Chemical Process Safety

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.

Daniel A. Crowl is the Herbert H. Dow Professor for Chemical Process Safety at Michigan Technological University. Professor Crowl received his B.S. in fuel science from Pennsylvania State University and his M.S. and Ph.D. in chemical engineering from the University of Illinois. He is coauthor of the textbook Chemical Process Safety: Fundamentals with Applications, published by Pearson. He is also author/editor of several AIChE books on process safety and editor of the safety section in the eighth edition of Perry's Chemical Engineer's Handbook. Professor Crowl has won numerous awards, including the Bill Doyle award from AIChE, the Chemical Health and Safety Award from ACS, the Walton/Miller award from the Safety and Health Division of AIChE, and the Gary Leach Award from the AIChE Board. Professor Crowl is a Fellow of AIChE, ACS Safety and Health Division, and CCPS. Joseph F. Louvar has a B.S., M.S., and Ph.D. in chemical engineering. He is currently a professor at Wayne State University after having retired from the BASF Corporation. While working at the BASF Corporation, he was a director of BASF's chemical engineering department; his responsibilities included the production of specialty chemicals, and he managed the implementation and maintenance of five processes that handled highly hazardous chemicals that were covered by Process Safety Management. As a professor at Wayne State University, he teaches chemical process safety, risk assessment, and process design. Professor Louvar is the author of many safety-related publications and the coauthor of two books, Chemical Process Safety: Fundamentals with Applications and Health and Environmental Risk Analysis: Fundamentals with Applications, both published by Pearson. Professor Louvar has been the chair of the Loss Prevention Committee and the Safety and Health Division. He is the CCPS staff consultant for the Undergraduate Education Committee, commonly known as the Safety and Chemical Engineering Education Committee (SAChE), and he is the coeditor of AIChE's journal for process safety, Process Safety Progress.

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