Sanders Chemical Process Safety

Learning from Case Histories
4. Auflage 2015
ISBN: 978-0-12-801667-1
Verlag: Elsevier Science & Techn.
Format: EPUB
Kopierschutz: Adobe DRM (»Systemvoraussetzungen)

E-Book, Englisch, 506 Seiten

Chemical Process Safety: Learning from Case Histories, Fourth Edition gives insight into eliminating specific classes of hazards while also providing real case histories with valuable lessons to be learned. This edition also includes practical sections on mechanical integrity, management of change, and incident investigation programs, along with a list of helpful resources. The information contained in this book will help users stay up-to-date on all the latest OSHA requirements, including the OSHA-required Management of Change, Mechanical Integrity, and Incident Investigation regulations. Learn how to eliminate hazards in the design, operation, and maintenance of chemical process plants and petroleum refineries. World-renowned expert in process safety, Roy Sanders, shows how to reduce risks in plants and refineries, including a summary of case histories from high profile disasters and recommendations for how to avoid repeating the same mistakes. Following the principles outlined in this text will help save lives and reduce loss. - Features additional new chapters covering safety culture, maintaining a sense of vulnerability, and additional learning opportunities from recent incidents and near misses - Contains updated information from the US Bureau of Labor Statistics and the National Safety Council, with concise summaries of some of the most important case histories of the twenty-first century - Includes significantly expanded information from the US Chemical Safety Board, US OSHA, American Institute of Chemical Engineers, and the UK Health and Safety Executive (HSE) - Provides a completely updated chapter to guide readers to a wealth of reference material available on the web and elsewhere

Sanders recently retired from PPG Industries in Lake Charles, LA. Roy worked for PPG for 42 years and specialized in Process Safety fundamentals since 1974. He is associated with the Mary Kay O'Connor Process Safety Center at Texas A&M, McNeese State University, Lake Charles, and is a member of the editorial boards of both the AIChE's Process Safety Progress and Putman's Chemical Processing. He has taught brief process safety courses across the USA, as well as, Bahrain, Canada, India, the Netherlands Saudi Arabia and Taiwan.

Autoren/Hrsg.

Sanders, Roy E.

Leseproben

Acknowledgments

Fourth Edition

I am delighted with all of the support I was given for the fourth edition. First, I am grateful that my family and friends understood I had to make some sacrifices and had to neglect somethings in order to get this edition to the publisher, even if it arrived a little tardy.

Equally important, I want to thank the late Trevor A. Kletz for encouraging me to attempt to write a book, decades ago, and always helping me along the way by sharing his knowledge. Furthermore, I appreciate the encouragement from Dr M. Sam Mannan at the Mary Kay O’Connor Process Safety Center and the generous help from numerous presenters at the Lake Area Industries/McNeese Engineering Partnership. A special thanks to Manuel David – a talented draftsman. Manuel continued to provide new crisp concise sketches to support the words in several chapters of the fourth edition.

Second, I appreciate the guidance support of Natasha Welford, Fiona Geraghty and Nicky Carter of Elsevier. They did all they could to promptly and professionally assist in all the things must be done to improve my drafts in to well-formatted book.

Finally, I want to thank the individuals and groups for technical and interpersonal support to make this edition a reality. For lack of a better method, I will acknowledge their support by chapters.

Received help from the Mary Kay O’Connor Process Safety Center for Chapter 1, “Perspective, Perspective, Perspective.” Sonny Sachdeva and Jiaqi Zhang, two very bright, energetic Texas A&M folks helped find data on “Risks” and proof read major portions of this chapter.

In Chapter 3 “Focusing on Water and Steam; The Ever-Present and Sometimes Evil Twins,” I appreciate John R. Lockwood’s case history on a tragic silo washing incident.

Received lots of help for Chapter 4 “Major US Incidents in the twenty-first century.” Dr Vic Edwards was kind enough to review this chapter as it was being developed and his input was appreciated and useful.

Chapter 5 Addressed two powerful unconfined vapor cloud explosions. One incident occurred in the United Kingdom and one happened in Venezuela. Natasha Welford worked hard to obtain two excellent aerial photos of Buncefield. Olga Reyes Valdes a PhD Candidate Mary Kay O’Connor Process Safety Center had developed a research presentation on the Amuay Refinery incident in Venezuela and generously shared her work. I am grateful that Dr Steven D. Emerson critically reviewed my first draft of this chapter to help shape it.

The portion of Chapter 9 focused on hoses also benefitted from the help of John R. Lockwood.

Chapter 13 focusing on Management of Change benefitted from Michael Bearrow’s and Jack Chosnek’s recent articles.

While updating Chapter 14, on incident investigation, I received excellent professional guidance from Jack Philley. Philley has had extensive incident investigation experience and was the principal author of the text “CCPS Guidelines for Incident Investigation.”

Chapter 15 is entitled “Keep a Sense of Vulnerability for Safety Safe.” I appreciate the input from two masters. I thank Joseph Louvar for encouraging me to write the topic as an AIChE Process Safety Progress article and to help shape it. I am grateful for Mark Rosenzweig, Editor-in-Chief, of Putman’s Chemical Processing magazine for his skillful enhancements to polish the chapter.

Chapter 16 addressed “Safety Culture” now recognized as one of the most important parts of a process safety. Steve Arendt (of ABS Consulting) provided various presentations at McNeese State University, which were the main ingredients of this chapter. This chapter was also shaped by input from Jiaqi Zhang and Sonny Sachdeva of The Mary Kay O’Connor Process Safety Center at Texas A&M.

Chapter 17 was also reviewed and enhanced by Sonny Sachdeva and Jiaqi Zhang from the Mary kay O’Connor Process Safety Center.

There are a few photos of pressure vessel and piping fabrication, which are courtesy of Custom Metal Fabricators of Lake Charles, Louisiana.

Finally, I am grateful for the assistance of Delma Porter of Superior Writing, LLC, for her professional skills to clarify some of my ramblings.

Third Edition

I am appreciative of all the support I received to make this third edition a reality. I am grateful that my family and close friends understood that I had to make a few sacrifices and miss some activities to get this third edition completed.

Without the editor’s support by Christine Kloiber and Phil Carmical of Elsevier Science, no words would have been written. But, once the words are written I continue to rely on the guidance and keenly developed proofreading skills, and candid critiques of Selina Cascio to convert my blemished sentences into free flowing, easily understood thoughts. Selina has helped me with nearly all of my technical writings over the past 20 years, and her input has really made a positive impact.

I am grateful for the additional material that appears in this third edition courtesy of David Chung of the US Environmental Protection Agency, from Douglas S. Giles and Peter N. Lodal of Eastman Chemical Company, from Dr Trevor A. Kletz, from Nir Keren of the Mary Kay O’Connor Process Safety Center, from Catherine Vickers of PPG, and countless others who are referenced throughout the text. I was also lucky to get talented drafting help from Manuel David. Manuel created easy-to-understand illustrations to support the narratives of the incidents.

I would be also be remiss if I did not thank the PPG Professionals in Monroeville, Pennsylvania for their technical and legal review. The Monroeville supporters include Jeff Solomon, David McKeough, and Maria Revetta.

Second Edition

I am grateful for Michael Forster of Butterworth–Heinemann for encouraging a second edition of this book. He has been a steady support for this challenge for several years. Without his energy and support this second edition would not have happened.

The professional proofreading skills of my daughter Laura Sanders and her husband Morgan Grether have be instrumental in adding life and clarity to about one half of the chapters. And the project could not be finished without the guidance, keenly developed proofreading skills, and candid critiques of Selina Cascio. I would be also be remiss if I did not thank the PPG Professionals in Monroeville, Pennsylvania for their technical review. The Monroeville supporters include David McKeough, Maria Revetta, and Irwin Stein.

I am grateful to Dr Mark Smith, of the Institution of Chemical Engineers, for extending the permission granted in the first edition to use a few sketches and photos to enhance several case histories.

Also a note of thanks to Manuel David and Warren Schindler, talented drafters, who provided several excellent sketches to add visual images to clarify important concepts. Naturally, I am very grateful and appreciate the continuing support of Dr Trevor A. Kletz. He has never been too busy to provide guidance.

To my wife, Jill, and to Julie and Lisa, my two daughters who live with me, thanks for understanding. When you have a full-time job, a project like this requires sacrifice. I appreciate their patience as I had to avoid some family activities for over a year while I whittled away on this project.

First Edition

A number of people deserve thanks for encouraging me and helping me with this challenge. As an engineer within a chemical manufacturing facility, opportunities to write articles did not seem realistic to me. In the early 1980s after submitting a rather primitive proposed technical paper, Bill Bradford encouraged me to draft a manuscript. My first technical paper was on the subject of Plant Modifications and it was presented to the AIChE in 1982.

In 1983, Trevor A. Kletz asked me to help him teach an American Institute of Chemical Engineers Continuing Education Course. I was shocked and elated to be considered. It was such a great opportunity to learn from this living legend in Loss Prevention. It has been educational and enjoyable ever since; he has become my teacher, my coach, and my friend.

I assisted Trevor Kletz in teaching a two-day course entitled “Chemical Plant Accidents – A Workshop on Causes and Preventions.” We periodically taught the course for six years, and then he encouraged me to consider writing this book on Plant Modifications. Jayne Holder, formerly of Butterworth, was extremely supportive with all my concerns and questions.

Before I got started, I was searching for help and William E. Cleary, Jack M. Jarnagin, Selina C. Cascio, and Trevor A. Kletz volunteered to support the project. Then the hard part came. Again, Trevor Kletz and Jayne Holder encouraged me to get started.

I am grateful to Bill Cleary for his technical and grammatical critique, and to Selina Cascio for her skill in manuscript preparation including endless suggestions on style and punctuation. Jack Jarnagin’s drafting assistance provided the clear illustrations throughout the text, and to Trevor for his continuous support.

Also, thanks to my wife, Jill, for both her patience and her clerical help, to my daughter Laura for proofreading, and to Warren H. Woolfolk for his help on Chapter 8. Thanks to Bernard Hancock, of...