Elements of Process Safety
The four pillars and the twenty elements of risk based process safety can be designed and implemented at varying levels of rigor to optimize process safety management, performance, efficiency, and effectiveness.
The complexity of today's risk decisions is well known. Beyond cost and risk there are many other factors contributing to these decisions, including type of risk (such as human injury or fatality), the economic impact on the local community, profitability, availability of capital, alternatives for...
The causes of catastrophic accidents in the process industries, now recognized as complex and interrelated, need to be matched by multi-faceted technical management systems. These principles apply to companies of any size and to a full range of industries beyond the chemical industry, such as pulp...
OSHA (29 CFR 1910.119) has recognized AIChE/DIERS two-phase flow publications as examples of "good engineering practice" for process safety management of highly hazardous materials. The prediction of when two-phase flow venting will occur, and the applicability of various sizing methods for two-...
The book supplements Guidelines for Chemical Process Quantitative Risk Analysis by providing the failure rate data needed to perform a chemical process quantitative risk analysis.
Guidelines for Vapor Release Mitigation is a survey of current industrial practice for controlling accidental releases of hazardous vapors and preventing their escape from the source area.
Proper installation, maintenance, and inspection of metal tubing is important in preventing fires and toxic material releases in process plants. Do not forget about tubing just because it is usually small. Even a small leak can cause a fire that can...
Check out warning devices for hazardous areas and high-visibility work vests that reduce static electricity.
This book provides guidance on characterizing, recognizing, and responding to warning signs to help avoid process incidents and injuries before they occur. The guidance can be used by both process safety management (PSM) professionals in evaluating their processes and PSM systems as well as for...
At last, smaller chemical processing operations have truly easy access to process safety and risk management programs tailored to meet their needs. Written as a "how to" book with checklists, it offers sufficient information for managers of facilities with small chemical operations to implement a...
Richard P. Palluzi
Safety standards can significantly improve pilot plant safety and increase efficiency. This article addresses many of the issues involved in developing, deploying and using such standards.
Walter L. Frank
Changes to OSHA's PSM rule and EPA's RMP programs are underway, due to pressures from various groups and the need for greater security.
David K. Whittle, Kevin Smith
Process hazard analyses must be revamped — or redone from scratch — every five years by law. Following the guidance given here will facilitate this effort.
The OSHA Process Safety Management National Emphasis Program will soon apply to the chemical industry, targeting compliance with safety standards associated with chemical hazards.
James A. Klein, Bruce K. Vaughen
Built on a solid foundation of leadership support and employee involvement, an operational discipline program can help to prevent serious incidents and injuries, and improve overall site safety and business performance.
The December 2011 Beacon described an incident where a missing plug on a vent line resulted in a flammable material leak that caught fire, causing a fatality. That incident reminded us of the importance of caps and plugs on process vent lines and...
This book discusses the fundamental skills, techniques, and tools of auditing, and the characteristics of a good process safety management system. A variety of approaches are given so the reader can select the best methodology for a given audit. This book updates the original CCPS Auditing...
A contract welder and a foreman were repairing an agitator support on top of an atmospheric-pressure storage tank. The tank contained a polyvinyl fluoride slurry with a flammable concentration if vinyl fluoride in the vapor space. An explosion...
In the safety culture of some companies, the first recognition of trouble may be a sudden and massive failure. Learn how to decipher the warning signals to avoid safety incidents. <BR><BR>
Gregory M. Hanggi
The key to low injury and incident rates is creating a work environment that encourages employees to always take action to resolve potential problems. Here's how to do that.
John F. Murphy, P.E.
Heed these lessons learned from investigations conducted by the Chemical Safety and Hazard Investigation Board to prevent accidents at your site.
Originally developed for discrete manufacturing, this method can be applied to process units to detect which components may fail, and correct the situation before trouble happens.
Reviewing incident reports at a HAZOP meeting is more than just a lessons learned activity. It can spur sharper thinking and lead to a more telling analysis of your processes.
Judy A. Perry
Use this checklist-based technique of process-hazard analysis (PHA) to identify and assess potential dust hazards and to evaluate safeguards that can mitigate risks.
Frederick T. Dyke
Information that can reveal the root cause of an incident resides in many places — within the plant or process unit, in control rooms and offices, and even in witnesses’ minds. Here’s how to find the data and conduct effective witness interviews.
Many CPI firms are looking at safety costs as investments, rather than expenses, and are reaping the wide-range benefits. Here's a roadmap of how best to accomplish this.
V. Anthony Ciliberti
When information is organized and accessible, more people will use it and thus be better informed. Better information means better decisions, which results in safer facilities and more efficient operations.
Michael J. Dolan
As chemical engineers and leaders in the chemical process industries, we must ensure that process safety is integral to every aspect of what we and our companies do.
Richard C. Wedlich
Knowing the safe operating conditions for a reaction allows us to select appropriate safety measures and thereby lower both the likelihood and the severity of a thermal runaway.
Think of process safety management (PSM) as a project deliverable, and follow these best practices for scheduling and performing process hazard analyses (PHAs) and completing other PSM requirements during key phases of a major project.