Handbook for Process Safety in Laboratories and Pilot Plants

Handbook for Process Safety in Laboratories and Pilot Plants

by CCPS (Center for Chemical Process Safety)
Released August 2023
Publisher(s): Wiley-AIChE
ISBN: 9781119010135

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Book description

Handbook for Process Safety in Laboratories and Pilot Plants

Effectively manage physical and chemical risks in your laboratory or pilot plant

In Handbook for Process Safety in Laboratories and Pilot Plants: A Risk-based Approach, the Center for Chemical Process Safety delivers a comprehensive and authoritative presentation of process safety procedures and methods for use in laboratories and pilot plants (LAPPs). Of the four broad hazard categories — chemical, physical, biological, and ionizing radiation — this book focuses on the two most common: chemical and physical hazards. It addresses the storage and handling of the hazardous materials associated with activities commonly performed in LAPPs and presents many of the physical and chemical analytical techniques used to verify and validate the efficacy of safety management systems.

This book will present tools and techniques for effectively managing the risks in any laboratory or pilot plant using engineered and administrative controls, as well as the CCPS Risk Based Process Safety (RBPS) Management Systems.

Readers will also find:

  • A thorough introduction to process safety
  • Comprehensive explorations of understanding hazards and risks, as well as managing risk with engineered controls, administrative controls, and RBPS Management Systems
  • Practical discussions of how to learn from the experiences of your own LAPP and others
  • Detailed case reports and examples, as well as practical tools, control banding strategies, and glass equipment design

Perfect for any LAPP staff member working with or managing hazardous materials, Handbook for Process Safety in Laboratories and Pilot Plants: A Risk-based Approach will also benefit LAPP engineering and scientific professionals, LAPP technical support staff, and LAPP managers.

The Center for Chemical Process Safety is a world leader in developing and distributing information on process safety management and technology. Since 1985, CCPS has published over 100 books in its process safety guidelines and concept series, 33 training modules as part of its Safety in Chemical Engineering Education series, and over 220 online offerings.

Table of contents

  1. Cover
  2. Table of Contents
  3. Title Page
  4. Copyright
  5. List of Figures
  6. List of Tables
  7. Abbreviations and Acronyms
  8. Glossary
  9. Acknowledgments
  10. Dedication
  11. Online Materials Accompanying this Handbook
  12. Preface
  13. Part 1 – Introduction and Overview
    1. 1 Purpose and Scope
      1. 1.1 Purpose
      2. 1.2 Scope of Book and Target Audience
      3. 1.3 Terms for Laboratories and Pilot Plants
      4. 1.4 Distinctions between Laboratories and Pilot Plants
      5. 1.5 Organization of This Handbook
    2. 2 Managing Risk to Prevent Incidents
      1. 2.1 Some LAPP Characteristics
      2. 2.2 Safety in Laboratories and Pilot Plants
      3. 2.3 Where to Start with a Risk‐based Approach in the LAPP
      4. 2.4 Gain Leadership Support to Implement Risk Based Process Safety
      5. 2.5 Laboratory Safety Management System Considerations
      6. 2.6 Resources for Risk Based Process Safety Management System
    3. 3 Leaks and Spills in the LAPP
      1. 3.1 Leaks of Hazardous Materials
      2. 3.2 Spills of Hazardous Materials
  14. Part 2 – Committing to Process Safety
    1. 4 LAPP Risk Management Concepts
      1. 4.1 Occupational Safety and Process Safety
      2. 4.2 Hierarchy of Controls
      3. 4.3 Inherently Safer Design (ISD)
      4. 4.4 Basic Risk Concepts
      5. 4.5 A Risk Management Program
      6. 4.6 Anatomy of an Incident
      7. 4.7 Preventive and Mitigative Safeguards
      8. 4.8 Applying a Risk‐Based Approach in a LAPP
    2. 5 Process Safety Culture in the LAPP
      1. 5.1 RBPS Element 1: Process Safety Culture
      2. 5.2 Leaders’ Responsibilities for Positive Safety Culture
      3. 5.3 Resources and Examples for Process Safety Culture
    3. 6 Standards for the LAPP
      1. 6.1 RBPS Element 2: Compliance with Standards
      2. 6.2 Risk Management Focus
      3. 6.3 Different Codes and Standards When Scaling Up from Laboratory to Pilot Plant
      4. 6.4 Jurisdictional Requirements
      5. 6.5 Resources for Compliance with Standards
    4. 7 Process Safety Competency and Training in the LAPP
      1. 7.1 RBPS Element 3: Process Safety Competency
      2. 7.2 RBPS Element 12: Training and Performance Assurance
    5. 8 Workforce Involvement and Stakeholder Outreach in the LAPP
      1. 8.1 RBPS Element 4: Workforce Involvement
      2. 8.2 RBPS Element 5: Stakeholder Outreach
  15. Part 3 – Understanding Hazards and Risks
    1. 9 Process Safety Knowledge Management in the LAPP
      1. 9.1 RBPS Element 6: Process Knowledge Management
      2. 9.2 Overview of Information and Data Needs
      3. 9.3 Sources of Information and Data
      4. 9.4 Process Safety Information during Scale‐up
    2. 10 Types of Hazards
      1. 10.1 Reactive Chemistry Hazards
      2. 10.2 Toxicity Hazards
      3. 10.3 Flammability and Combustibility Hazards
      4. 10.4 Temperature Hazards
      5. 10.5 Overpressure Hazards
      6. 10.6 Other Common LAPP Hazards
    3. 11 Hazard Identification and Risk Analysis (HIRA) in the LAPP
      1. 11.1 RBPS Element 7: Hazard Identification and Risk Analysis
      2. 11.2 HIRA Team Members
      3. 11.3 HIRA Approaches Used in LAPPs
      4. 11.4 Qualitative versus Quantitative Analysis of Risks in LAPPs
      5. 11.5 ACS Hazard Analysis Tools
      6. 11.6 Evaluating the Effort Level for HIRAs
      7. 11.7 Determining the Extent of the HIRAs
  16. Part 4 – Managing Risk: Engineered Controls
    1. 12 Spill and Leak Protection
      1. 12.1 Containment
      2. 12.2 Flexible hose and tubing
    2. 13 Fire and Over‐Temperature Protection
      1. 13.1 Fire Prevention
      2. 13.2 Fire Mitigation
      3. 13.3 Over‐Temperature Protection
    3. 14 Overpressure Prevention and Protection
      1. 14.1 Pressure Protection for Equipment
      2. 14.2 Pressure and Vacuum Relief for Atmospheric Pressure Vessels
      3. 14.3 Process Conditions/Situations to Consider in Pressure Relief Device Design
      4. 14.4 Blast Containment Cells and Pressure Relief for Building Areas
      5. 14.5 Venting Location and Downstream Treatment of Material Vented
    4. 15 Ventilation Controls
      1. 15.1 Ventilation Systems
      2. 15.2 Laboratory Chemical Fume Hoods
      3. 15.3 Pilot Plant Ventilation
      4. 15.4 Permanent Total Enclosures for Containment in the LAPP
    5. 16 Automated Shut‐down Systems
      1. 16.1 Selection and Design Based on Hazard Identification and Risk Analysis
      2. 16.2 Basic Control Systems and Safety Shut‐down Systems
      3. 16.3 Independent Automated Safety Shut‐down Systems
      4. 16.4 Fail‐Safe Design Considerations
      5. 16.5 Important Design Features for Control Systems
      6. 16.6 Control of Changes and Maintenance for Engineered Safeguards
      7. 16.7 Additional References
    6. 17 Engineered Controls for Common Hazards
      1. 17.1 Cryogenic Fluids and Compressed Gases
      2. 17.2 Cryogenic Fluids and Compressed Gas Cylinders
      3. 17.3 Glass Equipment
      4. 17.4 Gloveboxes
  17. Part 5 – Managing Risk: Administrative Controls
    1. 18 Administrative Fire and Explosion Safeguards
      1. 18.1 Standards and Guidance for Fire Prevention
      2. 18.2 Ignition Source Control: Procedures
      3. 18.3 Manual Fire Suppression
    2. 19 Administrative Safeguards for Hazards in LAPPs
      1. 19.1. Good Practices for Compressed Gas and Cryogenic Cylinders
      2. 19.2 Regulations and Standards for Compressed Gases and Cryogenic Fluids
      3. 19.3 Procedures and Best Practices for Compressed Gases
      4. 19.4 Good Practices for Storage, Movement, and Use of Cryogenic Fluids
      5. 19.5 Good Practices For Handling Glass
      6. 19.6 Administrative Controls for Reactive Hazards
  18. Part 6 – Managing Risk: RBPS Management Systems
    1. 20 Operating Procedures and Conduct of Operations in the LAPP
      1. 20.1 RBPS Element 8: LAPP Operating Procedures
      2. 20.2 RBPS Element 15: Conduct of Operations
    2. 21 Safe Work Practices and Contractor Management in the LAPP
      1. 21.1 RBPS Element 9: Safe Work Practices
      2. 21.2 RBPS Element 11: Contractor Management
    3. 22 Asset Integrity and Reliability in the LAPP
      1. 22.1 RBPS Element 10: Asset Integrity and Reliability
      2. 22.2 A Management Approach for Assuring Asset Integrity and Reliability
      3. 22.3 Examples of Asset Integrity and Reliability Management System Failures
      4. 22.4 Glass Equipment—Asset Integrity and Reliability Challenge for LAPPs
    4. 23 Management of Change (MOC) and Operational Readiness in the LAPP
      1. 23.1 RBPS Element 13: Management of Change
      2. 23.2 RBPS Element 14: Operational Readiness
    5. 24 Emergency Management in the LAPP
      1. 24.1 RBPS Element 16: Emergency Management
      2. 24.2 Emergency Planning
      3. 24.3 Implementing an Emergency Management Plan
      4. 24.4 Emergency Equipment
      5. 24.5 Training and Drills
      6. 24.6 Deficiencies in Emergency Planning and Response in LAPP Cases
      7. 24.7 Controlling Unattended Experimental Work and Working Alone in LAPPs
  19. Part 7 – Learning from Experience
    1. 25 Investigating Incidents
      1. 25.1 Incident Terminology
      2. 25.2 Incident Investigation
      3. 25.3 Steps of an Incident Investigation
      4. 25.4 Ensure Lessons Are Learned and Remembered
      5. 25.5 Learn from Experience of Others
    2. 26 Metrics, Auditing, and Management Review in the LAPP
      1. 26.1 RBPS Element 18: Measurement and Metrics
      2. 26.2 RBPS Element 19: Auditing
      3. 26.3 RBPS Element 20: Management Review and Continuous Improvement
  20. Part 8 – Conclusion
    1. References
    2. Appendix A: Cases
    3. Appendix B: Examples
    4. Appendix C: Control Banding Strategies
      1. C.1. Laboratory Fire Hazard Ratings
      2. C.2. Laboratory Chemical Safety Level (CSL) Ratings
      3. C.3. Toxicity Hazard Ratings
      4. C.4. Biosafety Level Ratings
      5. C.5. Other Hazards in Biological Research Labs
    5. Appendix D: Glass Equipment Design
      1. D.1. Glass Equipment Integrity Challenges
      2. D.2. General Glass Properties and Performance Characteristics
  21. Index
  22. End User License Agreement

Product information

  • Title: Handbook for Process Safety in Laboratories and Pilot Plants
  • Author(s): CCPS (Center for Chemical Process Safety)
  • Release date: August 2023
  • Publisher(s): Wiley-AIChE
  • ISBN: 9781119010135