Chemical Process Safety: Learning from Case Histories, Fourth Edition gives insight into eliminating specific classes of hazards while also providing real case histories with valuable lessons to be learned. This edition also includes practical sections on mechanical integrity, management of change, and incident investigation programs, along with a list of helpful resources. The information contained in this book will help users stay up-to-date on all the latest OSHA requirements, including the OSHA-required Management of Change, Mechanical Integrity, and Incident Investigation regulations. Learn how to eliminate hazards in the design, operation, and maintenance of chemical process plants and petroleum refineries. World-renowned expert in process safety, Roy Sanders, shows how to reduce risks in plants and refineries, including a summary of case histories from high profile disasters and recommendations for how to avoid repeating the same mistakes. Following the principles outlined in this text will help save lives and reduce loss. - Features additional new chapters covering safety culture, maintaining a sense of vulnerability, and additional learning opportunities from recent incidents and near misses - Contains updated information from the US Bureau of Labor Statistics and the National Safety Council, with concise summaries of some of the most important case histories of the twenty-first century - Includes significantly expanded information from the US Chemical Safety Board, US OSHA, American Institute of Chemical Engineers, and the UK Health and Safety Executive (HSE) - Provides a completely updated chapter to guide readers to a wealth of reference material available on the web and elsewhere

The use of hazardous chemicals such as methyl isocyanate can be a significant concern to the residents of communities adjacent to chemical facilities, but is often an integral part of the chemical manufacturing process. In order to ensure that chemical manufacturing takes place in a manner that is safe for workers, members of the local community, and the environment, the philosophy of inherently safer processing can be used to identify opportunities to eliminate or reduce the hazards associated with chemical processing. However, the concepts of inherently safer process analysis have not yet been adopted in all chemical manufacturing plants. The Use and Storage of Methyl Isocyanate (MIC) at Bayer CropScience presents a possible framework to help plant managers choose between alternative processing options-considering factors such as environmental impact and product yield as well as safety- to develop a chemical manufacturing system. In 2008, an explosion at the Bayer CropScience chemical production plant in Institute, West Virginia, resulted in the deaths of two employees, a fire within the production unit, and extensive damage to nearby structures. The accident drew renewed attention to the fact that the Bayer facility manufactured and stores methyl isocyanate, or MIC - a volatile, highly toxic chemical used in the production of carbamate pesticides and the agent responsible for thousands of death in Bhopal, India, in 1984. In the Institute accident, debris from the blast hit the shield surrounding a MIC storage tank, and although the container was not damaged, an investigation by the U.S. Chemical Safety and Hazard Investigation Board found that the debris could have struck a relief valve vent pipe and cause the release of MIC to the atmosphere. The Board's investigation also highlighted a number of weaknesses in the Bayer facility's emergency response systems. In light of these concerns, the Board requested the National Research Council convene a committee of independent experts to write a report that examines the use and storage of MIC at the Bayer facility. The Use and Storage of Methyl Isocyanate (MIC) at Bayer CropScience also evaluates the analyses on alternative production methods for MIC and carbamate pesticides preformed by Bayer and the previous owners of the facility.

This book is about the engineering management of hazardous industries, such as oil and gas production, hydrocarbon refining, nuclear power and the manufacture of chemicals and pharmaceuticals. Its scope includes an overview of design standards and processes for high integrity systems,safety management processes as applied to hazardous industries and details best practices in design, operations, maintenance and regulation. Selected case studies are used to show how the complex multidisciplinary enterprises to design and operate hazardous plant can sometimes fail. This includes the subtlety and fragility of the robust safety culture that is required. It is aimed at professional engineers who design, build and operate these hazardous plants. This book is also written for business schools and university engineering departments where engineering management is studied. - An overview of design standards and processes for high integrity systems - An overview of safety management processes as applied to hazardous industries - Best practices in design, operations, maintenance and regulation

The human element is the principle cause of incidents and accidents in all technology industries; hence it is evident that an understanding of the interaction between humans and technology is crucial to the effective management of risk. Despite this, no tested model that explicitly and quantitatively includes the human element in risk prediction is currently available. Managing Risk: the Human Element combines descriptive and explanatory text with theoretical and mathematical analysis, offering important new concepts that can be used to improve the management of risk, trend analysis and prediction, and hence affect the accident rate in technological industries. It uses examples of major accidents to identify common causal factors, or “echoes”, and argues that the use of specific experience parameters for each particular industry is vital to achieving a minimum error rate as defined by mathematical prediction. New ideas for the perception, calculation and prediction of risk are introduced, and safety management is covered in depth, including for rare events and “unknown” outcomes Discusses applications to multiple industries including nuclear, aviation, medical, shipping, chemical, industrial, railway, offshore oil and gas; Shows consistency between learning for large systems and technologies with the psychological models of learning from error correction at the personal level; Offers the expertise of key leading industry figures involved in safety work in the civil aviation and nuclear engineering industries; Incorporates numerous fascinating case studies of key technological accidents. Managing Risk: the Human Element is an essential read for professional safety experts, human reliability experts and engineers in all technological industries, as well as risk analysts, corporate managers and statistical analysts. It is also of interest to professors, researchers and postgraduate students of reliability and safety engineering, and to experts in human performance. “...congratulations on what appears to be, at a high level of review, a significant contribution to the literature...I have found much to be admired in (your) research” Mr. Joseph Fragola – Vice President of Valador Inc. “The book is not only technically informative, but also attractive to all concerned readers and easy to be comprehended at various level of educational background. It is truly an excellent book ever written for the safety risk managers and analysis professionals in the engineering community, especially in the high reliability organizations...” Dr Feng Hsu, Head of Risk Assessment and Management, NASA Goddard Space Flight Center “I admire your courage in confronting your theoretical ideas with such diverse, ecologically valid data, and your success in capturing a major trend in them....I should add that I find all this quite inspiring . ...The idea that you need to find the right measure of accumulated experience and not just routinely used calendar time makes so much sense that it comes as a shock to realize that this is a new idea”, Professor Stellan Ohlsson, Professor of Psychology, University of Illinois at Chicago

An essential guide that offers an understanding of and the practices needed to assess and strengthen process safety culture Essential Practices for Developing, Strengthening and Implementing Process Safety Culture presents a much-needed guide for understanding an organization's working culture and contains information on why a good culture is essential for safe, cost-effective, and high-quality operations. The text defines process safety culture and offers information on a safety culture’s history, organizational impact and benefits, and the role that leadership plays at all levels of an organization. In addition, the book outlines the core principles needed to assess and strengthen process safety culture such as: maintain a sense of vulnerability; combat normalization of deviance; establish an imperative for safety; perform valid, timely, hazard and risk assessments; ensure open and frank communications; learn and advance the culture. This important guide also reviews leadership standards within the organizational structure, warning signs of cultural degradation and remedies, as well as the importance of using diverse methods over time to assess culture. This vital resource: Provides an overview for understanding an organization's working culture Offers guidance on why a good culture is essential for safe, cost-effective, and high quality operations Includes down-to-earth advice for recognizing, assessing, strengthening and sustaining a good process safety culture Contains illustrative examples and cases studies, and references to literature, codes, and standards Written for corporate, business and line managers, engineers, and process safety professionals interested in excellent performance for their organization, Essential Practices for Developing, Strengthening and Implementing Process Safety Culture is the go-to reference for implementing and keeping in place a culture of safety.

Fundamentals of Risk Management for Process Industry Engineers outlines foundational principles of human-centered, sociotechnical risk management, and how they can be applied to deliver real improvements in risk identification, understanding, analysis, control, communication, and governance. To maximize sustainable competitiveness requires the identification and optimization of the range of risks that can impact a business. Hence, understanding the foundational principles of sociotechnical risk management is required to design and execute effective risk identification, optimization, and management strategies. - Covers the foundations of risk management - Explains how risk management and professional engineering practice are interrelated - Describes the role and importance of humans in risk management activities - Discusses the fundamentals surrounding how to identify, assess, treat, monitor, and review risks in high hazard industries - Presents the range of operational risks faced by process companies, including safety and health, environmental and social risk, project risk, and supply chain risk

Advanced technologies and increasing automation have forever changed how systems work and how people interact with them. Transportation systems, energy extraction and production systems, medical devices, and manufacturing processes are increasingly complex. With the use of these complex systems comes increased potential for harm to humans, property, and the environment. System safety is a widely accepted management and engineering approach to analyze and address risks in these complex systems. When used correctly, system safety methods can provide tremendous benefits, focusing resources to reduce risk and improve safety. But poor system safety analyses can lead to overconfidence, and can result in a misunderstanding of the potential for harm. The System Safety Skeptic describes critical aspects of the discipline of system safety, including: Safety planning Hazard identification Hazard risk assessment and associated risk decision making Risk reduction and hazard controls Risk reduction verification Hazard tracking and anomaly reporting Safety management and culture Accidents in multiple industries and organizations are used to illustrate potential missteps in the system safety process, including: Failure to plan and implement systematic safety efforts, and failure to plan for emergencies Failure to accurately identify the hazards and what can go wrong Underestimating the chances that an accident could happen Underestimating the worst possible outcomes Overestimating the effectiveness of safeguards Failure to properly verify that safeguards actually work Failure to learn from the past Failure of the organization to adequately manage system safety efforts This book provides hundreds of lessons learned in safety management and engineering, drawing from examples from many industries as well as the author's years of experience in the field. These real-world lessons help foster a healthy skepticism toward safety analysis and management in order to prevent future accidents.

Describes a six-stage process which can be adopted by organisations wishing to implement a programme of performance monitoring for process safety risks.