Guidelines for Inherently Safer Chemical Processes: A Life Cycle Approach

ISBN-13: 9781119529163 / Angielski / Twarda / 2019 / 528 str.

Center for Chemical Process Safety (CCPS)

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Preface viiAcknowledgements ixFigures xxiiiTables xxvi1. Introduction 11.1 Objectives, Intended Audience, and Scope of this Book 11.1.1 Objectives 11.1.2 Intended Audience 21.1.3 Scope 21.2 Integration of this Guidance with Other CCPS Guidance 21.3 Organization of this Book 31.4 History of Inherent Safety 41.5 References 92. The Concept of Inherent Safety 122.1 Inherent Safety and Process Risk Management 122.2 Inherent Safety Defined 152.3 Shared characteristics 162.4 Inherently Safer Strategies 182.5 Inherent safety throughout the process Life cycle 222.6 Inherently Safer Approaches 242.6.1 Orders of Inherent Safety 272.7 Layers of Protection 302.8 Integrating Inherent Safety in Process Risk Management Systems 322.9 Summary 402.10 References 403. Minimize - An Inherently Safer Strategy 443.1 Minimize 443.2 Reactors 473.3 Continuous Stirred Tank Reactors 483.4 Tubular Reactors 493.5 Loop Reactors 493.6 Reactive Distillation 513.7 Storage of Hazardous Materials 543.8 Process Piping 573.9 Process Equipment 583.10 Limitation of Effects 603.11 References 614. Substitute - An Inherently Safer Strategy 644.1 Reaction Chemistry 644.2 Green Chemistry 724.3 Solvents 734.4 Refrigerants 754.5 Firefighting Agents 764.6 Heat Transfer Media 764.7 Informed Substitution 774.8 References 835. Moderate - An Inherently Safer Strategy 875.1 Dilution 875.2 Refrigeration 885.3 Less Energetic Process Conditions 915.4 Secondary Containment - Dikes and Containment Buildings 945.5 Segregation 985.6 References 1006. Simplify - An Inherently Safer Strategy 1036.1 Leaving Things Out 1046.2 Eliminating Unnecessary Spares 1056.3 Inherently Robust Process Equipment 1076.4 Preventing Runaway Reactions 1106.5 Simplifying Heat Transfer 1136.6 Simplifying Liquid Transfer 1146.7 Reactor Geometry 1166.8 Optimizing Catalyst Selectivity 1166.9 Separation of Process Steps 1166.10 Limitation of Available Energy 1196.11 Simplification of the Human-Machine Interface 1206.11.1 Overview 1206.11.2 Equipment Layout, Accessibility, and Operability 1216.11.3 Maintainability 1216.11.4 Error Prevention 1236.11.5 Design of Equipment and Controls - Making Status Clear 1236.12 Summary 1246.13 References 1247. Applying Inherent Safety Strategies to Protection Layers 1267.1 Operating Procedures 1287.2 Maintenance Procedures 1297.3 Relocation 1297.4 Containment 1307.5 More Robust Process Equipment and Design 1317.6 Simplified Process Equipment and Design 1327.7 Distributed Control Systems 1337.8 Summary 1347.9 References 1348. Life Cycle Stages 1368.1 General Principles Across All Life cycle Stages 1368.2 Concept 1378.3 Research 1398.3.1 Inherently Safer Synthesis 1418.3.2 Types of Hazards Associated with Research 1428.3.3 Hazards Identification Methods 1488.4 Design Development 1598.4.1 Unit Operations - General 1608.4.2 Unit Operations - Specific 1618.5 Detailed Engineering Design 1698.5.1 Process Design Basis 1708.5.2 Equipment 1718.5.3 Process Controls 1758.5.4 Utility & Supporting Systems 1798.5.5 Batch Processes 1808.5.6 Other Design Considerations 1828.6 Procurement, Construction, and Commissioning 1838.7 Operations & Maintenance 1858.7.1 Preservation of Inherent Safety 1858.7.2 Inherent Safety - Continuous Improvement 1878.8 Change Management 1918.9 Decommissioning 1928.10 Transportation 1958.10.1 Location Relative to Raw Materials 1978.10.2 Shipping Conditions 1988.10.3 Transportation Mode and Route Selection 1998.10.4 Improved Transportation Containers 2008.10.5 Administrative Controls 2018.10.6 Management of Transportation Containers On-site 2028.11 References 2039. Inherent Safety and Security 2129.1 Introduction 2129.2 Chemical Security Risk 2139.3 Security Strategies 2179.4 Countermeasures 2199.5 Assessing Security Vulnerabilities 2209.6 Inherent Safety and Chemical Security 2219.7 Limitations to Implementing IS Concepts in Security Management 2269.8 Conclusion 2289.9 References 22910. Implementing Inherently Safer Design 23010.1 Introduction 23010.2 Management System Approach for IS 23110.3 Education and awareness 23210.3.1 Making IS a Corporate Philosophy 23210.3.2 IS in Education 23310.4 Organizational culture 23410.4.1 Multiple Demands of IS in the PSM program 23510.4.2 Incorporating IS into Normal Design Process 23610.5 Inherent Safety Reviews 24110.5.1 Inherent Safety Review Objectives 24210.5.2 Good Preparation is Required for Effective Inherent Safety Reviews 24310.5.3 Inherent Safety Review Timing 24410.5.4 Inherent Safety Review Team Composition 24610.5.5 Inherent Safety Review Process Overview 24610.5.6 Focus of Inherent Safety Reviews at Different Stages 25010.5.7 Stage in the Process Life Cycle 25210.6 Reactive Chemicals Screening 25610.7 Inherent Safety Review Training 25810.8 Documentation of the Inherently Safer Design Features of a Process 26010.8.1 IS Review Documentation 26110.8.2 Time Required for an Inherent Safety Review 26310.9 Summary 26410.10 References 26511. Inherent Safety & the Elements of a RBPS Program 26811.1 Process Safety Culture 27011.2 Compliance with Standards 27111.3 Workforce Involvement 27211.4 Process Knowledge Management 27211.5 Hazard Identification and Risk Analysis 27311.6 Safe Work Practices 28011.7 Asset Integrity and Reliability 28211.8 Contractor Management 28411.9 Training and Performance Assurance / Process Safety Competency 28511.10 Management of Change / Operational Readiness 28611.11 Conduct of Operations / Operating Procedures 29011.11.1 Minimization 29111.11.2 Simplification 29411.12 Emergency Management 29611.13 Incident Investigation 29711.14 Measurements and Metrics / Auditing / Management Review and Continuous Improvement 29711.15 Summary 29911.16 References 29912. Tools for IS Implementation 30212.1 IS Review Methods - Overview 30212.1.1 Three Approaches 30212.1.2 Formal IS Reviews 30312.1.3 IS Review Methods 30412.1.4 Research & Development Application 30412.1.5 PHA - Incorporation into HAZOP or other PHA Techniques 30512.1.6 "What-If?" Method 30712.1.7 Checklist Method 30812.1.8 Consequence-Based Methods 31112.1.9 Other Methods 31212.2 Summary 31712.3 References 31813. Inherently Safer Design Conflicts 32013.1 Introduction 32013.2 Examples of inherent safety conflicts 32413.2.1 Continuous vs. batch reactor 32413.2.2 Reduced toxicity vs. reactive hazard 32713.2.3 Reduced inventory vs. dynamic stability 32813.2.4 Risk transfer vs. risk reduction 32913.2.5 Inherent safety and security conflicts 33113.3 Inherent safety - Environmental Hazards 33213.3.1 PCBs 33213.3.2 CFCs 33213.4 Inherent Safety and Health Conflicts 33313.4.1 Water Disinfection 33313.5 Inherent safety and economic conflicts 33413.5.1 Existing plants - operational vs. re-investment economics in a capital-intensive industry 33413.5.2 Often more economical, but not necessarily 33613.6 Tools for understanding and resolving conflicts 33713.6.1 Tools for understanding and resolving conflicts 33913.7 Measuring inherent safety characteristics 34313.7.1 Dow Fire and Explosion Index 34413.7.2 Dow Chemical Exposure Index 34413.7.3 Mond Index 34413.7.4 Proposed Inherent Safety indices 34513.8 Summary 34613.9 References 34714. Inherent Safety Regulatory Initiatives 35014.1 Inherent Safety Regulatory Developments and Issues 35014.2 Experience with Inherent Safety Provisions in United States Regulations 35114.2.1 Inherently Safer Regulatory Requirements - Contra Costa County, California, USA 35214.2.2 New Jersey Toxic Catastrophe Prevention Act (TCPA) and Prescriptive Order for Chemical Plant Security 37014.2.3 Inherently Safer Systems Requirements - California Accidental Release Prevention (CalARP) Regulations 37814.2.4 Safer Technology & Alternatives Analysis - Revised US EPA Risk Management Program (RMP) Rule 38014.3 Issues in Regulating Inherent Safety 38214.3.1 Consistent Understanding of Inherent Safety 38314.3.2 Needed Tools 38414.4 Summary 38514.5 References 38615. Worked Examples and Case Studies 38815.1 Introduction 38815.2 Application of an Inherent Safety Strategic Approach to a Process 38815.3 Case studies from carrithers 39415.3.1 An Exothermic Batch Reaction 39515.3.2 Refrigeration of Monomethylamine 39815.3.3 Elimination of a Chlorine Water Treatment System 39915.3.4 Reduction of Chlorine Transfer Line Size 40015.3.5 Substitution of Aqueous Ammonia for Anhydrous Ammonia 40015.3.6 Limitation of Magnitude of Deviations for Aqueous Ammonia 40315.3.7 A Vessel Entry Example 40815.4 Process Route Selection - Early R&D Example 41115.5 Example of an Inherently Safer Study of a Steam Production Facility 41215.5.1 Facility Description 41215.5.2 Initial Design Proposal (Liquid Anhydrous Ammonia) 41215.5.3 Aqueous Ammonia Design Proposal 41315.5.4 Final Round of Option Selection 41515.5.5 Consequence Analysis 41615.5.6 Conclusion and Action 41715.5.7 Conclusion 41915.6 Case Study: Bhopal 41915.6.1 Minimization 42015.6.2 Substitution 42015.6.3 Moderation 42015.6.4 Simplification 42115.7 Example: Inherently Safer Process for Production of Trialkyl Phosphate Esters 42115.8 Summaries in brief: Examples by IS Strategy 42215.8.1 Minimize 42315.8.2 Substitute 42515.8.3 Moderate 42715.8.4 Simplify 42915.9 Additional literature giving examples of inherently Safer Operations 43015.10 References 43116. Future Initiatives 43316.1 Incorporating Inherently Safer Design into Process Safety Management 43316.2 Encouraging Invention within the Chemical and Chemical Engineering Community 43416.3 Including Inherent Safety into the Education of Chemists and Chemical Engineers 43416.4 Developing Inherently Safer Design Databases and Libraries 43416.5 Developing Tools to Apply Inherently Safer Design 43516.5.1 The Broad View and Life Cycle Cost of Alternatives 43516.5.2 Benefits of Reliability Analysis 43616.5.3 Potential Energy 43616.5.4 A Table of Distances and Consequence/Risk-Based Siting 43716.5.5 Quantitative Measures of Inherent Safety 43716.5.6 Other Suggestions 43816.6 References 439Appendix A. Inherently Safer Technology (IST) Checklist 442A.1 IST Checklist Procedure 442A.2 IST Checklist Questions 444Appendix B. Inherent Safety Analysis Approaches 455B.1 Inherent Safety Analysis - Guided Checklist Process Hazard Analysis (PHA) 459B.2 Inherent Safety Analysis - Independent Process Hazard Analysis (PHA) 464B.3 Inherent Safety Analysis - Integral to Process Hazard Analysis (PHA) 467Glossary 469Index 497

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The Center for Chemical Process Safety (CCPS) was founded in 1985 to develop technology and management practices that mitigate or eliminate process safety incidents in the chemical and petrochemical industries. Since that time, CCPS has published more than 100 books and held dozens of international conferences, each representing the most advanced thinking in process safety. CCPS is supported by the contributions and voluntary participation of more than 200 companies globally. CCPS is also the world's largest provider of undergraduate engineering curriculum materials through its SAChE program, with more than 160 universities participating from around the world.