This Page Has Been Reformatted by Knovel To Provide Easier Navigation

Contents
List of Tables .........................................................................
xi
List of Figures ........................................................................
xiii
Preface ..................................................................................
xvii
Glossary ................................................................................
xxi
Acronyms and Abbreviations ................................................. xxix

1. Introduction ...................................................................
1.1 Objective ............................................................................
1.2 Scope .................................................................................
1.3 Applicability ........................................................................
1.4 Organization of This Book .................................................
1.5 References ........................................................................
2. Inherently Safer Plants .................................................
2.1 Introduction ........................................................................
2.2 Intensification .....................................................................
11
2.3 Substitution ........................................................................
17
2.4 Attenuation .........................................................................
21
2.5 Limitation of Effects ............................................................
29
2.6 Simplification and Error Tolerance .....................................
37
2.7 Inherent Safety Checklist ...................................................
40
This page has been reformatted by Knovel to provide easier navigation.
vi
Contents
2.8 Summary - A Fable ............................................................
42
Appendix 2A Inherent Process Safety Checklist .......................
44
2.9 References ........................................................................
47
3. Plant Design ..................................................................
53
3.1 Process Safety Review through the Life of the Plant .........
54
3.2 Process Design ..................................................................
56
3.3 Site Selection and Evaluation ............................................
63
3.4 Plant Layout and Plot Plan ................................................
66
3.5 Civil Engineering Design ....................................................
75
3.6 Structural Engineering Design ...........................................
80
3.7 Architectural Design ...........................................................
86
3.8 Plant Utilities ......................................................................
88
3.9 Plant Modifications .............................................................
97
3.10 References ........................................................................
97
4. Equipment Design ......................................................... 101

4.1 Introduction ........................................................................
4.2 Loading and Unloading Facilities ........................................
101
101
4.3 Material Storage ................................................................
106
4.4 Process Equipment ............................................................
117
4.5 References ........................................................................
150
5. Materials Selection ........................................................ 157

5.1 Introduction ........................................................................
157
5.2 Corrosion ...........................................................................
162
5.3 Design Considerations .......................................................
168
5.4 Fabrication and Installation ................................................
169
5.5 Corrosion Monitoring and Control Techniques ..................
170
5.6 References ........................................................................
175
Contents
vii
6. Piping Systems ............................................................. 179

6.1 Introduction ........................................................................
179
6.2 Detailed Specification ........................................................
180
6.3 Specifying Valves to Increase Process Safety ...................
187
6.4 Joints and Flanges .............................................................
190
6.5 Support and Flexibility ........................................................
192
6.6 Vibration .............................................................................
197
6.7 Special Cases ....................................................................
199
Appendix 6A: Examples of Safety Design Concerns .................
202
6.8 References ........................................................................
205
7. Heat Transfer Fluid Systems ........................................ 211

7.1 Introduction ........................................................................
211
7.2 General Description of Heat Transfer Fluids ......................
212
7.3 System Design Considerations ..........................................
219
7.4 Heat Transfer Fluid System Components ..........................
223
7.5 Safety Issues .....................................................................
230
7.6 References ........................................................................
234
8. Thermal Insulation ........................................................ 237

8.1 Properties of Thermal Insulation ........................................
237
8.2 Selection of Insulation System Materials ...........................
241
8.3 Corrosion under Wet Thermal Insulation ...........................
242
8.4 References ........................................................................
247
9. Process Monitoring and Control .................................. 251

9.1 Introduction ........................................................................
251
9.2 Instrumentation ..................................................................
252
9.3 Process Monitoring Using Computer-Based

Systems .............................................................................
262
9.4 Alarm Systems Philosophy ................................................
273
viii
Contents
9.5 Safety System Maintenance Testing .................................
273
9.6 Implementing the Process Control System ........................
275
9.7 Summary ...........................................................................
290
Appendix 9A Safety Considerations for Monitoring and

Control ...............................................................................
291
Appendix 9B Instrumentation and Control Checklist .................
293
9.8 References ........................................................................
294
10. Documentation .............................................................. 299

10.1 Design ................................................................................
300
10.2 Operations .........................................................................
303
10.3 Maintenance ......................................................................
305
10.4 Records Management .......................................................
309
Appendix 10A: Typical Inspection Points and

Procedures ........................................................................
311
10.5 References ........................................................................
313
11. Sources of Ignition ........................................................ 317

11.1 Introduction ........................................................................
317
11.2 Types of Ignition Source ....................................................
318
11.3 Ignition by Flames ..............................................................
318
11.4 Spontaneous Ignition (Autoignition) ...................................
321
11.5 Electrical Sources ..............................................................
326
11.6 Physical Sources ...............................................................
334
11.7 Chemical Reactions ...........................................................
337
11.8 Design Alternatives ............................................................
342
11.9 References ........................................................................
343
12. Electrical System Hazards ........................................... 349

12.1 Electrical Equipment Hazards ............................................
349
12.2 Lightning Protection ...........................................................
354
Contents
ix
12.3 Bonding and Grounding .....................................................
360
12.4 References ........................................................................
367
13. Deflagration and Detonation Flame Arresters ............ 371

13.1 Definitions and Explanations of Terms ..............................
371
13.2 Introduction ........................................................................
375
13.3 Types of Flame Arresters ..................................................
380
13.4 Regulatory Use, Testing and Certification .........................
386
13.5 Application Considerations ................................................
396
13.6 Special Applications and Alternatives ................................
401
13.7 Conclusions .......................................................................
403
13.8 Future Developments ........................................................
404
13.9 References ........................................................................
405
14. Pressure Relief Systems .............................................. 409

14.1 Introduction ........................................................................
409
14.2 Relief Design Scenarios ....................................................
410
14.3 Pressure Relief Devices ....................................................
420
14.4 Sizing of Pressure Relief Systems .....................................
428
14.5 Design of Relief Devices: Other Considerations ................
430
14.6 DIERS Methods of Overpressure Protection for TwoPhase Flows ......................................................................
431
14.7 Emergency Depressuring ..................................................
440
14.8 References ........................................................................
441
15. Effluent Disposal Systems ........................................... 445

15.1 Flare Systems ....................................................................
446
15.2 Blowdown Systems ............................................................
465
15.3 Incineration Systems .........................................................
470
15.4 Vapor Control Systems ......................................................
482
15.5 References ........................................................................
486
Contents
16. Fire Protection ............................................................... 489

16.1 Introduction ........................................................................
489
16.2 Detection and Alarm Systems ...........................................
491
16.3 Water-Based Fire Protection Systems ...............................
497
16.4 Chemical and Special Agent Extinguishing

Systems .............................................................................
502
16.5 Passive Fire Protection ......................................................
507
16.6 References ........................................................................
515
17. Explosion Protection .................................................... 521

17.1 Introduction ........................................................................
521
17.2 Energy Release on Noncombustive Vessel Rupture .........
521
17.3 Flammability .......................................................................
523
17.4 Flame Events .....................................................................
530
17.5 Flammability Control Measures Inside Equipment ............
538
17.6 Flame Mitigation Inside Equipment ....................................
540
17.7 References ........................................................................
554
Index ..................................................................................... 557

This Page Has Been Reformatted by Knovel To Provide Easier Navigation

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

This Page Has Been Reformatted by Knovel To Provide Easier Navigation

Uploaded by

Copyright:

Available Formats

Contents

List of Tables .........................................................................

List of Figures ........................................................................

Acronyms and Abbreviations ................................................. xxix

1.1 Objective ............................................................................

1.2 Scope .................................................................................

1.3 Applicability ........................................................................

1.4 Organization of This Book .................................................

1.5 References ........................................................................

2. Inherently Safer Plants .................................................

2.1 Introduction ........................................................................

2.2 Intensification .....................................................................

2.3 Substitution ........................................................................

2.4 Attenuation .........................................................................

2.5 Limitation of Effects ............................................................

2.6 Simplification and Error Tolerance .....................................

2.7 Inherent Safety Checklist ...................................................

This page has been reformatted by Knovel to provide easier navigation.

Appendix 2A Inherent Process Safety Checklist .......................

2.9 References ........................................................................

3. Plant Design ..................................................................

3.2 Process Design ..................................................................

3.3 Site Selection and Evaluation ............................................

3.4 Plant Layout and Plot Plan ................................................

3.5 Civil Engineering Design ....................................................

3.6 Structural Engineering Design ...........................................

3.7 Architectural Design ...........................................................

3.8 Plant Utilities ......................................................................

3.9 Plant Modifications .............................................................

3.10 References ........................................................................

4. Equipment Design ......................................................... 101

4.3 Material Storage ................................................................

4.4 Process Equipment ............................................................

4.5 References ........................................................................

5. Materials Selection ........................................................ 157

5.2 Corrosion ...........................................................................

5.3 Design Considerations .......................................................

5.4 Fabrication and Installation ................................................

5.5 Corrosion Monitoring and Control Techniques ..................

5.6 References ........................................................................

This page has been reformatted by Knovel to provide easier navigation.

6. Piping Systems ............................................................. 179

6.2 Detailed Specification ........................................................

6.3 Specifying Valves to Increase Process Safety ...................

6.4 Joints and Flanges .............................................................

6.5 Support and Flexibility ........................................................

6.6 Vibration .............................................................................

6.7 Special Cases ....................................................................

Appendix 6A: Examples of Safety Design Concerns .................

6.8 References ........................................................................

7. Heat Transfer Fluid Systems ........................................ 211

7.2 General Description of Heat Transfer Fluids ......................

7.3 System Design Considerations ..........................................

7.4 Heat Transfer Fluid System Components ..........................

7.5 Safety Issues .....................................................................

7.6 References ........................................................................

8. Thermal Insulation ........................................................ 237

8.2 Selection of Insulation System Materials ...........................

8.3 Corrosion under Wet Thermal Insulation ...........................

8.4 References ........................................................................

9. Process Monitoring and Control .................................. 251

9.2 Instrumentation ..................................................................

9.3 Process Monitoring Using Computer-Based