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In the chemical industry, judgements related to process safety hold the potential to lead to process incidents, such as chemical leaks and mechanical failures that can have severe consequences. Many of these judgements require engineers to juxtapose competing criteria including leadership, production, relationships, safety, spending, and time. For such judgements, numerous factors are at play, including our beliefs about ourselves and our intention to behave a particular way. As part of a larger research project funded through the NSF Research in the Formation of Engineers (RFE) program, we are working to investigate: 1) What do engineering students and practitioners believe about how they approach making judgements?, 2) how do they behave when actually making judgements?, 3) what gap, if any, exists between their beliefs and behavior?, and 4) how do they reconcile any gaps between their beliefs and behaviors? After completion of the first year of the project, we have interviewed fourteen senior chemical engineering students about how they believe they will approach process safety judgements in scenarios where they must juxtapose competing criteria. During our initial analysis to characterize students’ espoused beliefs about their approaches towards making process safety judgements, we identified an emergent finding about how they justify these beliefs. We present this emergent finding by answering the research question: How do undergraduate engineering students justify their beliefs about how they will make judgements in process safety contexts? When we asked students to provide reasoning for the beliefs they conveyed about how they will approach process safety judgements, we found that overwhelmingly, students used their lived experiences in different work settings to justify their beliefs. These lived experiences included engineering co-ops, internships, volunteer, and retail work. This emergent finding suggests that students’ lived experiences may be greatly informing their espoused beliefs about how they will approach process safety judgements. This paper will also briefly discuss implications for process safety educators on how they may incorporate lived experiences, or other ways of knowing, so students may develop more robust beliefs about process safety judgements. 

This research paper focuses on comparing engineering students’ beliefs and behaviors related to making process safety judgements. Despite emphasis on process safety education, serious health and safety accidents in the chemical process industry continue to occur. Investigations of major incidents have reported that, in many cases, tension caused by the need to balance several competing criteria was the culprit. While there have been substantial improvements in process safety education, most efforts have focused on preventing incidents through safer design, while few have focused on making process safety judgements in situations that have competing criteria. This pilot study investigates (1) what are engineering students’ beliefs about how they would approach process safety judgements with competing criteria? and (2) how do students react to the process of comparing their beliefs and behaviors in process safety judgements? We interviewed three chemical engineering students to determine their beliefs about making judgements in process safety contexts with competing criteria. Next, the students played through a digital process safety game, Contents Under Pressure (CUP). In CUP, students make process safety judgements in a digital chemical plant setting, and the judgements they encounter include a variety of criteria juxtapositions. Upon completing CUP, students were asked to reflect on their criteria priorities as they believed they played CUP through an online survey. GAP Profiles were generated as a way to directly compare initial beliefs, gameplay, and reflection criteria priorities. Finally, students reconciled differences between their beliefs and behaviors through a semi-structured interview, prompting students to think about the cause of the observed differences. In the initial beliefs interviews, we identified themes tied to prioritization of competing criteria. Some students rationalized their prioritizations by aligning them with their perceived priorities of the company, while others overcomplicated proposed hypotheticals in an attempt to find an optimized outcome. None of the participants could understand the link between process safety judgements and relationships, so they tended to devalue this criterion in their prioritizations. After playing CUP, the students communicated a better awareness of how relationships influence process safety judgements. Following gameplay, all participants stated that in-game feedback was critical to the ways in which they made judgements during CUP. Some participants indicated that their behaviors in CUP were more representative of the way they would approach process safety judgements in real life than their responses in the initial interview. This result may suggest that students have difficulty accurately predicting how they will apply process safety criteria in judgements without practicing these priorities in context. Results of this pilot study indicate that using a game-based approach to practice judgements with competing criteria gives students an opportunity to gain awareness about their approaches to process safety judgements and any differences that exist with their formulated beliefs. 

Every year new safety features and regulations are employed within the process industry to reduce risks associated with operations. Despite these advancements chemical plants remain hazardous places, and the role of the engineer will always involve risk mitigation through real time decision making. Results from a previous study by Kongsvik et al., 2015 indicated that there were three types of decisions in major chemical plants: strategic decisions, operational decisions, and instantaneous decisions. The study showed the importance for improving upon engineers’ operational and instantaneous choices when tasked with quick solutions in the workforce. In this research study, we dive deeper to understand how senior chemical engineering students’ prioritize components of decision making such as budget, productivity, relationships, safety, and time, and how this prioritization may change as a result of participation in a digital immersive training environment called Contents Under Pressure. More specifically, we seek to address the following two research questions: (1) How do senior chemical engineering students prioritize safety in comparison to criteria such as budget, personal relationships, plant productivity, and time in a process safety context, and (2) How does senior chemical engineering students’ prioritization of decision making criteria (budget, personal relationships, plant productivity, safety, and time) change after exposure to a virtual process safety decision making environment? As part of this study, 187 senior chemical engineering students from three separate institutions completed a pre- and post-reflection survey around their engagement with Contents Under Pressure and asked them to rank their prioritizations of budget, productivity, relationships, safety, and time. Data was analyzed using descriptive statistics, and Friedman and Wilcoxon-sign-rank post hoc analyses were completed to determine any statistical differences between the rankings of decision making factors before and after engagement with Contents Under Pressure. Simulating process safety decision making with interactive educational supports may increase students’ understanding of genuine workplace environments and factors that contribute to process safety, without the real world hazards that result from poor decision making. By understanding how students prioritize these factors, chemical engineering curricula can be adapted to focus on the areas of process safety decision making where students need the largest improvement, thereby better preparing them to enter the engineering workforce. 

Process safety incidents, ranging from the relatively minor to the catastrophic, are a major concern in the chemical engineering profession with impacts including lost time incidents, serious personal injury, fatalities, and negative public perception. These events can also have significant impacts on the environment and local infrastructure. However, many of these incidents could be avoided if better process safety management or risk mitigation was employed. For example, the fire and explosion that occurred at ExxonMobil in Baton Rouge was the result of operators manually opening a gearbox due to lack of familiarity with the equipment. This incident could have been avoided if better maintenance or training procedures had been in place, if the operators had recognized the old valve had a different design than the new ones, or if the old valves had been switched to a newer valve design. This accident indicates how process safety incidents can occur due to a series of decisions. 

Despite process safety and ethical decision making being recognized priorities in many chemical companies, process safety incidents continue to occur with unfortunate regularity. In order to understand why such incidents keep occurring, and to prevent future accidents from happening, it is important to study the decision-making habits of people employed at chemical companies, and to inform students of the difference between the influences of ethics and behavioral ethics in process safety decision making. This study seeks to determine how senior chemical engineering students approach reasoning through process safety scenarios through the use of a mixed methods study. This study found that four out of the five students who participated in the study demonstrated post-conventional reasoning, and the remaining student showed conventional reasoning based on the quantitative analysis of their responses. Students showed mostly post-conventional reasoning in their responses based on a qualitative analysis; however, through comparison of these results it was found that the moral schema students were classified as was not always truly representative of their moral reasoning. 

Process safety has become a critical component of chemical engineering education. However, students may find it difficult to fully understand the ramifications of decisions they make during classroom exercises due to their lack of real world experience. Use of an immersive digital environment where students could role play as chemical engineering employees making process safety decisions could be one method of achieving this goal. Through this experience, students could observe the outcomes of their decisions in a safe, controlled environment without the disastrous real-world consequences that could come from making a mistake. This digital environment could have further features, such as time constraints or interactions with other characters, to make the experience feel more authentic than an in-class discussion or case study. In order to evaluate the efficacy of such a virtual environment, a portion of this work centered around the creation of the Engineering Process Safety Research Instrument (EPSRI). The instrument asks participants to evaluate process safety dilemmas and rank a set of considerations based on how influential they were in their decision-making process. The instrument then classifies each decision based on the stages of Kohlberg’s moral development theory, ranging from pre-conventional (i.e. more self-centered) thinking to post-conventional (i.e. more global) thinking. This instrument will be used to assess how students’ thinking about process safety decisions changes as a result of engaging in the virtual safety decision making environment. This paper will summarize the progress since the project’s start in summer 2017, highlighting the work completed in development and validation of the EPSRI. This process included content validation, think-aloud studies to improve clarity of the instrument, and factor analysis based on a large scale implementation at multiple universities. The paper will also discuss the development of the minimum viable product digital process safety experience, including establishment of learning outcomes and the mechanics that reinforce those outcomes. By presenting these findings, we intend to spread awareness of the EPSRI, which can evaluate the safety decisions of chemical engineering students while having the potential to launch discussions about safety and ethics in other engineering disciplines. We also hope that these results will provide educators with insights into how to translate educational objectives to elements of a digital learning environment through collaboration with digital media companies. 

Process safety has become a critical component of chemical engineering education. However, students may find it difficult to fully understand the ramifications of decisions they make during classroom exercises due to their lack of real world experience. Use of an immersive digital environment where students could role play as chemical engineering employees making process safety decisions could be one method of achieving this goal. Through this experience, students could observe the outcomes of their decisions in a safe, controlled environment without the disastrous real-world consequences that could come from making a mistake. This digital environment could have further features, such as time constraints or interactions with other characters, to make the experience feel more authentic than an in-class discussion or case study. In order to evaluate the efficacy of such a virtual environment, a portion of this work centered around the creation of the Engineering Process Safety Research Instrument (EPSRI). The instrument asks participants to evaluate process safety dilemmas and rank a set of considerations based on how influential they were in their decision-making process. The instrument then classifies each decision based on the stages of Kohlberg’s moral development theory, ranging from pre-conventional (i.e. more self-centered) thinking to post-conventional (i.e. more global) thinking. This instrument will be used to assess how students’ thinking about process safety decisions changes as a result of engaging in the virtual safety decision making environment. This paper will summarize the progress since the project’s start in summer 2017,, highlighting the work completed in development and validation of the EPSRI. This process included content validation, think-aloud studies to improve clarity of the instrument, and factor analysis based on a large scale implementation at multiple universities. The paper will also discuss the development of the minimum viable product digital process safety experience, including establishment of learning outcomes and the mechanics that reinforce those outcomes. By presenting these findings, we intend to spread awareness of the EPSRI, which can evaluate the safety decisions of chemical engineering students while having the potential to launch discussions about safety and ethics in other engineering disciplines. We also hope that these results will provide educators with insights into how to translate educational objectives to elements of a digital learning environment through collaboration with digital media companies. 

Process safety is at the heart of operation of many chemical processing companies. However, the Chemical Safety Board (CSB) has still documented over 800 investigations of process safety failures since the year 2000. While not all of these incidents were severe, some did lead to employee injuries or death and environmental harm. As a result, chemical engineering companies are increasingly dedicated to process safety through training programs and detailed vigilance as part of their operations practice. AIChE and OSHA also offer courses in process safety to help support the industry. These efforts illustrate the paramount importance that chemical engineering graduates have an appreciation and understanding of process safety as they transition from their degree program into industrial positions. Previous studies have shown that despite difficulties due to course load constraints, process safety has been incorporated into chemical engineering curriculum through either the addition of new courses, incorporation of the content within existing classes, or a combination of the two methods. A review performed in Process Safety Progress suggested that a key step for departments moving forward is to perform an assessment of the process safety culture within their institution in order to determine how faculty and students view process safety. An issue with completing this task is the lack of assessment tools that can be used to determine how students are developing their understanding of process safety decision making. This observation led to the development of the Engineering Process Safety Research Instrument (EPSRI). This instrument is modeled after the Defining Issues Test version 2 (DIT2) and the Engineering Ethical Reasoning Instrument (EERI). Similar to these instruments, the EPSRI provides dilemmas, three decisions, and 12 additional considerations that individuals must rate based on their relative importance to their decision making process. The dilemmas developed in the EPSRI are based on case studies and investigations from process safety failures that have occurred in industry to provide a realistic context for the decision making decisions that engineers may be faced with upon employment. The considerations provided after the scenario are derived to reflect pre-conventional, conventional, and post-conventional decision making thinking as described by Kohlberg’s Moral Development Theory. Pre-conventional decision making thinking focuses particularly on what is right/wrong or good/bad from an individual level, whereas post-conventional thinking seeks to determine what is correct from moral and value perspectives at the society level. This WIP paper describes the content validity study conducted while developing the EPSRI. Dilemmas were examined by context experts including professionals in the process industry, chemical engineering departments, and learning sciences field. Content experts reviewed the dilemmas and determined whether they represented accurate examples of process safety decision making that individuals may face in real-world engineering settings. The experts also reviewed the 12 considerations for each dilemma for their accuracy in capturing pre-conventional, conventional and post-conventional thinking. This work represents the first step in the overall instrument validation that will take place over the next academic year.