What Went Wrong?: Case Studies of Process Plant Disasters
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Table of contents
- Cover
- What Went Wrong?: Case Histories of Process Plant Disastersiii
- Copyright Pageiv
- Contentsv
- Acknowledgmentsxi
- Prefacexiii
- Units and Nomenclaturexix
- Chapter 1. Preparation for Maintenance1
- 1.1 Isolation1
- 1.2 Identification11
- 1.3 Removal of hazards16
- 1.4 Procedures not followed24
- 1.5 Quality of maintenance32
- 1.6 A personal note44
- Chapter 2. Modifications48
- 2.1 Startup modifications48
- 2.2 Minor modifications49
- 2.3 Modifications made during maintenance55
- 2.4 Temporary modifications56
- 2.5 Sanctioned modifications58
- 2.6 Process modifications60
- 2.7 New tools63
- 2.8 Organizational changes64
- 2.9 Gradual changes66
- 2.10 Modification chains66
- 2.11 Modifications made to improve the environment69
- 2.12 Control of modifications74
- Chapter 3. Accidents Caused by Human Error78
- 3.1 Introduction78
- 3.2 Accidents caused by simple slips79
- 3.3 Accidents that could be prevented by better training90
- Chapter 4. Labeling98
- 4.1 Labeling of equipment98
- 4.2 Labeling of instruments101
- 4.3 Labeling of chemicals104
- 4.4 Labels not understood106
- Chapter 5. Storage Tanks108
- 5.1 Overfilling108
- 5.2 Overpressuring110
- 5.3 Sucking in114
- 5.4 Explosions117
- 5.5 Floating-roof tanks125
- 5.6 Miscellaneous incidents129
- 5.7 FRP tanks133
- Chapter 6. Stacks136
- 6.1 Stack explosions136
- 6.2 Blocked stacks140
- 6.3 Heat radiation142
- Chapter 7. Leaks144
- 7.1 Some common sources of leaks145
- 7.2 Control of leaks154
- 7.3 Leaks onto water, wet ground, or insulation159
- 7.4 Detection of leaks160
- 7.5 Fugitive emissions162
- Chapter 8. Liquefied Flammable Gases165
- 8.1 Major leaks166
- 8.2 Minor leaks174
- 8.3 Other leaks175
- Chapter 9. Pipe and Vessel Failures179
- 9.1 Pipe failures179
- 9.2 Pressure vessel failures195
- Chapter 10. Other Equipment205
- 10.1 Centrifuges205
- 10.2 Pumps206
- 10.3 Air coolers208
- 10.4 Relief valves209
- 10.5 Heat exchangers218
- 10.6 Cooling towers221
- 10.7 Furnaces221
- Chapter 11. Entry to Vessels229
- 11.1 Vessels not freed from hazardous material229
- 11.2 Hazardous materials introduced231
- 11.3 Vessels not isolated from sources of danger233
- 11.4 Unauthorized entry236
- 11.5 Entry into vessels with irrespirable atmospheres238
- 11.6 Rescue239
- 11.7 Analysis of vessel atmosphere241
- 11.8 What is a confined space?241
- 11.9 Every possible error242
- Chapter 12. Hazards of Common Materials244
- 12.1 Compressed air244
- 12.2 Water246
- 12.3 Nitrogen248
- 12.4 Heavy oils (including heat transfer oils)255
- Chapter 13. Tank Trucks and Cars262
- 13.1 Overfilling262
- 13.2 Burst hoses263
- 13.3 Fires and explosions265
- 13.4 Liquefied flammable gases266
- 13.5 Compressed air266
- 13.6 Tipping up267
- 13.7 Emptying into or filling from the wrong place268
- 13.8 Contact with live power lines270
- Chapter 14. Testing of Trips and Other Protective Systems272
- 14.1 Testing should be thorough272
- 14.2 All protective equipment should be tested275
- 14.3 Testing can be overdone279
- 14.4 Protective systems should not reset themselves279
- 14.5 Trips should not be disarmed without authorization281
- 14.6 Instruments should measure directly what we need to know284
- 14.7 Trips are for emergencies, not for routine use285
- 14.8 Tests may find faults286
- 14.9 Some miscellaneous incidents286
- 14.10 Some accidents at sea287
- Chapter 15. Static Electricity290
- 15.1 Static electricity from flowing liquids291
- 15.2 Static electricity from gas and water jets293
- 15.3 Static electricity from powders and plastics294
- 15.4 Static electricity from clothing296
- Chapter 16. Materials of Construction299
- 16.1 Wrong material used299
- 16.2 Hydrogen produced by corrosion303
- 16.3 Other effects of corrosion305
- 16.4 Loss of protective coatings305
- 16.5 Some other incidents caused by corrosion306
- 16.6 Fires306
- 16.7 Choosing materials307
- Chapter 17. Operating Method309
- 17.1 Trapped pressure309
- 17.2 Clearing choked lines311
- 17.3 Faulty valve positioning313
- 17.4 Responsibilities not defined314
- 17.5 Communication failures315
- 17.6 Work at open manholes318
- 17.7 One line, two duties318
- 17.8 Inadvertent isolation319
- 17.9 Incompatible storage319
- 17.10 Maintenance„is it really necessary?320
- 17.11 An interlock failure321
- 17.12 Emulsion breaking322
- 17.13 Chimney effects323
- Chapter 18. Reverse Flow and Other Unforeseen Deviations327
- 18.1 Reverse flow from a product receiver or blowdown line back into the plant327
- 18.2 Reverse flow into service mains329
- 18.3 Reverse flow through pumps331
- 18.4 Reverse flow from reactors331
- 18.5 Reverse flow from drains333
- 18.6 Other deviations334
- 18.7 A method for foreseeing deviations335
- 18.8 Some pitfalls in hazop337
- 18.9 Hazop of batch plants338
- 18.10 Hazop of tank trucks340
- Chapter 19. I Didn't Know That343
- 19.1 Ammonia can explode343
- 19.2 Hydraulic pressure tests can be hazardous345
- 19.3 Diesel engines can ignite leaks346
- 19.4 Carbon dioxide can ignite a flammable mixture348
- 19.5 Mists can explode348
- 19.6 The source of the problem lay elsewhere350
- Chapter 20. Problems with Computer Control353
- 20.1 Hardware and software faults353
- 20.2 Treating the computer as a black box354
- 20.3 Misjudging the way operators will respond359
- 20.4 Other problems360
- 20.5 Unauthorized interference362
- 20.6 New applications363
- 20.7 Conclusions365
- Chapter 21. Inherently Safer Design367
- 21.1 Bhopal368
- 21.2 Other examples of inherently safer design372
- 21.3 User-friendly design377
- Chapter 22. Reactions„Planned and Unplanned380
- 22.1 Lack of knowledge381
- 22.2 Poor mixing383
- 22.3 Contamination385
- 22.4 Reactions with auxiliary materials387
- 22.5 Poor training or procedures387
- 22.6 Use-by dates388
- Appendix 1. Relative Frequencies of Incidents392
- Appendix 2. Final Thoughts395
- Appendix 3. Recommended Reading397
- Index399
Expert Trevor Kletz examines the causes and aftermaths of numerous plant disasters--almost every one of which could have been prevented. Case histories illustrate what went wrong, why it went wrong, and then guide you in how to circumvent similar tragedies.
Learn from the mistakes of others. This invaluable and respected book examines the causes and aftermaths of numerous plant disasters - almost every one of which could have been prevented. Case histories illustrate what went wrong and why it went wrong, and then guide you in how to circumvent similar tragedies.
* Learn from the mistakes of others with this important book!
* Examines the causes and aftermaths of numerous plant disasters - most of which could have been prevented
* Case histories illustrate what went wrong, why it went wrong, and then guide you in how to circumvent similar tragedies
Learn from the mistakes of others. This invaluable and respected book examines the causes and aftermaths of numerous plant disasters - almost every one of which could have been prevented. Case histories illustrate what went wrong and why it went wrong, and then guide you in how to circumvent similar tragedies.
* Learn from the mistakes of others with this important book!
* Examines the causes and aftermaths of numerous plant disasters - most of which could have been prevented
* Case histories illustrate what went wrong, why it went wrong, and then guide you in how to circumvent similar tragedies