Chemical Process Safety

Chemical Process Safety

Fourth Edition

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Chemical Process Safety

Fundamentals with Applications

Fourth Edition

Daniel A. Crowl Joseph F. Louvar

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Library of Congress Control Number: 2019930097

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ISBN-13: 978-0-13-485777-0 ISBN-10: 0-13-485777-1

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Contents

Prefacexv About the Authors xviii Nomenclaturexx 1 Introduction1

1-1 Engineering Ethics 6 1-2 Myths about Process Safety 7

Myth 1: Process safety costs a lot of money and has a negative impact on the company's bottom line. 7

Myth 2: Process safety is the same as personal or even laboratory safety. 8 Myth 3: Process safety is no more than following rules and regulations. 8 Myth 4: Process safety is a soft science--no more than hard hats or safety

shoes--not engineering science. 9 Myth 5: Process safety applies only to the petrochemical industry. 9 Myth 6: Industry should train graduates in process safety; this topic should

not be a part of the undergraduate engineering curriculum. 10 Myth 7: Process safety does not include product safety. 10 1-3 Safety Culture 10 1-4 Individual Risk, Societal Risk, and Risk Populations 13 1-5 Voluntary and Involuntary Risk 14 1-6 Safety Metrics 15 1-7 Accident and Loss Statistics 17 1-8 Risk Perception 27 1-9 Risk Tolerance/Acceptance and Risk Matrix 27

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viContents

1-10 Codes, Standards, and Regulations 31 1-11 Safeguards33 1-12 The CCPS 20 Elements of Risk-Based Process Safety 36 1-13 Inherently Safer Design 42 1-14 The Worst Chemical Plant Tragedy: Bhopal, India, 1984 46 1-15 Overview of Chemical Process Safety 49

Suggested Reading 49 Problems50

2 Toxicology55

2-1 How Toxicants Enter the Body 56 Gastrointestinal Tract 57 Skin58 Respiratory System 58

2-2 How Toxicants Are Eliminated from the Body 59 2-3 Effects of Toxicants on the Body 60 2-4 Toxicological Studies 61 2-5 Dose versus Response 62 2-6 Dose and Response Using Probit Equation 68 2-7 Relative Toxicity 74 2-8 Threshold Limit Values 75

Online Resources 76 Suggested Reading 77 Problems77

3 Industrial Hygiene 79

3-1 Anticipating and Identifying Hazardous Workplace Exposures 80 3-2 Globally Harmonized System 83

Globally Harmonized System for Safety Data Sheets 83 Globally Harmonized System for Labeling 87 3-3 Evaluate the Magnitude of Exposures and Responses 89 Evaluating Exposures to Volatile Toxicants by Monitoring 90 Evaluating Worker Exposures to Dusts 93 Evaluating Worker Exposures to Noise 94 Evaluating Worker Exposures to Thermal Radiation 96 Estimating Worker Exposures to Toxic Vapors 97 Estimating the Vaporization Rate of a Liquid 100 Estimating Worker Exposures during Vessel Filling Operations 103 3-4 Develop and Evaluate Control Techniques to Prevent Exposures 106 Respirators108 Ventilation109 3-5 National Fire Protection Association Diamond 115 Online Resources 116 Suggested Reading 117 Problems117

Contents

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4 Source Models 119

4-1 Introduction to Source Models 121 4-2 Flow of Liquid through a Hole 123 4-3 Flow of Liquid through a Hole in a Tank 126 4-4 Flow of Liquids through Pipes 130

2-K Method 134 4-5 Flow of Gases or Vapors through Holes 140 4-6 Flow of Gases or Vapors through Pipes 145

Adiabatic Flows 146 Isothermal Flows 152 4-7 Flashing Liquids 162 4-8 Liquid Pool Evaporation or Boiling 168 4-9 Realistic and Worst-Case Releases 169 4-10 Conservative Analysis 169 Suggested Reading 172 Problems173

5 Hazardous Material Dispersion 177

5-1 Parameters Affecting Dispersion 178 5-2 Neutrally Buoyant Dispersion Models 183 5-3 Pasquill?Gifford Model 184

Case 1: Puff with Instantaneous Point Source at Ground Level, Coordinates Fixed at Release Point, Constant Wind Only in x Direction with Constant Velocity u 189

Case 2: Plume with Continuous Steady-State Source at Ground Level and Wind Moving in x Direction at Constant Velocity u 190

Case 3: Plume with Continuous Steady-State Source at Height Hr above Ground Level and Wind Moving in x Direction at Constant Velocity u 190

Case 4: Puff with Instantaneous Point Source at Height Hr above Ground Level and a Coordinate System on the Ground That Moves with the Puff 191

Case 5: Puff with Instantaneous Point Source at Height Hr above Ground Level and a Coordinate System Fixed on the Ground at the Release Point192

Isopleths192 Effect of Release Momentum and Buoyancy 193 Worst-Case Dispersion Conditions 194 Limitations to Pasquill?Gifford Dispersion Modeling 195 5-4 Dense Gas Dispersion 197 5-5 Toxic Effect Criteria 198 Emergency Response Planning Guidelines 199 Immediately Dangerous to Life and Health 199 Emergency Exposure Guidance Levels and Short-Term Public Emergency

Guidance Levels 202 Acute Exposure Guideline Levels 204

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