Inherently Safer Chemical Processes, A Life Cycle Approach

Appendix A: Sample Inherently Safer Process Checklist......Page 0
Front Matter......Page 1
Foreword......Page 3
Preface......Page 5
Acknowledgments......Page 7
Table of Contents......Page 10
1. Introduction......Page 15
2.1 A Way of Thinking......Page 20
2.2 The Role of Inherently Safer Design Concepts in Process Risk Management......Page 25
2.3 When Do We Consider Inherently Safer Options?......Page 28
2.4 Inherent Safety Tradeoffs......Page 30
2.5 Resolving Inherent Safety Issues......Page 33
2.6 Inherently Safer Design Strategies......Page 35
2.7 Summary......Page 37
3.1 Minimize......Page 39
Reactors......Page 41
Reactive Distillation......Page 44
Storage and Material Transfer......Page 46
Other Examples......Page 47
Reaction Chemistry......Page 48
Solvents......Page 51
Dilution......Page 52
Refrigeration......Page 53
Less Severe Process Conditions......Page 55
Secondary Containment - Dikes and Containment Buildings......Page 57
3.4 Simplify......Page 60
Containment within Process Equipment......Page 61
Fail Safe Valves......Page 62
Separation of Process Steps......Page 63
3.5 Summary......Page 64
4.1 General Principles across All Life Cycle Stages......Page 66
4.2 Research......Page 67
Inherently Safer Synthesis......Page 68
Types of Hazards and Hazardous Events......Page 69
Tools for Hazards Identification......Page 71
Alternatives......Page 76
4.3 Process Development......Page 77
Unit Operations - General......Page 78
Unit Operations - Specific......Page 79
4.4 Design and Construction......Page 83
Process Design Basis......Page 84
Equipment......Page 85
Process Control......Page 88
Other Design Considerations......Page 95
4.5 Operations, Maintenance, and Modifications......Page 96
4.6 Decommissioning......Page 99
5. Transportation......Page 102
5.1 Location Relative to Raw Materials......Page 103
5.3 Transportation Mode and Route Selection......Page 104
5.4 Improved Transportation Containers......Page 105
5.5 Administrative Controls......Page 106
6. Human Factors......Page 107
6.1 Overview......Page 108
6.2 Operability and Personnel Safety......Page 109
6.3 Maintainability......Page 111
Knowledge and Understanding......Page 112
Control Design......Page 114
6.5 Error Recovery......Page 119
6.6 System Audits......Page 122
6.7 Organization Culture......Page 123
7.1 Inherent Safety Reviews......Page 124
Inherent Safety Review Timing......Page 126
Inherent Safety Review Team Composition......Page 127
Inherent Safety Review Process Overview......Page 128
Focus of the Different Inherent Safety Reviews......Page 131
Inherent Safety Review Initiates Project Human Factors/Ergonomics Effort......Page 132
Good Preparation Required for Effective Inherent Safety Reviews......Page 133
7.2 Inherent Safety Review Training......Page 134
7.3 Summary......Page 135
Incorporating Inherently Safer Technology into Process Safety Management......Page 136
Including Inherently Safer Technology into the Education of Chemists and Chemical Engineers......Page 137
The Broad View and Life Cycle Cost of Alternatives......Page 138
Benefits of Reliability Analysis......Page 139
Quantitative Measures of Inherently Safer Technology......Page 140
1. Minimize......Page 141
2. Substitution/Elimination......Page 142
4. Simplify......Page 143
5. Location/Sitting/Transportation......Page 144
C......Page 145
D......Page 146
E......Page 147
H......Page 148
I......Page 149
K......Page 150
L......Page 151
P......Page 152
R......Page 153
S......Page 154
T......Page 155
W......Page 156