Recognizing Catastrophic Incident Warning Signs in the Process Industries

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.

"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)

• List of Tables xix List of Figures xxiFiles on the Web Accompanying This Book xxiiAcknowledgements xxvForeword xxviiPreface xxix1. Introduction 11.1 Process safety management 31.2 Normalization of deviance 41.3 A strategy for response 51.4 Maintaining organizational memory and a healthy sense of vulnerability 71.5 Risk based process safety 81.6 Our target audience 111.7 How to use this book 121.8 Case study – Toxic gas release in India 132. Incident Mechanics 172.1 Incidents do not just happen 172.2 Incident models 172.3 Case study – Benzene plant explosion in China 273. Leadership and Culture 293.1 How does leadership affect culture? 293.2 The leadership and culture related warning signs 323.3 Case study – Challenger space shuttle explosion in the US 464. Training and Competency 494.1 What is effective training and how is competency measured? 494.2 The training and competency related warning signs 514.3 Case study – Gas plant vapor cloud explosion in Australia 625. Process Safety information 655.1 Critical information to identify hazards and manage risk 655.2 The process safety information related warning signs 665.3 Case study – Batch still fire and explosion in the UK6. Procedures 796.1 Safe and consistent operation 796.2 The procedure related warning signs 816.3 Case study – Nuclear plant meltdown and explosion in the Ukraine 957. Asset Integrity 977.1 Systematic implementation 977.2 The asset integrity related warning signs 997.3 Case study – Refinery naphtha fire in the US 1148. Analyzing Risk and Managing Change 1778.1 Risk management 1178.2 The risk analysis and management of change related warning signs 1218.3 Case study – Cyclohexane explosion in the UK9. Audits 1399.1 Audits support operational excellence 1399.2 The audit related warning signs 1419.3 Case study – Chemical warehouse fire in the UK10. Learning From Experience 14910.1 Methods for continuous improvement 14910.2 The learning from experience warning signs 15110.3 Case study – Space shuttle Columbia incident in the US 15911. Physical Warning Signs 16311.1 The everyday things matter 16311.2 The physical warning signs 16411.3 Case study – Resin plant dust explosion in the US 17212. A Call to Action 17512.1 Actions you can take now for each warning sign 17612.2 A simple plan to consider for rigorous implementation and follow-up 17712.3 Actions to consider 18012.4 Summary 183Appendix A. Incident Warning Sign Self Assessment Tool 187Appendix B. Composite List of Catastrophic Incident Warning Signs 199References & Selected Regulations 205Acronyms and Abbreviations 213Glossary 215Index 221