Chemical process safety learning from case histories 3rd Edition by Roy E Sanders ISBN 075067749X 9780750677493

Chemical process safety learning from case histories 3rd Edition by Roy E Sanders – Ebook PDF Instant Download/Delivery: 075067749X, 9780750677493
Full download Chemical process safety learning from case histories 3rd Edition after payment

Product details:

ISBN 10: 075067749X 
ISBN 13: 9780750677493
Author: Roy E Sanders

Chemical process safety learning from case histories 3rd Table of contents:

1. Perspective, Perspective, Perspective
Introduction
The Media Rarely Focuses on the Benefits of the Chemical Industry
A Glance at the History of Chemical Manufacturing before the Industrial Revolution
The Modern Industrial Chemical Industry Modifies Our Way of Living
Risks Are Not Necessarily How They Are Perceived
Plant Employee Safety versus Life-style Choices
The Chemical Industry’s Excellent Safety Record
Who Has the Most Dangerous Jobs?
Just How Dangerous Is It to Work in a U.S. Chemical Plant?
Just How Dangerous Is It to Work in a Chemical Plant in the United Kingdom?
Fatal Risks Data for Various Activities in the United Kingdom
How Are the Chemical and Refinery Industries Doing when It Comes to Major Losses?
2. Good Intentions
Modifications Made with Good Intentions
A Tank Truck Catastrophically Fails
Siphoning Destroys a Tender Tank
Tank Roof Splits from Overfilling
A Well-Intended Change Yields a Storage Tank Collapse
A Water Drain Line Is Altered and a Reactor Explodes
An Air System Is Improved and a Vessel Blows Up
A New Air System Improved Economics, but Jeopardized Safety
Another Incident with Nitrogen Backup for a Compressed Air Supply
The Hazards of Nitrogen Asphyxiation
Concerns for Safety on a Refrigerated Ethylene Tank
Beware of Impurities, Stabilizers, or Substitute Chemicals
Good Intentions on Certain New Protection Systems Lead to Troubles
A Gas Compressor Is Protected from Dirt, But the Plant Catches Fire
The Lighter Side
Another Good Intentions Project: New Tank Are Destroyed and the Neighborhood is Disrupted
Another Tragic Incident Involving Hydrogen Sulfide Takes the Lives of Two Workers
Closing Thoughts on Sewers
A Review of Good Intentions
3. Focusing on Water and Steam: The Ever-Present and Sometimes Evil Twins
A Hydrotest Goes Awry
A Flooded Column Collapses as Water Is Being Drained from the System
Water Reacting with Strong Chemicals
Easy-to-Use Steam Heat Can Push Equipment beyond Safe Design Limits
Heating Water in a Confined System
Steam Condenses and a Mega-Vessel Is Destroyed During Commissioning
A Tragedy Develops When Hot Oil Is Pumped upon a Layer of Water
4. Preparation for Maintenance
Some Problems When Preparing for Maintenance
A Tank Vent Is Routed to a Water-Filled Drum to “Avoid” Problems
Preparing to Paint Large Tanks
Preparing a Brine Sludge Dissolving System for Maintenance
What Happened in the Brine System?
A Violent Eruption from a Tank Being Prepared for Maintenance
An Explosion While Preparing to Replace a Valve in an Ice Cream Plant
A Chemical Cleaning Operation Kills Sparrows, But Improves Procedures
Other Cleaning, Washing, Steaming, and Purging Operations
A Tragedy When Preparing for Valve Maintenance
A Review of Changes Made to Prepare for Maintenance
5. Maintenance-Induced Accidents and Process Piping Problems
Planning and Communication
Filter Cartridges Are Replaced and an Iron-in-Chlorine Fire Develops
Repairs to a Pipeline Result in Another Iron-in-Chlorine Fire
Repaired Reboiler Passes the Hydrotest and Later Creates a Fire
A Tank Explodes during Welding Repairs after Passing a Flammable Gas Test
A Phenol Tank’s Roof Lifts as Repairs are made
Catastrophic Failures of Storage Tanks as Reported by the Environmental Protection Agency
Repair Activity to a Piping Spool Results in a Massive Leak from a Sphere
The Phillips 66 Incident: Tragedy in Pasadena, Texas
A Massive Fire, BLEVEs, and $5 Million Damages after a Mechanic Improperly Removes a Valve Actuator
Misdirected Precautions on a Reactor System Isolation Plug Valve Result in a Vapor Cloud Explosion
A Breathing Air System on a Compressed Air Main Is Repaired
A Hidden Blind Surprises the Operators
Poor Judgment by Mechanics Allowed a Bad Steam Leak to Result in a Minor Explosion
The Flixborough Disaster and the Lessons We Should Never Forget
Do Piping Systems Contribute to Major Accidents?
Specific Piping System Problems Reported as Major Incidents
OSHA Citations
Four Case Histories of Catastrophic Pipe Failures
Piping Problems Review
Concluding Thoughts on Maintenance-Induced Accidents and Process Piping Problems
6. One-Minute Modifications: Small Quick Changes in a Plant Can Create Bad Memories
Explosion Occurs after an Analyzer Is Repaired
Just a Little of the Wrong Lubricant
When Cooling Methods Were Changed, a Tragedy Occurred
Instrument Air Backup Is Disconnected
An Operator Modifies the Instrumentation to Handle an Aggravating Alarm
A Furnace Temperature Safeguard Is Altered
The Wrong Gasket Material Creates Icicles in the Summer
Another Costly Gasket Error
As Compressed Asbestos Gaskets Are Phased Out, Other Leaks Will Occur
Other Piping Gasket Substitution Problems
New Stud Bolts Fail Unexpectedly
Hurricane Procedures Are Improperly Applied to a Tank Conservation Vent Lid
Painters Create Troubles
Pipefitters Can Create Troubles When Reinstalling Relief Valves
Another Pipefitter’s Error
A Cooling Water System Is Safeguarded and an Explosion Occurs Some Months Later
Lack of Respect for an Open Vent as a Vacuum-Relief Device Results in a Partial Tank Collapse
A Bucket of Water Destroys a Tank
Lack of Respect for an Open Vent as a Pressure-Relief Device Costs Two Lives
One-Minute Modifications Review
7. Accidents Involving Compressors, Hoses, and Pumps
Reciprocating Compressors
A Piece of Compressor Water Jacket is Launched
The Misuse of Hoses Can Quickly Create Problems
Some of the Many Unpublished Errors Created with Hoses
The Water Hose at the Flixborough Disaster
Hoses Used to Warm Equipment
Three-Mile Island Incident Involved a Hose
The Bhopal Tragedy Was Initiated by Use of a Hose
Improper Purge Hose Set Up for Maintenance Creates Major Problems
High-Pressure Hydrogen Inadvertently Backs Into the Nitrogen System and an Explosion Occurs
A Nitric Acid Delivery to the Wrong Tank Makes Front-Page News
How Do You Prevent Such an Incident?
Other Truck Delivery Incidents
An Operator Averts a Sulfuric Acid Unloading Tragedy
Hoses Cannot Take Excessive Abuse
Centrifugal Pumps
River Water Pump Piping Explodes
A Severe Pump Explosion Surprises Employees
A Large Condensate Pump Explodes
8. Failure to Use, Consult, or Understand Specifications
Failure to Provide Operating Instructions Cost $100,000 in Property Damages
Other Thoughts on Furnaces
Low-Pressure Tank Fabrication Specifications Were Not Followed
Explosion Relief for Low-Pressure Tanks
Tinkering with Pressured Vessel Closure Bolts Ends with a Harmless Bang
Piping Specifications Were Not Utilized
Pump Repairs Potentially Endanger the Plant, but Are Corrected in Time to Prevent Newspaper Headline
Plastic Pumps Installed to Pump Flammable Liquids
Weak Walls Wanted—But Alternate Attachments Contributed to the Damage
An Explosion Could Have Been Avoided If Gasket Specifications Were Utilized
Surprises within Packaged Units
9. Imagine IfŽ Modifications and Practical Problem Solving
“Imagine If” Modifications—Let Us Not Exaggerate the Dangers as We Perform Safety Studies
New Fire-Fighting Agent Meets Opposition—“Could Kill Men as Well as Fires”
A Process Safety Management Quiz
New Fiber Production Methods Questioned
Practical Problem Solving
The Physics Student and His Mischievous Methods
10. The Role of Mechanical Integrity in Chemical Process Safety
Mechanical Integrity in a Chemical Plant
A Regulatory View of Mechanical Integrity
Mechanical Integrity Programs Must Be Tailored to the Specific Site
Mechanical Integrity in Design and Installation
Equipment Covered by Mechanical Integrity
Regulatory Enforcement of Mechanical Integrity
An Industry View of Mechanical Integrity
Written Procedures and Training
Classification of Equipment by Hazard Potential
Mechanical Integrity Programs for Pumps/Compressors
Thermography Techniques for Rotating and Stationary Equipment
Mechanical Integrity Programs for Piping, Pressure Vessels, Storage Tanks, and Process Piping
Inspecting Pressure Vessels, Storage Tanks, and Piping
Inspection of Pressure Vessels and Storage Tanks
Inspection of Above-Ground Piping
Mechanical Programs for Safety-Critical Instruments and Safety Relief Valves
The Critical Role of Safety Relief Valves
“In-House” Testing Safety Relief Valves
Mechanical Integrity Program for Process Safety Interlocks and Alarms
Protective Process Safety Interlocks at a DuPont Plant
Another Company—A Different Emphasis on Safety Critical Instrument Systems
Another Approach—Prooftesting at a Louisiana Plant
Additional Information on Mechanical Integrity
11. Effectively Managing Change within the Chemical Industry
Introduction
Preliminary Thoughts on Managing Change
Are Management of Change Systems Like Snowflakes?
A Reality Check Provided by Previous Chapters
Keeping MOC Systems Simple
Losing Tribal Knowledge
Some Historical Approaches to Plant Changes
The U.S. OSHA Process Safety Management Standard Addresses “Management of Change”
Principles of an Effective Management of Change System That Prevents Uncontrolled Change and Satisfi
An Overall Process Description to Create or Improve a Management of Change System
Clear Definitions Are Imperative
Key Steps for an Effective Management of Change System for a Medium or Large Organization
Key Steps for an Effective Management of Change System for a Small Company
Multidisciplined Committee Can Provide an In-Depth Look When Identifying Hazards
Operational Variances for Maintenance Need A Close Examination Too
Variances, Exceptions, and Special Cases of Change
Should the MOC System be Paperless?
Over Two Dozen Plants Share Their MOC Practices
Management of Change Approvals, Documentation, and Auditing
Closing Thoughts on a Management of Change Policy
Appendix A
Some Historical Approaches to Plant Changes
How Are Chemical Plants Addressing Plant Modifications during the 1980s and Beyond?
The Center for Chemical Process Safety
New Recommendations and New Regulations
Appendix B
How Should Potential Hazards Be Identified and Evaluated?
12. Investigating and Sharing Near Misses and Unfortunate Incidents
Introduction
What Does the Regulation Say about Incident Investigations?
Plant Cultures Can Affect Investigations
More Guidelines on the Culture of Incident Reporting
An OSHA Program Coordinator’s View
Layers of Incident Causes
A Furnace Tube Failure Case History is Revised
Process Safety Incident Investigation Techniques
Applying Root Cause Analysis
Some Chemical Manufacturers’ Approaches to Incident Investigation
What Is a Root Cause?
Some Thoughts on Process Safety Incident Investigation Techniques
Complying with the OSHA Element on Incident Investigation
Report Approval, Report Distribution, Sharing the Findings, Corrective Action Tracking, and Report R
Conclusions
Appendix A Interviewing Tips
General Concepts and Preplanning
Opening the Interview
Conducting the Interview
Closing the Interview and Documenting It
13. Sources of Helpful Information for Chemical Process Safety
The Best Seven Books in Chemical Process Safety—From a Process Engineer’s Viewpoint
General Chemical Process Safety Books
Practical Information on Safety Critical Instruments and Pressure Vessels, Tanks, and Piping
Other Helpful Resources

People also search for Chemical process safety learning from case histories 3rd:

what is chemical safety
    
chemical process safety fundamentals with applications 4th edition
    
chemical process safety incidents
    
chemical process safety board
    
what is chemical process safety

Tags: Roy E Sanders, Chemical process, case histories