Joseph F. Louvar is Research Professor at Wayne State University’s College of Engineering, where he teaches chemical process safety, risk assessment, and process design. He was recently the CCPS staff consultant for the Undergraduate Education Committee, commonly known as the Safety and Chemical Engineering Education Committee (AIChE’s SACHE) and has previously chaired this committee for over ten years. His books include Health and Environmental Risk Analysis: Fundamentals with Applications (Prentice Hall, 1997).

Chapter 1: Introduction          1

1-1 Safety Programs   2

1-2 Engineering Ethics   4

1-3 Accident and Loss Statistics   4

1-4 Acceptable Risk   12

1-5 Public Perceptions   14

1-6 The Nature of the Accident Process   15

1-7 Inherent Safety   20

1-8 Seven Significant Disasters   23

Suggested Reading   31

Problems   32

Chapter 2: Toxicology         37

2-1 How Toxicants Enter Biological Organisms   38

2-2 How Toxicants Are Eliminated from Biological Organisms   41

2-3 Effects of Toxicants on Biological Organisms   42

2-4 Toxicological Studies   43

2-5 Dose versus Response   44

2-6 Models for Dose and Response Curves   50

2-7 Relative Toxicity   56

2-8 Threshold Limit Values   56

2-9 National Fire Protection Association (NFPA) Diamond   58

On-Line Resources   59

Suggested Reading   60

Problems   60

Chapter 3: Industrial Hygiene         65

3-1 Government Regulations   66

3-2 Industrial Hygiene: Anticipation and Identification   78

3-3 Industrial Hygiene: Evaluation   84

3-4 Industrial Hygiene: Control   99

On-Line Resources   109

Suggested Reading   109

Problems   110

Chapter 4: Source Models         119

4-1 Introduction to Source Models   119

4-2 Flow of Liquid through a Hole   122

4-3 Flow of Liquid through a Hole in a Tank   126

4-4 Flow of Liquids through Pipes   131

4-5 Flow of Gases or Vapors through Holes   140

4-6 Flow of Gases or Vapors through Pipes   146

4-7 Flashing Liquids   163

4-8 Liquid Pool Evaporation or Boiling   169

4-9 Realistic and Worst-Case Releases   170

4-10 Conservative Analysis   172

Suggested Reading   173

Problems   174

Chapter 5: Toxic Release and Dispersion Models         185

5-1 Parameters Affecting Dispersion   186

5-2 Neutrally Buoyant Dispersion Models   190

5-3 Dense Gas Dispersion   209

5-4 Dense Gas Transition to Neutrally Buoyant Gas   219

5-5 Toxic Effect Criteria   225

5-6 Effect of Release Momentum and Buoyancy   233

5-7 Release Mitigation   234

Suggested Reading   235

Problems   236

Chapter 6: Fires and Explosions         245

6-1 The Fire Triangle   245

6-2 Distinction between Fires and Explosions   247

6-3 Definitions   247

6-4 Flammability Characteristics of Liquids and Vapors   249

6-5 Limiting Oxygen Concentration and Inerting   260

6-6 Flammability Diagram   262

6-7 Ignition Energy   270

6-8 Autoignition   270

6-9 Auto-Oxidation   271

6-10 Adiabatic Compression   272

6-11 Ignition Sources   273

6-12 Sprays and Mists   274

6-13 Explosions   275

Suggested Reading   304

Problems   305

Chapter 7: Concepts to Prevent Fires and Explosions         317

7-1 Inerting   318

7-2 Static Electricity   333

7-3 Controlling Static Electricity   356

7-4 Explosion-Proof Equipment and Instruments   363

7-5 Ventilation   367

7-6 Sprinkler Systems   370

7-7 Miscellaneous Concepts for Preventing Fires and Explosions   374

Suggested Reading   374

Problems   375

Chapter 8: Chemical Reactivity         381

8-1 Background Understanding   382

8-2 Commitment,Awareness, and Identification of Reactive Chemical Hazards   384

8-3 Characterization of Reactive Chemical Hazards Using Calorimeters   390

8-4 Controlling Reactive Hazards   416

Suggested Reading   418

Problems   418

Chapter 9: Introduction to Reliefs         429

9-1 Relief Concepts   430

9-2 Definitions   432

9-3 Location of Reliefs   433

9-4 Relief Types and Characteristics   436

9-5 Relief Scenarios   443

9-6 Data for Sizing Reliefs   444

9-7 Relief Systems   444

Suggested Reading   452

Problems   453

Chapter 10: Relief Sizing         459

10-1 Conventional Spring-Operated Reliefs in Liquid Service   460

10-2 Conventional Spring-Operated Reliefs in Vapor or Gas Service   466

10-3 Rupture Disc Reliefs in Liquid Service   470

10-4 Rupture Disc Reliefs in Vapor or Gas Service   471

10-5 Two-Phase Flow during Runaway Reaction Relief   472

10-6 Pilot-Operated and Bucking-Pin Reliefs   481

10-7 Deflagration Venting for Dust and Vapor Explosions   481

10-8 Venting for Fires External to Process Vessels   488

10-9 Reliefs for Thermal Expansion of Process Fluids   492

Suggested Reading   496

Problems   497

Chapter 11: Hazards Identification         505

11-1 Process Hazards Checklists   508

11-2 Hazards Surveys   508

11-3 Hazards and Operability Studies   524

11-4 Safety Reviews   530

11-5 Other Methods   537

Suggested Reading   538

Problems   538

Chapter 12: Risk Assessment         549

12-1 Review of Probability Theory   550

12-2 Event Trees   564

12-3 Fault Trees   569

12-4 QRA and LOPA   577

Suggested Reading   588

Problems   588

Chapter 13: Safety Procedures and Designs         597

13-1 Process Safety Hierarchy   598

13-2 Managing Safety   599

13-3 Best Practices   600

13-4 Procedures–Operating   600

13-5 Procedures–Permits   601

13-6 Procedures–Safety Reviews and Accident Investigations   603

13-7 Designs for Process Safety   604

13-8 Miscellaneous Designs for Fires and Explosions   615

13-9 Designs for Runaway Reactions   615

13-10 Designs for Handling Dusts   616

Suggested Reading   617

Problems   618

Chapter 14: Case Histories         621

14-1 Static Electricity   622

14-2 Chemical Reactivity   626

14-3 System Designs   631

14-4 Procedures   637

14-5 Training   642

14-6 Conclusion   645

Suggested Reading  646

Problems   646

Appendix A: Unit Conversion Constants         649

Appendix B: Flammability Data for Selected Hydrocarbons         653

Appendix C: Detailed Equations for Flammability Diagrams         659

Equations Useful for Gas Mixtures   659

Equations Useful for Placing Vessels into and out of Service   664

Appendix D: Formal Safety Review Report for Example 10-4         669

Appendix E: Saturation Vapor Pressure Data         679

Appendix F: Special Types of Reactive Chemicals         681

Appendix G: Hazardous Chemicals Data for a Variety of Chemical Substances         687

Index 695

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