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.
Acronyms and Abbreviations xv
Glossary xxi
Acknowledgments xxxiii
Foreward xxxv
Preface xxxvii
1. Introduction 1
1.1 Engineering Design for Process Safety Through the Life Cycle of the Facility 2
1.2 Regulatory Review / Impact on Process Safety 5
1.3 Who Will Benefit From These Guidelines? 7
1.4 Organization of this Book 7
1.5 Other CCPS Resources 9
1.6 References 10
2. Foundational Concepts 13
2.1 Understanding the Hazard 14
2.2 Risk-Based Design 21
2.3 Intentional Unsteady State Condition Evaluation 27
2.4 Unintentional Unsteady State Issues 31
2.5 Non-Linearity of the Design Process 33
2.6 References 36
3. Basic Physical Properties / Thermal Stability Data 39
3.1 Basic Physical Properties 39
3.2 Flammability Data 40
3.3 Reactivity / Thermal Stability Data 47
3.4 References 60
4. Analysis Techniques 63
4.1 Hazard Identification 63
4.2 Hazard Analysis Techniques 94
4.3 Risk Assessment 108
4.4 Reliability / Maintainability Analysis 118
4.5 References 119
5. General Design 123
5.1 Safeguarding Strategies 123
5.2 Inherently Safer Design 128
5.3 Basic Process Control Systems 132
5.4 Instrumented Safety Systems 135
5.5 Process Design / Process Chemistry 135
5.6 Plant Siting and Layout 137
5.7 Materials of Construction 140
5.8 Corrosion 143
5.9 Civil / Structural / Support Design 146
5.10 Thermal Insulation 150
5.11 Human Factors in Design 155
5.12 Site Security Issues 158
5.13 References 161
6. Equipment Design 165
6.1 Vessels 167
6.2 Reactors 183
6.3 Mass Transfer Equipment 194
6.4 Heat Transfer Equipment 204
6.5 Dryers 214
6.6 Fluid Transfer Equipment 223
6.7 Solid-Fluid Separators 236
6.8 Solids Handling and Processing Equipment 244
6.9 Fired Equipment 256
6.10 Piping and Piping Components 266
6.11 Material Handling and Warehousing 291
6.12 Utility Systems 305
7. Protection Layers 315
7.1 Ignition Control 316
7.2 Instrumented Safety Systems 325
7.3 Pressure / Vacuum Relief Systems 332
7.4 Equipment Isolation / Blowdown 340
7.5 Effluent Disposal Systems 342
7.6 Emergency Response Alarm Systems 350
7.7 Fire Protection 357
7.8 Deflagration / Detonation Arresters 363
7.9 Explosion Suppression 366
7.10 Specialty Mitigation Systems 369
7.11 Effluent Handling / Post-Release Mitigation / Waste Treatment Issues 372
7.12 References 374
8. Documentation to Support Process Safety 379
8.1 Process Knowledge Management 379
8.2 Engineering Design Package 384
8.3 Operating / Maintenance Procedures 385
8.4 Asset Integrity / Reliability / Predictive Maintenance Data 389
8.5 References 390
