Hazards and Safety in Process Industries - Case Studies - CRC Press 2021
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Mihir Kumar Purkait, Piyal Mondal,
Murchana Changmai, Vikranth Volli
and Chi-Min Shu
First edition published 2021
by CRC Press
6000 Broken Sound Parkway NW, Suite 300, Boca Raton, FL 33487-2742
and by CRC Press
2 Park Square, Milton Park, Abingdon, Oxon, OX14 4RN
CRC Press is an imprint of Taylor & Francis Group, LLC
© 2021 Mihir Kumar Purkait, Piyal Mondal, Murchana Changmai, Vikranth Volli and Chi-Min Shu
Preface.....................................................................................................................xvii
Authors.....................................................................................................................xix
Chapter 1 Introduction to Industrial Safety and Hazard........................................1
1.1 Background.................................................................................1
1.2 Work Domain and Safety Instructions........................................2
1.3 Records and Reports of Prevalent Industrial Accidents.............3
1.3.1 Energy Industry.............................................................3
1.3.2 Food Industry................................................................4
1.3.3 Manufacturing Industry.................................................4
1.4 Hazards in Process Units............................................................5
1.4.1 General Process Hazards...............................................5
1.4.1.1 Exothermic Reactions with Mild Risk...........5
1.4.1.2 Exothermic Reactions
with Sufficient Risk.......................................6
1.4.1.3 Exothermic Reactions with High Risk..........6
1.4.1.4 Endothermic Reactions with Low Risk.........6
1.4.2 Special Process Hazards................................................6
1.4.3 Confined Space Hazards................................................7
1.4.4 Electrical Hazards.........................................................8
1.4.5 Fire and Explosion Hazard............................................9
1.5 Accident Investigation and Analysis........................................10
1.5.1 Accident Investigation.................................................10
1.5.2 Phases of Accident Investigation and Background
Knowledge...................................................................12
1.5.3 Analysis of Direct and Root Causes of Accident........12
1.5.3.1 Models required...........................................14
1.5.3.2 Pitfalls in analysis........................................15
1.5.3.3 Specificity of Root Causes Analysis............16
1.5.3.4 Various Other Analysis Techniques.............17
1.6 Hazard Control for Safety Provisions.......................................18
1.7 Summary...................................................................................18
References...........................................................................................19
Chapter 2 A Study of a Caprolactam Storage Tank Accident through
Root Cause Analysis with a Computational Approach.......................21
2.1 Introduction to Caprolactum Storage in Industries..................21
2.2 Case Study of a Caprolactum Accident....................................22
2.2.1 Personnel Interview Record........................................22
2.2.2 On-the-Scene Investigation Record.............................24
Chapter 3 Fire Explosion Accident Caused by Static Electricity
in a Propylene Plant.............................................................................39
3.1 Static Electricity and Propylene Plant Integrated Industries....39
3.2 Structural Features of a High-Tech Plant.................................40
3.3 Fire Prevention Features...........................................................41
3.4 Case Review on Disaster..........................................................42
3.5 Investigation of Cause for Accident.........................................43
3.6 Summary...................................................................................45
References...........................................................................................46
Chapter 4 Thermal Hazard Accident During Hydrogen Peroxide Mixing
with Propanone: Case Study...............................................................47
4.1 Overview of H2O2 Uses in Various Industries..........................47
4.2 Hazardous and Toxic Effects of H2O2......................................48
4.3 Investigating Thermal Explosion Accident of H2O2.................48
4.3.1 Samples.......................................................................49
4.3.2 Differential Scanning Calorimetry (DSC)...................49
4.3.3 Vent Sizing Package 2 (VSP2)....................................49
4.3.4 Thermokinetics Application for Adiabatic System.....50
4.3.5 Critical temperature (Tc) of H2O2 calculation.............50
4.4 Thermal Analysis by DSC for H2O2 with Propanone...............51
4.5 Adiabatic Kinetics Study..........................................................53
4.6 Summary...................................................................................54
References...........................................................................................56
Chapter 5 Hydroelectric Power Plant Fire Accident: Fire Dynamics
Simulator (FDS)..................................................................................59
5.1 Overview of a Hydroelectric Power Plant
in Different Sectors...................................................................59
5.2 Selection of Fire Scene.............................................................60
Chapter 19 Analysis of Off-Site Emergency Procedures and Reciprocation
for Nuclear Accidents........................................................................297
19.1 Introduction............................................................................297
19.2 Study on Nuclear Accidents...................................................298
19.3 Different Phases of a Nuclear Accident..................................298
19.3.1 Planning Phase..........................................................298
19.3.1.1 Requirements.............................................298
19.3.1.2 Contents of An Emergency Plan................300
19.3.2 Response Phase.........................................................302
19.3.2.1 Pre-Release Phase......................................302
19.3.2.2 Post-Release Phase....................................303
19.3.3 Recovery Phase.........................................................307
19.4 Economic Cost Analysis.........................................................312
19.4.1 EFactors Affecting the Economic Costs
of a Nuclear Accident................................................313
19.4.2 Economic Modelling in the UK................................314
19.5 Factors Impacting Health and Economic Cost.......................316
19.5.1 Siting and Demography.............................................316
19.5.2 Source Terms.............................................................317
19.5.3 Weather and Dispersion.............................................317
19.5.4 Food...........................................................................318
19.6 Summary.................................................................................319
References.........................................................................................319
Index 327
