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Recognizing Catastrophic Incident Warning Signs in the Process Industries

  • ID: 2067800
  • Book
  • January 2012
  • 264 Pages
  • John Wiley and Sons Ltd

Practical advice for recognizing potential process incidents before they happen

Serious process incidents can occur at any time, but in many cases, warning signs unusual odors, observable corrosion, or past operating history concerns that could prevent potentially catastrophic accidents go unrecognized. Recognizing Catastrophic Incident Warning Signs in the Process Industries presents a comprehensive look at how to design and implement effective process safety management (PSM) systems. Going beyond other books on the market, it also offers unique guidance on how to recognize and respond to warning signs before it′s too late.

Providing guidance on characterizing and responding to the warning signs that anticipate process incidents, the book is an invaluable tool for PSM professionals evaluating their processes and systems, the operators at the front lines of defense against process incidents, and anyone involved with or interested in improving process safety. Packed with practical tips and photos, and with an accompanying website that contains an assortment of auxiliary documents, the book is designed to turn anyone in a process plant into a hazard lookout.

Note: Product cover images may vary from those shown
List of Tables xix

List of Figures xxi

Files on the Web Accompanying This Book xxii

Acknowledgements xxv

Foreword xxvii

Preface xxix

1. Introduction 1

1.1 Process safety management 3

1.2 Normalization of deviance 4

1.3 A strategy for response 5

1.4 Maintaining organizational memory and a healthy sense of vulnerability 7

1.5 Risk based process safety 8

1.6 Our target audience 11

1.7 How to use this book 12

1.8 Case study Toxic gas release in India 13

2. Incident Mechanics 17

2.1 Incidents do not just happen 17

2.2 Incident models 17

2.3 Case study Benzene plant explosion in China 27

3. Leadership and Culture 29

3.1 How does leadership affect culture? 29

3.2 The leadership and culture related warning signs 32

3.3 Case study Challenger space shuttle explosion in the US 46

4. Training and Competency 49

4.1 What is effective training and how is competency measured? 49

4.2 The training and competency related warning signs 51

4.3 Case study Gas plant vapor cloud explosion in Australia 62

5. Process Safety information 65

5.1 Critical information to identify hazards and manage risk 65

5.2 The process safety information related warning signs 66

5.3 Case study Batch still fire and explosion in the UK

6. Procedures 79

6.1 Safe and consistent operation 79

6.2 The procedure related warning signs 81

6.3 Case study Nuclear plant meltdown and explosion in the Ukraine 95

7. Asset Integrity 97

7.1 Systematic implementation 97

7.2 The asset integrity related warning signs 99

7.3 Case study Refinery naphtha fire in the US 114

8. Analyzing Risk and Managing Change 177

8.1 Risk management 117

8.2 The risk analysis and management of change related warning signs 121

8.3 Case study Cyclohexane explosion in the UK

9. Audits 139

9.1 Audits support operational excellence 139

9.2 The audit related warning signs 141

9.3 Case study Chemical warehouse fire in the UK

10. Learning From Experience 149

10.1 Methods for continuous improvement 149

10.2 The learning from experience warning signs 151

10.3 Case study Space shuttle Columbia incident in the US 159

11. Physical Warning Signs 163

11.1 The everyday things matter 163

11.2 The physical warning signs 164

11.3 Case study Resin plant dust explosion in the US 172

12. A Call to Action 175

12.1 Actions you can take now for each warning sign 176

12.2 A simple plan to consider for rigorous implementation and follow–up 177

12.3 Actions to consider 180

12.4 Summary 183

Appendix A. Incident Warning Sign Self Assessment Tool 187

Appendix B. Composite List of Catastrophic Incident Warning Signs 199

References & Selected Regulations 205

Acronyms and Abbreviations 213

Glossary 215

Index 221 

Note: Product cover images may vary from those shown
CCPS (Center for Chemical Process Safety)
Note: Product cover images may vary from those shown