Guidelines for Engineering Design for Process Safety, Second Edition -- CONTENTS -- Acronyms and Abbreviations -- Glossary -- Acknowledgments -- Foreword -- Preface -- 1 INTRODUCTION -- 1.1 Engineering Design for Process Safety Through the Life Cycle of the Facility -- 1.2 Regulatory Review / Impact on Process Safety -- 1.3 Who Will Benefit From These Guidelines? -- 1.4 Organization of this Book -- 1.5 Other CCPS Resources -- 1.6 References -- 2 FOUNDATIONAL CONCEPTS -- 2.1 Understanding the Hazard -- 2.1.1 Dangerous Properties of Process Materials -- 2.1.2 Process Conditions -- 2.1.3 Inventory -- 2.2 Risk-Based Design -- 2.2.1 The Concept of Risk -- 2.2.2 Selection of Design Bases for Process Safety Systems -- 2.3 Intentional Unsteady State Condition Evaluation -- 2.3.1 Batch Reaction Systems -- 2.4 Unintentional Unsteady State Issues -- 2.4.1 Runaway Reactions -- 2.4.2 Deviating from the Design Intent -- 2.5 Non-Linearity of the Design Process -- 2.6 References -- 3 BASIC PHYSICAL PROPERTIES / THERMAL STABILITY DATA -- 3.1 Basic Physical Properties -- 3.2 Flammability Data -- 3.2.1 Flash Point -- 3.2.2 Fire Point -- 3.2.3 Autoignition Temperature -- 3.2.4 Flammable Limits -- 3.2.5 Minimum / Limiting Oxygen Concentration -- 3.2.6 Dust Deflagration Index - KSt -- 3.2.7 Gas Deflagration Index - Kg -- 3.3 Reactivity / Thermal Stability Data -- 3.3.1 Chemical Reactivity -- 3.3.2 Detonations and Deflagrations -- 3.3.3 Runaway Reactions -- 3.3.4 Calorimetric Data -- 3.3.5 Interaction Matrix -- 3.3.6 Testing Methods -- 3.4 References -- 4 ANALYSIS TECHNIQUES -- 4.1 Hazard Identification -- 4.1.1 Process Hazards -- 4.1.2 Chemical / Material Hazards -- 4.1.3 Human Impact Data -- 4.2 Hazard Analysis Techniques -- 4.2.1 A Life Cycle Approach -- 4.2.2 Qualitative -- 4.2.3 Semi-Quantitative -- 4.2.4 Quantitative -- 4.2.5 Human Factors.

4.2.6 Selecting the Appropriate Technique -- 4.3 Risk Assessment -- 4.3.1 Technical Aspects of QRA -- 4.3.2 Risk Criteria -- 4.3.3 Quantitative Risk Assessment -- 4.3.4 Risk Tolerance / Decision Making Criteria -- 4.4 Reliability / Maintainability Analysis -- 4.5 References -- 5 GENERAL DESIGN -- 5.1 Safeguarding Strategies -- 5.1.1 Inherent -- 5.1.2 Passive -- 5.1.3 Active -- 5.1.4 Procedural -- 5.1.5 Characteristics of Design Solution Categories -- 5.1.6 Safety Factor -- 5.1.7 Safeguard Stewardship -- 5.2 Inherently Safer Design -- 5.2.1 Minimize -- 5.2.2 Substitute -- 5.2.3 Moderate -- 5.2.4 Dilution -- 5.2.5 Simplify -- 5.3 Basic Process Control Systems -- 5.3.1 Alarm Management -- 5.3.2 Testing Instrumentation -- 5.4 Instrumented Safety Systems -- 5.5 Process Design / Process Chemistry -- 5.5.1 Process Equipment Safe Operating Limits -- 5.5.2 Consequences of Deviation -- 5.6 Plant Siting and Layout -- 5.6.1 Site Layout -- 5.6.2 Unit Layout -- 5.6.3 Storage Layout -- 5.6.4 Occupied Building Location -- 5.7 Materials of Construction -- 5.7.1 Properties of Materials -- 5.7.2 Corrosive Environments -- 5.7.3 Pitfalls in Material Selection -- 5.8 Corrosion -- 5.8.1 General Corrosion and Metallurgical Changes -- 5.8.2 Stress-Related Corrosion -- 5.8.3 Design Considerations -- 5.8.4 Erosion -- 5.9 Civil / Structural / Support Design -- 5.9.1 Site Preparation and Analysis -- 5.10 Thermal Insulation -- 5.10.1 Properties of Thermal Insulation -- 5.10.2 Selection of Insulation Materials -- 5.10.3 Corrosion Under Insulation -- 5.11 Human Factors in Design -- 5.11.1 Human Factors Tools for Project Management -- 5.12 Site Security Issues -- 5.12.1 Physical Security -- 5.12.2 Cyber / Electronic Security -- 5.13 References -- 6 EQUIPMENT DESIGN -- 6.1 Vessels -- 6.1.1 Past Incidents -- 6.1.2 Failure Scenarios and Design Solutions -- 6.1.3 Design Considerations.

6.1.4 References -- 6.2 Reactors -- 6.2.1 Past Incidents -- 6.2.2 Failure Scenarios and Design Solutions -- 6.2.3 Design Considerations -- 6.2.4 References -- 6.3 Mass Transfer Equipment -- 6.3.1 Past Incidents -- 6.3.2 Failure Scenarios and Design Solutions -- 6.3.3 Design Considerations -- 6.3.4 References -- 6.4 Heat Transfer Equipment -- 6.4.1 Past Incidents -- 6.4.2 Failure Scenarios and Design Solutions -- 6.4.3 Design Considerations -- 6.4.4 References -- 6.5 Dryers -- 6.5.1 Past Incidents -- 6.5.2 Failure Scenarios and Design Solutions -- 6.5.3 Design Considerations -- 6.5.4 References -- 6.6 Fluid Transfer Equipment -- 6.6.1 Past Incidents -- 6.6.2 Failure Scenarios and Design Solutions -- 6.6.3 Design Considerations -- 6.6.4 References -- 6.7 Solid-Fluid Separators -- 6.7.1 Past Incidents -- 6.7.2 Failure Scenarios and Design Solutions -- 6.7.3 Design Considerations -- 6.7.4 References -- 6.8 Solids Handling and Processing Equipment -- 6.8.1 Past Incidents -- 6.8.2 Failure Scenarios and Design Solutions -- 6.8.3 Design Considerations -- 6.8.4 References -- 6.9 Fired Equipment -- 6.9.1 Past Incidents -- 6.9.2 Failure Scenarios and Design Solutions -- 6.9.3 Design Considerations -- 6.9.4 References -- 6.10 Piping and Piping Components -- 6.10.1 Past Incidents -- 6.10.2 Failure Scenarios and Design Solutions -- 6.10.3 Design Considerations -- 6.10.4 References -- 6.11 Material Handling and Warehousing -- 6.11.1 Past Incidents -- 6.11.2 Failure Scenarios and Design Solutions -- 6.11.3 Design Considerations -- 6.11.4 References -- 6.12 Utility Systems -- 6.12.1 Past Incidents -- 6.12.2 Design Considerations -- 6.12.3 References -- 7 PROTECTION LAYERS -- 7.1 Ignition Control -- 7.1.1 Electrical Area Classification -- 7.1.2 Purging and Pressurized Enclosures -- 7.1.3 Low Energy Electrical Equipment for Hazardous Locations.

7.1.4 Ventilation / Exhaust -- 7.1.5 Static Electricity -- 7.1.6 Lightning -- 7.2 Instrumented Safety Systems -- 7.2.1 Safety Instrumented Systems -- 7.2.2 Engineering Aspects of Instrumented Safety Systems -- 7.3 Pressure / Vacuum Relief Systems -- 7.3.1 Relief Design Scenarios -- 7.3.2 Pressure Relief Devices -- 7.3.3 Sizing of Pressure Relief Systems -- 7.3.4 Sizing of Rupture Disks -- 7.3.5 Other Considerations -- 7.3.6 Methods of Overpressure Protection for Two-Phase Flows -- 7.4 Equipment Isolation / Blowdown -- 7.4.1 Equipment Isolation -- 7.4.2 Depressurization -- 7.5 Effluent Disposal Systems -- 7.5.1 Flares -- 7.5.2 Design Considerations for Flares -- 7.5.3 Blowdown Systems -- 7.5.4 Incineration Systems -- 7.5.5 Vapor Control Systems -- 7.6 Emergency Response Alarm Systems -- 7.6.1 Plant Emergency Alarm and Surveillance -- 7.6.2 Gas / Fire Detection -- 7.6.3 Leak Detection -- 7.7 Fire Protection -- 7.7.1 Structural Fireproofing -- 7.7.2 Firefighting Agents -- 7.7.3 Fire Water Systems -- 7.7.4 Mitigation Systems -- 7.7.5 Portable Fire Suppression Equipment -- 7.7.6 Fire Extinguishers -- 7.8 Deflagration / Detonation Arresters -- 7.8.1 Selection and Design Criteria -- 7.9 Explosion Suppression -- 7.9.1 Oxidant Concentration Reduction -- 7.9.2 Deflagration Pressure Containment -- 7.9.3 Explosion Venting -- 7.9.4 Equipment and Piping Isolation -- 7.10 Specialty Mitigation Systems -- 7.10.1 Water / Steam Curtain -- 7.10.2 Steam Snuffing -- 7.10.3 Mechanical Interlocks -- 7.10.4 Inhibitor Injection -- 7.10.5 Quench System -- 7.10.6 Dump System -- 7.11 Effluent Handling / Post-Release Mitigation / Waste Treatment Issues -- 7.12 References -- 8 DOCUMENTATION TO SUPPORT PROCESS SAFETY -- 8.1 Process Knowledge Management -- 8.1.1 Importance of Process Knowledge Management -- 8.1.2 Types of Process Knowledge and Information Documentation.

8.1.3 Design Basis -- 8.1.4 Managing Change -- 8.1.5 Other Considerations -- 8.2 Engineering Design Package -- 8.3 Operating / Maintenance Procedures -- 8.3.1 Need for Procedures -- 8.3.2 Developing Procedures -- 8.3.3 Maintaining Procedures -- 8.4 Asset Integrity / Reliability / Predictive Maintenance Data -- 8.5 References -- INDEX.