Handbook for Process Safety in Laboratories and Pilot Plants A Risk based Approach 1st Edition by Center for Chemical Process Safety ISBN 1119693365 9781119693369

Part 1 – Introduction and Overview

1. Purpose and Scope

1.1 Purpose
1.2 Scope of Book and Target Audience
1.3 Terms for Laboratories and Pilot Plants
1.4 Distinctions between Laboratories and Pilot Plants
1.5 Organization of This Handbook

2. Managing Risk to Prevent Incidents

2.1 Some LAPP Characteristics
2.2 Safety in Laboratories and Pilot Plants
2.3 Where to Start with a Risk-Based Approach in the LAPP
2.4 Gain Leadership Support to Implement Risk-Based Process Safety
2.5 Laboratory Safety Management System Considerations
2.6 Resources for Risk-Based Process Safety Management System

3. Leaks and Spills in the LAPP

3.1 Leaks of Hazardous Materials
3.2 Spills of Hazardous Materials

Part 2 – Committing to Process Safety

4. LAPP Risk Management Concepts

4.1 Occupational Safety and Process Safety
4.2 Hierarchy of Controls
4.3 Inherently Safer Design (ISD)
4.4 Basic Risk Concepts
4.5 A Risk Management Program
4.6 Anatomy of an Incident
4.7 Preventive and Mitigative Safeguards
4.8 Applying a Risk-Based Approach in a LAPP

5. Process Safety Culture in the LAPP

5.1 RBPS Element 1: Process Safety Culture
5.2 Leaders’ Responsibilities for Positive Safety Culture
5.3 Resources and Examples for Process Safety Culture

6. Standards for the LAPP

6.1 RBPS Element 2: Compliance with Standards
6.2 Risk Management Focus
6.3 Different Codes and Standards When Scaling Up from Laboratory to Pilot Plant
6.4 Jurisdictional Requirements
6.5 Resources for Compliance with Standards

7. Process Safety Competency and Training in the LAPP

7.1 RBPS Element 3: Process Safety Competency
7.2 RBPS Element 12: Training and Performance Assurance

8. Workforce Involvement and Stakeholder Outreach in the LAPP

8.1 RBPS Element 4: Workforce Involvement
8.2 RBPS Element 5: Stakeholder Outreach

Part 3 – Understanding Hazards and Risks

9. Process Safety Knowledge Management in the LAPP

9.1 RBPS Element 6: Process Knowledge Management
9.2 Overview of Information and Data Needs
9.3 Sources of Information and Data
9.4 Process Safety Information during Scale-Up

10. Types of Hazards

10.1 Reactive Chemistry Hazards
10.2 Toxicity Hazards
10.3 Flammability and Combustibility Hazards
10.4 Temperature Hazards
10.5 Overpressure Hazards
10.6 Other Common LAPP Hazards

11. Hazard Identification and Risk Analysis (HIRA) in the LAPP

11.1 RBPS Element 7: Hazard Identification and Risk Analysis
11.2 HIRA Team Members
11.3 HIRA Approaches Used in LAPPs
11.4 Qualitative versus Quantitative Analysis of Risks in LAPPs
11.5 ACS Hazard Analysis Tools
11.6 Evaluating the Effort Level for HIRAs
11.7 Determining the Extent of the HIRAs

Part 4 – Managing Risk: Engineered Controls

12. Spill and Leak Protection

12.1 Containment
12.2 Flexible Hose and Tubing

13. Fire and Over-Temperature Protection

13.1 Fire Prevention
13.2 Fire Mitigation
13.3 Over-Temperature Protection

14. Overpressure Prevention and Protection

14.1 Pressure Protection for Equipment
14.2 Pressure and Vacuum Relief for Atmospheric Pressure Vessels
14.3 Process Conditions/Situations to Consider in Pressure Relief Device Design
14.4 Blast Containment Cells and Pressure Relief for Building Areas
14.5 Venting Location and Downstream Treatment of Material Vented

15. Ventilation Controls

15.1 Ventilation Systems
15.2 Laboratory Chemical Fume Hoods
15.3 Pilot Plant Ventilation
15.4 Permanent Total Enclosures for Containment in the LAPP

16. Automated Shut-Down Systems

16.1 Selection and Design Based on Hazard Identification and Risk Analysis
16.2 Basic Control Systems and Safety Shut-Down Systems
16.3 Independent Automated Safety Shut-Down Systems
16.4 Fail-Safe Design Considerations
16.5 Important Design Features for Control Systems
16.6 Control of Changes and Maintenance for Engineered Safeguards
16.7 Additional References

17. Engineered Controls for Common Hazards

17.1 Cryogenic Fluids and Compressed Gases
17.2 Cryogenic Fluids and Compressed Gas Cylinders
17.3 Glass Equipment
17.4 Gloveboxes

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Part 5 – Managing Risk: Administrative Controls

18. Administrative Fire and Explosion Safeguards

18.1 Standards and Guidance for Fire Prevention
18.2 Ignition Source Control: Procedures
18.3 Manual Fire Suppression

19. Administrative Safeguards for Hazards in LAPPs

19.1 Good Practices for Compressed Gas and Cryogenic Cylinders
19.2 Regulations and Standards for Compressed Gases and Cryogenic Fluids
19.3 Procedures and Best Practices for Compressed Gases
19.4 Good Practices for Storage, Movement, and Use of Cryogenic Fluids
19.5 Good Practices for Handling Glass
19.6 Administrative Controls for Reactive Hazards

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Part 6 – Managing Risk: RBPS Management Systems

20. Operating Procedures and Conduct of Operations in the LAPP

20.1 RBPS Element 8: LAPP Operating Procedures
20.2 RBPS Element 15: Conduct of Operations

21. Safe Work Practices and Contractor Management in the LAPP

21.1 RBPS Element 9: Safe Work Practices
21.2 RBPS Element 11: Contractor Management

22. Asset Integrity and Reliability in the LAPP

22.1 RBPS Element 10: Asset Integrity and Reliability
22.2 A Management Approach for Assuring Asset Integrity and Reliability
22.3 Examples of Asset Integrity and Reliability Management System Failures
22.4 Glass Equipment—Asset Integrity and Reliability Challenge for LAPPs

23. Management of Change (MOC) and Operational Readiness in the LAPP

23.1 RBPS Element 13: Management of Change
23.2 RBPS Element 14: Operational Readiness

24. Emergency Management in the LAPP

24.1 RBPS Element 16: Emergency Management
24.2 Emergency Planning
24.3 Implementing an Emergency Management Plan
24.4 Emergency Equipment
24.5 Training and Drills
24.6 Deficiencies in Emergency Planning and Response in LAPP Cases
24.7 Controlling Unattended Experimental Work and Working Alone in LAPPs

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Part 7 – Learning from Experience

25. Investigating Incidents

25.1 Incident Terminology
25.2 Incident Investigation
25.3 Steps of an Incident Investigation
25.4 Ensure Lessons Are Learned and Remembered
25.5 Learn from Experience of Others

26. Metrics, Auditing, and Management Review in the LAPP

26.1 RBPS Element 18: Measurement and Metrics
26.2 RBPS Element 19: Auditing
26.3 RBPS Element 20: Management Review and Continuous Improvement

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Part 8 – Conclusion