Hazards and Safety in Process Industries

Cover
Half Title
Title Page
Copyright Page
Dedication
Table of Contents
Preface
Authors
Chapter 1: Introduction to Industrial Safety and Hazard
	1.1 Background
	1.2 Work Domain and Safety Instructions
	1.3 Records and reports of prevalent industrial accidents
		1.3.1 Energy Industry
		1.3.2 Food Industry
		1.3.3 Manufacturing Industry
	1.4 Hazards in Process Units
		1.4.1 General Process Hazards
			1.4.1.1 Exothermic Reactions with Mild Risk
			1.4.1.2 Exothermic Reactions with Sufficient Risk
			1.4.1.3 Exothermic Reactions with High Risk
			1.4.1.4 Endothermic Reactions with Low Risk
		1.4.2 Special Process Hazards
		1.4.3 Confined Space Hazards
		1.4.4 Electrical Hazards
		1.4.5 Fire and Explosion Hazard
	1.5 Accident Investigations and Analysis
		1.5.1 Accident Investigation
		1.5.2 Phases of Accident Investigation and Background Knowledge
		1.5.3 Analysis of Direct and Root Causes of Accident
			1.5.3.1 Models required
			1.5.3.2 Pitfalls in analysis
				1.5.3.2.1 Pitfalls in Systems Modelling
				1.5.3.2.2 Fallacies in Analytic Reasoning
			1.5.3.3 Specificity of Root Causes Analysis
			1.5.3.4 Various Other Analysis Techniques
				1.5.3.4.1 Gross Hazard Analysis
				1.5.3.4.2 Job Safety Analysis
				1.5.3.4.3 Failure Mode and Effect Analysis
				1.5.3.4.4 Fault Tree Analysis
	1.6 Hazard Control for Safety Provisions
	1.7 Summary
	References
Chapter 2: A Study of a Caprolactam Storage Tank Accident through Root Cause Analysis with a Computational Approach
	2.1 Introduction to Caprolactum Storage in Industries
	2.2 Case Study of a Caprolactum Accident
		2.2.1 Personnel Interview Record
		2.2.2 On-the-Scene Investigation Record
	2.3 Computational Approach
		2.3.1 Three-Dimensional Finite Element Simulation on Stress Analysis
	2.4 Investigation and Analysis for the Cause of Accident
	2.5 Clarification for the Cause of Accident
		2.5.1 Improper Design and Construction of the Storage Tank
		2.5.2 Corrosion of the Weld Seam of the Storage Tank
		2.5.3 Blockage of the Storage Tank Venting Pipe
		2.5.4 Nitrogen System Malfunction
		2.5.5 Improper Management
	2.6 Summary
	References
Chapter 3: Fire Explosion Accident Caused by Static Electricity in a Propylene Plant
	3.1 Static Electricity and Propylene Plant Integrated Industries
	3.2 Structural Features of a High-Tech Plant
	3.3 Fire Prevention Features
	3.4 Case Review on Disaster
	3.5 Investigation of Cause for Accident
	3.6 Summary
	References
Chapter 4: Thermal Hazard Accident during Hydrogen Peroxide Mixing with Propanone: Case Study
	4.1 Overview of H 2 O 2 Uses in Various Industries
	4.2 Hazardous and Toxic Effects of H 2 O 2
	4.3 Investigating Thermal Explosion Accidents of H 2 O 2
		4.3.1 Samples
		4.3.2 Differential Scanning Calorimetry (DSC)
		4.3.3 Vent Sizing Package 2 (VSP2)
		4.3.4 Thermokinetics Application for Adiabatic System
		4.3.5 Critical temperature (T c) of H 2 O 2 calculation
	4.4 Thermal Analysis by DSC for H 2 O 2 with Propanone
	4.5 Adiabatic Kinetics Study
	4.6 Summary
	References
Chapter 5: Hydroelectric Power Plant Fire Accident: Fire Dynamics Simulator (FDS)
	5.1 Overview of a Hydroelectric Power Plant in Different Sectors
	5.2 Selection of Fire Scene
	5.3 Fire Space Simulation
	5.4 Results of Fire Space Simulation
	5.5 Actual Escape Time Calculation
	5.6 Analysis and Observation in Real Fire Scene Case
	5.7 Summary
	References
Chapter 6: Thermal Accident of Methyl Ethyl Ketone Peroxide Plant: Calorimetric Analysis
	6.1 Overview About Methyl Ethyl Ketone Peroxide (MEKP) in Chemical Plants
	6.2 Case Selection
	6.3 Thermal Hazard Analysis of MEKP by DSC
	6.4 Thermal Analysis of MEKP and H 2 O 2 Through DSC Analysis
		6.4.1 Thermal Decomposition Analysis of 31 Mass% MEKPO for DSC
		6.4.2 Thermal Decomposition Analysis of 20 Mass% H 2 O 2 by DSC
	6.5 Kinetic Analysis of Thermal Degradation
	6.6 Safety Parameter Evaluation
	6.7 Summary
	References
Chapter 7: Case Study on the Integrated Self-Assessment Module for Fire Rescue Safety in a Chemical Plant
	7.1 Introduction
	7.2 Research Methods
		7.2.1 Environmental Data Analysis
		7.2.2 Impact Analysis Program
			7.2.2.1 Physical Mode
			7.2.2.2 Effect Mode
		7.2.3 Integrated Assessment
			7.2.3.1 Integrated Risk Frequency Analysis
			7.2.3.2 Integrated Impact Analysis
	7.3 Case Study
		7.3.1 Site Location
		7.3.2 Storage of Hazardous Materials
		7.3.3 Case Study on the Fire Rescue Unit
		7.3.4 Environmental Data Analysis
		7.3.5 Integrated Impact Analysis
	7.4 Results and Discussions of the Initial Accident and the Second Accident
		7.4.1 Initial Accident
			7.4.1.1 Domino Effect
			7.4.1.2 Safety Distance for Rescue Personnel
		7.4.2 Second Accident
			7.4.2.1 Domino Effect
			7.4.2.2 Safety Distance for Rescue Personnel
	7.5 Summary
	References
Chapter 8: Chemical Releases in a Semiconductor Plant: Emergency Response Study
	8.1 Introduction
	8.2 Semiconductor Process Overview
	8.3 Hazards of the Semiconductor Industry
	8.4 Chemical Hazards in a Semiconductor Plant
	8.5 Emergency Response Procedures
	8.6 Problems Faced in an Emergency Response
	8.7 Common Problems During the Emergency Response Process
	8.8 Summary
	References
Chapter 9: Thermal Hazard and Safety during Combustion of 1-Butylimidazolium Nitrate
	9.1 Introduction
	9.2 Understanding Ionic Liquids
	9.3 Experimental Studies on 1-butylimidazolium Nitrate
		9.3.1 Apparatus and Materials
		9.3.2 Preliminary Combustion Experiment
		9.3.3 Thermogravimetry and Differential Scanning Calorimetry
		9.3.4 Adiabatic Runaway Reaction – Experiment and Prediction
		9.3.5 Flash Point Analyzer
		9.3.6 Qualitative Investigation
	9.4 Results and Discussion
		9.4.1 Combustion Experiment
		9.4.2 Inherent Thermal Hazards for TGA and DSC
		9.4.3 FPA Test
		9.4.4 Concentration of Ignition
		9.4.5 Prediction of Adiabatic Runaway Reaction
		9.4.6 Estimating safety limits
	9.5 Summary
	References
Chapter 10: Safety and Flammability Analysis for Fuel–Air–Diluent Mixtures Plant: Safety and Flammability Analysis
	10.1 Introduction
	10.2 Understanding the Flammability of Inert Gas Mixtures
	10.3 Experimental Procedures
		10.3.1 Apparatus and Materials
		10.3.2 Spherical Explosion Vessel
		10.3.3 Fourier Transform Infrared Spectroscopy
		10.3.4 Theory
			10.3.4.1 Mathematical Model
				Estimation Procedure
	10.4 Results and Discussions
		10.4.1 Combustion Products of Acetone and Methyl Formate
		10.4.2 Experimental and Estimated Flammability Limits
			10.4.2.1 Condition for the Simulation
			10.4.2.2 Radiation Heat Loss Effect on the Estimated Flammability Boundaries
			10.4.2.3 Steam Dilution Effect on Flammability Envelope
			10.4.2.4 Nitrogen Dilution Effect on the Flammability Envelope
			10.4.2.5 Location of the LOC and Flammability Limit at the LOC
	10.5 Summary
	A.1 Energy Balance Equation
	A.2 Lower Flammability Boundary
		A.2.1 Estimation of LFL
		A.2.2 Estimation of x L
	A.3 Upper Flammability Boundary
		A.3.1 UFL Estimate for 1 − x ≤ 1 − x U
		A.3.2 Estimation of xU
		A.3.3 UFL Estimate for 1 − x > 1 – x U
	A.4 Flame Temperature
	References
Chapter 11: Advanced Calorimetric Technology for the Kinetic and Thermal Safety Analysis of Tert-butylperoxy-3,5, 5-trimethylhexanoate
	11.1 Introduction
	11.2 Thermal Sensitivity and Runaway Characteristics of Tert-butyl peroxy-3,5,5-trimethylhexanoate
	11.3 Sample Preparation
		11.3.1 Sample
		11.3.2 Differential Scanning Calorimetry
	11.4 Determination of the Kinetic Model
	11.5 Time for Maximum Rate at Adiabatic Conditions
	11.6 Self-accelerating Decomposition Temperature
	11.7 Results and Discussion
	11.8 Summary
	References
Chapter 12: Thermal Hazard Analysis and Its Application on Process Safety Assessments
	12.1 Introduction
	12.2 Organic Peroxides and Its Associated Thermal Hazards
	12.3 Thermal Hazard Analysis
		12.3.1 Thermal Analysis Technology
			12.3.1.1 Experimental Setup
		12.3.2 Isothermal Calorimetry Technology
			12.3.2.1 Experimental Setup
		12.3.3 Adiabatic Calorimetry Technology
			12.3.3.1 Experimental Setup
	12.4 Summary
	References
Chapter 13: Safety of Flammable Liquid Mixtures
	13.1 Introduction
	13.2 Flash Point Evaluation
	13.3 Experimental Protocol
	13.4 Flash Point Model Prediction for Partially Miscible Mixtures
		13.4.1 Model for Aqueous–Organic Solutions
		13.4.2 Model for Mixtures of Flammable Solvents
	13.5 Results and Discussion
		13.5.1 Parameters Used
		13.5.2 Partially Miscible Aqueous–Organic Mixtures
		13.5.3 Partially Miscible Mixtures of Flammable Solvents
	13.6 Summary
	References
Chapter 14: Calorimetric Approach on the Thermal Hazard Assessment of Cumene Hydroperoxide
	14.1 Introduction
	14.2 Thermal Runaway of Cumene Hydroperoxide
	14.3 Experimental Studies
		14.3.1 Samples
		14.3.2 DSC (Differential Scanning Calorimeter)
		14.3.3 TAM (Thermal Activity Monitor)
		14.3.4 Applications
	14.4 Results and Discussion
		14.4.1 Significance and Applications of CHP Derived by DSC and TAM
		14.4.2 Comparison of Thermokinetic Parameters for CHP Derived From DSC and TAM
	14.5 Summary
	References
Chapter 15: Evaluation of the Information System of Maintenance Efficiency in Petrochemical Plants
	15.1 Introduction
	15.2 Maintenance Management of Facilities
	15.3 Preliminary Design and Index Establishment
	15.4 Design of the System
		15.4.1 Index Design
		15.4.2 System Development
			Management of Security and the Associated User Privilege
			System Structure
			System Interface
		15.4.3 Data Requirements
		15.4.4 Function Requirements
	15.5 Summary
	References
Chapter 16: A Study on the Challenges in Emerging Economies to Industry 4.0 Initiatives for Supply Chain Sustainability
	16.1 Introduction
	16.2 Understanding Industry 4.0
		16.2.1 Industry 4.0
		16.2.2 Challenges to Industry 4.0 Initiatives for Sustainability in Supply Chains
	16.3 Methodology
	16.4 Data Collection and Results
		16.4.1 Instrument Development and Data Collection
		16.4.2 Reliability, Validity and Non-Biasness
		16.4.3 Explanatory Factor Analysis (EFA)
		16.4.4 Analytical Hierarchy Process (AHP)
	16.5 Discussion
	16.6 Summary
		16.6.1 Theoretical Benefaction
		16.6.2 Managerial Benefaction
		16.6.3 Shortcomings and Future Proposals
	References
Chapter 17: A Detailed Study on the Spatial Characteristics of Heavy Metal Pollution and Ecological Risk of Mining Area
	17.1 Introduction
	17.2 Heavy Metal Pollution
	17.3 Sample Collection and Analysis
		17.3.1 Location
		17.3.2 Sample Collection and Analysis
		17.3.3 Data Source and Processing
	17.4 Research Survey
		17.4.1 Data Processing
		17.4.2 Potential Ecological Risk Index Method
		17.4.3 IDW Interpolation of Heavy Metals in Soil
	17.5 Detailed Analysis of Results
		17.5.1 Soil Heavy Metal Pollution
			17.5.1.1 Characteristic Value Analysis of Heavy Metals in Soil
			17.5.1.2 Heavy Metal Pollution in the Case Study Area
		17.5.2 Ecological Risk Assessment of Heavy Metals
			17.5.2.1 Single Factor Ecological Risk Assessment of Heavy Metals in Soil
	17.6 Risk Assessment and Its Adjustment at the Township Scale
		17.6.1 Potential Ecological Risk Assessment of Arsenic
		17.6.2 Potential Ecological Risk Assessment of Mercury
		17.6.3 Comprehensive Ecological Risk Evaluation of Heavy Metals in Soil
	17.7 Results and Discussion
		17.7.1 Heavy Metals in Soil Based on Township Scale
		17.7.2 The Adjustment of the Potential Ecological Risk Assessment Domain
		17.7.3 Selection of Spatial Interpolation Methods for Heavy Metals in Soil
	17.8 Summary
	References
Chapter 18: Evaluation of Human Factors Risk and Management in Process Safety in Engineering
	18.1 Introduction
	18.2 Assessment of Human Factors
	18.3 Human Factors Risk Assessment Model
	18.4 Applied Methodology
		18.4.1 Set Pair Analysis (SPA)
		18.4.2 Risk Trend Analysis
		18.4.3 SPA–Markov Risk Prediction Method
	18.5 Assessment and Management Procedure
		18.5.1 Assessment Procedure
		18.5.2 Management Procedure
	18.6 Application
		18.6.1 Determine the Factor Weight (W) and the Identity-discrepant-Contrast Assessment Matrix (R)
		18.6.2 Calculate the Connection Number and Partial Connection Number
		18.6.3 Risk Analysis
		18.6.4 Risk Trend Analysis
		18.6.5 Risk Prediction
		18.6.6 Risk Management
	18.7 Discussions
	18.8 Summary
	Appendix 18A
	References
Chapter 19: Analysis of Off-Site Emergency Procedures and Reciprocation for Nuclear Accidents
	19.1 Introduction
	19.2 Study on Nuclear Accidents
	19.3 Different Phases of a Nuclear Accident
		19.3.1 Planning Phase
			19.3.1.1 Requirements
			19.3.1.2 Contents of An Emergency Plan
		19.3.2 Response Phase
			19.3.2.1 Pre-Release Phase
			19.3.2.2 Post-Release Phase
		19.3.3 Recovery Phase
	19.4 Economic Costs Analysis
		19.4.1 Factors Affecting the Economic Costs of a Nuclear Accident
		19.4.2 Economic Modelling in the UK
	19.5 Factors Impacting Health and Economic Cost
		19.5.1 Siting and Demography
		19.5.2 Source Terms
		19.5.3 Weather and Dispersion
		19.5.4 Food
	19.6 Summary
	References
Index
	A
	B
	C
	D
	E
	f
	G
	H
	I
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	L
	M
	N
	O
	P
	R
	S
	T
	U
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	W