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Examines the concept of aging process facilities and infrastructure in high hazard industries and highlights options for dealing with the problem while addressing safety issues This book explores the many ways in which process facilities, equipment, and infrastructure might deteriorate upon continuous exposure to operating and climatic conditions. It covers the functional and physical failure modes for various categories of equipment and discusses the many warning signs of deterioration. Dealing with Aging Process Facilities and Infrastructure also explains how to deal with equipment that may not be safe to operate. The book describes a risk-based strategy in which plant leaders and supervisors can make more informed decisions on aging situations and then communicate them to upper management effectively. Additionally, it discusses the dismantling and safe removal of facilities that are approaching their intended lifecycle or have passed it altogether. Filled with numerous case studies featuring photographs to illustrate the positive and negative experiences of others who have dealt with aging facilities, Dealing with Aging Process Facilities and Infrastructure covers the causes of equipment failures due to aging and their consequences; plant management commitment and responsibility; inspection and maintenance practices for managing life cycle; specific aging asset integrity management practices; and more. Describes symptoms and causal mechanisms of aging in various categories of process equipment Presents key considerations for making informed risk-based decisions regarding the repair or replacement of aging process facilities and infrastructure Discusses practices for managing process facility and infrastructure life cycle Includes examples and case histories of failures related to aging Dealing with Aging Process Facilities and Infrastructure is an important book for industrial practitioners who are often faced with the challenge of managing process facilities and infrastructure as they approach the end of their useful lifecycle.

Process vent header collection systems are subject to continually varying compositions and flow rates and thus present significant challenges for safe design. Due to increasingly demanding safety, health, environmental, and property protection requirements, today's industrial designers are faced with the need to create increasingly complex systems for more effective treatment, dispersal, or disposal of process gases. Safe Design and Operation of Process Vents and Emission Control Systems provides cutting-edgeguidance for the design, evaluation, and operation of these systems, with emphasis on: Preventing fires, explosions, and toxic releases Maintaining safe vent conditions Understanding normal process operations, such as intentional routine controlled venting and emergency operations, like overpressure relief Mitigating the impacts of end-of-line treatment devices, such as scrubbers, flares, and thermal oxidizers, on the vent header system Complying with regulations Written by a team of process safety experts from the chemical, pharmaceutical, and petroleum industries, the book includes a wealth of real-world examples and a thorough overview of the tools and methods used in the profession.

Written by reliability data experts, the book gives plant managers and supervisors the guidance they need to collect, and use with confidence, process equipment reliability data for risk-based decisions. Focusing on the process industries, it provides the protocol and techniques to collect and organize high quality plant performance, maintenance, and repair data from your own operations, and includes methods and examples on how the data can be converted into useful information for engineering, maintenance, safety, and loss prevention. This data can be used for: facility reliability/availability assessments; making decisions on the need for redundant systems; improving equipment designs; selecting the best equipment for specific tasks; estimating required work force; benchmarking current efforts both frequency and time; integrating predictive and preventive maintenance effort; integrating shutdowns with production needs; quantifying risks; and minimizing human reliability issues.

While there are many resources available on fire protection and prevention in chemical petrochemical and petroleum plants—this is the first book that pulls them all together in one comprehensive resource. This book provides the tools to develop, implement, and integrate a fire protection program into a company or facility’s Risk Management System. This definitive volume is a must-read for loss prevention managers, site managers, project managers, engineers and EHS professionals. Note: CD-ROM/DVD and other supplementary materials are not included as part of eBook file.

Inherently Safer Chemical Processes presents a holistic approach to making the development, manufacture, and use of chemicals safer. It discusses strategies for substituting more benign chemicals at the development stage, minimizing risk in the transportation of chemicals, using safer processing methods at the manufacturing stage, and decommissioning a manufacturing plant. Since the publication of the original concept book in 1996, there have been many developments on the concept of inherent safety. This new edition provides the latest knowledge so that engineers can derive maximum benefit from inherent safety.

Layer of protection analysis (LOPA) is a recently developed, simplified method of risk assessment that provides the much-needed middle ground between a qualitative process hazard analysis and a traditional, expensive quantitative risk analysis. Beginning with an identified accident scenario, LOPA uses simplifying rules to evaluate initiating event frequency, independent layers of protection, and consequences to provide an order-of-magnitude estimate of risk. LOPA has also proven an excellent approach for determining the safety integrity level necessary for an instrumented safety system, an approach endorsed in instrument standards, such as ISA S84 and IEC 61511. Written by industry experts in LOPA, this pioneering book provides all the necessary information to undertake and complete a Layer of Protection Analysis during any stage in a processes' life cycle. Loaded with tables, charts, and examples, this book is invaluable to technical experts involved with ensuring the safety of a process. Because of its simplified, quicker risk assessment approach, LOPA is destined to become a widely used technique. Join other major companies and start your LOPA efforts now by purchasing this book.

The book is a guide for Layers of Protection Analysis (LOPA) practitioners. It explains the onion skin model and in particular, how it relates to the use of LOPA and the need for non-safety instrumented independent protection layers. It provides specific guidance on Independent Protection Layers (IPLs) that are not Safety Instrumented Systems (SIS). Using the LOPA methodology, companies typically take credit for risk reductions accomplished through non-SIS alternatives; i.e. administrative procedures, equipment design, etc. It addresses issues such as how to ensure the effectiveness and maintain reliability for administrative controls or “inherently safer, passive” concepts. This book will address how the fields of Human Reliability Analysis, Fault Tree Analysis, Inherent Safety, Audits and Assessments, Maintenance, and Emergency Response relate to LOPA and SIS. The book will separate IPL’s into categories such as the following: Inherent Safety eliminates a scenario or fundamentally reduces a hazard Preventive/Proactive prevents initiating event from occurring such as enhanced maintenance Preventive/Active stops chain of events after initiating event occurs but before an incident has occurred such as high level in a tank shutting off the pump. Mitigation (active or passive) minimizes impact once an incident has occurred such as closing block valves once LEL is detected in the dike (active) or the dike preventing contamination of groundwater (passive).

At last, a book that covers safety procedures and standards with information that is rarely available outside of proprietary materials. A comprehensive source for basic and essential operations and procedures in use in any facility, the book offers chemical operators and first line supervisors guidance in applying appropriate practices to prevent accidents, and suggests which practices to avoid.

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 accident, and they are in the best position to spot problem conditions and to act to contain them. This book offers these managers «how-to» information on process safety management program execution in the operations and maintenance departments, recommending technical and administrative process safety activities for the entire life cycle of the plant. Helpful tables and references add to the value of this process safety resource.

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.

Almost all the major accident investigations–Texas City, Piper Alpha, the Phillips 66 explosion, Feyzin, Mexico City–show human error as the principal cause, either in design, operations, maintenance, or the management of safety. This book provides practical advice that can substantially reduce human error at all levels. In eight chapters–packed with case studies and examples of simple and advanced techniques for new and existing systems–the book challenges the assumption that human error is «unavoidable.» Instead, it suggests a systems perspective. This view sees error as a consequence of a mismatch between human capabilities and demands and inappropriate organizational culture. This makes error a manageable factor and, therefore, avoidable.

Guidelines for Risk Based Process Safety provides guidelines for industries that manufacture, consume, or handle chemicals, by focusing on new ways to design, correct, or improve process safety management practices. This new framework for thinking about process safety builds upon the original process safety management ideas published in the early 1990s, integrates industry lessons learned over the intervening years, utilizes applicable «total quality» principles (i.e., plan, do, check, act), and organizes it in a way that will be useful to all organizations – even those with relatively lower hazard activities – throughout the life-cycle of a company.

Incidents That Define Process Safety describes approximately fifty incidents that have had a significant impact on the chemical and refining industries' approaches to modern process safety. Events are described in detail so readers get a fundamental understanding of the root causes, the consequences, the lessons learned, and actions that can prevent a recurrence. There are exhaustive investigative reports about these events, allowing you to apply the resulting safety principles to their current operations.

Over the years, companies have developed independent systems for managing process safety, environment, health, safety, and quality. Many aspects of these management systems are similar. Integrating EHS management systems can yield economies and improved system effectiveness. This book explains how integration reduces cost of delivery through a reduction in the number of management program steps and avoidance of redundancy; how it results in more effective programs, since the best practices can be combined into a single process; and how this integration brings a faster, and more cost effective response to new demands.

Batch reaction systems pose unique challenges to process safety managers because they do not operate in a steady state. The sequence of processing steps, and frequent start-ups and shutdowns, increase the possibility of human errors and equipment failures. And, since batch plants are often designed for shared use, frequent modification of piping and layout may occur, resulting in complex «management of change» issues. This book identifies the singular concerns of batch reaction systems—including potential sources of unsafe conditions—and provides a «how-to» guide for the practicing engineer in dealing with them by applying appropriate practices to prevent accidents.

In today’s competitive economy, companies often augment in-house production by outsourcing chemical reaction processes and distillation, drying, formulating, blending, and packaging operations. While most of these tolling, or contracted manufacturing services, proceed without incident, recent major accidents have pointed to weaknesses in some tolling arrangements, such as reactivity of materials and processes. This Guidelines book provides the reader with proven procedures to improve process safety throughout the life cycle of a contracted manufacturing operation. Extensive checklists and examples used throughout the book make it a valuable learning tool and reference for companies conducting toll manufacturing, or considering outsourcing manufacturing operations.

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 knowledge and experience, and avoiding relearning old lessons. Following an introduction, which offers examples of how proper documentation might have prevented major explosions and serious incidents, the 21 sections in this book clearly present aims, goals, and methodology in all areas of documentation. The text contains examples of dozens of needed forms, lists of relevant industry organizations, sources for software, references, OSHA regulations, sample plans, and more.

Over 40 papers and posters that share the latest practices in emergency planning related to fixed chemical, pharmaceutical, LNG, and petroleum facilities, storage facilities, transportation, and security.

This CCPS Guideline book outlines current transportation risk analysis software programs and demonstrates several available risk assessment programs for land transport by rail, truck, and pipeline for consequences that may affect the public or the environment. Provides introductory transport risk considerations for process engineers Gives guidance on route selection, equipment factors and materials Describes transportation security risk issues and industry practices to mitigate them Includes loading and unloading checklists for several transport modes Develops specific operating procedures and checklists to reduce human error Discusses considerations for transportation security, including threat and vulnerability assessments and potential countermeasures Summarizes key transportation security regulations, guidelines and industry initiatives. Note: CD-ROM/DVD and other supplementary materials are not included as part of eBook file.

Complemented by an estimating tool spreadsheet based on a fixed set of chemicals to assist in risk estimations, Probability of Ignition of a Released Flammable Mass converts a «best guess» to a calculated value based on available information and current technology. The text documents and explains the science and background of the technology-based approach. The tool, when populated with appropriate data, yields an estimate of the probability that a defined release of a flammable material will ignite if exposed to an ignition source. This information can be used to make risk assessments with a higher degree of confidence than estimates made before and it provides valuable information for use in the development of a facility's Emergency Response Plan.

This book has been written to address many of the developments since the 1st Edition which have improved how companies survey and select new sites, evaluate acquisitions, or expand their existing facilities. This book updates the appendices containing both the recommended separation distances and the checklists to help the teams obtain the information they need when locating the facility within a community, when arranging the processes within the facility, and when arranging the equipment within the process units.

Drawn from international sources, this book provides principles and strategies for the evaluation of chemical reactions, and for using this information in process design and management. A useful resource for engineers who design, start-up, operate, and manage chemical and petrochemical plants, the book places special emphasis on the use of state-of-the-art technology in theory, testing methods, and applications in design and operations.

The serious consequences of vapor cloud explosions, flash fires, and BLEVEs are very well known. Better understanding of the characteristics of these phenomena and models to calculate their consequences are key to effective prevention and mitigation. Cited by EPA in its 1996 document, "Off-site Consequence Analysis Guidance, " the first half of the book describes the characteristics of these phenomena and gives an overview of past experimental and theoretical research and methods to estimate consequences. The second part focuses on methods for consequence estimating by presenting sample problems. The entire book is heavily illustrated with photos, charts, tables, and diagrams, and each chapter has a full set of references for additional reading.

This book combines the synergies between performance improvement systems to help ensure safe and reliable operations, streamline procedures and cross-system auditing, and supporting regulatory and corporate compliance requirements. Many metrics are common to more than one area, such that a well-designed and implemented integrated management system will reduce the load on the Process Safety, SHE, Security and Quality groups, and improve manufacturing efficiency and customer satisfaction. Systems to improve performance include: process safety; traditional safety, health and environment; and, product quality. Chapters include: Integrating Framework; Securing Support & Preparing for Implementation; Establishing Common Risk Management Systems – How to Integrate PSM into Other EH; Testing Implementation Approach; Developing and Agreeing on Metrics; Management Review; Tracking Integration Progress and Measuring Performance; Continuous Improvement; Communication of Results to Different Stakeholders; Case Studies; and Examples for Industry.