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.
Written and edited by engineering contractors and industry project/maintenance managers as an easy-to-use guide for other industry professionals, this book identifies important process safety issues in the contractor-client relationship,which are not addressed by other groups and publications...
The second edition of this essential reference updates and combines two earlier titles to capture the many technological advances for predicting the "footprint" of a vapor cloud release. Cited by EPA in its 1996 document, "Off-Site Consequence Analysis Guidance," the aim of the book is to encourage...
This book puts together a body of very recent information never before presented in one volume on the design of post-release mitigation systems. The development of a fundamental knowledge base on post-release mitigation systems, through testing and data correlation, is very new. While further...
The EPA investigation of a 1994 chemical plant tragedy concluded that "the explosion resulted from a lack of written safe operating procedures…" While good written procedures can't guarantee zero accidents, they can reduce the number of accidents caused by human error. This new book shows how to...
A brief introduction to a complex topic, giving a description of the processes involved in an accidental or emergency release and the resulting downwind transport and dilution of gases, vapors, and aerosols.
Prevention, preparedness, response and recovery--the key components of emergency planning--form the major sections of this work. The book first describes PSM (Process Safety Management) as the key to prevention, then goes on to consider the main features of a preparedness program, including...
The process industry has developed integrated process safety management programs to reduce or eliminate incidents and major consequences, such as injury, loss of life, property damage, environmental harm, and business interruption. Good documentation practices are a crucial part of retaining past...
This Guidelines book provides technical information on how to conduct a consequence analysis to satisfy your company's needs and the EPA rules. It covers quantifying the size of a release, dispersion of vapor clouds to an endpoint concentration, outcomes for various types of explosions and fires,...
First-line managers have to maintain the integrity of facilities, control manufacturing processes, and handle unusual or emergency situations, as well as respond to the pressures of production demand. On a daily basis, they are closest to the operating personnel who may be injured by a process...
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.
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...
The OSHA Process Safety Management National Emphasis Program will soon apply to the chemical industry, targeting compliance with safety standards associated with chemical hazards.
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.
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...
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.
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.
Thiago Tinoco Pires
Here’s how to construct and apply continuous-value and single-value network diagrams, which can better represent system failure mechanisms than other logic diagrams.
Faisal I. Khan
Posing various possible incidents - rather than just the worst-case one - illuminates those that are really important and those that are most likely to occur