Process Plants : A Handbook for Inherently Safer Design, Second Edition book cover
2nd Edition

Process Plants
A Handbook for Inherently Safer Design, Second Edition

ISBN 9781439804551
Published May 17, 2010 by CRC Press
384 Pages 97 B/W Illustrations

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Book Description

How far will an ounce of prevention really go? While the answer to that question may never be truly known, Process Plants: A Handbook for Inherently Safer Design, Second Edition takes us several steps closer. The book demonstrates not just the importance of prevention, but the importance of designing with prevention in mind. It emphasizes the role of inherent safety in process safety management systems and in ensuring an appropriate process safety culture. Keeping the easy to understand style that made the first edition so popular, this book clearly delineates practical, everyday issues and complex technical ones.

The second edition provides:

  • Coverage of new inherent safety metrics and how to measure the degree or level of inherent safety
  • New examples of application of the various principles of inherently safer design and 20 new figures
  • New emphasis on the role of inherently safer design in process safety management systems and in ensuring an appropriate process safety culture
  • Discussion of dust explosion risk reduction by means of inherently safer approaches
  • New chapter on case study development, providing a comprehensive approach to the prevention and mitigation of process incidents by timely incorporation of inherently safer design

This updated version of a classic text examines how to incorporate inherently safer design into process industry activities, revising and updating information based on recent research and developments. A how-to resource at its core, the book includes numerous examples that illustrate the principles of inherently safer design and how to apply them in practice. It explains how to measure the inherent safeness of a process, referencing metric tools that have been developed during the past decade and the tried and true methods that have become industry stand bys.

Table of Contents

Introduction: What are Inherently Safer and User-Friendly Plants?
Inherently Safer and Friendlier Design as Part of an Overall Approach
Hierarchy of Controls
Inherently Safer Design: The Concept and Its Scope and Benefits
The Concept
Defense in Depth
The Scope
The Benefits of Inherently Safer Design
Appendix: The Lady and the Tiger—A New Version of an Old Tale
References and Notes
Process Intensification
Heat Transfer
Other Unit Operations
Intensification by Detailed Design
Many Small Plants or One Big One?
Some Thoughts on Intensification as Minimization
Appendix: Conference Report—New Technology
References and Notes
The Use of Safer Nonreactive Agents
Choosing Less Hazardous Processes
References and Notes
Attenuated Reactions
Attenuated Storage and Transport
A Railway Analogy
References and Notes
Limitation of Effects
Limitation of Effects by Equipment Design
Limitation of Effects by Changing Reaction Conditions
Elimination of Hazards
References and Notes
The Reasons for Complexity
Stronger Equipment Can Replace Relief Systems
Resistant Materials of Construction Can Replace Protective Instruments
Designs Free from Opportunities for Human Error
Design Change Can Avoid the Need for Better Instrumentation
Relocation Can Avoid the Need for Complication
Simple Technology Can Replace High Technology
Leaving Things Out
Power Fluidics: Avoiding Moving Parts
Other Examples of Simplification
Modification Chains
References and Notes
Simplification: Specifications and Flexibility
Following Rules to the Letter
Asking for Too Much Flexibility
Three Problems
Appendix: Some Comments on Simplification
Other Ways of Making Plants Friendlier
Avoiding Knock-On Effects
Making Incorrect Assembly Impossible
Making Status Clear
Tolerance of Misuse
Ease of Control
Computer Control
Instructions and Other Procedures
Life-Cycle Friendliness
Other Industries
Passive Safety
References and Notes
The Road to Friendlier Plants
Constraints on the Development of Friendlier Plants
The Action Needed
The Influence of the Law
The Measurement of Friendliness
Looking for New Knowledge
The Final Decision
Inherently Safer Design Offshore: A Case History
Appendix: Finding Examples of Inherently Safer Design
References and Notes
Inherently Safer Design and Process-Safety Management
Safety Management Systems
Process-Safety Management System Elements
Safety Culture
References and Notes
Friendlier Plants and the Nuclear Industry
New Types of Reactor
Features of Nuclear Plants
The Role of Inherently Safer Design in Dust Explosion Prevention and Mitigation
Dust Explosion Overview
Use of the Hierarchy of Controls
Other Examples
Summary of Prevention and Mitigation Measures
Concluding Remarks
Inherent-Safety Case Studies
Everyday Life Experiences
Newspapers and Magazines
Topical Conferences
Technical Papers
Process-Safety Books
Case Study Books
Other Inherent-Safety Books
Books from Other Industries and Applications
Training Packages
Trade Literature
Loss Prevention Bulletins
Chemical Safety Board Reports
Concluding Remarks
Do We Go Too Far in Removing Risk?
Risks to Output and Efficiency
Risks to Life and Limb
The Contribution of the Operator
The History and Future of Inherently Safer and User-Friendly Design
The Start of the Story
The Idea Develops
Extensions of the Idea
A True Story (except for the Names): August 2009
A Final Thought
References and Notes
Further Reading
Index to First Edition
Appendix A: An Atlas of Safety Thinking

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