Inherently safer chemical processes: a life cycle approach
Saved in:
| Format: | Book |
|---|---|
| Language: | English |
| Published: |
New York, NY
CCPS [u.a.]
2009
|
| Edition: | 2. ed. |
| Subjects: | |
| Online Access: | Inhaltsverzeichnis |
| Item Description: | Includes index. |
| Physical Description: | XVIII, 411 S. Ill., graph. Darst. |
| ISBN: | 9780471778929 |
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MARC
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| 245 | 1 | 0 | |a Inherently safer chemical processes |b a life cycle approach |c Center for Chemical Process Safety |
| 250 | |a 2. ed. | ||
| 264 | 1 | |a New York, NY |b CCPS [u.a.] |c 2009 | |
| 300 | |a XVIII, 411 S. |b Ill., graph. Darst. | ||
| 336 | |b txt |2 rdacontent | ||
| 337 | |b n |2 rdamedia | ||
| 338 | |b nc |2 rdacarrier | ||
| 500 | |a Includes index. | ||
| 650 | 7 | |a Génie chimique - Mesures de sécurité |2 ram | |
| 650 | 4 | |a Chemical engineering |x Safety measures | |
| 710 | 2 | |a American Institute of Chemical Engineers |b Center for Chemical Process Safety |e Sonstige |0 (DE-588)5046408-5 |4 oth | |
| 856 | 4 | 2 | |m Digitalisierung UB Bayreuth |q application/pdf |u http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=017317897&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA |3 Inhaltsverzeichnis |
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Record in the Search Index
| _version_ | 1804138823013105664 |
|---|---|
| adam_text | Contents
1.
Introduction
1
1.1
.Objectives, Intended Audience and Scope of This Book
1
1.1.1.
Objectives
1
1.1.2.
Intended Audience
2
1.1.3.
Scope
2
1.2
Integration of this Guidance with Other CCPS Guidance
2
1.3
Organization of the Book
3
1.4
History of Inherent Safety
5
2.
The Concept of Inherent Safety
9
2.1
Process Risk Management and Inherent Safety
9
2.2
Inherent Safety Defined
11
2.3
Inherently Safer Approaches
11
2.4
Layers of Protection
13
2.5
Levels of Inherent Safety
15
2.6
Worked Example
17
2.7
Summary
19
3.
The Role of Inherently Safer Concepts in Process Risk
Management
21
3.1
Integrating Inherent Safety in Process Risk
Management Systems
21
3.2
Timing for Consideration of Inherently Safer Options
24
3.3
Inherent Safety Constraints
25
3.4
Resolving Inherent Safety Issues
25
3.5
Inherently Safer Strategies
26
3.6
Summary
27
4.
Inherently Safer Strategies
29
4.1
Definition of Inherently Safer Strategies
29
4.2
Minimize
30
4.2.1
Reactors
32
4.2.2
Continuous Stirred Reactors
33
4.2.3
Tubular Reactors
33
VII
viii
INHERENTLY SAFER CHEMICAL PROCESSES
4.2.4
Loop Reactors
34
4.2.5
Reactive Distillation
36
4.2.6
Storage of Hazardous Materials
39
4.2.7
Process Piping
41
4.2.8
Process Equipment
41
4.3
Substitute
42
4.3.1.
Reaction Chemistry
43
4.3.2
Solvents
49
4.3.3
Refrigerants and Firefighting Agents
50
4.4
Moderate
51
4.4.1
Dilution
51
4.4.2
Refrigeration
52
Less Severe Process Conditions
54
Secondary Containment-Dikes and
Containment Buildings
56
61
Inherently Robust Process Equipment
63
Vacuum
64
Runaway Reactions
64
Containment Vessels
66
Heat Transfer
67
Liquid Transfer
68
Reactor Geometry
68
Distributed Control Systems
69
Separation of Process Steps
69
Limitation of Available Energy
72
4.6
Other Strategies
73
4.6.1
Limitation of Effects
73
4.6.2
Global Hazards
74
4.6.3
Avoid Incorrect Assembly
75
4.6.4
Making Status Clear
75
4.7
Summary
76
5.
Life Cycle Stages
77
5.1
General Principles Across All Life Cycle Stages
77
5.2
Research
78
5.2.1
Inherently Safer Synthesis
79
5.2.2
Types of Hazards Associated With Research
80
5.2.3
Research Stage
—
Hazards Identification Methods
83
5.3
Process Development
91
5.3.
1 Unit Operations
-
General
92
5.3.2
Unit Operations
-
Specific
92
5.4
Detailed Design and Construction
98
5.4.1
Process Design Basis
99
5.4.2
Equipment
100
5.4.3
Process Controls
103
5.4.4
Supporting Facilities
107
4.4.3
4.4
.4
4.5
Simplify
4.5
.1
4.5
2
4.5
.3
4.5
.4
4.5
.5
4.5
.6
4.5
.7
4.5
.8
4.5
.9
4.5
.10
CONTENTS ix
5.4.5
Batch Processes
107
5.4.6
Other Design Considerations
109
5.5
Operations, Maintenance, and Modifications
110
5.5.1
Preservation of Inherent Safety
110
5.5.2
Inherent Safety
-
Continuous Improvement 111
5.6
Decommissioning
114
5.7
Transportation
116
5.7.1
Location Relative to Raw Materials
117
5.7.2
Shipping Conditions
118
5.7.3
Transportation Mode and Route Selection
118
5.7.4
Improved Transportation Containers
119
5.7.5
Administrative Controls
120
5.7.6
Management of Transportation Containers On-site
120
6.
Human Factors
123
6.1
Overview
123
6.2
Operability
and Personnel Safety
127
6.3
Maintainability
129
6.4
Error Prevention
131
6.4.1
Knowledge and Understanding
131
6.4.2
Design of Equipment and Controls
133
6.4.2
Standard Operating Procedures
140
6.5
Error Recovery
141
6.6
System Audits
143
6.7
Organizational Culture
144
6.8
Summary
144
7.
Inherent Safety and Security
147
7.1
Introduction
147
7.2
Chemical Security Risk
147
7.3
Security Strategies
151
7.4
Countermeasures
153
7.5
Assessing Security Vulnerabilities
153
7.6
Inherent Safety and Chemical Security
154
7.7
Limitations to Implementing IS Concepts in
Security Management
158
7.8
Conclusions
160
8.
Implementing Inherently Safer Design
161
8.1
Introduction
161
8.2
Management Systems Approach for IS
162
8.3
Education and Awareness
163
8.3.1
Making IS Corporate Philosophy
163
INHERENTLY SAFER CHEMICAL PROCESSES
8.3.2
IS in Education
163
8.4
Organizational Culture
164
8.4.1
Multiple Demands of IS in the PSM Program
165
8.4.2
Incorporating IS Into Normal Design Process
166
8.5
Inherent Safety Reviews
169
8.5.1
Inherent Safety Review Objectives
170
8.5.2
Good Preparation is Required for Effective
171
8.5.3
Inherent Safety Review Timing
172
8.5.4
Inherent Safety Review Team Composition
173
8.5.5
Inherent Safety Review Process Overview
174
8.5.6
Focus of Inherent Safety Reviews at Different Stages
177
8.5.7
Stages in Process Life Cycle
178
8.6
IS Review Methods
—
Overview
181
8.6.1
Three Approaches
181
8.6.2
Formal IS Reviews
182
8.6.3
IS Review Methods
183
8.6.4
Research
&
Development Application
183
8.6.5
PHA
-
Incorporation into HAZOP or other
PHA Techniques
184
8.6.6
What-if? Method
185
8.6.7
Checklist Method
186
8.6.8
Consequence-Based Methods
188
8.6.9
Other Methods
188
8.7
Incorporating IS Consideration into Existing
PSM Activities
192
8.8.
Human Factors and Inherent Safety Reviews
195
8.9
Reactive Chemicals Screening
196
8.10
Inherent Safety Review Training
198
8.11
Documentation of the Inherently Safer
Design Features of a Process
200
8.12.
IS Review Documentation
200
8.13
Time Required for an Inherent Safety Review
202
8.14
Summary
203
9.
Inherently Safer Design Conflicts
205
9.1
Introduction
205
9.2
Examples of inherent safety conflicts
208
9.2.1
Continuous vs. batch reactor
208
9.2.2
Reduced
toxicity
vs. reactive hazard
210
9.2.3
Reduced inventory vs. dynamic stability
211
9.2.4
Risk transfer vs. risk reduction
212
9.2.5
Inherent safety and security conflicts
213
9.3
Inherent Safety
-
Environmental Hazards
214
9.3.1
PCBs
214
9.3.2
CFCs
214
9.4
Inherent Safety and Health Conflicts
215
CONTENTS xi
9.4.1
Water Disinfection
215
9.5
Inherent Safety and Economic Conflicts
216
9.5.1
Existing plants
—
Operational vs. re-investment
economics in a capital intensive industry
216
9.5.2
Often more economical, but not necessarily
217
9.6
Tools for understanding and resolving conflicts
218
9.6.1
Tools for understanding and resolving conflicts
220
9.7
Measuring Inherent Safety characteristics
223
9.7.1
Dow Fire and Explosion Index
224
9.7.2
Dow Chemical Exposure Index
224
9.7.3 Mond
Index
224
9.7.4
Proposed Inherent Safety indices
225
9.8
Summary
225
10.
Inherently Safer Design Regulatory Initiatives
227
10.1
Inherent Safety Regulatory Developments
and Issues
227
10.2
Experience with IS Regulations
228
10.2.1
Inherently Safer Systems Requirements
—
Contra Costa County, California
229
10.2.2
New Jersey Toxic Catastrophe Prevention Act
(TCPA) and Prescriptive Order for
Chemical Plant Security
235
10.3
Issues in Regulating Inherent Safety
242
10.3.1
Consistent Understanding of
Inherent Safety
242
10.3.2
Needed Tools
243
10.4
Summary
244
11.
Worked Examples and Case Studies
251
11.1
Introduction
251
11.2
Application of an Inherent Safety Strategic
Approach to a Process
251
11.3
Case studies from Carrithers,
et al.
258
1.3.1
An Exothermic Batch Reaction
258
1.3.2
Refrigeration of Monomethylamine
261
1.3.3
Elimination of a Chlorine Water Treatment System
262
1.3.4
Reduction of Chlorine Transfer Line Size
262
1.3.5
Substitution of Aqueous Ammonia for
Anhydrous Ammonia
263
11.3.6.
Limitation of Magnitude of Deviations for
Aqueous Ammonia
265
11.3.7
A Vessel Entry Example 26X
11.4
Process Route Selection
-
Early R&D Example
271
11.5
Example of an Inherently Safer Study of a
Steam Production Facility
272
xii
INHERENTLY SAFER CHEMICAL PROCESSES
11.6
Case Study: Bhopal
277
11.7
Summaries in Brief: Examples by IS Strategy
279
11.8
Additional Literature Giving Examples of
Inherently Safer Operations
285
12.
Future Initiatives
287
12.1
Incorporating Inherently Safer Design into
Process Safety Management
287
12.2
Encouraging Invention within the Chemical
and Chemical Engineering Community
288
12.3
Including Inherent Safety into the Education
of Chemists and Chemical Engineers
288
12.4
Developing Inherently Safer Design
Databases and Libraries
288
12.5
Developing Tools to Apply Inherently
Safer Design
289
1
2.5.1
The Broad View and Life Cycle Cost of Alternatives
289
12.5.2
Benefits of Reliability Analysis
290
12.5.3
Potential Energy
290
12.5.4
A Table of Distances
290
12.5.5
Quantitative Measures of Inherent Safety
291
12.5.6
Other Suggestions
291
Appendix A. Inherently Safer Technology Checklist
293
Appendix B. Inherent Safety Analysis Approaches
331
B.I Inherent Safety Analysis-
Checklist Process Hazard Analysis (PHA)
333
B.2 Inherent Safety Analysis-
Independent Process Hazard Analysis (PHA)
338
B.3 Inherent Safety Analysis-
Integral to Process Hazard Analysis (PHA)
341
Appendix C. Applying Inherent Safety to
Risk Based Process Safety
345
Glossary
351
References
357
Chapter References
357
Key Literature in Inherent Safety and Additional Reading
377
Index
399
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| id | DE-604.BV035397194 |
| illustrated | Illustrated |
| indexdate | 2024-07-09T21:34:18Z |
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| isbn | 9780471778929 |
| language | English |
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| physical | XVIII, 411 S. Ill., graph. Darst. |
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| publisher | CCPS [u.a.] |
| record_format | marc |
| spelling | Inherently safer chemical processes a life cycle approach Center for Chemical Process Safety 2. ed. New York, NY CCPS [u.a.] 2009 XVIII, 411 S. Ill., graph. Darst. txt rdacontent n rdamedia nc rdacarrier Includes index. Génie chimique - Mesures de sécurité ram Chemical engineering Safety measures American Institute of Chemical Engineers Center for Chemical Process Safety Sonstige (DE-588)5046408-5 oth Digitalisierung UB Bayreuth application/pdf http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=017317897&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA Inhaltsverzeichnis |
| spellingShingle | Inherently safer chemical processes a life cycle approach Génie chimique - Mesures de sécurité ram Chemical engineering Safety measures |
| title | Inherently safer chemical processes a life cycle approach |
| title_auth | Inherently safer chemical processes a life cycle approach |
| title_exact_search | Inherently safer chemical processes a life cycle approach |
| title_full | Inherently safer chemical processes a life cycle approach Center for Chemical Process Safety |
| title_fullStr | Inherently safer chemical processes a life cycle approach Center for Chemical Process Safety |
| title_full_unstemmed | Inherently safer chemical processes a life cycle approach Center for Chemical Process Safety |
| title_short | Inherently safer chemical processes |
| title_sort | inherently safer chemical processes a life cycle approach |
| title_sub | a life cycle approach |
| topic | Génie chimique - Mesures de sécurité ram Chemical engineering Safety measures |
| topic_facet | Génie chimique - Mesures de sécurité Chemical engineering Safety measures |
| url | http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=017317897&sequence=000002&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA |
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