Process Safety for Engineers: An Introduction

Description

Process Safety for Engineers Familiarizes an engineer new to process safety with the concept of process safety management In this significantly revised second edition of Process Safety for Engineers: An Introduction, CCPS delivers a comprehensive book showing how Process Safety concepts are used to reduce operational risks. Students, new engineers, and others new to process safety will benefit from this book. In this updated edition, each chapter begins with a detailed incident case study, provides steps that help address issues, and contains problem sets which can be assigned to students. The second edition covers: Process Safety: including an overview of CCPS’ Risk Based Process Safety Hazards: specifically fire and explosion, reactive chemical, and toxicity Design considerations for hazard control: including Hazard Identification and Risk Analysis Management of operational risk: including management of change In addition, the book presents how Process Safety performance is monitored and sustained. The associated online resources are linked to the latest online CCPS resources and lectures. 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 – 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 – Concluding Exercises Appendix B – Relationship Between Book Content and Typical Engineering Courses Appendix C – Example RAGAGEP List Appendix D – Reactive Chemicals Checklist Appendix E – Classifying Process Safety Events Using API RP 754 3nd Edition Appendix F – Example Process Operations Readings and Evaluations Appendix G – List of CSB Videos Appendix H – Major Process Safety Incident Vs Root Cause Map Index EULA