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Recognizing Catastrophic Incident Warning Signs in the Process Industries

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ISBN-10: 047076774X

ISBN-13: 9780470767740

Edition: 2012

Authors: Center for Chemical Process Safety (CCPS) Staff

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Description:

This book provides guidance on characterizing, recognizing, and responding to warning signs to help avoid process incidents and injuries before they occur. The guidance can be used by both process safety management (PSM) professionals in evaluating their processes and PSM systems as well as for operators who are often the frontline defense against process incidents. Warning signs may consist of process deviations or upsets, instrumentation warnings or alarms, past operating history and incidents, observable problems such as corrosion or unusual odors, audit results indicating procedures are not being followed, or a number of other indicators. Filled with photos and practical tips, this book will turn anyone in a process plant into a hazard lookout and will help prevent potential incidents before they turn into catastrophic events.
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Book details

Copyright year: 2012
Publisher: John Wiley & Sons, Limited
Publication date: 1/24/2012
Binding: Hardcover
Pages: 264
Size: 6.50" wide x 9.75" long x 1.00" tall
Weight: 1.232

List of Tables
List of Figures
Files on the Web Accompanying This Book
Acknowledgements
Foreword
Preface
Introduction
Process safety management
Normalization of deviance
A strategy for response
Maintaining organizational memory and a healthy sense of vulnerability
Risk based process safety
Our target audience
How to use this book
Case study - Toxic gas release in India
Incident Mechanics
Incidents do not just happen
Incident models
Case study - Benzene plant explosion in China
Leadership and Culture
How does leadership affect culture?
The leadership and culture related warning signs
Case study - Challenger space shuttle explosion in the US
Training and Competency
What is effective training and how is competency measured?
The training and competency related warning signs
Case study - Gas plant vapor cloud explosion in Australia
Process Safety information
Critical information to identify hazards and manage risk
The process safety information related warning signs
Case study - Batch still fire and explosion in the UK
Procedures
Safe and consistent operation
The procedure related warning signs
Case study - Nuclear plant meltdown and explosion in the Ukraine
Asset Integrity
Systematic implementation
The asset integrity related warning signs
Case study - Refinery naphtha fire in the US
Analyzing Risk and Managing Change
Risk management
The risk analysis and management of change related warning signs
Case study - Cyclohexane explosion in the UK
Audits
Audits support operational excellence
The audit related warning signs
Case study - Chemical warehouse fire in the UK
Learning From Experience
Methods for continuous improvement
The learning from experience warning signs
Case study - Space shuttle Columbia incident in the US
Physical Warning Signs
The everyday things matter
The physical warning signs
Case study - Resin plant dust explosion in the US
A Call to Action
Actions you can take now for each warning sign
A simple plan to consider for rigorous implementation and follow-up
Actions to consider
Summary
Incident Warning Sign Self Assessment Tool
Composite List of Catastrophic Incident Warning Signs
References & Selected Regulations
Acronyms and Abbreviations
Glossary
Index