Student Handbook for Process Safety

Hazard Identification and Risk Assessment: Esso Longford Gas Plant Explosion, 1998 733.5.1 Summary 733.5.2 Detailed Description 743.5.3 Cause 763.5.4 Key Lessons 763.5.5 References and Links to Investigation Reports 773.6 Operating Procedures: Port Neal, IA, Ammonium Nitrate Explosion, 1994 773.6.1 Summary 773.6.2 Detailed Description 773.6.3 Causes 793.6.4 Key Lessons 803.6.5 References and Links to Investigation Reports 803.7 Safe Work Practices: Piper Alpha, North Sea, UK, 1988 803.7.1 Summary 803.7.2 Detailed Description 813.7.3 Causes 833.7.4 Key Lessons 843.7.5 References and Links to Investigation Reports 853.8 Contractor Management: Partridge Raleigh Oilfield Explosion, Raleigh, MS, 2006 853.8.1 Summary 853.8.2 Detailed Description 853.8.3 Cause 863.8.4 Key Lessons 863.8.5 References and Links to Investigation Reports 883.9 Asset Integrity and Reliability: Explosion at Texaco Oil Refinery, Milford Haven, UK, 1994 883.9.1 Summary 883.9.2 Detailed Description 883.9.3 Causes 893.9.4 Key Lessons 903.9.5 References and Links to Investigation Reports 913.10 Conduct of Operations: Formosa Plastics VCM Explosion, Illiopolis, IL, 2004 913.10.1 Summary 913.10.2 Detailed Description 913.10.3 Causes 943.10.4 Key Lessons 943.10.5 References and Links to Investigation Reports 953.11 Management of Change: Flixborough Explosion, UK, 1974 953.11.1 Summary 953.11.2 Detailed Description 953.11.3 Cause 983.11.4 Key Lessons 983.11.5 References and Links to Investigation Reports 993.12 Emergency Management: Sandoz Warehouse Fire, Switzerland, 1986 993.12.1 Summary 993.12.2 Key Lessons 1013.12.3 References and links to investigation reports 1023.13 Conduct of Operations: Exxon Valdez, Alaska, 1989 1023.13.1 Summary 1023.13.2 Detailed Description 1023.13.3 Causes 1053.13.4 Key Lessons 1053.13.5 References and Links to Investigation Reports 1063.14 Compliance with Standards: Mexico City, PEMEX LPG Terminal, 1984 1063.14.1 Summary 1063.14.2 Detailed Description 1063.14.3 Causes 1093.14.4 Key Lessons 1093.14.5 References and Links to Investigation Reports 1093.15 Process Safety Culture: Methyl Isocyanate Release, Bhopal, India, 1984 1103.15.1 Summary 1103.15.2 Detailed Description 1103.15.3 Key Lessons 1113.15.4 References and Links to Investigation Reports 1123.16 Failure to Learn, BP Macondo Well Blowout, Gulf of Mexico, 2010 1133.16.1 Summary 1133.16.2 Detailed Description 1133.16.3 Key Lessons 1183.16.4 References and Links to Investigation Reports 1193.17 Summary 1193.18 References 1204. Process Safety for Engineering Disciplines 1214.1 Introduction 1214.2 Process Knowledge Management 1214.3 Compliance with Standards 1244.4 Hazard Identification and Risk Analysis, Management Of Change 126Management of Organizational Change 1274.5 Asset Integrity and Reliability 1284.6 Safe Work Practices 1294.7 Incident Investigation 1304.8 Resources for Further Learning 1304.8 Summary 1324.9 References 1325. Process Safety in Design 1335.1 Process Safety Design Strategies 1335.2 General Unit Operations and Their Failure Modes 1345.2.1 Pumps, Compressors, Fans 1345.2.2 Heat Exchange Equipment 1415.2.3 Mass Transfer; Distillation, Leaching and Extraction, Absorption 1465.2.4 Mechanical Separation / Solid-Fluid Separation 1525.2.5 Reactors and Reactive Hazards 1585.2.6 Fired Equipment 1635.2.7 Storage 1675.3 Petroleum Processing 1795.3.1 General Process Safety Hazards in a Refinery 1805.3.2 Crude Handling and Separation 1825.3.3 Light Hydrocarbon Handling and Separation 1835.3.4 Hydrotreating 1845.3.5 Catalytic Cracking 1855.3.6 Reforming 1875.3.7 Alkylation 1885.3.8 Coking 1905.4 Transient Operating States 1925.4.1 Overview 1925.4.2 Example Process Safety Incidents 1925.4.3 Design Considerations 1945.5 References 1946. Course Material 1996.1 Introduction 1996.2 Inherently Safer Design 1996.3 Process Safety Management and Conservation of Life 1996.4 Process Safety Overview and Safety in the Chemical Process Industries 2006.5 Process Hazards 2016.5.1 Chemical Reactivity Hazards 2016.5.2 Fires and Explosions 2026.5.3 Other Hazards 2036.6 Hazard Identification and Risk Analysis 2036.7 Emergency Relief Systems 2056.8 Case Histories 2066.8.1 Runaway Reactions 2066.8.2 Other Case Histories 2076.9 Other Modules 2096.10 Summary 2096.11 References 2097. Process Safety in the Workplace 2117.1 What to Expect 2117.1.1 Formal Training 2117.1.2 Interface with Operators, Craftsmen 2147.2 New Skills 2157.2.1 Non-Technical 2157.2.2 Technical 2167.3 Safety Culture 2177.4 Conduct of Operations 2187.4.1 Operational Discipline 2187.4.2 Engineering Discipline 2307.4.3 Management Discipline 2327.4.4 Other Conduct of Operations Topics for the New Engineer 2377.5 Summary 2387.6 References 238APPENDIX A - EXAMPLE RAGAGEP LIST 241APPENDIX B - LIST OF CSB VIDEOS 245APPENDIX C - REACTIVE CHEMICALS CHECKLIST 249C.1 Chemical Reaction Hazard Identification 249C.2 Reaction Process Design Considerations 252C.3 Resources and Publications 254APPENDIX D - LIST OF SACHE COURSES 257APPENDIX E - Reactivity Hazard Evaluation Tools 259E.1 Screening Table and Flowchart 259E.2 Reference 262INDEX 263