Cover
Title Page
Copyright
Contents
List of Figures
List of Tables
Acronyms and Abbreviations
Glossary
Acknowledgments
Online Materials Accompanying this Book
Preface
1 Introduction and Regulatory Overview
1.1 Purpose of this Book
1.2 Target Audience
1.3 Process Safety โ What Is It?
1.4 Process Safety, Occupational Safety, and Environmental Impact
1.5 History of Process Safety
1.6 Basic Process Safety Definitions
1.7 Organization of the Book
1.8 Use of this Book in University Courses
1.9 Exercises
1.10 References
2 Risk Based Process Safety
2.1 Learning Objectives
2.2 Incident: BP Refinery Explosion, Texas City, Texas, 2005
2.3 Risk Based Process Safety
2.4 Pillar: Commit to Process Safety
2.5 Pillar: Understand Hazards and Risk
2.6 Pillar: Manage Risk
2.7 Pillar: Learn from Experience
2.8 What a New Engineer Might Do
2.9 Summary
2.10 Exercises
2.11 References
3 Process Safety Regulations, Codes, and Standards
3.1 Learning Objectives
3.2 Incident: Montreal, Maine & Atlantic Railway Derailment and Fire, Quebec, Canada, 2013
3.3 Regulations, Codes and Standards
3.4 What a New Engineer Might Do
3.5 Tools
3.6 Summary
3.7 Other Incidents
3.8 Exercises
3.9 References
4 Fire and Explosion Hazards
4.1 Learning Objectives
4.2 Incident: Imperial Sugar Dust Explosion, Port Wentworth, Georgia, 2008
4.3 Introduction to Fires
4.4 Types of Fires
4.5 Types of Explosions
4.4 Fire and Explosion Prevention
4.7 What a New Engineer Might Do
4.8 Tools
4.9 Summary
4.10 Other Incidents
4.11 Exercises
4.12 References
5 Reactive Chemical Hazards
5.1 Learning Objectives
5.2 Incident: T-2 Laboratories Reactive Chemicals Explosion, Jacksonville, Florida, 2007
5.3 Introduction to Chemical Reactivity
5.4 Reactive Chemicals Testing
5.5 Reactive Chemicals Hazard Screening and Evaluation
5.6 Reactive Chemical Incident Prevention and Mitigation
5.7 What a New Engineer Might Do
5.8 Tools
5.9 Summary
5.10 Other incidents
5.11 Exercises
5.12 References
6 Toxic Hazards
6.1 Learning Objectives
6.2 Incident: Methyl Isocyanate Release Bhopal, India, 1984
6.3 Toxins and Pathways
6.4 Exposure and concentration limits
6.5 Toxic Incident Prevention and Mitigation
6.6 What a New Engineer Might Do
6.7 Tools
6.8 Summary
6.9 Other Incidents
6.10 Exercises
6.11 References
7 Chemical Hazards Data Sources
7.1 Learning Objectives
7.2 Incident: Concept Sciences Explosion, Allentown, Pennsylvania, 1999
7.3 Chemical Hazards Data
7.4 What a New Engineer Might Do
7.5 Tools
7.6 Summary
7.7 Exercises
7.8 References
8 Other Hazards
8.1 Learning Objectives
8.2 Incident: Fukushima Daiichi Nuclear Power Plant Release, Japan, 2011
8.3 Types of Hazards (Beyond Chemical Hazards)
8.4 What a New Engineer Might Do
8.5 Tools
8.6 Summary
8.7 Other Incidents
8.8 Exercises
8.9 References
9 Process Safety Incident Classification
9.1 Learning Objectives
9.2 Incident: Petrobras P-36 Sinking, Brazil, 2001
9.3 Introduction to Metrics
9.4 What a New Engineer Might Do
9.5 Tools
9.6 Summary
9.7 Exercises
9.8 References
10 Project Design Basics
10.1 Learning Objectives
10.2 Incident: Mars Climate Orbiter lost contact, 1999
10.3 Introduction to Engineering Documentation
10.4 Common Engineering Documentation
10.5 Phases of a Project
10.6 Important Pieces of Process Safety Information
10.7 Methods to Prevent and Mitigate Process Safety Risks During Project Design
10.8 What a New Engineer Might Do
10.9 Tools
10.10 Summary
10.11 Other incidents
10.12 Exercises
10.13 References
11 Equipment Failure
11.1 Learning Objectives
11.2 Incident: Buncefield Storage Tank Overflow and Explosion, Hemel Hempstead, England, 2005
11.3 Typical Process Equipment
11.4 Asset Integrity and Reliability
11.5 What a New Engineer Might Do
11.6 Tools
11.7 Summary
11.8 Other Incidents
11.9 Exercises
11.10 References
12 Hazard Identification
12.1 Learning Objectives
12.2 Incident: Esso Longford Gas Plant Explosion, Victoria, Australia, 1998
12.3 Hazard Identification Introduction
12.4 What a New Engineer Might Do
12.5 Tools
12.6 Summary
12.7 Other Incidents
12.8 Exercises
12.9 References
13 Consequence Analysis
13.1 Learning Objectives
13.2 Incident: DPC Enterprises L.P. Chlorine Release, Festus, Missouri, 2002
13.3 Consequence Analysis Overview
13.4 Source Term Models
13.5 Transport Models
13.6 Consequence Effect Modeling
13.7 Outcome Models
13.8 Data and Uncertainties
13.9 What a New Engineer Might Do
13.10 Tools
13.11 Summary
13.12 Other Incidents
13.13 Exercises
13.14 References
14 Risk Assessment
14.1 Learning Objectives
14.2 Incident: Phillips 66 Explosion Pasadena, Texas, 1989
14.3 Risk Analysis Overview
14.4 Frequency Analysis
14.5 Risk Analysis
14.6 Risk Criteria
14.7 Layer of Protection Analysis (LOPA)
14.8 What a New Engineer Might Do
14.9 Tools
14.10 Summary
14.11 Other Incidents
14.12 Exercises
14.13 References
15 Risk Mitigation
15.1 Learning Objectives
15.2 Incident: Celanese Explosion, Pampa, Texas, 1987
15.3 Safeguards, Barriers, IPLs, and Other Layers of Protection
15.4 Risk Reduction Measures
15.5 What a New Engineer Might Do
15.6 Tools
15.7 Summary
15.8 Other Incidents
15.9 Exercises
15.10 References
16 Human Factors
16.1 Learning Objectives
16.2 Incident: Formosa Plastics VCM Explosion, Illiopolis, Illinois, 2004
16.3 Introduction to Human Factors
16.4 The Human Individual
16.5 The Work Team
16.6 Human Factors in the Process Workplace
16.7 What a New Engineer Might Do
16.8 Tools
16.9 Summary
16.10 Other Incidents
16.11 Exercises
16.12 References
17 Operational Readiness
17.1 Learning Objectives
17.2 Incident: Piper Alpha Explosion and Fire, Scotland, 1988
17.3 Introduction to Operational Readiness
17.4 What a New Engineer Might Do
17.5 Tools
17.6 Summary
17.7 Other Incidents
17.8 Exercises
17.9 References
18 Management of Change
18.1 Learning Objectives
18.2 Incident: Nypro Explosion, Flixborough, England, 1974
18.3 Introduction to Management of Change
18.4 What a New Engineer Might Do
18.5 Tools
18.6 Summary
18.7 Other Incidents
18.8 Exercises
18.9 References
19 Operating Procedures, Safe Work Practices, Conduct of Operations, and Operational Discipline
19.1 Learning Objectives
19.2 Incident: Exxon Valdez Oil Spill, Alaska, 1989
19.3 Operating Procedures
19.4 Safe Work Practices
19.5 Conduct of Operations and Operational Discipline
19.6 What a New Engineer Might Do
19.7 Tools
19.8 Summary
19.9 Other Incidents
19.10 Exercises
19.11 References
20 Emergency Management
20.1 Learning Objectives
20.2 Incident: West Fertilizer Explosion, West, Texas, 2013
20.3 Introduction to Emergency Management
20.4 Recovery and Recommissioning
20.5 What a new Engineer Might Do
20.6 Tools
20.7 Summary
20.8 Other Incidents
20.9 Exercises
20.10 References
21 People Management Aspects of Process Safety Management
21.1 Learning Objectives
21.2 Incident: Deepwater Horizon Well Blowout, Gulf of Mexico, 2010
21.3 Overview
21.4 Process Safety Competency
21.5 Training and Performance Assurance
21.6 Process Knowledge Management
21.7 Contractor Management
21.8 Workforce Involvement
21.9 Stakeholder outreach
21.10 What a New Engineer Might Do
21.11 Tools
21.12 Summary
21.13 Other Incidents
21.14 Exercises
21.15 References
22 Sustaining Process Safety Performance
22.1 Learning Objectives
22.2 Incident: Space Shuttle Columbia, 2003
22.3 Overview
22.4 Incident investigation
22.5 Measurement and metrics
22.6 Auditing
22.7 Management review and continuous improvement
22.8 What a New Engineer Might Do
22.9 Tools
22.10 Summary
22.11 Other Incidents
22.12 Exercises
22.13 References
23 Process Safety Culture
23.1 Learning Objectives
23.2 Overview
23.3 Beyond the Management of Process Safety
23.4 What a New Engineer Might Do
23.5 Tools
23.6 Exercises
23.7 References
Appendix A โ Concluding Exercises
Appendix B โ Relationship Between Book Content and Typical Engineering Courses
Appendix C โ Example RAGAGEP List
Appendix D โ Reactive Chemicals Checklist
Appendix E โ Classifying Process Safety Events Using API RP 754 3nd Edition
Appendix F โ Example Process Operations Readings and Evaluations
Appendix G โ List of CSB Videos
Appendix H โ Major Process Safety Incident Vs Root Cause Map
Index
EULA