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Process Safety for Engineers Familiarizes an engineer new to process safety with the concept of process safety management In this significantly revised second edition of Process Safety for Engineers: An Introduction, CCPS delivers a comprehensive book showing how Process Safety concepts are used to reduce operational risks. Students, new engineers, and others new to process safety will benefit from this book. In this updated edition, each chapter begins with a detailed incident case study, provides steps that help address issues, and contains problem sets which can be assigned to students. The second edition covers: Process Safety: including an overview of CCPS’ Risk Based Process Safety Hazards: specifically fire and explosion, reactive chemical, and toxicity Design considerations for hazard control: including Hazard Identification and Risk Analysis Management of operational risk: including management of change In addition, the book presents how Process Safety performance is monitored and sustained. The associated online resources are linked to the latest online CCPS resources and lectures.

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While there are many resources available on fire protection and prevention in chemical petrochemical and petroleum plants—this is the first book that pulls them all together in one comprehensive resource. This book provides the tools to develop, implement, and integrate a fire protection program into a company or facility’s Risk Management System. This definitive volume is a must-read for loss prevention managers, site managers, project managers, engineers and EHS professionals. Note: CD-ROM/DVD and other supplementary materials are not included as part of eBook file.

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Prevention, preparedness, response and recovery--the key components of emergency planning--form the major sections of this work. The book first describes PSM (Process Safety Management) as the key to prevention, then goes on to consider the main features of a preparedness program, including recognizing credible incidents, planning practical strategy to deal with these incidents, selecting necessary physical support systems and equipment, and developing a complete emergency response plan. The Response section presents the functions implemented during an actual emergency and concludes with a section on managing cleanup and restoration of operations. The many tables and figures include Sample Incident Command System Plans for both large and small organizations, OSHA and EPA regulations affecting planning, sample Fire Emergency Action Levels, HAZMAT Responder Levels, and OSHA Emergency Training Requirements.

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This book puts together a body of very recent information never before presented in one volume on the design of post-release mitigation systems. The development of a fundamental knowledge base on post-release mitigation systems, through testing and data correlation, is very new. While further research and development is needed, this practical work offers guidance on putting post-release countermeasures to work now. The book presents current engineering methods for minimizing the consequences of the release of toxic vapors, or ignition of flammable vapors, including passive and active systems intended to reduce or eliminate significant acute effects of a dispersing vapor cloud in the plant facility, or into the surrounding community. As in all CCPS works, the book emphasizes planning and a systems approach, shows limitations of any methods discussed, and provides numerous references so that the reader may continue to learn.

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This CCPS Guideline book outlines current transportation risk analysis software programs and demonstrates several available risk assessment programs for land transport by rail, truck, and pipeline for consequences that may affect the public or the environment. Provides introductory transport risk considerations for process engineers Gives guidance on route selection, equipment factors and materials Describes transportation security risk issues and industry practices to mitigate them Includes loading and unloading checklists for several transport modes Develops specific operating procedures and checklists to reduce human error Discusses considerations for transportation security, including threat and vulnerability assessments and potential countermeasures Summarizes key transportation security regulations, guidelines and industry initiatives. Note: CD-ROM/DVD and other supplementary materials are not included as part of eBook file.

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The first part of this book (Chapters 1 and 2) provides an introduction and discusses basic concepts. Chapter 3 deals with the use of the basic human senses for identifying hazards. Chapter 4 deals with different classes and categories of hazards. Chapter 5 deals with techniques and methodologies for identifying and evaluating hazards. Chapter 6 deals with making risk based decisions. Chapter 7 deals with follow-up and call to action. Chapter 8 deals with learning and continuous improvement. The Appendices provide references, case studies, hazard presentations and additional pictures. Note: CD-ROM/DVD and other supplementary materials are not included as part of eBook file.

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The chemical process industry is a rich target for cyber attackers who are intent on causing harm. Current risk management techniques are based on the premise that events are initiated by a single failure and the succeeding sequence of events is predictable. A cyberattack on the Safety, Controls, Alarms, and Interlocks (SCAI) undermines this basic assumption. Each facility should have a Cybersecurity Policy, Implementation Plan and Threat Response Plan in place. The response plan should address how to bring the process to a safe state when controls and safety systems are compromised. The emergency response plan should be updated to reflect different actions that may be appropriate in a sabotage situation. IT professionals, even those working at chemical facilities are primarily focused on the risk to business systems. This book contains guidelines for companies on how to improve their process safety performance by applying Risk Based Process Safety (RBPS) concepts and techniques to the problem of cybersecurity.

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Complemented by an estimating tool spreadsheet based on a fixed set of chemicals to assist in risk estimations, Probability of Ignition of a Released Flammable Mass converts a "best guess" to a calculated value based on available information and current technology. The text documents and explains the science and background of the technology-based approach. The tool, when populated with appropriate data, yields an estimate of the probability that a defined release of a flammable material will ignite if exposed to an ignition source. This information can be used to make risk assessments with a higher degree of confidence than estimates made before and it provides valuable information for use in the development of a facility's Emergency Response Plan.

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This Guideline presents the framework of process safety knowledge and expertise versus the desired competency level in a "super-matrix" format, vertically and diagonally. The matrix references for potential remedies/required training may be tailored to a company's internally developed training, reference externally available training, or some combination of the two. Chapters include: Identify Process Safety Roles & Competency Needs; Process Safety Competency Matrix; Individual and Corporate Process Safety Competencies; Conduct Assessments vs. Needs; Develop Gap Closure Plans; and Sustaining Competencies.

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New perspectives on how to successfully drive changes in companies’ process safety management systems Simply learning from process safety incidents has proven to be insufficient to drive performance improvements. To truly change, organizations must seek out & embed learnings in their programs & systems. This book picks up from previous CCPS books, Incidents That Define Process Safety and Investigating Process Safety Incidents. This important book: Offers guidelines for improving process safety performance by embedding the lessons learned from publicly available investigations Recommends a continuous improvement learning model focused on organizational learning Provides examples for using the model’s techniques to drive ­continuous improvements Contains an index of more than 400 investigated incidents and introduces the concept of Drilldown to help find lessons that might not have been mentioned before. Written for safety professionals and process safety consultants, Driving Continuous Process Safety Improvement from Investigated Incidents is a hands-on guide for adopting a model for successfully driving the learnings from process safety incident investigations.

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GUIDELINES FOR REVALIDATING A PROCESS HAZARD ANALYSIS This book is derived from the experience of many companies in the chemical and hydrocarbon processing industries, and presents demonstrated, concise, and common sense approaches for a resource-effective revalidation of process hazard analyses (PHAs). It includes flowcharts, checklists, and worksheets that provide invaluable assistance to the revalidation process. The new edition, now as a guideline, provides a compete and thorough update of the first book and will provide much needed and requested guidance on PHA Revalidations including evaluating Prior PHA Studies, Identifying an Appropriate Revalidation Methodology, Preparing and Conducting the Revalidation Study Sessions, and Documenting the Revalidation Study.

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Human Factors Handbook for Process Plant Operations Provides clear and simple instructions for integrating Human Factors principles and practices in the design of processes and work tasks Human Factors, the science of interaction between humans and other elements of a system, draws from disciplines such as psychology, ergonomics, anthropometrics, and physiology to understand how and why people behave and perform as they do—and how best to support them in performing tasks. The goals of the Human Factors approach are to improve human reliability, minimize the risk from human error, and optimize the working environment, human wellbeing, and overall system performance. Human Factors Handbook for Process Plant Operations guides supervisors, managers, and engineers on incorporating Human Factors principles and practices into plant maintenance and operations. With thorough and accessible coverage of all Human Factors topics of relevance to process industries, this easy-to-use handbook uses real-world anecdotes and case studies to demonstrate effective training and learning, task planning, communications, emergency response, risk and error management, and more. Throughout the text, the authors offer valuable insights into why people make mistakes while providing advice on how to help workers perform their process operational tasks successfully. Explains all essential Human Factors concepts and knowledge with clear descriptions and illustrative examples Offers actionable advice and models of good practice that can be applied to design, process operations, start-ups and shut-downs, and maintenance Addresses job aids, equipment design, competence, task support, non-technical skills, working with contractors, and managing change Discusses how lack of Human Factors considerations during the engineering design phase can adversely affect safety and performance Describes how to use indicators to both recognize and learn from human error and performance issues Written by highly experienced operating and maintenance personnel, Human Factors Handbook for Process Plant Operations is an indispensable resource for everyone involved with defining, planning, training, and managing process operations, maintenance, and emergency response in the food, pharmaceutical, chemical, petroleum, and refining industries. The missions of both the CCPS and EI include developing and disseminating knowledge, skills and good practices to protect people, the environment, and property by bringing the best knowledge and practices to industry, academia, governments and the public around the world through collective wisdom, tools, training and expertise. The CCPS, an industrial technology alliance of the American Institute of Chemical Engineers (AIChE), has been at the forefront of documenting and sharing important process safety risk assessment methodologies for more than 35 years and has published over 100 books in its process safety guidelines and process safety concept book series. The EI’s Technical Work Program addresses the depth and breadth of the energy sector from fuels and fuels distribution to health and safety, sustainability and the environment. The EI program provides cost-effective, value-adding knowledge on key current and future international issues affecting those in the energy sector.

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The book makes the case for process safety and provides a brief overviews of the upstream industry and of CCPS Risk Based Process Safety. The majority of the book focuses on the concepts of implementing process safety in wells, onshore, offshore, and projects. Topics include Overview of Upstream Operations; Overview of Risk Based Process Safety (RBPS); Application of RBPS in Drilling, Completions, Work-Overs & Interventions, Application of RBPS in Onshore Production, Application of RBPS in Offshore Production, Application of RBPS to Engineering Design, Installation, and Construction, Future Developments in the Field

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Since the publication of the second edition several United States jurisdictions have mandated consideration of inherently safer design for certain facilities. Notable examples are the inherently safer technology (IST) review requirement in the New Jersey Toxic Chemical Prevention Act (TCPA), and the Inherently Safer Systems Analysis (ISSA) required by the Contra Costa County (California) Industrial Safety Ordinance. More recently, similar requirements have been proposed at the U.S. Federal level in the pending EPA Risk Management Plan (RMP) revisions. Since the concept of inherently safer design applies globally, with its origins in the United Kingdom, the book will apply globally. The new edition builds on the same philosophy as the first two editions, but further clarifies the concept with recent research, practitioner observations, added examples and industry methods, and discussions of security and regulatory issues. Inherently Safer Chemical Processes presents a holistic approach to making the development, manufacture, and use of chemicals safer. The main goal of this book is to help guide the future state of chemical process evolution by illustrating and emphasizing the merits of integrating inherently safer design process-related research, development, and design into a comprehensive process that balances safety, capital, and environmental concerns throughout the life cycle of the process. It discusses strategies of how to: substitute more benign chemicals at the development stage, minimize risk in the transportation of chemicals, use safer processing methods at the manufacturing stage, and decommission a manufacturing plant so that what is left behind does not endanger the public or environment.

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Prevent operational incidents and reduce risks with an essential CCPS guide You can help your company reduce its operating risks by learning how to effectively manage transient operations and avoid major incidents. Startups and shutdowns, known as transient operations, can be high-risk periods for manufacturing facilities. Guidelines for Process Safety During Transient Operations offers useful guidance in preparing for the safe startup and shutdown of chemical processes. With an understanding of the risks involved, you can work proactively to prevent fatalities, serious injuries, reduced productivity, and costly damage. This essential guide for plants provides clear examples of how to anticipate and avoid major issues. The book examines safe shutdown procedures in the event of an emergency. You will also gain direction on how to resume operations safely after an unexpected shutdown. The book supports anyone tasked with regulating and overseeing chemical plants and procedures, whether you are an engineer, manager, or government professional. Minimize operating risks through the effective management of transient operations Establish safe start-up and shutdown procedures for chemical processes Be ready to safely shut down processes in the event of an emergency Learn from real world examples of start-up or shutdown incidents Review procedures and engineering controls that help prevent or reduce the effects of incidents involving transient operations Guidelines for Process Safety comes to you from The Center for Chemical Process Safety (CCPS), which offers advanced thinking in the critical area of process safety. The organization develops technology and management practices for companies seeking to reduce hazards within the chemical and petrochemical industries.

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This book provides a comprehensive treatment of investing chemical processing incidents. It presents on-the-job information, techniques, and examples that support successful investigations. Issues related to identification and classification of incidents (including near misses), notifications and initial response, assignment of an investigation team, preservation and control of an incident scene, collecting and documenting evidence, interviewing witnesses, determining what happened, identifying root causes, developing recommendations, effectively implementing recommendation, communicating investigation findings, and improving the investigation process are addressed in the third edition. While the focus of the book is investigating process safety incidents the methodologies, tools, and techniques described can also be applied when investigating other types of events such as reliability, quality, occupational health, and safety incidents.

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An essential guide for recognizing and responding to normalization of deviance to help organizations improve their process safety performance This book provides an introduction and offers approaches for finding and addressing normalization of deviation both in operational and organizational activities. It addresses the initial and long-term effects of normalization of deviations as seen in reduced efficiencies, reduced product quality, extended batch run time, and near miss process safety incidents which can lead to loss of containment of hazardous materials and energies. Recognizing and Responding to Normalization of Deviance addresses how to recognize and respond to the normalization of deviation that can, and almost certainly will, occur in any ongoing operations that involves humans. The book’s primary focus is on reducing the incidence of normalization of deviation and the associated increased risk exposure due to its effects when operating chemical or petrochemical manufacturing facilities. It contains an introduction to the concept and offers approaches for finding and addressing normalization of deviation when it presents itself in both operational and organizational activities. Contains guidance to assist facilities in recognizing and addressing the phenomenon of normalization of deviation Provides techniques for addressing normalized deviations and techniques to eliminate waste in all manufacturing processes Describes methods for identifying normalized deviation as well as where to find deviations Includes techniques to reduce operational normalization of deviance and to reduce organizational normalization of deviance Aimed at process safety professionals and consultants applying process safety risk reduction efforts in manufacturing areas, Recognizing and Responding to Normalization of Deviance is an important book for any organization that has seen its process safety performance deteriorate over time.

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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.

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Over 40 papers and posters that share the latest practices in emergency planning related to fixed chemical, pharmaceutical, LNG, and petroleum facilities, storage facilities, transportation, and security.

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Powders and bulk solids, handled widely in the chemical, pharmaceutical, agriculture, smelting, and other industries present unique fire, explosion, and toxicity hazards. Indeed, substances which are practically inert in consolidated form may become quite hazardous when converted to powders and granules. The U.S. Chemical Safety and Hazard Investigation Board is currently investigating dust explosions that occured in 2003 at WestPharma, CTA Acoustics, and Hayes-Lemmerz, and is likely to recommend that companies that handle powders or whose operations produce dust pay more attention to understanding the hazards that may exist at their facility. This new CCPS guidelines book will discuss the types of hazards that can occur in a wide range of process equipment and with a wide range of substances, and will present measures to address these hazards.

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Chemical process quantitative risk analysis (CPQRA) as applied to the CPI was first fully described in the first edition of this CCPS Guidelines book. This second edition is packed with information reflecting advances in this evolving methodology, and includes worked examples on a CD-ROM. CPQRA is used to identify incident scenarios and evaluate their risk by defining the probability of failure, the various consequences and the potential impact of those consequences. It is an invaluable methodology to evaluate these when qualitative analysis cannot provide adequate understanding and when more information is needed for risk management. This technique provides a means to evaluate acute hazards and alternative risk reduction strategies, and identify areas for cost-effective risk reduction. There are no simple answers when complex issues are concerned, but CPQRA2 offers a cogent, well-illustrated guide to applying these risk-analysis techniques, particularly to risk control studies. Special Details: Includes CD-ROM with example problems worked using Excel and Quattro Pro. For use with Windows 95, 98, and NT.

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Over the years, companies have developed independent systems for managing process safety, environment, health, safety, and quality. Many aspects of these management systems are similar. Integrating EHS management systems can yield economies and improved system effectiveness. This book explains how integration reduces cost of delivery through a reduction in the number of management program steps and avoidance of redundancy; how it results in more effective programs, since the best practices can be combined into a single process; and how this integration brings a faster, and more cost effective response to new demands.

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A comprehensive understanding of the potential dangers inherent in warehousing chemicals is the first step in managing the associated risks. Written by industry professionals for warehouse operators, designers, and all who are concerned with the safe warehousing of chemicals, this book offers a performance-based approach to such hazards as health effects, environmental pollution, fire, and explosion, and presents practical means to minimize the risk of these hazards to employees, the surrounding population, the environment, property, and business operations. These basic precepts can be used to evaluate the risks in initial or existing designs for warehousing facilities on a manufacturing site, for freestanding offsite buildings, and for strictly chemical or mixed-use storage. Each of the book’s ten chapters has a list of references and suggestions for further reading. The numerous topics covered make this book invaluable for warehousing designers and operators.

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At last, a book that covers safety procedures and standards with information that is rarely available outside of proprietary materials. A comprehensive source for basic and essential operations and procedures in use in any facility, the book offers chemical operators and first line supervisors guidance in applying appropriate practices to prevent accidents, and suggests which practices to avoid.

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Guidelines for Hazard Evaluation Procedures, 3rd Edition keeps process engineers updated on the effective methodologies that process safety demands. Almost 200 pages of worked examples are included to facilitate understanding. References for further reading, along with charts and diagrams that reflect the latest views and information, make this a completely accessible work. The revised and updated edition includes information not included in previous editions giving a comprehensive overview of this topic area.

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This 39-year compilation of two leading process safety conferences presents in one convenient and easy-to-search resource over 2000 of the best papers on the subject. Using this product, users can access information across the full spectrum of chemical and petroleum process safety topics, as well as learn the historic basis for the most important process safety guidelines. Hundreds of case histories provide a deeper insight into what can go wrong. The Folio interface enables deep searching, annotation, bookmarking, and other powerful tools. The CCPS International Conference, held annually since 1986, focuses each year on one specific area of process safety and explores that area in depth with an international perspective. A rigorous paper selection process is used, in which fewer than half of all proposals are accepted for publication. Speakers and attendees from outside the US make up a large percentage of participation, providing a broad range of perspectives. Now in its 20th year, the CCPS conference has addressed all areas of process safety in depth several times, with extensive case histories. The AIChE Loss Prevention Symposium, held annually since 1967, brings together invited, peer reviewed papers covering a broad range of the process safety and loss prevention fields each year. The proceedings of the Loss Prevention Symposium are a rare and valuable source of the early history of process safety.

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Providing in-depth guidance on how to design and rate emergency pressure relief systems, Guidelines for Pressure Relief and Effluent Handling Systems incorporates the current best designs from the Design Institute for Emergency Relief Systems as well as American Petroleum Institute (API) standards. Presenting a methodology that helps properly size all the components in a pressure relief system, the book includes software with the CCFlow suite of design tools and the new Superchems for DIERS Lite software, making this an essential resource for engineers designing chemical plants, refineries, and similar facilities.Access to Software Access the Guidelines for Pressure Relief and Effluent Handling Software and documents using a web browser at: http://www.aiche.org/ccps/PRTools Each folder will have a readme file and installation instructions for the program. After downloading SuperChems™ for DIERS Lite the purchaser of this book must contact the AIChE Customer Service with the numeric code supplied within the book. The purchaser will then be supplied with a license code to be able to install and run SuperChems™ for DIERS Lite. Only one license per purchaser will be issued.

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This book discusses the fundamental skills, techniques, and tools of auditing, and the characteristics of a good process safety management system. A variety of approaches are given so the reader can select the best methodology for a given audit. This book updates the original CCPS Auditing Guideline project since the implementation of OSHA PSM regulation, and is accompanied by an online download featuring checklists for both the audit program and the audit itself. This package offers a vital resource for process safety and process development personnel, as well as related professionals like insurers.

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It is crucial for process safety professionals to be aware of best practices for post merger integration at any level. A compilation of industry best practices from both technical and financial perspectives, this book provides a single reference that addresses acquisitions and merger integration issues related to process safety. Presently, there are limited references on how to handle acquisitions in several different CCPS publications and almost no coverage of the post-merger integration issue, so this reference fills a notable gap in the coverage.

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Layer of protection analysis (LOPA) is a recently developed, simplified method of risk assessment that provides the much-needed middle ground between a qualitative process hazard analysis and a traditional, expensive quantitative risk analysis. Beginning with an identified accident scenario, LOPA uses simplifying rules to evaluate initiating event frequency, independent layers of protection, and consequences to provide an order-of-magnitude estimate of risk. LOPA has also proven an excellent approach for determining the safety integrity level necessary for an instrumented safety system, an approach endorsed in instrument standards, such as ISA S84 and IEC 61511. Written by industry experts in LOPA, this pioneering book provides all the necessary information to undertake and complete a Layer of Protection Analysis during any stage in a processes' life cycle. Loaded with tables, charts, and examples, this book is invaluable to technical experts involved with ensuring the safety of a process. Because of its simplified, quicker risk assessment approach, LOPA is destined to become a widely used technique. Join other major companies and start your LOPA efforts now by purchasing this book.

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The book is a guide for Layers of Protection Analysis (LOPA) practitioners. It explains the onion skin model and in particular, how it relates to the use of LOPA and the need for non-safety instrumented independent protection layers. It provides specific guidance on Independent Protection Layers (IPLs) that are not Safety Instrumented Systems (SIS). Using the LOPA methodology, companies typically take credit for risk reductions accomplished through non-SIS alternatives; i.e. administrative procedures, equipment design, etc. It addresses issues such as how to ensure the effectiveness and maintain reliability for administrative controls or “inherently safer, passive” concepts. This book will address how the fields of Human Reliability Analysis, Fault Tree Analysis, Inherent Safety, Audits and Assessments, Maintenance, and Emergency Response relate to LOPA and SIS. The book will separate IPL’s into categories such as the following: Inherent Safety eliminates a scenario or fundamentally reduces a hazard Preventive/Proactive prevents initiating event from occurring such as enhanced maintenance Preventive/Active stops chain of events after initiating event occurs but before an incident has occurred such as high level in a tank shutting off the pump. Mitigation (active or passive) minimizes impact once an incident has occurred such as closing block valves once LEL is detected in the dike (active) or the dike preventing contamination of groundwater (passive).

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The definitive leadership guide on safe practices The release of chemicals and other hazardous materials pose significant, potentially catastrophic threats worldwide. An alarming number of such events, all of which are preventable, occur too often. Reducing the frequency of serious incidents is a fundamental responsibility of leadership at all levels, from frontline managers and supervisors to C-suite executives and the board of directors as well. Process Safety Leadership from the Boardroom to the Frontline is a practical, authoritative guide that clearly demonstrates how to create a viable culture of safety within an organization, implement and maintain disciplined management systems, and address the risks of process safety deficiencies. The most important factor in any management system is leadership. For chemical process safety management, effective and informed leadership provides direction, reinforces commitment, and drives responsibility. Written by experts from the Center for Chemical Process Safety, the world's largest provider of engineering curriculum materials for process safety, this pragmatic book contains the critical information and guidelines required to lead and manage process safety. Detailed yet accessible chapters examine topics such as strengthening management system accountability, driving operation within constraints, ensuring corporate memory, verifying execution, and more. Designed to be frequently used, shared, and discussed by leadership teams throughout an organization, this indispensable resource: Demonstrates the many ways process safety benefits an organization, based on benchmarking and broad industrial experience Develops skills and expands knowledge needed to drive consistent, reliable process safety performance Describes essential behaviors and actions for leaders to drive excellence in process safety cultures and disciplined management systems Helps establish risk criteria and safeguards for companies Presents new and previously unpublished experiences, approaches, and thinking Written for executives, plant leaders, functional managers, frontline supervisors and also individual contributors, Process Safety Leadership from the Boardroom to the Frontline provides a much-needed guide for instituting safe practices within a company. The Center for Chemical Process Safety (CCPS) has been the world leader in developing and disseminating information on process safety management and technology since 1985. The CCPS, an industry technology alliance of the American Institute of Chemical Engineers (AIChE), has published over 100 books in its process safety guidelines and process safety concepts series, and over 10 training modules through its Safety in Chemical Engineering Education (SAChE) series.

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AN AUTHORITATIVE GUIDE THAT EXPLAINS THE EFFECTIVENESS AND IMPLEMENTATION OF BOW TIE ANALYSIS, A QUALITATIVE RISK ASSESSMENT AND BARRIER MANAGEMENT METHODOLOGY From a collaborative effort of the Center for Chemical Process Safety (CCPS) and the Energy Institute (EI) comes an invaluable book that puts the focus on a specific qualitative risk management methodology – bow tie barrier analysis. The book contains practical advice for conducting an effective bow tie analysis and offers guidance for creating bow tie diagrams for process safety and risk management. Bow Ties in Risk Management clearly shows how bow tie analysis and diagrams fit into an overall process safety and risk management framework. Implementing the methods outlined in this book will improve the quality of bow tie analysis and bow tie diagrams across an organization and the industry. This important guide: Explains the proven concept of bow tie barrier analysis for the preventing and mitigation of incident pathways, especially related to major accidents Shows how to avoid common pitfalls and is filled with real-world examples Explains the practical application of the bow tie method throughout an organization Reveals how to treat human and organizational factors in a sound and practical manner Includes additional material available online Although this book is written primarily for anyone involved with or responsible for managing process safety risks, this book is applicable to anyone using bow tie risk management practices in other safety and environmental or Enterprise Risk Management applications. It is designed for a wide audience, from beginners with little to no background in barrier management, to experienced professionals who may already be familiar with bow ties, their elements, the methodology, and their relation to risk management. The missions of both the CCPS and EI include developing and disseminating knowledge, skills, and good practices to protect people, property and the environment by bringing the best knowledge and practices to industry, academia, governments and the public around the world through collective wisdom, tools, training and expertise. The CCPS has been at the forefront of documenting and sharing important process safety risk assessment methodologies for more than 30 years. The EI's Technical Work Program addresses the depth and breadth of the energy sector, from fuels and fuels distribution to health and safety, sustainability and the environment. The EI program provides cost-effective, value-adding knowledge on key current and future international issues affecting those in the energy sector.

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In today’s competitive economy, companies often augment in-house production by outsourcing chemical reaction processes and distillation, drying, formulating, blending, and packaging operations. While most of these tolling, or contracted manufacturing services, proceed without incident, recent major accidents have pointed to weaknesses in some tolling arrangements, such as reactivity of materials and processes. This Guidelines book provides the reader with proven procedures to improve process safety throughout the life cycle of a contracted manufacturing operation. Extensive checklists and examples used throughout the book make it a valuable learning tool and reference for companies conducting toll manufacturing, or considering outsourcing manufacturing operations.

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Written by reliability data experts, the book gives plant managers and supervisors the guidance they need to collect, and use with confidence, process equipment reliability data for risk-based decisions. Focusing on the process industries, it provides the protocol and techniques to collect and organize high quality plant performance, maintenance, and repair data from your own operations, and includes methods and examples on how the data can be converted into useful information for engineering, maintenance, safety, and loss prevention. This data can be used for: facility reliability/availability assessments; making decisions on the need for redundant systems; improving equipment designs; selecting the best equipment for specific tasks; estimating required work force; benchmarking current efforts both frequency and time; integrating predictive and preventive maintenance effort; integrating shutdowns with production needs; quantifying risks; and minimizing human reliability issues.

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First-line managers have to maintain the integrity of facilities, control manufacturing processes, and handle unusual or emergency situations, as well as respond to the pressures of production demand. On a daily basis, they are closest to the operating personnel who may be injured by a process accident, and they are in the best position to spot problem conditions and to act to contain them. This book offers these managers "how-to" information on process safety management program execution in the operations and maintenance departments, recommending technical and administrative process safety activities for the entire life cycle of the plant. Helpful tables and references add to the value of this process safety resource.

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The complexity of today's risk decisions is well known. Beyond cost and risk there are many other factors contributing to these decisions, including type of risk (such as human injury or fatality), the economic impact on the local community, profitability, availability of capital, alternatives for reducing or eliminating the risk, costs of implementing alternatives, codes, standards, regulation, and good industry practice. This book presents a large range of decision aids for risk analysts and decision makers in industry so that vital decisions can be made in a more consistent, logical, and rigorous manner. Though primarily aimed at the process industry, this book can be used by anyone who makes similar decisions in other industries, including those in management science.

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The book supplements Guidelines for Chemical Process Quantitative Risk Analysis by providing the failure rate data needed to perform a chemical process quantitative risk analysis.

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Process vent header collection systems are subject to continually varying compositions and flow rates and thus present significant challenges for safe design. Due to increasingly demanding safety, health, environmental, and property protection requirements, today's industrial designers are faced with the need to create increasingly complex systems for more effective treatment, dispersal, or disposal of process gases. Safe Design and Operation of Process Vents and Emission Control Systems provides cutting-edgeguidance for the design, evaluation, and operation of these systems, with emphasis on: Preventing fires, explosions, and toxic releases Maintaining safe vent conditions Understanding normal process operations, such as intentional routine controlled venting and emergency operations, like overpressure relief Mitigating the impacts of end-of-line treatment devices, such as scrubbers, flares, and thermal oxidizers, on the vent header system Complying with regulations Written by a team of process safety experts from the chemical, pharmaceutical, and petroleum industries, the book includes a wealth of real-world examples and a thorough overview of the tools and methods used in the profession.

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This updated version of one of the most popular and widely used CCPS books provides plant design engineers, facility operators, and safety professionals with key information on selected topics of interest. The book focuses on process safety issues in the design of chemical, petrochemical, and hydrocarbon processing facilities. It discusses how to select designs that can prevent or mitigate the release of flammable or toxic materials, which could lead to a fire, explosion, or environmental damage. Key areas to be enhanced in the new edition include inherently safer design, specifically concepts for design of inherently safer unit operations and Safety Instrumented Systems and Layer of Protection Analysis. This book also provides an extensive bibliography to related publications and topic-specific information, as well as key information on failure modes and potential design solutions.

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Incidents That Define Process Safety describes approximately fifty incidents that have had a significant impact on the chemical and refining industries' approaches to modern process safety. Events are described in detail so readers get a fundamental understanding of the root causes, the consequences, the lessons learned, and actions that can prevent a recurrence. There are exhaustive investigative reports about these events, allowing you to apply the resulting safety principles to their current operations.

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The Chemical Reactivity Hazards Training CD is a self-paced teaching tool intended to teach people how to recognize and manage reactive chemical hazards. It provides an introduction to the topic and many online links to additional resources. The CD has three main objectives: to introduce reactive chemical hazard recognition, including hazards that can be present in facilities which do not "intentionally" practice chemistry; to provide an overview of tools for identifying reactive chemical hazards; and to Introduce chemical reactivity hazard management tools and techniques. The CD contains approximately 100 instructional screens with extensive links, graphics, videos, and supplemental slides. It can be used either as a self-paced tutorial or as an aid in lecture presentations. The CD shows how uncontrolled chemical reactions in industry can lead to serious harm and introduces key concepts for avoiding unintended reactions. The module concludes with a ten-question information quiz. An extensive glossary and bibliography are directly accessible from any page within the product.

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There is much industry guidance on implementing engineering projects and a similar amount of guidance on Process Safety Management (PSM). However, there is a gap in transferring the key deliverables from the engineering group to the operations group, where PSM is implemented. This book provides the engineering and process safety deliverables for each project phase along with the impacts to the project budget, timeline and the safety and operability of the delivered equipment.

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This book provides designers and operators of chemical process facilities with a general philosophy and approach to safe automation, including independent layers of safety. An expanded edition, this book includes a revision of original concepts as well as chapters that address new topics such as use of wireless automation and Safety Instrumented Systems. This book also provides an extensive bibliography to related publications and topic-specific information.

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