Recognizing Catastrophic Incident Warning Signs in the Process Industries (eBook)

Since 1985, the Center for Chemical Process Safety (CCPS) has been the world leader in developing and disseminating information on process safety management and technology. CCPS, an industry technology alliance of the American Institute of Chemical Engineers (AIChE), has published over eighty books in its process safety guidelines and process safety concepts series, and over a hundred training modules through its Safety in Chemical Engineering Education (SACHE) series.

List of Tables xix

List of Figures xxi

Files on the Web Accompanying This Book xxii

Acknowledgements xxv

Foreword xxvii

Preface xxix

1. Introduction 1

1.1 Process safety management 3

1.2 Normalization of deviance 4

1.3 A strategy for response 5

1.4 Maintaining organizational memory and a healthy sense of
vulnerability 7

1.5 Risk based process safety 8

1.6 Our target audience 11

1.7 How to use this book 12

1.8 Case study - Toxic gas release in India 13

2. Incident Mechanics 17

2.1 Incidents do not just happen 17

2.2 Incident models 17

2.3 Case study - Benzene plant explosion in China 27

3. Leadership and Culture 29

3.1 How does leadership affect culture? 29

3.2 The leadership and culture related warning signs 32

3.3 Case study - Challenger space shuttle explosion in the
US 46

4. Training and Competency 49

4.1 What is effective training and how is competency measured?
49

4.2 The training and competency related warning signs 51

4.3 Case study - Gas plant vapor cloud explosion in
Australia 62

5. Process Safety information 65

5.1 Critical information to identify hazards and manage risk
65

5.2 The process safety information related warning signs 66

5.3 Case study - Batch still fire and explosion in the
UK

6. Procedures 79

6.1 Safe and consistent operation 79

6.2 The procedure related warning signs 81

6.3 Case study - Nuclear plant meltdown and explosion in
the Ukraine 95

7. Asset Integrity 97

7.1 Systematic implementation 97

7.2 The asset integrity related warning signs 99

7.3 Case study - Refinery naphtha fire in the US 114

8. Analyzing Risk and Managing Change 177

8.1 Risk management 117

8.2 The risk analysis and management of change related warning
signs 121

8.3 Case study - Cyclohexane explosion in the UK

9. Audits 139

9.1 Audits support operational excellence 139

9.2 The audit related warning signs 141

9.3 Case study - Chemical warehouse fire in the UK

10. Learning From Experience 149

10.1 Methods for continuous improvement 149

10.2 The learning from experience warning signs 151

10.3 Case study - Space shuttle Columbia incident in the
US 159

11. Physical Warning Signs 163

11.1 The everyday things matter 163

11.2 The physical warning signs 164

11.3 Case study - Resin plant dust explosion in the US
172

12. A Call to Action 175

12.1 Actions you can take now for each warning sign 176

12.2 A simple plan to consider for rigorous implementation and
follow-up 177

12.3 Actions to consider 180

12.4 Summary 183

Appendix A. Incident Warning Sign Self Assessment Tool 187

Appendix B. Composite List of Catastrophic Incident Warning
Signs 199

References & Selected Regulations 205

Acronyms and Abbreviations 213

Glossary 215

Index 221

"The CCPS and the authors (AntiEntropcis, Inc,) are to be commended
on producing a very informative and useful book that will help to
minimize process plant accidents if the principles in the book are
followed . . . This book will be very useful to plant operating
personnel and process safety/loss prevention specialists to help
them evaluate their processes and systems." (Process Safety
Progress, 1 June 2012)