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The Leading Guide To Process Safety Now Extensively Updated For Today's Processes And Systems As chemical processes have grown more complex, so have the safety systems required to prevent accidents. Chemical Process Safety, Third Edition, offers students and practitioners a more fundamental understanding of safety and the application required to safely design and manage today's sophisticated processes.The third edition continues the definitive standard of the previous editions. The content has been extensively updated to today's techniques and procedures, and two new chapters have been added. A new chapter on chemical reactivity provides the information necessary to identify, characterize, control, and manage reactive chemical hazards. A new chapter on safety procedures and designs includes new content on safely management, and specific procedures including hot work permits, lock-tag-try, and vessel entry.Subjects IncludeInherently safer designToxicology and industrial hygieneToxic release and dispersion modelsFires and explosions, and how to prevent themReliefs and relief sizingHazard identificationRisk assessmentSafe designs and proceduresCase historiesChemical Process Safety, Third Edition, is an ideal reference for professionals. It can be used for both graduate and undergraduate instruction. This edition contains more than 480 end-of-chapter problems. A solutions manual is available for instructors.
Contents
Preface xv About the Authors xviiOn the Cover xviiiNomenclature xixChapter 1: Introduction 11-1 Safety Programs 21-2 Engineering Ethics 41-3 Accident and Loss Statistics 41-4 Acceptable Risk 121-5 Public Perceptions 141-6 The Nature of the Accident Process 151-7 Inherent Safety 201-8 Seven Significant Disasters 23Suggested Reading 31Problems 32Chapter 2: Toxicology 372-1 How Toxicants Enter Biological Organisms 382-2 How Toxicants Are Eliminated from Biological Organisms 412-3 Effects of Toxicants on Biological Organisms 422-4 Toxicological Studies 432-5 Dose versus Response 442-6 Models for Dose and Response Curves 502-7 Relative Toxicity 562-8 Threshold Limit Values 562-9 National Fire Protection Association (NFPA) Diamond 58On-Line Resources 59Suggested Reading 60Problems 60Chapter 3: Industrial Hygiene 653-1 Government Regulations 663-2 Industrial Hygiene: Anticipation and Identification 783-3 Industrial Hygiene: Evaluation 843-4 Industrial Hygiene: Control 99On-Line Resources 109Suggested Reading 109Problems 110Chapter 4: Source Models 1194-1 Introduction to Source Models 1194-2 Flow of Liquid through a Hole 1224-3 Flow of Liquid through a Hole in a Tank 1264-4 Flow of Liquids through Pipes 1314-5 Flow of Gases or Vapors through Holes 1404-6 Flow of Gases or Vapors through Pipes 1464-7 Flashing Liquids 1634-8 Liquid Pool Evaporation or Boiling 1694-9 Realistic and Worst-Case Releases 1704-10 Conservative Analysis 172Suggested Reading 173Problems 174Chapter 5: Toxic Release and Dispersion Models 1855-1 Parameters Affecting Dispersion 1865-2 Neutrally Buoyant Dispersion Models 1905-3 Dense Gas Dispersion 2095-4 Dense Gas Transition to Neutrally Buoyant Gas 2195-5 Toxic Effect Criteria 2255-6 Effect of Release Momentum and Buoyancy 2335-7 Release Mitigation 234Suggested Reading 235Problems 236Chapter 6: Fires and Explosions 2456-1 The Fire Triangle 2456-2 Distinction between Fires and Explosions 2476-3 Definitions 2476-4 Flammability Characteristics of Liquids and Vapors 2496-5 Limiting Oxygen Concentration and Inerting 2606-6 Flammability Diagram 2626-7 Ignition Energy 2706-8 Autoignition 2706-9 Auto-Oxidation 2716-10 Adiabatic Compression 2726-11 Ignition Sources 2736-12 Sprays and Mists 2746-13 Explosions 275Suggested Reading 304Problems 305Chapter 7: Concepts to Prevent Fires and Explosions 3177-1 Inerting 3187-2 Static Electricity 3337-3 Controlling Static Electricity 3567-4 Explosion-Proof Equipment and Instruments 3637-5 Ventilation 3677-6 Sprinkler Systems 3707-7 Miscellaneous Concepts for Preventing Fires and Explosions 374Suggested Reading 374Problems 375Chapter 8: Chemical Reactivity 3818-1 Background Understanding 3828-2 Commitment,Awareness, and Identification of Reactive Chemical Hazards 3848-3 Characterization of Reactive Chemical Hazards Using Calorimeters 3908-4 Controlling Reactive Hazards 416Suggested Reading 418Problems 418Chapter 9: Introduction to Reliefs 4299-1 Relief Concepts 4309-2 Definitions 4329-3 Location of Reliefs 4339-4 Relief Types and Characteristics 4369-5 Relief Scenarios 4439-6 Data for Sizing Reliefs 4449-7 Relief Systems 444Suggested Reading 452Problems 453Chapter 10: Relief Sizing 45910-1 Conventional Spring-Operated Reliefs in Liquid Service 46010-2 Conventional Spring-Operated Reliefs in Vapor or Gas Service 46610-3 Rupture Disc Reliefs in Liquid Service 47010-4 Rupture Disc Reliefs in Vapor or Gas Service 47110-5 Two-Phase Flow during Runaway Reaction Relief 47210-6 Pilot-Operated and Bucking-Pin Reliefs 48110-7 Deflagration Venting for Dust and Vapor Explosions 48110-8 Venting for Fires External to Process Vessels 48810-9 Reliefs for Thermal Expansion of Process Fluids 492Suggested Reading 496Problems 497Chapter 11: Hazards Identification 50511-1 Process Hazards Checklists 50811-2 Hazards Surveys 50811-3 Hazards and Operability Studies 52411-4 Safety Reviews 53011-5 Other Methods 537Suggested Reading 538Problems 538Chapter 12: Risk Assessment 54912-1 Review of Probability Theory 55012-2 Event Trees 56412-3 Fault Trees 56912-4 QRA and LOPA 577Suggested Reading 588Problems 588Chapter 13: Safety Procedures and Designs 59713-1 Process Safety Hierarchy 59813-2 Managing Safety 59913-3 Best Practices 60013-4 Procedures-Operating 60013-5 Procedures-Permits 60113-6 Procedures-Safety Reviews and Accident Investigations 60313-7 Designs for Process Safety 60413-8 Miscellaneous Designs for Fires and Explosions 61513-9 Designs for Runaway Reactions 61513-10 Designs for Handling Dusts 616Suggested Reading 617Problems 618Chapter 14: Case Histories 62114-1 Static Electricity 62214-2 Chemical Reactivity 62614-3 System Designs 63114-4 Procedures 63714-5 Training 64214-6 Conclusion 645Suggested Reading 646Problems 646Appendix A: Unit Conversion Constants 649Appendix B: Flammability Data for Selected Hydrocarbons 653Appendix C: Detailed Equations for Flammability Diagrams 659Equations Useful for Gas Mixtures 659Equations Useful for Placing Vessels into and out of Service 664Appendix D: Formal Safety Review Report for Example 10-4 669Appendix E: Saturation Vapor Pressure Data 679Appendix F: Special Types of Reactive Chemicals 681Appendix G: Hazardous Chemicals Data for a Variety of Chemical Substances 687Index 695
