Chemical Process Safety: Fundamentals with Applications, 4th Edition

Description

• Copyright 2019
• Pages: 656
• Edition: 4th

• eBook
• ISBN-10: 0-13-485791-7
• ISBN-13: 978-0-13-485791-6

The #1 Process Safety Guide, Now Extensively Updated for Current Industrial Processes, Systems, and Practices

Process safety has seen a dramatic consolidation of concepts in the past few years. Chemical Process Safety, Fourth Edition, provides students and working engineers with the understanding necessary to apply these new concepts to safely design and operate any process.

Long the definitive guide in the field, this edition fully reflects major recent advances in process safety technology and practice. Readers will find extensive new and updated coverage of relief sizing, hazards identification, risk assessment, and many other topics. Several chapters have been completely rewritten, and all are substantially modified. This textbook includes 50 new problems and solutions (mostly in SI units), and 25 new case histories.

• Safety culture
• Preventive and mitigative safeguards
• The CCPS 20 elements of Risk Based Process Safety (RBPS)
• Toxicology, industrial hygiene, and source models
• Hazardous material dispersion
• Fires, explosions, and concepts for preventing them
• Chemical reactivity
• Reliefs and relief sizing
• Hazards identification and evaluation
• Risk analysis and assessment, including Layer of Protection Analysis (LOPA)
• Safety strategies, procedures, designs, case histories, and lessons learned

Crowl and Louvar link key academic concepts to modern industrial practice, making this guide invaluable for all engineering students and for all working engineers.

Register your product for convenient access to downloads, updates, and/or corrections as they become available. See inside book for details.

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Sample Content

Table of Contents

Preface xv

About the Authors xviii

Nomenclature xx

Chapter 1: Introduction 1

1-1 Engineering Ethics 6

1-2 Myths about Process Safety 7

1-3 Safety Culture 10

1-4 Individual Risk, Societal Risk, and Risk Populations 13

1-5 Voluntary and Involuntary Risk 14

1-6 Safety Metrics 15

1-7 Accident and Loss Statistics 17

1-8 Risk Perception 27

1-9 Risk Tolerance/Acceptance and Risk Matrix 27

1-10 Codes, Standards, and Regulations 31

1-11 Safeguards 33

1-12 The CCPS 20 Elements of Risk-Based Process Safety 36

1-13 Inherently Safer Design 42

1-14 The Worst Chemical Plant Tragedy: Bhopal, India, 1984 46

1-15 Overview of Chemical Process Safety 49

Suggested Reading 49

Problems 50

Chapter 2: Toxicology 55

2-1 How Toxicants Enter the Body 56

2-2 How Toxicants Are Eliminated from the Body 59

2-3 Effects of Toxicants on the Body 60

2-4 Toxicological Studies 61

2-5 Dose versus Response 62

2-6 Dose and Response Using Probit Equation 68

2-7 Relative Toxicity 74

2-8 Threshold Limit Values 75

Online Resources 76

Suggested Reading 77

Problems 77

Chapter 3: Industrial Hygiene 79

3-1 Anticipating and Identifying Hazardous Workplace Exposures 80

3-2 Globally Harmonized System 83

3-3 Evaluate the Magnitude of Exposures and Responses 89

3-4 Develop and Evaluate Control Techniques to Prevent Exposures 106

3-5 National Fire Protection Association Diamond 115

Online Resources 116

Suggested Reading 117

Problems 117

Chapter 4: Source Models 119

4-1 Introduction to Source Models 121

4-2 Flow of Liquid through a Hole 123

4-3 Flow of Liquid through a Hole in a Tank 126

4-4 Flow of Liquids through Pipes 130

4-5 Flow of Gases or Vapors through Holes 140

4-6 Flow of Gases or Vapors through Pipes 145

4-7 Flashing Liquids 162

4-8 Liquid Pool Evaporation or Boiling 168

4-9 Realistic and Worst-Case Releases 169

4-10 Conservative Analysis 169

Suggested Reading 172

Problems 173

Chapter 5: Hazardous Material Dispersion 177

5-1 Parameters Affecting Dispersion 178

5-2 Neutrally Buoyant Dispersion Models 183

5-3 Pasquill–Gifford Model 184

5-4 Dense Gas Dispersion 197

5-5 Toxic Effect Criteria 198

5-6 Release Prevention and Mitigation 209

Suggested Reading 212

Problems 212

Chapter 6: Fires and Explosions 219

6-1 The Fire Triangle 220

6-2 Distinction between Fires and Explosions 221

6-3 Definitions 221

6-4 Flammability Characteristics of Liquids and Vapors 224

6-5 Flammability Characteristics of Dusts 247

6-6 Sprays and Mists 248

6-7 Ignition Energy 248

6-8 Ignition Sources 250

6-9 Experimental Characterization of Gas/Vapor and Dust Explosions 251

6-10 Explosions 258

Suggested Reading 278

Problems 278

Chapter 7: Concepts to Prevent Fires and Explosions 283

7-1 Inerting 284

7-2 Static Electricity 299

7-3 Controlling Static Electricity 315

7-4 Explosion-Proof Equipment and Instruments 323

7-5 Ventilation 325

7-6 Sprinkler Systems 329

7-7 Industry’s Fire and Explosion Protection Strategy 332

Suggested Reading 334

Problems 334

Chapter 8: Chemical Reactivity 337

8-1 Background Understanding 338

8-2 Commitment, Awareness, and Identification of Reactive Chemical Hazards 340

8-3 Characterization of Reactive Chemical Hazards Using Calorimeters 346

8-4 Controlling Reactive Hazards 372

Suggested Reading 374

Problems 374

Chapter 9: Introduction to Reliefs 379

9-1 Relief Concepts 380

9-2 Definitions 381

9-3 Code Requirements 383

9-4 Relief System Design 386

9-5 Relief Types and Characteristics 391

9-6 Relief Installation Practices 400

9-7 Relief Effluent Handling 403

Suggested Reading 406

Problems 406

Chapter 10: Relief Sizing 411

10-1 Set Pressure and Accumulation Limits for Reliefs 413

10-2 Relief Sizing for Liquid Service 415

10-3 Relief Sizing for Vapor and Gas Service 422

10-4 Two-Phase Flow during Runaway Reaction Relief 428

10-5 Deflagration Venting for Dust and Vapor Explosions 434

10-6 Venting for Fires External to the Process 440

10-7 Reliefs for Thermal Expansion of Process Fluids 444

Suggested Reading 447

Problems 449

Chapter 11: Hazards Identification and Evaluation 453

11-1 Introduction to Hazard Identification/Evaluation and Risk Analysis 455

11-2 Non-Scenario-Based Hazard Identification/Evaluation Methods 463

11-3 Scenario-Based Hazard Identification/Evaluation Methods 471

11-4 Documentation and Actions Required for Hazard Identification and Evaluation 483

Suggested Reading 483

Problems 483

Chapter 12: Risk Analysis and Assessment 487

12-1 Review of Probability Theory 487

12-2 Event Trees 501

12-3 Fault Trees 506

12-4 Bow-Tie Diagrams 513

12-5 Quantitative Risk Analysis 514

12-6 Layer of Protection Analysis 515

12-7 Risk Assessment 526

Suggested Reading 530

Problems 530

Chapter 13: Safety Strategies, Procedures, and Designs 533

13-1 Process Safety Strategies 533

13-2 Safe Operating Procedures 537

13-3 Safe Work Practices 538

13-4 Designs for Process Safety 541

13-5 Designs for Runaway Reactions 547

13-6 Designs and Practices for the Safe Handling of Dusts 548

Suggested Reading 549

Problems 550

Chapter 14: Case Histories and Lessons Learned 551

14-1 Process Safety Culture 552

14-2 Compliance with Standards 553

14-3 Process Safety Competency 554

14-4 Workplace Involvement 555

14-5 Stakeholder Outreach 556

14-6 Process Knowledge Management 556

14-7 Hazard Identification and Risk Analysis 557

14-8 Operating Procedures 558

14-9 Safe Work Practices 559

14-10 Asset Integrity and Reliability 560

14-11 Contractor Management 561

14-12 Training and Performance Assurance 562

14-13 Management of Change 563

14-14 Operational Readiness 564

14-15 Conduct of Operations 565

14-16 Emergency Management 566

14-17 Incident Investigation 567

14-18 Measurement and Metrics 569

14-19 Auditing 570

14-20 Management Review and Continuous Improvement 570

14-21 Summary 571

Suggested Reading 571

Problems 572

Appendix A: Unit Conversion Constants 573

Appendix B: Flammability Data for Selected Hydrocarbons 577

Appendix C: Saturation Vapor Pressure Data 583

Appendix D: Special Types of Reactive Chemicals 585

Appendix E: Hazardous Chemicals Data for a Variety of Chemical Substances 591

Appendix F: Process Diagrams 599

Index 603

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