rate of the reactant. The operator noticed the addition rate was too low and, contrary to the operating procedures, he opened a bypass valve around the flow control valve to increase the flow rate. As a result, the operator added the remaining reactant too quickly, and a runaway reaction occurred. Weaknesses in which of the following Risk Based Process Safety elements could have contributed to the cause of this incident? (Select all that apply)

                                                      Answer: A,C,E


                                                      NEW QUESTION # 64
                                                      ......

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