While there is no "perfect" solution or absolute zero risk, engineering design can significantly reduce risk potential in the CPI. In Guidelines for Design Solutions to Process Equipment Failures, industry experts offer their broad experience in identifying numerous solutions to the more common process equipment failures including inherent safer/passive, active, and procedural solutions, in decreasing order of robustness and reliability. The book challenges the engineer to identify opportunities for inherent and passive safety features early, and use a risk-based approach to process safety systems specification. The book is organized into three basic sections: 1) a technique for making risk-based design decisions; 2) potential failure scenarios for 10 major processing equipment categories; and 3) two worked examples showing how the techniques can be applied. The equipment categories covered are: vessels, reactors, mass transfer equipment, fluid transfer equipment, solids-fluid separators, solids handling and processing equipment, and piping and piping components. Special Details: Hardcover book plus 3.5" diskette for use in any word processing program with design solutions for use in PHAs.
This updated version of one of the most popular and widely used CCPS books provides plant design engineers, facility operators, and safety professionals with key information on selected topics of interest. The book focuses on process safety issues in the design of chemical, petrochemical, and hydrocarbon processing facilities. It discusses how to select designs that can prevent or mitigate the release of flammable or toxic materials, which could lead to a fire, explosion, or environmental damage. Key areas to be enhanced in the new edition include inherently safer design, specifically concepts for design of inherently safer unit operations and Safety Instrumented Systems and Layer of Protection Analysis. This book also provides an extensive bibliography to related publications and topic-specific information, as well as key information on failure modes and potential design solutions.
Ludwig's Applied Process Design for Chemical and Petrochemical Plants Incorporating Process Safety Incidents is ever evolving starting with the first edition some 60 years ago. The volumes in this fifth edition provide improved techniques and fundamental design methodologies to guide the practicing engineer in designing process equipment and applying chemical processes to the properly detailed hardware. As indicative of the new title, process safety incidents are incorporated in many of the chapters, reviewing the root causes, and how these could be mitigated in future. Like its predecessor, this new edition continues to present updated information for achieving optimum operational and process conditions and to avoid problems caused by inadequate sizing and lack of internally detailed hardware. The volumes provide both fundamental theories where applicable and direct application of these theories to applied equations essential in the design effort. This approach in presenting design information is essential for troubleshooting process equipment and in executing system performance analysis. Volume 1B continues to cover mixing of liquids, process safety and pressure[1]relieving devices, metallurgy and corrosion, and process optimization. It builds upon Ernest E. Ludwig's classic text to further enhance its use as a chemical engineering process design manual of methods and proven fundamentals. This new edition includes new content on three-phase separation, mixing of liquids, ejectors, and mechanical vacuum systems, process safety and pressure-relieving devices, metallurgy and corrosion, and optimization of chemical process/blending. Some chapters review pressure-relieving devices and provide case studies for process safety incidents, which are well illustrated from US Chemical Safety Hazard Investigation Board (www.csb.gov). Finally, this book contains a glossary of Petroleum and Petrochemical Terminologies and Physical and Chemical Characteristics of Major Hydrocarbons.? Provides improved design manual for methods and proven fundamentals of process design with related data and charts? Covers complete range of basic day-to-day petrochemical operation topics? Extensively revised with new material added on three-phase separation, metallurgy, and corrosion? Process safety management/HAZOP and hazard analyses, and optimization of chemical process/blending? Presents many examples using Honeywell UniSim Design software, developed and executable computer programs, and Excel spreadsheet programs? Includes case studies of process safety incidents, guidance for troubleshooting, and checklists? Includes Software of Conversion Table and 30+ process data sheets in excel format
Since the publication of the second edition several United States jurisdictions have mandated consideration of inherently safer design for certain facilities. Notable examples are the inherently safer technology (IST) review requirement in the New Jersey Toxic Chemical Prevention Act (TCPA), and the Inherently Safer Systems Analysis (ISSA) required by the Contra Costa County (California) Industrial Safety Ordinance. More recently, similar requirements have been proposed at the U.S. Federal level in the pending EPA Risk Management Plan (RMP) revisions. Since the concept of inherently safer design applies globally, with its origins in the United Kingdom, the book will apply globally. The new edition builds on the same philosophy as the first two editions, but further clarifies the concept with recent research, practitioner observations, added examples and industry methods, and discussions of security and regulatory issues. Inherently Safer Chemical Processes presents a holistic approach to making the development, manufacture, and use of chemicals safer. The main goal of this book is to help guide the future state of chemical process evolution by illustrating and emphasizing the merits of integrating inherently safer design process-related research, development, and design into a comprehensive process that balances safety, capital, and environmental concerns throughout the life cycle of the process. It discusses strategies of how to: substitute more benign chemicals at the development stage, minimize risk in the transportation of chemicals, use safer processing methods at the manufacturing stage, and decommission a manufacturing plant so that what is left behind does not endanger the public or environment.
Process vent header collection systems are subject to continually varying compositions and flow rates and thus present significant challenges for safe design. Due to increasingly demanding safety, health, environmental, and property protection requirements, today's industrial designers are faced with the need to create increasingly complex systems for more effective treatment, dispersal, or disposal of process gases. Safe Design and Operation of Process Vents and Emission Control Systems provides cutting-edgeguidance for the design, evaluation, and operation of these systems, with emphasis on: Preventing fires, explosions, and toxic releases Maintaining safe vent conditions Understanding normal process operations, such as intentional routine controlled venting and emergency operations, like overpressure relief Mitigating the impacts of end-of-line treatment devices, such as scrubbers, flares, and thermal oxidizers, on the vent header system Complying with regulations Written by a team of process safety experts from the chemical, pharmaceutical, and petroleum industries, the book includes a wealth of real-world examples and a thorough overview of the tools and methods used in the profession.
Over 40 papers and posters that share the latest practices in emergency planning related to fixed chemical, pharmaceutical, LNG, and petroleum facilities, storage facilities, transportation, and security.
The foundation of any successful process safety program is a current set of process hazard analyses (PHAs) for each of its processes. Revalidating PHAs to keep them up to date and applicable is a must. This book is derived from the experience of many companies in the chemical and hydrocarbon processing industries, and presents demonstrated, concise, and common sense approaches for a resource-effective revalidation of PHAs. It includes flowcharts, checklists, and worksheets that provide invaluable assistance to the revalidation process.
PETROLEUM REFINING This fourth volume in the Petroleum Refining set, this book continues the most up-to-date and comprehensive coverage of the most significant and recent changes to petroleum refining, presenting the state-of-the-art to the engineer, scientist, or student. This book provides the design of heat exchanger equipment, crude oil fouling in pre-heat train exchangers, crude oil fouling models, fouling mitigation and monitoring, prevention and control of liquid and gas side fouling, using the Excel spreadsheet and UniSim design software for the design of shell and tube heat exchangers, double pipe heat exchangers, air-cooled exchangers, heat loss tracing for process piping, pinch analysis for hot and cold utility targets and process safety incidents involving these equipment items and pertinent industrial case studies. Use of UniSim Design (UniSim STE) software is illustrated in further elucidation of the design of shell and tube heat exchangers, condensers, and UniSim ExchangerNet R470 for the design of heat exchanger networks using pinch analysis. This is important for determining minimum cold and hot utility requirements, composite curves of hot and cold streams, the grand composite curve, the heat exchanger network, and the relationship between operating cost index target and the capital cost index target against ΔTmin. Useful as a textbook, this is also an excellent, handy go-to reference for the veteran engineer, a volume no chemical or process engineering library should be without. Written by one of the world’s foremost authorities, this book sets the standard for the industry and is an integral part of the petroleum refining renaissance. It is truly a must-have for any practicing engineer or student in this area. This groundbreaking new volume: Assists engineers in rapidly analyzing problems and finding effective design methods and select mechanical specifications Provides improved design manuals to methods and proven fundamentals of process design with related data and charts Covers a complete range of basic day–to–day petroleum refining operations topics with new materials on significant industry changes Extensive Excel spreadsheets for the design of process vessels for mechanical separation of two-phase and three-phase fluids, double-pipe heat exchanger, air-cooled exchanger, pinch analysis for hot and cold utility targets. Provides UniSim ®-based case studies for enabling simulation of key processes outlined in the book Helps achieve optimum operations and process conditions and shows how to translate design fundamentals into mechanical equipment specifications Has a related website that includes computer applications along with spreadsheets and concise applied process design flow charts and process data sheets Provides various case studies of process safety incidents in refineries and means of mitigating these from investigations by the US Chemical Safety Board Includes a vast Glossary of Petroleum and Technical Terminology
Layer of protection analysis (LOPA) is a recently developed, simplified method of risk assessment that provides the much-needed middle ground between a qualitative process hazard analysis and a traditional, expensive quantitative risk analysis. Beginning with an identified accident scenario, LOPA uses simplifying rules to evaluate initiating event frequency, independent layers of protection, and consequences to provide an order-of-magnitude estimate of risk. LOPA has also proven an excellent approach for determining the safety integrity level necessary for an instrumented safety system, an approach endorsed in instrument standards, such as ISA S84 and IEC 61511. Written by industry experts in LOPA, this pioneering book provides all the necessary information to undertake and complete a Layer of Protection Analysis during any stage in a processes' life cycle. Loaded with tables, charts, and examples, this book is invaluable to technical experts involved with ensuring the safety of a process. Because of its simplified, quicker risk assessment approach, LOPA is destined to become a widely used technique. Join other major companies and start your LOPA efforts now by purchasing this book.
