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Cover image for Recognizing catastrophic incident warning signs in the process industries
Recognizing catastrophic incident warning signs in the process industries
Publication Information:
Hoboken, NJ : John Wiley & Sons, c2012
Physical Description:
xxix, 227 p. : ill. ; 24 cm.


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Call Number
Material Type
Item Category 1
30000010325210 TP150.S24 R44 2012 Open Access Book Book

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This book provides guidance on characterizing, recognizing, and responding to warning signs to help avoid process incidents and injuries before they occur. The guidance can be used by both process safety management (PSM) professionals in evaluating their processes and PSM systems as well as for operators who are often the frontline defense against process incidents. Warning signs may consist of process deviations or upsets, instrumentation warnings or alarms, past operating history and incidents, observable problems such as corrosion or unusual odors, audit results indicating procedures are not being followed, or a number of other indicators. Filled with photos and practical tips, this book will turn anyone in a process plant into a hazard lookout and will help prevent potential incidents before they turn into catastrophic events.

Author Notes

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.

Table of Contents

List of Tablesp. xix
List of Figuresp. xxi
Files on the Web Accompanying This Bookp. xxii
Acknowledgementsp. xxv
Forewordp. xxvii
Prefacep. xxix
1 Introductionp. 1
1.1 Process safety managementp. 3
1.2 Normalization of deviancep. 4
1.3 A strategy for responsep. 5
1.4 Maintaining organizational memory and a healthy sense of vulnerabilityp. 7
1.5 Risk based process safetyp. 8
1.6 Our target audiencep. 11
1.7 How to use this bookp. 12
1.8 Case study - Toxic gas release in Indiap. 13
2 Incident Mechanicsp. 17
2.1 Incidents do not just happenp. 17
2.2 Incident modelsp. 17
2.3 Case study - Benzene plant explosion in Chinap. 27
3 Leadership and Culturep. 29
3.1 How does leadership affect culture?p. 29
3.2 The leadership and culture related warning signsp. 32
3.3 Case study - Challenger space shuttle explosion in the USp. 46
4 Training and Competencyp. 49
4.1 What is effective training and how is competency measured?p. 49
4.2 The training and competency related warning signsp. 51
4.3 Case study - Gas plant vapor cloud explosion in Australiap. 62
5 Process Safety informationp. 65
5.1 Critical information to identify hazards and manage riskp. 65
5.2 The process safety information related warning signsp. 66
5.3 Case study - Batch still fire and explosion in the UK
6 Proceduresp. 79
6.1 Safe and consistent operationp. 79
6.2 The procedure related warning signsp. 81
6.3 Case study - Nuclear plant meltdown and explosion in the Ukrainep. 95
7 Asset Integrityp. 97
7.1 Systematic implementationp. 97
7.2 The asset integrity related warning signsp. 99
7.3 Case study - Refinery naphtha fire in the USp. 114
8 Analyzing Risk and Managing Changep. 177
8.1 Risk managementp. 117
8.2 The risk analysis and management of change related warning signsp. 121
8.3 Case study - Cyclohexane explosion in the UK
9 Auditsp. 139
9.1 Audits support operational excellencep. 139
9.2 The audit related warning signsp. 141
9.3 Case study - Chemical warehouse fire in the UK
10 Learning From Experiencep. 149
10.1 Methods for continuous improvementp. 149
10.2 The learning from experience warning signsp. 151
10.3 Case study - Space shuttle Columbia incident in the USp. 159
11 Physical Warning Signsp. 163
11.1 The everyday things matterp. 163
11.2 The physical warning signsp. 164
11.3 Case study - Resin plant dust explosion in the USp. 172
12 A Call to Actionp. 175
12.1 Actions you can take now for each warning signp. 176
12.2 A simple plan to consider for rigorous implementation and follow-upp. 177
12.3 Actions to considerp. 180
12.4 Summaryp. 183
Appendix A Incident Warning Sign Self Assessment Toolp. 187
Appendix B Composite List of Catastrophic Incident Warning Signsp. 199
References & Selected Regulationsp. 205
Acronyms and Abbreviationsp. 213
Glossaryp. 215
Indexp. 221
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