An edition of Chemical Process Safety (1989)

Chemical process safety

fundamentals with applications

3rd ed.

by and

  • 6 Want to read
Cover of: Chemical process safety by Daniel A. Crowl, Joseph F. Louvar, Daniel A. Crowl
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Last edited by Drini
September 6, 2024 | History
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An edition of Chemical Process Safety (1989)

Chemical process safety

fundamentals with applications

3rd ed.

by and

  • 6 Want to read

This edition doesn't have a description yet. Can you add one?

Publish Date
Publisher
Prentice Hall
Language
English
Pages
752

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Previews available in: English

Subjects

Chemical plants, Safety measures, Industrial safety, Chemical processes, Chemical industry, safety measures

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Cover of: Chemical process safety
Chemical process safety: fundamentals with applications
2011, Prentice Hall
in English - 3rd ed.
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Cover of: Chemical Process Safety
Chemical Process Safety
May 14, 2011, Pearson Education India
paperback in English
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Book Details

Table of Contents

Preface
Page xv
About the Authors
Page xvii
On the Cover
Page xviii
Nomenclature
Page xix
1. Introduction
Page 1
1-1. Safety Programs
Page 2
1-2. Engineering Ethics
Page 4
1-3. Accident and Loss Statistics
Page 4
1-4. Acceptable Risk
Page 12
1-5. Public Perceptions
Page 14
1-6. The Nature of the Accident Process
Page 15
1-7. Inherent Safety
Page 20
1-8. Seven Significant Disasters
Page 23
Flixborough, England
Page 23
Bhopal, India
Page 25
Seveso, Italy
Page 26
Pasadena, Texas
Page 27
Texas City, Texas
Page 29
Jacksonville, Florida
Page 30
Port Wentworth, Georgia
Page 30
Suggested Reading
Page 31
Problems
Page 32
2. Toxicology
Page 37
2-1. How Toxicants Enter Biological Organisms
Page 38
Gastrointestinal Tract
Page 39
Skin
Page 39
Respiratory System
Page 40
2-2. How Toxicants Are Eliminated from Biological Organisms
Page 41
2-3. Effects of Toxicants on Biological Organisms
Page 42
2-4. Toxicological Studies
Page 43
2-5. Dose versus Response
Page 44
2-6. Models for Dose and Response Curves
Page 50
2-7. Relative Toxicity
Page 56
2-8. Threshold Limit Values
Page 56
2-9. National Fire Protection Association (NFPA) Diamond
Page 58
On-Line Resources
Page 59
Suggested Reading
Page 60
Problems
Page 60
3. Industrial Hygiene
Page 65
3-1. Government Regulations
Page 66
Laws and Regulations
Page 66
Creating a Law
Page 66
Creating a Regulation
Page 66
OSHA: Process Safety Management
Page 71
EPA: Risk Management Plan
Page 73
DHS: Chemical Facility Anti-Terrorism Standards (CFATS)
Page 76
3-2. Industrial Hygiene: Anticipation and Identification
Page 78
Material Safety Data Sheets
Page 81
3-3. Industrial Hygiene: Evaluation
Page 84
Evaluating Exposures to Volatile Toxicants by Monitoring
Page 84
Evaluating Worker Exposures to Dusts
Page 88
Evaluating Worker Exposures to Noise
Page 89
Estimating Worker Exposures to Toxic Vapors
Page 91
3-4. Industrial Hygiene: Control
Page 99
Respirators
Page 101
Ventilation
Page 103
On-Line Resources
Page 109
Suggested Reading
Page 109
Problems
Page 110
4. Source Models
Page 119
4-1. Introduction to Source Models
Page 119
4-2. Flow of Liquid through a Hole
Page 122
4-3. Flow of Liquid through a Hole in a Tank
Page 126
4-4. Flow of Liquids through Pipes
Page 131
2-K Method
Page 134
4-5. Flow of Gases or Vapors through Holes
Page 140
4-6. Flow of Gases or Vapors through Pipes
Page 146
4-7. Flashing Liquids
Page 163
4-8. Liquid Pool Evaporation or Boiling
Page 169
4-9. Realistic and Worst-Case Releases
Page 170
4-10. Conservative Analysis
Page 172
Suggested Reading
Page 173
Problems
Page 174
5. Toxic Release and Dispersion Models
Page 185
5-1. Parameters Affecting Dispersion
Page 186
5-2. Neutrally Buoyant Dispersion Models
Page 190
Case 1. Steady-State Continuous Point Release with No Wind
Page 194
Case 2. Puff with No Wind
Page 195
Case 3. Non-Steady-State Continuous Point Release with No Wind
Page 196
Case 4. Steady-State Continuous Point Source Release with Wind
Page 197
Case 5. Puff with No Wind and Eddy Diffusivity Is a Function of Direction
Page 197
Case 6. Steady-State Continuous Point Source Release with Wind and Eddy Diffusivity Is a Function of Direction
Page 198
Case 7. Puff with Wind
Page 198
Case 8. Puff with No Wind and with Source on Ground
Page 199
Case 9. Steady-State Plume with Source on Ground
Page 199
Case 10. Continuous Steady-State Source with Source at Height H, above the Ground
Page 200
Case 11. Puff with Instantaneous Point Source at Ground Level, Coordinates Fixed at Release Point, Constant Wind Only in x Direction with Constant Velocity u
Page 204
Case 12. Plume with Continuous Steady-State Source at Ground Level and Wind Moving in x Direction at Constant Velocity u
Page 205
Case 13. Plume with Continuous Steady-State Source at Height Hr above Ground Level and Wind Moving in x Direction at Constant Velocity u
Page 206
Case 14. Puff with Instantaneous Point Source at Height H, above Ground Level and a Coordinate System on the Ground That Moves with the Puff
Page 207
Case 15. Puff with Instantaneous Point Source at Height H, above Ground Level and a Coordinate System Fixed on the Ground at the Release Point
Page 208
Worst-Case Conditions
Page 208
Limitations to Pasquill-Gifford Dispersion Modeling
Page 208
5-3. Dense Gas Dispersion
Page 209
5-4. Dense Gas Transition to Neutrally Buoyant Gas
Page 219
Continuous Release Transition
Page 219
Continuous Release Downwind Concentration
Page 221
Instantaneous Release Transition
Page 221
Instantaneous Release Downwind Composition
Page 222
5-5. Toxic Effect Criteria
Page 225
5-6. Effect of Release Momentum and Buoyancy
Page 233
5-7. Release Mitigation
Page 234
Suggested Reading
Page 235
Problems
Page 236
6. Fires and Explosions
Page 245
6-1. The Fire Triangle
Page 245
6-2. Distinction between Fires and Explosions
Page 247
6-3. Definitions
Page 247
6-4. Flammability Characteristics of Liquids and Vapors
Page 249
Liquids
Page 250
Gases and Vapors
Page 253
Vapor Mixtures
Page 253
Flammability Limit Dependence on Temperature
Page 255
Flammability Limit Dependence on Pressure
Page 256
Estimating Flammability Limits
Page 256
6-5. Limiting Oxygen Concentration and Inerting
Page 260
6-6. Flammability Diagram
Page 262
6-7. Ignition Energy
Page 270
6-8. Autoignition
Page 270
6-9. Auto-Oxidation
Page 271
6-10. Adiabatic Compression
Page 272
6-11. Ignition Sources
Page 273
6-12. Sprays and Mists
Page 274
6-13. Explosions
Page 275
Detonation and Deflagration
Page 276
Confined Explosions
Page 277
Blast Damage Resulting from Overpressure
Page 287
TNT Equivalency
Page 291
TNO Multi-Energy Method
Page 293
Energy of Chemical Explosions
Page 296
Energy of Mechanical Explosions
Page 298
Missile Damage
Page 301
Blast Damage to People
Page 301
Vapor Cloud Explosions
Page 303
Boiling-Liquid Expanding-Vapor Explosions
Page 304
Suggested Reading
Page 304
Problems
Page 305
7. Concepts to Prevent Fires and Explosions
Page 317
7-1. Inerting
Page 318
Vacuum Purging
Page 318
Pressure Purging
Page 321
Combined Pressure-Vacuum Purging
Page 323
Vacuum and Pressure Purging with Impure Nitrogen
Page 323
Advantages and Disadvantages of the Various Pressure and Vacuum Inerting Procedures
Page 325
Sweep-Through Purging
Page 325
Siphon Purging
Page 327
Using the Flammability Diagram to Avoid Flammable Atmospheres
Page 327
7-2. Static Electricity
Page 333
Fundamentals of Static Charge
Page 333
Charge Accumulation
Page 334
Electrostatic Discharges
Page 335
Energy from Electrostatic Discharges
Page 337
Energy of Electrostatic Ignition Sources
Page 338
Streaming Current
Page 339
Electrostatic Voltage Drops
Page 342
Energy of Charged Capacitors
Page 342
Capacitance of a Body
Page 347
Balance of Charges
Page 350
7-3. Controlling Static Electricity
Page 356
General Design Methods to Prevent Electrostatic Ignitions
Page 357
Relaxation
Page 358
Bonding and Grounding
Page 358
Dip Pipes
Page 359
Increasing Conductivity with Additives
Page 362
Handling Solids without Flammable Vapors
Page 363
Handling Solids with Flammable Vapors
Page 363
7-4. Explosion-Proof Equipment and Instruments
Page 363
Explosion-Proof Housings
Page 365
Area and Material Classification
Page 365
Design of an XP Area
Page 366
7-5. Ventilation
Page 367
Open-Air Plants
Page 367
Plants Inside Buildings
Page 368
7-6. Sprinkler Systems
Page 370
7-7. Miscellaneous Concepts for Preventing Fires and Explosions
Page 374
Suggested Reading
Page 374
Problems
Page 375
8. Chemical Reactivity
Page 381
8-1. Background Understanding
Page 382
8-2. Commitment, Awareness, and Identification of Reactive Chemical Hazards
Page 384
8-3. Characterization of Reactive Chemical Hazards Using Calorimeters
Page 390
Introduction to Reactive Hazards Calorimetry
Page 391
Theoretical Analysis of Calorimeter Data
Page 397
Estimation of Parameters from Calorimeter Data
Page 408
Adjusting the Data for the Heat Capacity of the Sample Vessel
Page 412
Heat of Reaction Data from Calorimeter Data
Page 413
Using Pressure Data from the Calorimeter
Page 414
Application of Calorimeter Data
Page 415
8-4. Controlling Reactive Hazards
Page 416
Suggested Reading
Page 418
Problems
Page 418
9. Introduction to Reliefs
Page 429
9-1. Relief Concepts
Page 430
9-2. Definitions
Page 432
9-3. Location of Reliefs
Page 433
9-4. Relief Types and Characteristics
Page 436
Spring-Operated and Rupture Discs
Page 436
Buckling-Pin Reliefs
Page 440
Pilot-Operated Reliefs
Page 440
Chatter
Page 441
Advantages and Disadvantages of Various Reliefs
Page 442
9-5. Relief Scenarios
Page 443
9-6. Data for Sizing Reliefs
Page 444
9-7. Relief Systems
Page 444
Relief Installation Practices
Page 445
Relief Design Considerations
Page 447
Horizontal Knockout Drum
Page 448
Flares
Page 451
Scrubbers
Page 452
Condensers
Page 452
Suggested Reading
Page 452
Problems
Page 453
10. Relief Sizing
Page 459
10-1. Conventional Spring-Operated Reliefs in Liquid Service
Page 460
10-2. Conventional Spring-Operated Reliefs in Vapor or Gas Service
Page 466
10-3. Rupture Disc Reliefs in Liquid Service
Page 470
10-4. Rupture Disc Reliefs in Vapor or Gas Service
Page 471
10-5. Two-Phase Flow during Runaway Reaction Relief
Page 472
10-6. Pilot-Operated and Bucking-Pin Reliefs
Page 481
10-7. Deflagration Venting for Dust and Vapor Explosions
Page 481
Vents for Low-Pressure Structures
Page 483
Vents for High-Pressure Structures
Page 485
10-8. Venting for Fires External to Process Vessels
Page 488
10-9. Reliefs for Thermal Expansion of Process Fluids
Page 492
Suggested Reading
Page 496
Problems
Page 497
11. Hazards Identification
Page 505
11-1. Process Hazards Checklists
Page 508
11-2. Hazards Surveys
Page 508
11-3. Hazards and Operability Studies
Page 524
11-4. Safety Reviews
Page 530
Informal Review
Page 533
Formal Review
Page 534
11-5. Other Methods
Page 537
Suggested Reading
Page 538
Problems
Page 538
12. Risk Assessment
Page 549
12-1. Review of Probability Theory
Page 550
Interactions between Process Units
Page 552
Revealed and Unrevealed Failures
Page 558
Probability of Coincidence
Page 562
Redundancy
Page 564
Common Mode Failures
Page 564
12-2. Event Trees
Page 564
12-3. Fault Trees
Page 569
Determining the Minimal Cut Sets
Page 572
Quantitative Calculations Using the Fault Tree
Page 575
Advantages and Disadvantages of Fault Trees
Page 576
Relationship between Fault Trees and Event Trees
Page 576
12-4. QRA and LOPA
Page 577
Quantitative Risk Analysis
Page 577
Layer of Protection Analysis
Page 578
Consequence
Page 581
Frequency
Page 581
Typical LOPA
Page 585
Suggested Reading
Page 588
Problems
Page 588
13. Safety Procedures and Designs
Page 597
13-1. Process Safety Hierarchy
Page 598
Process Safety Strategies
Page 598
Layers of Protection
Page 598
13-2. Managing Safety
Page 599
Documentation
Page 599
Communications
Page 599
Delegation
Page 599
Follow-up
Page 600
13-3. Best Practices
Page 600
13-4. Procedures-Operating
Page 600
13-5. Procedures-Permits
Page 601
Hot Work Permit
Page 601
Lock-Tag-Try Permit
Page 601
Vessel Entry Permit
Page 602
13-6. Procedures-Safety Reviews and Accident Investigations
Page 603
Safety Reviews
Page 603
Incident Investigations
Page 603
13-7. Designs for Process Safety
Page 604
Inherently Safer Designs
Page 605
Controls-Double Block and Bleed
Page 606
Controls-Safeguards or Redundancy
Page 607
Controls-Block Valves
Page 608
Controls-Explosion Suppression
Page 608
Flame Arrestors
Page 608
Containment
Page 609
Materials of Construction
Page 610
Process Vessels
Page 610
Deflagrations
Page 612
Detonations
Page 612
13-8. Miscellaneous Designs for Fires and Explosions
Page 615
13-9. Designs for Runaway Reactions
Page 615
13-10. Designs for Handling Dusts
Page 616
Designs for Preventing Dust Explosions
Page 617
Management Practices for Preventing Dust Explosions
Page 617
Suggested Reading
Page 617
Problems
Page 618
14. Case Histories
Page 621
14-1. Static Electricity
Page 622
Tank Car Loading Explosion
Page 622
Explosion in a Centrifuge
Page 622
Duct System Explosion
Page 623
Conductor in a Solids Storage Bin
Page 623
14-1. Static Electricity
Page 622
Pigment and Filter
Page 624
Pipefitter's Helper
Page 624
Lessons Learned Concerning Static Electricity
Page 624
14-2. Chemical Reactivity
Page 626
Bottle of Isopropyl Ether
Page 630
Nitrobenzene Sulfonic Acid Decomposition
Page 630
Organic Oxidation
Page 631
Lessons Learned Concerning Chemical Reactivity
Page 631
14-3. System Designs
Page 631
Ethylene Oxide Explosion
Page 631
Ethylene Explosion
Page 632
Butadiene Explosion
Page 632
Light Hydrocarbon Explosion
Page 632
Pump Vibration
Page 633
Pump Failure
Page 633
Second Ethylene Explosion
Page 633
Third Ethylene Explosion
Page 634
Second Ethylene Oxide Explosion
Page 634
Lessons Learned Concerning Designs
Page 635
14-4. Procedures
Page 637
Leak Testing a Vessel
Page 637
Man Working in Vessel
Page 638
Vinyl Chloride Explosion
Page 638
Dangerous Water Expansion
Page 638
Phenol-Formaldehyde Runaway Reaction
Page 639
Conditions and Secondary Reaction Cause Explosion
Page 639
Fuel-Blending Tank Explosion
Page 640
Lessons Learned Concerning Procedures
Page 641
14-5. Training
Page 642
Weld Failure
Page 642
Safety Culture
Page 642
Training within Universities
Page 643
Training Regarding the Use of Standards
Page 643
Lessons Learned Concerning Training
Page 645
14-6. Conclusion
Page 645
Suggested Reading
Page 646
Problems
Page 646
A. Unit Conversion Constants
Page 649
B. Flammability Data for Selected Hydrocarbons
Page 653
C. Detailed Equations for Flammability Diagrams
Page 659
Equations Useful for Gas Mixtures
Page 659
Equations Useful for Placing Vessels into and out of Service
Page 664
D. Formal Safety Review Report for Example 10-4
Page 669
E. Saturation Vapor Pressure Data
Page 679
F. Special Types of Reactive Chemicals
Page 681
G. Hazardous Chemicals Data for a Variety of Chemical Substances
Page 687
Index
Page 695

Edition Notes

Includes bibliographical references and index.

Published in
Upper Saddle River, NJ

Classifications

Dewey Decimal Class
660/.2804
Library of Congress
TP155.5 .C76 2011, TP155.5.C76 2011

The Physical Object

Pagination
p. cm.
Number of pages
752

ID Numbers

Open Library
OL24822871M
Internet Archive
chemicalprocesss0000crow
ISBN 10
0131382268
LCCN
2011004168
OCLC/WorldCat
676726134, 741112846

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Library of Congress MARC record
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