Chemical Process Safety: Fundamentals with Applications

✍ Scribed by Crowl, Daniel A

• Publisher: Prentice Hall
• Year: 2001
• Tongue: English
• Leaves: 648
• Edition: 2nd Edition
• Category: Library

✦ Synopsis

Combines academic theory with practical industry experience
Updated to include the latest regulations and references
Covers hazard identification, risk assessment, and inherent safety
Case studies and problem sets enhance learning
Long-awaited revision of the industry best seller.This fully revised second edition of "Chemical Process Safety: Fundamentals with Applications" combines rigorous academic methods with real-life industrial experience to create a unique resource for students and professionals alike. The primary focus on technical fundamentals of chemical process safety provides a solid groundwork for understanding, with full coverage of both prevention and mitigation measures. Subjects include:
Toxicology and industrial hygiene
Vapor and liquid releases and dispersion modeling
Flammability characterization
Relief and explosion venting
In addition to an overview of government regulations, the book introduces the resources of the AICHE Center for Chemical Process Safety library. Guidelines are offered for hazard identification and risk assessment. The book concludes with case histories drawn directly from the authors' experience in the field.A perfect reference for industry professionals, "Chemical Process Safety: Fundamentals with Applications, Second Edition" is also ideal for teaching at the graduate and senior undergraduate levels. Each chapter includes 30 problems, and a solutions manual is now available for instructors.

✦ Table of Contents

Cover......Page 1
Contents......Page 6
Preface......Page 14
Nomenclature......Page 16
1 Introduction......Page 22
1-1 Safety Programs......Page 23
1-3 Accident and Loss Statistics......Page 25
1-4 Acceptable Risk......Page 33
1-5 Public Perceptions......Page 35
1-6 The Nature of the Accident Process......Page 36
1-7 Inherent Safety......Page 41
Flixborough, England......Page 44
Bhopal, India......Page 46
Seveso, Italy......Page 47
Pasadena, Texas......Page 48
Suggested Reading......Page 50
Problems......Page 51
2 Toxicology......Page 56
2-1 How Toxicants Enter Biological Organisms......Page 57
Skin......Page 58
Respiratory System......Page 59
2-2 How Toxicants Are Eliminated from Biological Organisms......Page 60
2-3 Effects of Toxicants on Biological Organisms......Page 61
2-4 Toxicological Studies......Page 62
2-5 Dose versus Response......Page 63
2-6 Models for Dose and Response Curves......Page 69
2-8 Threshold Limit Values......Page 75
Problems......Page 80
3 Industrial Hygiene......Page 84
Creating a Regulation......Page 85
OSHA: Process Safety Management......Page 89
EPA: Risk Management Plan......Page 92
Material Safety Data Sheets......Page 95
3-3 Industrial Hygiene: Evaluation......Page 99
Evaluating Exposures to Volatile Toxicants by Monitoring......Page 100
Evaluation of Worker Exposures to Dusts......Page 104
Evaluating Worker Exposures to Noise......Page 105
Estimating Worker Exposures to Toxic Vapors......Page 106
3-4 Industrial Hygiene: Control......Page 115
Respirators......Page 117
Ventilation......Page 118
Suggested Reading......Page 124
Problems......Page 125
4-1 Introduction to Source Models......Page 130
4-2 Flow of Liquid through a Hole......Page 133
4-3 Flow of Liquid through a Hole in a Tank......Page 137
4-4 Flow of Liquids through Pipes......Page 142
2-K Method......Page 145
4-5 Flow of Vapor through Holes......Page 151
Adiabatic Flows......Page 157
Isothermal Flows......Page 164
4-7 Flashing Liquids......Page 172
4-8 Liquid Pool Evaporation or Boiling......Page 178
4-10 Conservative Analysis......Page 180
Suggested Reading......Page 182
Problems......Page 183
5 Toxic Release and Dispersion Models......Page 192
5-1 Parameters Affecting Dispersion......Page 193
5-2 Neutrally Buoyant Dispersion Models......Page 197
Case 1: Steady-State Continuous Point Release with No Wind......Page 201
Case 2: Puff with No Wind......Page 202
Case 3: Non-Steady-State Continuous Point Release with No Wind......Page 203
Case 5: Puff with No Wind and Eddy Diffusivity Is a Function of Direction......Page 204
Case 7: Puff with Wind......Page 205
Case 9: Steady-State Plume with Source on Ground......Page 206
Pasquill-Gifford Model......Page 207
Case 11: Puff with Instantaneous Point Source at Ground Level, Coordinates Fixed at Release Point, Constant Wind Only in x Direction with Constant Velocity u......Page 211
Case 12: Plume with Continuous Steady-State Source at Ground Level and Wind Moving in x Direction at Constant Velocity u......Page 212
Case 13: Plume with Continuous Steady-State Source at Height H[sub(r)] above Ground Level and Wind Moving in x Direction at Constant Velocity u......Page 213
Case 14: Puff with Instantaneous Point Source at Height H[sub(r)] above Ground Level and a Coordinate System on the Ground That Moves with the Puff......Page 214
Limitations to Pasquill-Gifford Dispersion Modeling......Page 215
5-3 Dense Gas Dispersion......Page 216
5-4 Toxic Effect Criteria......Page 220
5-5 Effect of Release Momentum and Buoyancy......Page 233
5-6 Release Mitigation......Page 234
Suggested Reading......Page 235
Problems......Page 236
6-1 The Fire Triangle......Page 246
6-3 Definitions......Page 248
6-4 Flammability Characteristics of Liquids and Vapors......Page 250
Liquids......Page 251
Vapor Mixtures......Page 254
Flammability Limit Dependence on Temperature......Page 256
Estimating Flammability Limits......Page 257
6-5 Limiting Oxygen Concentration and Inerting......Page 259
6-6 Flammability Diagram......Page 261
6-7 Ignition Energy......Page 269
6-10 Adiabatic Compression......Page 270
6-11 Ignition Sources......Page 272
6-13 Explosions......Page 273
Detonation and Deflagration......Page 274
Confined Explosions......Page 276
Blast Damage Resulting from Overpressure......Page 286
TNT Equivalency......Page 290
TNO Multi-Energy Method......Page 292
Energy of Chemical Explosions......Page 295
Energy of Mechanical Explosions......Page 297
Blast Damage to People......Page 300
Vapor Cloud Explosions......Page 302
Suggested Reading......Page 303
Problems......Page 304
7 Designs to Prevent Fires and Explosions......Page 312
Vacuum Purging......Page 313
Pressure Purging......Page 316
Combined Pressure-Vacuum Purging......Page 318
Vacuum and Pressure Purging with Impure Nitrogen......Page 319
Sweep-Through Purging......Page 320
Using the Flammability Diagram To Avoid Flammable Atmospheres......Page 322
Fundamentals of Static Charge......Page 328
Charge Accumulation......Page 329
Electrostatic Discharges......Page 330
Energy from Electrostatic Discharges......Page 332
Energy of Electrostatic Ignition Sources......Page 333
Streaming Current......Page 334
Energy of Charged Capacitors......Page 337
Capacitance of a Body......Page 342
Balance of Charges......Page 345
7-3 Controlling Static Electricity......Page 351
General Design Methods To Prevent Electrostatic Ignitions......Page 352
Bonding and Grounding......Page 353
Dip Pipes......Page 354
Increasing Conductivity with Additives......Page 357
7-4 Explosion-Proof Equipment and Instruments......Page 358
Area and Material Classification......Page 360
Open-Air Plants......Page 361
Plants Inside Buildings......Page 362
7-6 Sprinkler Systems......Page 364
Suggested Reading......Page 368
Problems......Page 369
8 Introduction to Reliefs......Page 374
8-1 Relief Concepts......Page 375
8-2 Definitions......Page 377
8-3 Location of Reliefs......Page 378
8-4 Relief Types......Page 381
8-5 Relief Scenarios......Page 385
8-6 Data for Sizing Reliefs......Page 386
Relief Design Considerations......Page 389
Horizontal Knockout Drum......Page 392
Flares......Page 396
Suggested Reading......Page 397
Problems......Page 398
9 Relief Sizing......Page 404
9-1 Conventional Spring-Operated Reliefs in Liquid Service......Page 405
9-2 Conventional Spring-Operated Reliefs in Vapor or Gas Service......Page 410
9-4 Rupture Disc Reliefs in Vapor or Gas Service......Page 415
9-5 Two-Phase Flow during Runaway Reaction Relief......Page 416
Simplified Nomograph Method......Page 422
9-6 Deflagration Venting for Dust and Vapor Explosions......Page 425
Vents for Low-Pressure Structures......Page 427
Vents for High-Pressure Structures......Page 429
9-7 Venting for Fires External to Process Vessels......Page 432
9-8 Reliefs for Thermal Expansion of Process Fluids......Page 436
Suggested Reading......Page 439
Problems......Page 441
10 Hazards Identification......Page 450
10-2 Hazards Surveys......Page 453
10-3 Hazards and Operability Studies......Page 469
10-4 Safety Reviews......Page 475
10-5 Other Methods......Page 480
Problems......Page 481
11 Risk Assessment......Page 492
11-1 Review of Probability Theory......Page 493
Interactions between Process Units......Page 495
Revealed and Unrevealed Failures......Page 501
Probability of Coincidence......Page 505
11-2 Event Trees......Page 507
11-3 Fault Trees......Page 512
Determining the Minimal Cut Sets......Page 515
Quantitative Calculations Using the Fault Tree......Page 518
Relationship between Fault Trees and Event Trees......Page 519
Quantitative Risk Analysis......Page 520
Layer of Protection Analysis......Page 521
Frequency......Page 524
Suggested Reading......Page 528
Problems......Page 529
12-1 Learning from Accidents......Page 536
12-2 Layered Investigations......Page 537
12-3 Investigation Process......Page 539
12-4 Investigation Summary......Page 540
12-5 Aids for Diagnosis......Page 542
Explosions......Page 543
Pressure Effects......Page 544
Miscellaneous Aids to Diagnosis......Page 546
Control Plant Modifications......Page 549
Block Valves......Page 550
Preventive Maintenance......Page 551
Analyzers......Page 552
Problems......Page 553
13 Case Histories......Page 556
Explosion in a Centrifuge......Page 557
Conductor in a Solids Storage Bin......Page 558
Lessons Learned......Page 559
Nitrobenzene Sulfonic Acid Decomposition......Page 561
Lessons Learned......Page 562
Butadiene Explosion......Page 567
Pump Failure......Page 568
Ethylene Oxide Explosion......Page 569
Lessons Learned......Page 570
13-4 Procedures......Page 572
Vinyl Chloride Explosion......Page 573
Phenol-Formaldehyde Runaway Reaction......Page 574
Conditions and Secondary Reaction Cause Explosion......Page 575
Fuel-Blending Tank Explosion......Page 576
13-5 Conclusion......Page 577
Problems......Page 578
Appendix A: Unit Conversion Constants......Page 582
Appendix B: Flammability Data for Selected Hydrocarbons......Page 586
Equations Useful for Placing Vessels into and out of Service......Page 592
Appendix D: Formal Safety Review Report for Example 10-4......Page 602
Appendix E: Saturation Vapor Pressure Data......Page 612
A......Page 614
B......Page 616
C......Page 618
D......Page 620
E......Page 623
F......Page 625
G......Page 627
H......Page 628
I......Page 629
L......Page 631
M......Page 632
O......Page 635
P......Page 636
R......Page 639
S......Page 640
T......Page 642
V......Page 644
Z......Page 645