Reducing Risk in Chemical Process Operations, Equipment Considerations- Volume Two


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Reducing Risk in Chemical Process Operations, Equipment Considerations- Volume Two

During chemical process operations, risk can take many forms. For instance, risk associated with management and engineering decisions can create a range of environmental, health and safety consequences, lead to sub-optimal process operations and depressed production yields, and incur additional maintenance and repair requirements. Similarly, risk associated with project planning, modeling and execution can increase financial and business risk, by resulting in cost overruns and schedule delays, depressed profit margins and squandered market opportunities. This 2-volume Chemical Engineering Guidebook brings together a diverse array of engineering articles, to help facilities recognize all of the many forms of risk that can arise during chemical process operations, and take practical steps to manage the properly in order to optimize outcomes.


This volume includes articles that provide engineering recommendations to help reduce the risk associated with many risk-prone equipment components process operations. Several engineering articles focus on the safe handling of powdered solids to avoid dust explosions. Others areas provide tips for designing, operating and monitoring piping systems and component.

The articles in this volume address risks associated with the safe operation of pressure vessels, pneumatic conveying systems, burners, rotating machinery and more. 


Delivered in a PDF format, 150 pages.

Table of Contents

Prevent Explosions During Transfer Of Powders Into Flammable Solvents
Explanations of the development and characteristics of explosive atmospheres and the potential for an explosion to occur are given, along with the advantages and disadvantages of preventative practices

Fire-Water Pumps for CPI Facilities
Follow this guidance to improve the selection, design and operation of pumps handling water for firefighting and related systems

Protecting Against Compressor Pulsations
Minimizing detrimental pulsation behavior by examining harmonics improves operations and safety

Evaluating and Reducing the Risks of Pneumatic Pressure Testing
In applications where pressure testing with liquids is undesirable, the risks of pneumatic pressure testing of pipes and vessels must be evaluated and minimized

Inspecting Underground Piping
First consider noninvasive methods to determine where excavation is — and isn’t — necessary

Get the Most out of Vibration Analysis
By listening to the messages your components are sending, you will be better able to assess the status of your machinery and take action to address problems

Lubricating Rotating Machinery
Follow this guidance to improve lubricant selection, process operation and asset reliability

Pressure-Vessel Quality Control Requirements
Understanding what is required for boiler and pressure-vessel manufacturers can help scheduling and cost assessments

Dust Control in the Chemical Processing Industries
The prevention of dust hazards in the CPI is integral to process-safety management — wide-reaching mitigation schemes must be implemented

Piping Design for Hazardous Fluid Service
Extra considerations and precautions are needed beyond the requirements of codes and standards

Combining the use of Rupture Discs with Relief Valves
Using the two devices together offers significant benefits in chemical processes. Here is how to take advantage of them

Mass Transfer in Fermentation Scaleup
As fermenters are scaled up to huge sizes, mass transfer is a key consideration

Condition Monitoring for Rotating Machinery
This valuable insight into the performance of pumps and compressors will help improve operation

A Method for Quantifying Pipe Vibrations
A technique to quantify vibration forces can help prevent pipe failures due to vibration-induced fatigue

Piping-System Leak Detection and Monitoring for the CPI
Eliminating the potential for leaks is an integral part of the design process that takes place at the very onset of facility design

Piping: Minimizing the Risk of ‘Pre-buys’
Buying too early may risk a surplus; buying too late may impact the schedule and budget

Dust Explosions: Prevention & Protection
Understand what causes these disasters and then put these practical measures in place

Piping Design for Potentially Lethal Chemicals
Integrity and reliability are critical for piping and equipment that handle chemicals with extreme health hazards

Burner Inspection and Maintenance
Burners and their components can be quite complex. Establishing maintenance and inspection best practices encourages long-term operational reliability

Critical Connections Demand Certainty
Understanding bolts’ behavior during routine tightening procedures helps to ensure leak-free, reliable operations

Preventing Dust Explosions
Risk management programs are critical for safe handling and processing of combustible dust as well as for OSHA regulatory compliance

Static Electricity Discharge and Fire Prevention

Gas Hazard Definitions and Data

Liquefied-Industrial-Gas Safety

Scaleup Options and Risk
Often constrained by cost and time, engineers must take calculated risks in bringing a pilot process to commercial scale

An Exercise In Fire Protection
Asking the right questions about fire protection will prevent minor incidents from escalating

Safety-Instrumented Systems: Focus on Measurement Diagnostics
WirelessHART and other new approaches help operators to achieve the needed safety at the lowest lifecycle cost

Working with the CSB After a Major Accident.

Runaway Reactions: Ignore the Chemistry at Your Peril

Avoiding Runaway Reactions