Enhanced descriptions from Syndetics:

Focuses on technical fundamentals of chemical process safety, and provides basics for understanding, with a coverage of both prevention and mitigation measures. A reference for industry professionals, this second edition is also useful for teaching at the graduate and senior undergraduate levels.

Table of contents provided by Syndetics

• Preface (p. xiii)
• Nomenclature (p. xv)
• 1 Introduction (p. 1)
• 1-1 Safety Programs (p. 2)
• 1-2 Engineering Ethics (p. 4)
• 1-3 Accident and Loss Statistics (p. 4)
• 1-4 Acceptable Risk (p. 12)
• 1-5 Public Perceptions (p. 14)
• 1-6 The Nature of the Accident Process (p. 15)
• 1-7 Inherent Safety (p. 20)
• 1-8 Four Significant Disasters (p. 23)
• Flixborough, England (p. 23)
• Bhopal, India (p. 25)
• Seveso, Italy (p. 26)
• Pasadena, Texas (p. 27)
• Suggested Reading (p. 29)
• Problems (p. 30)
• 2 Toxicology (p. 35)
• 2-1 How Toxicants Enter Biological Organisms (p. 36)
• Gastrointestinal Tract (p. 37)
• Skin (p. 37)
• Respiratory System (p. 38)
• 2-2 How Toxicants Are Eliminated from Biological Organisms (p. 39)
• 2-3 Effects of Toxicants on Biological Organisms (p. 40)
• 2-4 Toxicological Studies (p. 41)
• 2-5 Dose versus Response (p. 42)
• 2-6 Models for Dose and Response Curves (p. 48)
• 2-7 Relative Toxicity (p. 54)
• 2-8 Threshold Limit Values (p. 54)
• Suggested Reading (p. 59)
• Problems (p. 59)
• 3 Industrial Hygiene (p. 63)
• 3-1 Government Regulations (p. 64)
• Laws and Regulations (p. 64)
• Creating a Law (p. 64)
• Creating a Regulation (p. 64)
• OSHA: Process Safety Management (p. 68)
• EPA: Risk Management Plan (p. 71)
• 3-2 Industrial Hygiene: Identification (p. 74)
• Material Safety Data Sheets (p. 74)
• 3-3 Industrial Hygiene: Evaluation (p. 78)
• Evaluating Exposures to Volatile Toxicants by Monitoring (p. 79)
• Evaluation of Worker Exposures to Dusts (p. 83)
• Evaluating Worker Exposures to Noise (p. 84)
• Estimating Worker Exposures to Toxic Vapors (p. 85)
• 3-4 Industrial Hygiene: Control (p. 94)
• Respirators (p. 96)
• Ventilation (p. 97)
• Suggested Reading (p. 103)
• Problems (p. 104)
• 4 Source Models (p. 109)
• 4-1 Introduction to Source Models (p. 109)
• 4-2 Flow of Liquid through a Hole (p. 112)
• 4-3 Flow of Liquid through a Hole in a Tank (p. 116)
• 4-4 Flow of Liquids through Pipes (p. 121)
• 2-K Method (p. 124)
• 4-5 Flow of Vapor through Holes (p. 130)
• 4-6 Flow of Gases through Pipes (p. 136)
• Adiabatic Flows (p. 136)
• Isothermal Flows (p. 143)
• 4-7 Flashing Liquids (p. 151)
• 4-8 Liquid Pool Evaporation or Boiling (p. 157)
• 4-9 Realistic and Worst-Case Releases (p. 159)
• 4-10 Conservative Analysis (p. 159)
• Suggested Reading (p. 161)
• Problems (p. 162)
• 5 Toxic Release and Dispersion Models (p. 171)
• 5-1 Parameters Affecting Dispersion (p. 172)
• 5-2 Neutrally Buoyant Dispersion Models (p. 176)
• Case 1 Steady-State Continuous Point Release with No Wind (p. 180)
• Case 2 Puff with No Wind (p. 181)
• Case 3 Non-Steady-State Continuous Point Release with No Wind (p. 182)
• Case 4 Steady-State Continuous Point Source Release with Wind (p. 183)
• Case 5 Puff with No Wind and Eddy Diffusivity Is a Function of Direction (p. 183)
• Case 6 Steady-State Continuous Point Source Release with Wind and Eddy Diffusivity Is a Function of Direction (p. 184)
• Case 7 Puff with Wind (p. 184)
• Case 8 Puff with No Wind and with Source on Ground (p. 185)
• Case 9 Steady-State Plume with Source on Ground (p. 185)
• Case 10 Continuous Steady-State Source with Source at Height H[subscript r] above the Ground (p. 186)
• Pasquill-Gifford Model (p. 186)
• 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 (p. 190)
• Case 12 Plume with Continuous Steady-State Source at Ground Level and Wind Moving in x Direction at Constant Velocity u (p. 191)
• Case 13 Plume with Continuous Steady-State Source at Height H[subscript r] above Ground Level and Wind Moving in x Direction at Constant Velocity u (p. 192)
• Case 14 Puff with Instantaneous Point Source at Height H[subscript r] above Ground Level and a Coordinate System on the Ground That Moves with the Puff (p. 193)
• Case 15 Puff with Instantaneous Point Source at Height H[subscript r] above Ground Level and a Coordinate System Fixed on the Ground at the Release Point (p. 194)
• Worst-Case Conditions (p. 194)
• Limitations to Pasquill-Gifford Dispersion Modeling (p. 194)
• 5-3 Dense Gas Dispersion (p. 195)
• 5-4 Toxic Effect Criteria (p. 199)
• 5-5 Effect of Release Momentum and Buoyancy (p. 212)
• 5-6 Release Mitigation (p. 213)
• Suggested Reading (p. 214)
• Problems (p. 215)
• 6 Fires and Explosions (p. 225)
• 6-1 The Fire Triangle (p. 225)
• 6-2 Distinction between Fires and Explosions (p. 227)
• 6-3 Definitions (p. 227)
• 6-4 Flammability Characteristics of Liquids and Vapors (p. 229)
• Liquids (p. 230)
• Gases and Vapors (p. 233)
• Vapor Mixtures (p. 233)
• Flammability Limit Dependence on Temperature (p. 235)
• Flammability Limit Dependence on Pressure (p. 236)
• Estimating Flammability Limits (p. 236)
• 6-5 Limiting Oxygen Concentration and Inerting (p. 238)
• 6-6 Flammability Diagram (p. 240)
• 6-7 Ignition Energy (p. 248)
• 6-8 Autoignition (p. 249)
• 6-9 Auto-Oxidation (p. 249)
• 6-10 Adiabatic Compression (p. 249)
• 6-11 Ignition Sources (p. 251)
• 6-12 Sprays and Mists (p. 252)
• 6-13 Explosions (p. 252)
• Detonation and Deflagration (p. 253)
• Confined Explosions (p. 255)
• Blast Damage Resulting from Overpressure (p. 265)
• TNT Equivalency (p. 269)
• TNO Multi-Energy Method (p. 271)
• Energy of Chemical Explosions (p. 274)
• Energy of Mechanical Explosions (p. 276)
• Missile Damage (p. 279)
• Blast Damage to People (p. 279)
• Vapor Cloud Explosions (p. 281)
• Boiling-Liquid Expanding-Vapor Explosions (p. 282)
• Suggested Reading (p. 282)
• Problems (p. 283)
• 7 Designs to Prevent Fires and Explosions (p. 291)
• 7-1 Inerting (p. 292)
• Vacuum Purging (p. 292)
• Pressure Purging (p. 295)
• Combined Pressure-Vacuum Purging (p. 297)
• Vacuum and Pressure Purging with Impure Nitrogen (p. 298)
• Advantages and Disadvantages of the Various Pressure and Vacuum Inerting Procedures (p. 299)
• Sweep-Through Purging (p. 299)
• Siphon Purging (p. 301)
• Using the Flammability Diagram To Avoid Flammable Atmospheres (p. 301)
• 7-2 Static Electricity (p. 307)
• Fundamentals of Static Charge (p. 307)
• Charge Accumulation (p. 308)
• Electrostatic Discharges (p. 309)
• Energy from Electrostatic Discharges (p. 311)
• Energy of Electrostatic Ignition Sources (p. 312)
• Streaming Current (p. 313)
• Electrostatic Voltage Drops (p. 316)
• Energy of Charged Capacitors (p. 316)
• Capacitance of a Body (p. 321)
• Balance of Charges (p. 324)
• 7-3 Controlling Static Electricity (p. 330)
• General Design Methods To Prevent Electrostatic Ignitions (p. 331)
• Relaxation (p. 332)
• Bonding and Grounding (p. 332)
• Dip Pipes (p. 333)
• Increasing Conductivity with Additives (p. 336)
• Handling Solids without Flammable Vapors (p. 337)
• Handling Solids with Flammable Vapors (p. 337)
• 7-4 Explosion-Proof Equipment and Instruments (p. 337)
• Explosion-Proof Housings (p. 339)
• Area and Material Classification (p. 339)
• Design of an XP Area (p. 340)
• 7-5 Ventilation (p. 340)
• Open-Air Plants (p. 340)
• Plants Inside Buildings (p. 341)
• 7-6 Sprinkler Systems (p. 343)
• 7-7 Miscellaneous Designs for Preventing Fires and Explosions (p. 347)
• Suggested Reading (p. 347)
• Problems (p. 348)
• 8 Introduction to Reliefs (p. 353)
• 8-1 Relief Concepts (p. 354)
• 8-2 Definitions (p. 356)
• 8-3 Location of Reliefs (p. 357)
• 8-4 Relief Types (p. 360)
• 8-5 Relief Scenarios (p. 364)
• 8-6 Data for Sizing Reliefs (p. 365)
• 8-7 Relief Systems (p. 368)
• Relief Installation Practices (p. 368)
• Relief Design Considerations (p. 368)
• Horizontal Knockout Drum (p. 371)
• Flares (p. 375)
• Scrubbers (p. 376)
• Condensers (p. 376)
• Suggested Reading (p. 376)
• Problems (p. 377)
• 9 Relief Sizing (p. 383)
• 9-1 Conventional Spring-Operated Reliefs in Liquid Service (p. 384)
• 9-2 Conventional Spring-Operated Reliefs in Vapor or Gas Service (p. 389)
• 9-3 Rupture Disc Reliefs in Liquid Service (p. 394)
• 9-4 Rupture Disc Reliefs in Vapor or Gas Service (p. 394)
• 9-5 Two-Phase Flow during Runaway Reaction Relief (p. 395)
• Simplified Nomograph Method (p. 401)
• 9-6 Deflagration Venting for Dust and Vapor Explosions (p. 404)
• Vents for Low-Pressure Structures (p. 406)
• Vents for High-Pressure Structures (p. 408)
• 9-7 Venting for Fires External to Process Vessels (p. 411)
• 9-8 Reliefs for Thermal Expansion of Process Fluids (p. 415)
• Suggested Reading (p. 418)
• Problems (p. 420)
• 10 Hazards Identification (p. 429)
• 10-1 Process Hazards Checklists (p. 432)
• 10-2 Hazards Surveys (p. 432)
• 10-3 Hazards and Operability Studies (p. 448)
• 10-4 Safety Reviews (p. 454)
• 10-5 Other Methods (p. 459)
• Suggested Reading (p. 460)
• Problems (p. 460)
• 11 Risk Assessment (p. 471)
• 11-1 Review of Probability Theory (p. 472)
• Interactions between Process Units (p. 474)
• Revealed and Unrevealed Failures (p. 480)
• Probability of Coincidence (p. 484)
• Redundancy (p. 486)
• Common Mode Failures (p. 486)
• 11-2 Event Trees (p. 486)
• 11-3 Fault Trees (p. 491)
• Determining the Minimal Cut Sets (p. 494)
• Quantitative Calculations Using the Fault Tree (p. 497)
• Advantages and Disadvantages of Fault Trees (p. 498)
• Relationship between Fault Trees and Event Trees (p. 498)
• 11-4 QRA and LOPA (p. 499)
• Quantitative Risk Analysis (p. 499)
• Layer of Protection Analysis (p. 500)
• Consequence (p. 503)
• Frequency (p. 503)
• Suggested Reading (p. 507)
• Problems (p. 508)
• 12 Accident Investigations (p. 515)
• 12-1 Learning from Accidents (p. 515)
• 12-2 Layered Investigations (p. 516)
• 12-3 Investigation Process (p. 518)
• 12-4 Investigation Summary (p. 519)
• 12-5 Aids for Diagnosis (p. 521)
• Fires (p. 522)
• Explosions (p. 522)
• Sources of Ignition in Vessels (p. 523)
• Pressure Effects (p. 523)
• Medical Evidence (p. 525)
• Miscellaneous Aids to Diagnosis (p. 525)
• 12-6 Aids for Recommendations (p. 528)
• Control Plant Modifications (p. 528)
• User-Friendly Designs (p. 529)
• Block Valves (p. 529)
• Double Block and Bleed (p. 530)
• Preventive Maintenance (p. 530)
• Analyzers (p. 531)
• Suggested Reading (p. 532)
• Problems (p. 532)
• 13 Case Histories (p. 535)
• 13-1 Static Electricity (p. 536)
• Tank Car Loading Explosion (p. 536)
• Explosion in a Centrifuge (p. 536)
• Duct System Explosion (p. 537)
• Conductor in a Solids Storage Bin (p. 537)
• Pigment and Filter (p. 536)
• Pipefitter's Helper (p. 536)
• Lessons Learned (p. 536)
• 13-2 Chemical Reactivity (p. 540)
• Bottle of Isopropyl Ether (p. 540)
• Nitrobenzene Sulfonic Acid Decomposition (p. 540)
• Organic Oxidation (p. 541)
• Lessons Learned (p. 541)
• 13-3 System Designs (p. 546)
• Ethylene Oxide Explosion (p. 546)
• Ethylene Explosion (p. 546)
• Butadiene Explosion (p. 546)
• Light Hydrocarbon Explosion (p. 547)
• Pump Vibration (p. 547)
• Pump Failure (p. 547)
• Ethylene Explosion (1) (p. 548)
• Ethylene Explosion (2) (p. 548)
• Ethylene Oxide Explosion (p. 548)
• Lessons Learned (p. 549)
• 13-4 Procedures (p. 551)
• Leak Testing a Vessel (p. 552)
• Man Working in Vessel (p. 552)
• Vinyl Chloride Explosion (p. 552)
• Dangerous Water Expansion (p. 553)
• Phenol-Formaldehyde Runaway Reaction (p. 553)
• Conditions and Secondary Reaction Cause Explosion (p. 554)
• Fuel-Blending Tank Explosion (p. 555)
• Lessons Learned (p. 556)
• 13-5 Conclusion (p. 556)
• Suggested Reading (p. 557)
• Problems (p. 557)
• Appendix A Unit Conversion Constants (p. 561)
• Appendix B Flammability Data for Selected Hydrocarbons (p. 565)
• Appendix C Detailed Equations for Flammability Diagrams (p. 571)
• Equations Useful for Placing Vessels into and out of Service (p. 576)
• Appendix D Formal Safety Review Report for Example 10-4 (p. 581)
• Appendix E Saturation Vapor Pressure Data (p. 591)

Excerpt provided by Syndetics

Preface This second edition of Chemical Process Safety is designed to enhance the process of teaching and applying the fundamentals of chemical process safety. It is appropriate for an industrial reference, a senior-level undergraduate course, or a graduate course in chemical process safety. It can be used by anyone interested in improving chemical process safety, including chemical and mechanical engineers and chemists. More material is presented than can be accommodated in a 3-credit course, providing instructors with the opportunity to emphasize their topics of interest. The primary objective of this textbook is to encapsulate the important technical fundamentals of chemical process safety. The emphasis on the fundamentals will help the student and practicing scientist to understand the concepts and apply them accordingly. This application requires a significant quantity of fundamental knowledge and technology. The second edition has been rewritten to include new process safety technology and new references that have appeared since the first edition was published in 1990. It also includes our combined experiences of teaching process safety in both industry and academia during the past 10 years. Significant modifications were made to the following topics: dispersion modeling, source modeling, flammability characterization, explosion venting, fundamentals of electrostatics, and case histories. This new edition also includes selected materials from the latest AICHE Center for Chemical Process Safety (CCPS) books and is now an excellent introduction to the CCPS library. This second edition also includes more problems (now 30 per chapter). A complete set of problem solutions is available to instructors using the book in their curriculum. These changes fulfill the requests of many professors who have used this textbook. We continue to believe that a textbook on safety is possible only with both industrial and academic inputs. The industrial input ensures that the material is industrially relevant. The academic input ensures that the material is presented on a fundamental basis to help professors and students understand the concepts. Although the authors are (now) both from universities, one has over 30 years of relevant experience in industry (J. F. L.) and the other (D. A. C.) has accumulated significant industrial experience since the writing of the first edition. Since the first edition was published, many universities have developed courses or course content in chemical process safety. This new emphasis on process safety is the result of the positive influences from industry and the Accreditation Board for Engineering and Technology (ABET). Based on faculty feedback, this textbook is an excellent application of the fundamental topics that are taught in the first three years of the undergraduate education. Although professors normally have little background in chemical process safety, they have found that the concepts in this text and the accompanying problems and solutions are easy to learn and teach. Professors have also found that industrial employees are enthusiastic and willing to give specific lectures on safety to enhance their courses. This textbook is designed for a dedicated course in chemical process safety. However, we continue to believe that chemical process safety should be part of every undergraduate and graduate course in chemistry and chemical and mechanical engineering, just as it is a part of all the industrial experiences. This text is an excellent reference for these courses. This textbook can also be used as a reference for a design course. Some will remark that our presentation is not complete or that some details are missing. The purpose of this book, however, is not to be complete but to provide a starting point for those who wish to learn about this important area. This book, for example, has a companion text titled Health and Environmental Risk Analysis that extends the topics relevant to risk analysis. We hope that this textbook helps prevent chemical plant and university accidents and contributes to a much safer future. Daniel A. Crowl and Joseph F. Louvar Excerpted from Chemical Process Safety: Fundamentals with Applications by Daniel A. Crowl, Joseph F. Louvar All rights reserved by the original copyright owners. Excerpts are provided for display purposes only and may not be reproduced, reprinted or distributed without the written permission of the publisher.

Reviews provided by Syndetics

CHOICE Review

This is the third edition (2nd ed., 2002; 1st ed., CH, Sep'90, 28-0310) of a book that is the primary textbook for courses in chemical process safety. It is also very useful as a reference in other courses such as process design, and is a must reference for engineers in the chemical process industries. Crowl (Michigan Technological Univ.) and Louvar (Wayne State Univ.) have updated their book considerably, including new chapters titled "Chemical Reactivity" and "Safety Procedures and Designs" as well as updated references and technical data. The book is very practical in nature, with many examples, a multitude of references, and many end-of-chapter problems for student exercises. It would have been better to place the new chapter on safety procedures, which deals with qualitative methods applicable to initial safety considerations, near the beginning of the book instead of following chapters dealing with the quantitative calculation procedures. Also, the section on fluid mechanics is somewhat outdated; there are more recent methods that are more accurate or more practical than some of those presented, but these are minor objections. The book is well written and clear, and the authors are eminent authorities in this field. Summing Up: Recommended. All academic students and their instructors, and professional engineers. R. Darby emeritus, Texas A&M University

Author notes provided by Syndetics

Daniel A. Crowl is the Herbert H. Dow Professor for Chemical Process Safety at Michigan Technological University
Joseph F. Louvar retired as director of BASF's Chemical Engineering Department to become a professor at Wayne State University, specializing in chemical process safety, risk assessment, and the design of experiments