Guidelines for Process Safety in Chemical Laboratories and Pilot Plants

ISBN-13: 9781119010135 / Angielski / Twarda / 2023 / 400 str.

CCPS (Center for Chemical Process Safety)

Opis

This book provides guidance on -what- can be done from a management systems perspective to identify hazards and manage risks of -loss of containment- events in chemical laboratories and pilot plants. It provides examples of -how to- implement such practices and descriptions of a range of typically encountered process safety hazards typical controls based on current best practices.

Spis treści

List of Figures xList of Tables xiAbbreviations and Acronyms xiiGlossary xvAcknowledgments xxiiDedication xxivOnline Materials Accompanying this Handbook xxvPreface xxviiPart 1 - Introduction and Overview 11 Purpose and Scope 31.1 Purpose 31.2 Scope of Book and Target Audience 41.3 Terms for Laboratories and Pilot Plants 51.4 Distinctions between Laboratories and Pilot Plants 71.5 Organization of This Handbook 82 Managing Risk to Prevent Incidents 132.1 Some LAPP Characteristics 132.2 Safety in Laboratories and Pilot Plants 242.3 Where to Start with a Risk-based Approach in the LAPP 252.4 Gain Leadership Support to Implement Risk Based Process Safety 292.5 Laboratory Safety Management System Considerations 292.6 Resources for Risk Based Process Safety Management System 313 Leaks and Spills in the LAPP 353.1 Leaks of Hazardous Materials 353.2 Spills of Hazardous Materials 38Part 2 - Committing to Process Safety 394 LAPP Risk Management Concepts 414.1 Occupational Safety and Process Safety 414.2 Hierarchy of Controls 414.3 Inherently Safer Design (ISD) 424.4 Basic Risk Concepts 444.5 A Risk Management Program 474.6 Anatomy of an Incident 484.7 Preventive and Mitigative Safeguards 494.8 Applying a Risk-Based Approach in a LAPP 515 Process Safety Culture in the LAPP 555.1 RBPS Element 1: Process Safety Culture 555.2 Leaders' Responsibilities for Positive Safety Culture 585.3 Resources and Examples for Process Safety Culture 596 Standards for the LAPP 636.1 RBPS Element 2: Compliance with Standards 636.2 Risk Management Focus 656.3 Different Codes and Standards When Scaling Up from Laboratory to Pilot Plant 656.4 Jurisdictional Requirements 676.5 Resources for Compliance with Standards 677 Process Safety Competency and Training in the LAPP 697.1 RBPS Element 3: Process Safety Competency 697.2 RBPS Element 12: Training and Performance Assurance 728 Workforce Involvement and Stakeholder Outreach in the LAPP 798.1 RBPS Element 4: Workforce Involvement 798.2 RBPS Element 5: Stakeholder Outreach 82Part 3 - Understanding Hazards and Risks 839 Process Safety Knowledge Management in the LAPP 859.1 RBPS Element 6: Process Knowledge Management 859.2 Overview of Information and Data Needs 869.3 Sources of Information and Data 899.4 Process Safety Information during Scale-up 9210 Types of Hazards 9510.1 Reactive Chemistry Hazards 9510.2 Toxicity Hazards 11510.3 Flammability and Combustibility Hazards 12110.4 Temperature Hazards 13710.5 Overpressure Hazards 14010.6 Other Common LAPP Hazards 142Table of Contents vii ix11 Hazard Identification and Risk Analysis (HIRA) in the LAPP 15311.1 RBPS Element 7: Hazard Identification and Risk Analysis 15311.2 HIRA Team Members 15611.3 HIRA Approaches Used in LAPPs 15611.4 Qualitative versus Quantitative Analysis of Risks in LAPPs 16511.5 ACS Hazard Analysis Tools 16811.6 Evaluating the Effort Level for HIRAs 16811.7 Determining the Extent of the HIRAs 169Part 4 - Managing Risk: Engineered Controls 17112 Spill and Leak Protection 17312.1 Containment 17312.2 Flexible hose and tubing 17313 Fire and Over-Temperature Protection 17513.1 Fire Prevention 17513.2 Fire Mitigation 18313.3 Over-Temperature Protection 18514 Overpressure Prevention and Protection 19114.1 Pressure Protection for Equipment 19114.2 Pressure and Vacuum Relief for Atmospheric Pressure Vessels 19614.3 Process Conditions/Situations to Consider in Pressure Relief Device Design 19714.4 Blast Containment Cells and Pressure Relief for Building Areas 19814.5 Venting Location and Downstream Treatment of Material Vented 20115 Ventilation Controls 20315.1 Ventilation Systems 20315.2 Laboratory Chemical Fume Hoods 20515.3 Pilot Plant Ventilation 20715.4 Permanent Total Enclosures for Containment in the LAPP 20716 Automated Shut-down Systems 20916.1 Selection and Design Based on Hazard Identification and Risk Analysis 20916.2 Basic Control Systems and Safety Shut-down Systems 20916.3 Independent Automated Safety Shut-down Systems 21016.4 Fail-Safe Design Considerations 21216.5 Important Design Features for Control Systems 21216.6 Control of Changes and Maintenance for Engineered Safeguards 21416.7 Additional References 21517 Engineered Controls for Common Hazards 21717.1 Cryogenic Fluids and Compressed Gases 21717.2 Cryogenic Fluids and Compressed Gas Cylinders 21817.3 Glass Equipment 22817.4 Gloveboxes 228Part 5 - Managing Risk: Administrative Controls 23518 Administrative Fire and Explosion Safeguards 23718.1 Standards and Guidance for Fire Prevention 23718.2 Ignition Source Control: Procedures 23718.3 Manual Fire Suppression 23819 Administrative Safeguards for Hazards in LAPPs 23919.1 Good Practices for Compressed Gas and Cryogenic Cylinders 23919.2 Regulations and Standards for Compressed Gases and Cryogenic Fluids 23919.3 Procedures and Best Practices for Compressed Gases 24119.4 Good Practices for Storage, Movement, and Use of Cryogenic Fluids 24819.5 Good Practices For Handling Glass 25119.6 Administrative Controls for Reactive Hazards 251Part 6 - Managing Risk: RBPS Management Systems 25320 Operating Procedures and Conduct of Operations in the LAPP 25520.1 RBPS Element 8: LAPP Operating Procedures 25520.2 RBPS Element 15: Conduct of Operations 26021 Safe Work Practices and Contractor Management in the LAPP 26321.1 RBPS Element 9: Safe Work Practices 26321.2 RBPS Element 11: Contractor Management 26622 Asset Integrity and Reliability in the LAPP 26922.1 RBPS Element 10: Asset Integrity and Reliability 26922.2 A Management Approach for Assuring Asset Integrity and Reliability 27022.3 Examples of Asset Integrity and Reliability Management System Failures 27122.4 Glass Equipment--Asset Integrity and Reliability Challenge for LAPPs 27423 Management of Change (MOC) and Operational Readiness in the LAPP 27723.1 RBPS Element 13: Management of Change 27723.2 RBPS Element 14: Operational Readiness 281Table of Contents ix xi24 Emergency Management in the LAPP 28324.1 RBPS Element 16: Emergency Management 28324.2 Emergency Planning 28324.3 Implementing an Emergency Management Plan 28424.4 Emergency Equipment 28524.5 Training and Drills 28524.6 Deficiencies in Emergency Planning and Response in LAPP Cases 28624.7 Controlling Unattended Experimental Work and Working Alone in LAPPs 288Part 7 - Learning from Experience 29125 Investigating Incidents 29325.1 Incident Terminology 29325.2 RBPS Element 17: Incident Investigation 29425.3 Steps of an Incident Investigation 29525.4 Ensure Lessons Are Learned and Remembered 29825.5 Learn from Experience of Others 29826 Metrics, Auditing, and Management Review in the LAPP 29926.1 RBPS Element 18: Measurement and Metrics 29926.2 RBPS Element 19: Auditing 30026.3 RBPS Element 20: Management Review and Continuous Improvement 302Part 8 - Conclusion 305References 307Appendix A Cases 323Appendix B Examples 453Appendix C Control Banding Strategies 501Appendix D Glass Equipment Design 517Index 525

O autorze

The Center for Chemical Process Safety is a world leader in developing and distributing information on process safety management and technology. Since 1985, the organization has published over 100 books in its process safety guidelines and concepts series, as well as over one hundred courses and 33 training modules as part of its Safety in Chemical Engineering Education series.