Chemical Process Industry Safety

Title
Contents
1 Introduction
	1.0 Introduction
	1.1 Factors Contributing to the Costs of Accidents
	1.2 List of Some Notable Accidents in the Process Industry/Selected Case Histories
	1.3 Some Common Features of High-Cost Accidents
	1.4 Reasons for High Priority Toward Safety
	Review Questions
2 Basic Principles
	2.1 Specific Gravity
	2.2 Liquid Density
	2.3 Density Differences of Liquids
	2.4 Vapor Density
	2.5 Newtonian Fluids
	2.6 Viscosity of Liquids
	2.7 Rheology
	2.8 Viscosity of Gases
	2.9 Yield Stress
	2.10 Turbulence
	2.11 Drag Coefficient
	2.12 Water Hammer
	2.13 Cavitation
	2.14 NPSH
	2.15 Two-Phase Flow
	2.16 Compressible Fluids
	2.17 Dielectric Properties
	2.18 Surface Tension
	2.19 Vapor Pressure
	2.20 Partial Pressure
	2.21 PVT Relationships
	2.22 Raoult’s Law
	2.23 K-Values
	2.24 Henry’s Law
	2.25 Heat and Thermodynamics
	2.26 Heat-Transfer Basics
	2.27 Diffusion and Mass Transfer
	2.28 Stoichiometry
	2.29 Combustion
	2.30 Chemical Reactions
	Review Questions
3 Material Hazards
	3.1 Introduction
	3.2 Hazardous Substances—Categories
	3.3 Toxicity
	3.4 Radiation
	3.5 Flammability, Ignition, Fires, and Explosions
	3.6 Flames, Fires, and Explosions
	3.7 Fires
	3.8 Nuclear Power Plant Explosions
	3.9 Electrical Fires and Explosions
	3.10 Fire Balls
	3.11 Fire Damage
	3.12 Runaway Chemical Reactions
	3.13 Incompatible Materials
	3.14 Material Safety Data Sheets
	3.15 Annexure
	Review Questions
4 Process and Plant Hazards
	4.1 Hazards of Pressure
	4.2 Causes for Overpressures
	4.3 Flow Deviations
	4.4 Effects of Leakages/Releases
	4.5 Hazards of Temperature
	4.6 Cryogenic Fluids
	4.7 Vibration and Noise
	4.8 Human Errors
	4.9 Ergonomics
	Review Questions
5 Hazard Analysis
	5.1 General
	5.2 Process Safety Management
	5.3 Process Hazard Analysis
	5.4 Hazard Analysis Methods
	5.5 Checklists
	5.6 Preliminary Hazard Analysis
	5.7 What-If
	5.8 What-If/Checklist
	5.9 Hazard and Operability Analysis
	5.10 FMEA—Failure Modes, Effects Analysis
	5.11 Fault Tree Analysis
	5.12 Cause and Consequence Analysis
	5.13 Dow Fire and Explosion Index
	5.14 Security Vulnerability Analysis
	5.15 Annexure
	Review Questions
6 Preventive and Protective Measures
	6.1 Safety Options
	6.2 Process Safety Approaches
	6.3 Inherent Safety and Design
	6.4 Plant Layout
	6.5 Inherent Security
	6.6 Explosion Prevention and Protection
	6.7 Storage Containers for Cryogenic Fluids
	6.8 Electrical Area Classification
	6.9 Safety in Maintenance Operations
	6.10 Personnel Protective Systems
	6.11 Plant Modifications and Management Change
	6.12 Industrial Hygiene
	6.13 Relief Valves and Rupture Discs
	6.14 Breather Vents for Storage Tanks
	6.15 Explosion Vents
	6.16 Flame Arresters
	6.17 Flare Systems
	6.18 Safety Considerations in Instrumentation Systems
	6.19 Planning for Emergencies – Considerations
	6.20 Annexure
	Review Questions
APPENDIX A
APPENDIX B
INDEX