Download or read book More Incidents That Define Process Safety written by CCPS (Center for Chemical Process Safety) and published by John Wiley & Sons. This book was released on 2019-10-14 with total page 270 pages. Available in PDF, EPUB and Kindle. Book excerpt: More Incidents that Define Process Safety book describes over 50 incidents which have had a significant impact on the chemical industry as well as the basic elements of process safety. Each incident is presented in sufficient detail to gain an understanding of root causes for the event with a focus on lessons learned and the impact the incident had on process safety. Incidents are grouped by incident type including Reactive chemical; Fires; Explosions; Environmental/toxic releases; and Transportation incidents. The book also covers incidents from other industries that illustrate the safety management elements. The book builds on the first volume and adds incidents from China, India, Italy and Japan. Further at the time the first volume was being written, CCPS was developing a new generation of process safety management elements that were presented as risk based process safety; these elements are addressed in the incidents covered.

Download or read book The Use and Storage of Methyl Isocyanate MIC at Bayer CropScience written by National Research Council and published by National Academies Press. This book was released on 2012-08-31 with total page 218 pages. Available in PDF, EPUB and Kindle. Book excerpt: The use of hazardous chemicals such as methyl isocyanate can be a significant concern to the residents of communities adjacent to chemical facilities, but is often an integral part of the chemical manufacturing process. In order to ensure that chemical manufacturing takes place in a manner that is safe for workers, members of the local community, and the environment, the philosophy of inherently safer processing can be used to identify opportunities to eliminate or reduce the hazards associated with chemical processing. However, the concepts of inherently safer process analysis have not yet been adopted in all chemical manufacturing plants. The Use and Storage of Methyl Isocyanate (MIC) at Bayer CropScience presents a possible framework to help plant managers choose between alternative processing options-considering factors such as environmental impact and product yield as well as safety- to develop a chemical manufacturing system. In 2008, an explosion at the Bayer CropScience chemical production plant in Institute, West Virginia, resulted in the deaths of two employees, a fire within the production unit, and extensive damage to nearby structures. The accident drew renewed attention to the fact that the Bayer facility manufactured and stores methyl isocyanate, or MIC - a volatile, highly toxic chemical used in the production of carbamate pesticides and the agent responsible for thousands of death in Bhopal, India, in 1984. In the Institute accident, debris from the blast hit the shield surrounding a MIC storage tank, and although the container was not damaged, an investigation by the U.S. Chemical Safety and Hazard Investigation Board found that the debris could have struck a relief valve vent pipe and cause the release of MIC to the atmosphere. The Board's investigation also highlighted a number of weaknesses in the Bayer facility's emergency response systems. In light of these concerns, the Board requested the National Research Council convene a committee of independent experts to write a report that examines the use and storage of MIC at the Bayer facility. The Use and Storage of Methyl Isocyanate (MIC) at Bayer CropScience also evaluates the analyses on alternative production methods for MIC and carbamate pesticides preformed by Bayer and the previous owners of the facility.

Download or read book Investigation Report Pesticide Chemical Runaway Reaction Pressure Vessel Explosion written by U.s. Chemical Safety and Hazard Investigation Report and published by CreateSpace. This book was released on 2014-08-01 with total page 172 pages. Available in PDF, EPUB and Kindle. Book excerpt: On August 28, 2008, at about 10:35 p.m., a runaway chemical reaction occurred inside a 4,500 gallon pressure vessel known as a residue treater, causing the vessel to explode violently in the methomyl unit at the Bayer CropScience facility in Institute, West Virginia. Highly flammable solvent sprayed from the vessel and immediately ignited, causing an intense fire that burned for more than 4 hours. The fire was contained inside the Methomyl-Larvin insecticide unit by the Bayer CropScience fire brigade with mutual aid assistance from local volunteer and municipal fire departments. The incident occurred during the restart of the methomyl unit after an extended outage to upgrade the control system and replace the original residue treater vessel. Two company employees who had been dispatched by the control room personnel to investigate why the residue treater pressure was increasing were near the residue treater when it ruptured. One died from blunt force trauma and burn injuries sustained at the scene; the second died 41 days later at the Western Pennsylvania Burn Center in Pittsburgh, Pennsylvania. Six volunteer firefighters who assisted in the unit fire suppression activities and two contractors working at the facility were treated for possible toxic chemical exposure. The Kanawha-Putnam County Emergency Management Director advised more than 40,000 residents, including the resident students at the West Virginia State University adjacent to the facility, to shelter-in-place for more than three hours as a precaution. The fire and drifting smoke forced the state police and local law enforcement authorities to close roads near the facility and the interstate highway, which disrupted traffic for hours. The Chemical Safety Board (CSB) investigation team determined that the runaway chemical reaction and loss of containment of the flammable and toxic chemicals resulted from deviation from the written start-up procedures, including bypassing critical safety devices intended to prevent such a condition. Other contributing factors included an inadequate pre-startup safety review; inadequate 1 operator training on the newly installed control system; unevaluated temporary changes, malfunctioning or missing equipment, misaligned valves, and bypassed critical safety devices; and insufficient technical expertise available in the control room during the restart. Poor communications during the emergency between the Bayer CropScience incident command and the local emergency response agency confused emergency response organizations and delayed public announcements on actions that should be taken to minimize exposure risk. Although Bayer CropScience reported that “no toxic chemicals were released because they were consumed in the intense fires,” the CSB later confirmed that the only air monitors suitably placed near the unit to detect toxic chemicals were, in fact, not operational at the time of the incident. No reliable data or analytical methods were available to determine what chemicals were released, or predict any exposure concentrations. The methomyl unit used the highly toxic chemical, methyl isocyanate (MIC), in a series of complex chemical reactions to produce methomyl, a dry chemical used to make the pesticide, Larvin. MIC is manufactured in a separate production unit at the facility and stored in large underground pressure vessels. Liquid MIC was pumped to a “day tank” pressure vessel near the Methomyl-Larvin unit, which provided the daily production quantity of MIC for the methomyl unit and the carbofuran unit, which is about 200 feet west of the methomyl unit. The MIC storage tank adjacent to the methomyl unit and the MIC transfer piping between the production unit and the manufacturing units were not damaged, nor did the MIC storage tank overheat or pressurize above the operating limits during the fire.

Download or read book Guidelines for Managing Process Safety Risks During Organizational Change written by CCPS (Center for Chemical Process Safety) and published by John Wiley & Sons. This book was released on 2013-12-13 with total page 156 pages. Available in PDF, EPUB and Kindle. Book excerpt: An understanding of organizational change management (OCM) — an often overlooked subject — is essential for successful corporate decision making with little adverse effect on the health and safety of employees or the surrounding community. Addressing the myriad of issues involved, this book helps companies bring their OCM systems to the same degree of maturity as other process safety management systems. Topics include corporate standard for organizational change management, modification of working conditions, personnel turnover, task allocation changes, organizational hierarchy changes, and organizational policy changes.

Download or read book Guidelines for Safe Automation of Chemical Processes written by CCPS (Center for Chemical Process Safety) and published by John Wiley & Sons. This book was released on 2017-01-06 with total page 604 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book provides designers and operators of chemical process facilities with a general philosophy and approach to safe automation, including independent layers of safety. An expanded edition, this book includes a revision of original concepts as well as chapters that address new topics such as use of wireless automation and Safety Instrumented Systems. This book also provides an extensive bibliography to related publications and topic-specific information.

Download or read book Domino Effects in the Process Industries written by Alessandro Tugnoli and published by Elsevier Inc. Chapters. This book was released on 2013-07-08 with total page 36 pages. Available in PDF, EPUB and Kindle. Book excerpt: Risk-based design has an important role in the inherent prevention of domino effect, limiting the possibility of escalation by both physical distances between units and introduction of robust safety barriers. In this chapter, the role of design in reducing domino hazard has been explored. Layout definition was identified as a key factor for the prevention of escalation. Threshold values for escalation to be used in design activities were defined. Thus, criteria for the assessment of appropriate safety distances were developed and implemented in layout design. The integration of different strategies in accident mitigation was identified as the key in achieving safer plants with respect to domino accidents. Since conceptual tools alone frequently fail in solving the tradeoffs related to the conflicting needs in the design improvement, inherent safety metrics were introduced to support design activities.

Download or read book Guidelines for Enabling Conditions and Conditional Modifiers in Layer of Protection Analysis written by CCPS (Center for Chemical Process Safety) and published by John Wiley & Sons. This book was released on 2013-11-18 with total page 134 pages. Available in PDF, EPUB and Kindle. Book excerpt: The initial Layer of protection analysis (LOPA) book published in 2001 set the rules and approaches for using LOPA as an intermediate method between purely qualitative hazards evaluation/analysis and more quantitative analysis methods. Basic LOPA provides an order-of-magnitude risk estimate of risk with fairly reproducible results. LOPA results are considered critical in determining safety integrity level for design of safety instrumented systems. This guideline clarifies key concepts and reinforces the limitations and the requirements of LOPA. The main scope of the guideline is to provide examples of CMs and ECs and to provide concrete guidance on the protocols that must be followed to use these concepts. The book presents a brief overview of Layer of Protection Analysis (LOPA) and its variations, and summarizes terminology used for evaluating scenarios in the context of a typical incident sequence. It defines and illustrates the most common types of ECs and CMs and shows how they interrelate to risk criteria as well as their application to other methods.

Download or read book Methods to Assess and Manage Process Safety in Digitalized Process System written by Faisal Khan and published by Academic Press. This book was released on 2022-07-06 with total page 670 pages. Available in PDF, EPUB and Kindle. Book excerpt: Methods to Assess and Manage Process Safety in Digitalized Process System, Volume Six, the latest release in the Methods in Chemical Process Safety series, highlights new advances in the field, with this new volume presenting interesting chapters written by an international board of authors. - Provides the authority and expertise of leading contributors from an international board of authors - Presents the latest release in the Methods in Chemical Process Safety series - Provides the authority and expertise of leading contributors from an international board of authors

Download or read book Guidelines for Managing Abnormal Situations written by CCPS (Center for Chemical Process Safety) and published by John Wiley & Sons. This book was released on 2022-11-14 with total page 277 pages. Available in PDF, EPUB and Kindle. Book excerpt: The book discusses why management of abnormal situations is important to process safety. The book provides guidance on practical steps to avoid or mitigate an accident or incident before it escalates into a more dangerous and costly issues which can include downtime, lost production, equipment damage, injuries, and external/ environmental damage. Through the use of case studies the book illustrates the impact these deviant occurrences can have on operating facilities. Management principles that can be established before an issue occurs are presented while case studies are used to illustrate the impact that an abnormal situation can have on an operating facility. The impact of plant design are detailed, with separate focus points on new plant design and retrofits to existing plants. A section on writing plant procedures and plant policies so that they incorporate the principles of managing abnormal situations is also included. Training content is provided on how to manage deviant situations, with guidance on presenting the information to specific target populations, such as front-line operators, operations managers, plant engineers, and process safety engineers. Readers are also shown tools that are currently available for recognizing and responding to abnormal situations, and actions that process safety engineers can use during Hazard Identification and Risk Analysis (HIRA).

Download or read book Guidelines for Process Safety During the Transient Operating Mode written by CCPS (Center for Chemical Process Safety) and published by John Wiley & Sons. This book was released on 2021-01-27 with total page 288 pages. Available in PDF, EPUB and Kindle. Book excerpt: Prevent operational incidents and reduce risks with an essential CCPS guide You can help your company reduce its operating risks by learning how to effectively manage transient operations and avoid major incidents. Startups and shutdowns, known as transient operations, can be high-risk periods for manufacturing facilities. Guidelines for Process Safety During Transient Operations offers useful guidance in preparing for the safe startup and shutdown of chemical processes. With an understanding of the risks involved, you can work proactively to prevent fatalities, serious injuries, reduced productivity, and costly damage. This essential guide for plants provides clear examples of how to anticipate and avoid major issues. The book examines safe shutdown procedures in the event of an emergency. You will also gain direction on how to resume operations safely after an unexpected shutdown. The book supports anyone tasked with regulating and overseeing chemical plants and procedures, whether you are an engineer, manager, or government professional. Minimize operating risks through the effective management of transient operations Establish safe start-up and shutdown procedures for chemical processes Be ready to safely shut down processes in the event of an emergency Learn from real world examples of start-up or shutdown incidents Review procedures and engineering controls that help prevent or reduce the effects of incidents involving transient operations Guidelines for Process Safety comes to you from The Center for Chemical Process Safety (CCPS), which offers advanced thinking in the critical area of process safety. The organization develops technology and management practices for companies seeking to reduce hazards within the chemical and petrochemical industries.

Download or read book Trevor Kletz Compendium written by Andy Brazier and published by Elsevier. This book was released on 2021-01-21 with total page 312 pages. Available in PDF, EPUB and Kindle. Book excerpt: Trevor Kletz has had a huge impact on the way people viewed accidents and safety, particularly in the process industries. His ideas were developed from nearly 40 years working in the chemical industry. When he retired from the field, he shared his experience and ideas widely in more than 15 books. Trevor Kletz Compendium: His Process Safety Wisdom Updated for a New Generation introduces Kletz's stories and ideas and brings them up to date in this valuable resource that equips readers to manage process safety in every workplace. Topics covered in this book include inherent safety, safety studies, human factors and design. Learn the lessons from past accidents to make sure they don't happen again. - Focuses on understanding systems and learning from past accidents - Describes approaches to safety that are practical and effective - Provides an engineer's perspective on safety

Download or read book What Went Wrong written by Trevor Kletz and published by Butterworth-Heinemann. This book was released on 2019-06-06 with total page 824 pages. Available in PDF, EPUB and Kindle. Book excerpt: What Went Wrong? 6th Edition provides a complete analysis of the design, operational, and management causes of process plant accidents and disasters. Co-author Paul Amyotte has built on Trevor Kletz's legacy by incorporating questions and personal exercises at the end of each major book section. Case histories illustrate what went wrong and why it went wrong, and then guide readers in how to avoid similar tragedies and learn without having to experience the loss incurred by others. Updated throughout and expanded, this sixth edition is the ultimate resource of experienced-based analysis and guidance for safety and loss prevention professionals. - 20% new material and updating of existing content with parts A and B now combined - Exposition of topical concepts including Natech events, process security, warning signs, and domino effects - New case histories and lessons learned drawn from other industries and applications such as laboratories, pilot plants, bioprocess plants, and electronics manufacturing facilities

Download or read book Dynamic Risk Assessment and Management of Domino Effects and Cascading Events in the Process Industry written by Valerio Cozzani and published by Elsevier. This book was released on 2021-06-08 with total page 406 pages. Available in PDF, EPUB and Kindle. Book excerpt: Dynamic Risk Assessment and Management of Domino Effects and Cascading Events in the Process Industry provides insights into emerging and state-of-the-art methods for the dynamic assessment of risk and safety barrier performance in the framework of domino effect risk management. The book presents methods and tools to manage the risk of cascading events involving the chemical and process industry. It is an ideal reference for both safety and security managers, industrial risk stakeholders, scientists and practitioners. In addition, laymen may find the state-of-the-art methods concerning domino effects (large-scale accidents) and how to prevent their propagation an interesting topic of study. - Includes dynamic hazard and risk assessment methods - Presents methods for safety barrier performance assessment - Addresses the effect of harsh environment on domino risk assessment - Relates physical security in relation to domino effects - Includes innovative methods and tools

Download or read book Process Safety written by James A. Klein and published by CRC Press. This book was released on 2017-06-01 with total page 389 pages. Available in PDF, EPUB and Kindle. Book excerpt: Effective process safety programs consist of three interrelated foundations—safety culture and leadership, process safety systems, and operational discipline—designed to prevent serious injuries and incidents resulting from toxic releases, fires, explosions, and uncontrolled reactions. Each of these foundations is important and one missing element can cause poor process safety performance. Process Safety: Key Concepts and Practical Approaches takes a systemic approach to the traditional process safety elements that have been identified for effective process safety programs. More effective process safety risk reduction efforts are achieved when these process safety systems, based on desired activities and results rather than by specific elements, are integrated and organized in a systems framework. This book provides key concepts, practical approaches, and tools for establishing and maintaining effective process safety programs to successfully identify, evaluate, and manage process hazards. It introduces process safety systems in a way that helps readers understand the purpose, design, and everyday use of overall process safety system requirements. Understanding what the systems are intended to achieve, understanding why they have been designed and implemented in a specific way, and understanding how they should function day-to-day is essential to ensure continued safe and reliable operations.

Download or read book Human Factors Handbook for Process Plant Operations written by CCPS (Center for Chemical Process Safety) and published by John Wiley & Sons. This book was released on 2022-04-26 with total page 484 pages. Available in PDF, EPUB and Kindle. Book excerpt: Human Factors Handbook for Process Plant Operations Provides clear and simple instructions for integrating Human Factors principles and practices in the design of processes and work tasks Human Factors, the science of interaction between humans and other elements of a system, draws from disciplines such as psychology, ergonomics, anthropometrics, and physiology to understand how and why people behave and perform as they do—and how best to support them in performing tasks. The goals of the Human Factors approach are to improve human reliability, minimize the risk from human error, and optimize the working environment, human wellbeing, and overall system performance. Human Factors Handbook for Process Plant Operations guides supervisors, managers, and engineers on incorporating Human Factors principles and practices into plant maintenance and operations. With thorough and accessible coverage of all Human Factors topics of relevance to process industries, this easy-to-use handbook uses real-world anecdotes and case studies to demonstrate effective training and learning, task planning, communications, emergency response, risk and error management, and more. Throughout the text, the authors offer valuable insights into why people make mistakes while providing advice on how to help workers perform their process operational tasks successfully. Explains all essential Human Factors concepts and knowledge with clear descriptions and illustrative examples Offers actionable advice and models of good practice that can be applied to design, process operations, start-ups and shut-downs, and maintenance Addresses job aids, equipment design, competence, task support, non-technical skills, working with contractors, and managing change Discusses how lack of Human Factors considerations during the engineering design phase can adversely affect safety and performance Describes how to use indicators to both recognize and learn from human error and performance issues Written by highly experienced operating and maintenance personnel, Human Factors Handbook for Process Plant Operations is an indispensable resource for everyone involved with defining, planning, training, and managing process operations, maintenance, and emergency response in the food, pharmaceutical, chemical, petroleum, and refining industries. The missions of both the CCPS and EI include developing and disseminating knowledge, skills and good practices to protect people, the environment, and property by bringing the best knowledge and practices to industry, academia, governments and the public around the world through collective wisdom, tools, training and expertise. The CCPS, an industrial technology alliance of the American Institute of Chemical Engineers (AIChE), has been at the forefront of documenting and sharing important process safety risk assessment methodologies for more than 35 years and has published over 100 books in its process safety guidelines and process safety concept book series. The EI’s Technical Work Program addresses the depth and breadth of the energy sector from fuels and fuels distribution to health and safety, sustainability and the environment. The EI program provides cost-effective, value-adding knowledge on key current and future international issues affecting those in the energy sector.

Download or read book Translating Diverse Environmental Data into Reliable Information written by Daniel A. Vallero and published by Academic Press. This book was released on 2017-09-15 with total page 502 pages. Available in PDF, EPUB and Kindle. Book excerpt: Translating Diverse Environmental Data into Reliable Information: How to Coordinate Evidence from Different Sources is a resource for building environmental knowledge, particularly in the era of Big Data. Environmental scientists, engineers, educators and students will find it essential to determine data needs, assess their quality, and efficiently manage their findings. Decision makers can explore new open access databases and tools, especially portals and dashboards. The book demonstrates how environmental knowledgebases are and can be built to meet the needs of modern students and professionals. Topics covered include concepts and principles that underpin air, water, and other public health and ecological topics. Integrated and systems perspectives are woven throughout, with clues on how to build and apply interdisciplinary data, which can increasingly be obtained from sources ranging from peer-reviewed research appearing in scientific journals to information gathered by citizen scientists. This opens the door to using vast amounts of open data and the necessary quality assurance and metadata considerations for their countless applications. - Provides tools to manage data of varying sizes and quality - Identifies both opportunities and cautions in using "other people's data - Updates physical, chemical and biological factors that must be considered in risk evaluations and life cycle assessments - Applies to data collected by academic, governmental, businesses, and citizen scientists across environmental systems - Improves readers' ability to organize and visualize their work in the age of Big Data

Download or read book Domino Effect Its Prediction and Prevention written by and published by Academic Press. This book was released on 2021-07-09 with total page 532 pages. Available in PDF, EPUB and Kindle. Book excerpt: Domino Effect: Its Prediction and Prevention, Volume Five in the Methods in Chemical Process Safety series, focuses on the process of learning from experience, including elements of process safety management, human factors in the chemical process industries, and the regulation of chemical process safety, including current approaches. Users will find this book to be an informative tool and user manual for process safety for a variety of professionals. This new release focuses on Domino effect – Case histories and accident statistics, the state-of-the-art in domino effect modeling, Fire Driven Domino Effect, Mitigation of Domino Effect, and much more. - Acquaints readers/researchers with the fundamentals of process safety - Provides the most recent advancements and contributions from a practical point-of-view - Gives readers the views/opinions of experts on each topic