The EPA investigation of a 1994 chemical plant tragedy concluded that "the explosion resulted from a lack of written safe operating procedures..." While good written procedures can't guarantee zero accidents, they can reduce the number of accidents caused by human error. This new book shows how to remedy this problem through selecting and implementing actions that promote safe, efficient operations and maintenance, improve quality, continuity, profitability and cost control, build upon and record process experience, and promote the concept that operating and maintenance procedures are vital plant components. It includes practical samples of procedure formats, checklists and many references.

Written by a professional chemical engineer with an insider's viewpoint, the author presents to managers, operators and engineers running process plants a much needed guide to writing operating procedures. This book is one of the first to codify and illustrate the steps necessary for reliable and enforceable operating procedures. Included are colour inserts to illustrate colour-coding procedures for equipments as well as desktopping guidelines for written reports, instruction and audits.

This is a guide and reference to preparing a systematic methodology for converting a newly constructed plant, as well as streamlining equipment into an operational process unit. It includes downloadable commissioning process checklists that comply with industry standard best practice which readers can adapt for their own situations.

Process Plant Operating Procedures presents an introduction to the theory and applications of procedure synthesis that is primarily concerned with the task of conjecturing the sequence of controller (or operator) actions needed to achieve designated operational goals in a given system. In order to facilitate practical implementation, the formal problem statement, two alternative approaches, their validation methods and a series of realistic examples are provided. The authors explore Petri nets and automata to identify the best paths leading to the specified goal of operation. The model-building methods for characterising all components in the given system, as well as the required control specifications, are explained with simple examples. The sequential control actions and the corresponding time schedule can then be identified accordingly. This book exposes practitioners to an important area of plant operations, teaching them effective approaches for procedure synthesis, enabling them to construct and solve scheduling models, and providing them with tools for simulation and validation of procedures and schedules. It is written for readers with a basic understanding of process design and control activities, and it will appeal to engineers in diverse fields with an interest in synthesizing operating procedures in process plants. Advances in Industrial Control reports and encourages the transfer of technology in control engineering. The rapid development of control technology has an impact on all areas of the control discipline. The series offers an opportunity for researchers to present an extended exposition of new work in all aspects of industrial control.

In contrast to nuclear plants and aerospace systems, human error is largely ignored in quantitative risk assessment for petroleum and chemical plants. Because of this, current risk analysis methods are able to calculate and predict only about one-third of the accidents happening in practice. Human Error in Process Plant Design and Operations: A Pra

Human Factors Handbook for Process Plant Operations Provides clear and simple instructions for integrating Human Factors principles and practices in the design of processes and work tasks Human Factors, the science of interaction between humans and other elements of a system, draws from disciplines such as psychology, ergonomics, anthropometrics, and physiology to understand how and why people behave and perform as they do—and how best to support them in performing tasks. The goals of the Human Factors approach are to improve human reliability, minimize the risk from human error, and optimize the working environment, human wellbeing, and overall system performance. Human Factors Handbook for Process Plant Operations guides supervisors, managers, and engineers on incorporating Human Factors principles and practices into plant maintenance and operations. With thorough and accessible coverage of all Human Factors topics of relevance to process industries, this easy-to-use handbook uses real-world anecdotes and case studies to demonstrate effective training and learning, task planning, communications, emergency response, risk and error management, and more. Throughout the text, the authors offer valuable insights into why people make mistakes while providing advice on how to help workers perform their process operational tasks successfully. Explains all essential Human Factors concepts and knowledge with clear descriptions and illustrative examples Offers actionable advice and models of good practice that can be applied to design, process operations, start-ups and shut-downs, and maintenance Addresses job aids, equipment design, competence, task support, non-technical skills, working with contractors, and managing change Discusses how lack of Human Factors considerations during the engineering design phase can adversely affect safety and performance Describes how to use indicators to both recognize and learn from human error and performance issues Written by highly experienced operating and maintenance personnel, Human Factors Handbook for Process Plant Operations is an indispensable resource for everyone involved with defining, planning, training, and managing process operations, maintenance, and emergency response in the food, pharmaceutical, chemical, petroleum, and refining industries. The missions of both the CCPS and EI include developing and disseminating knowledge, skills and good practices to protect people, the environment, and property by bringing the best knowledge and practices to industry, academia, governments and the public around the world through collective wisdom, tools, training and expertise. The CCPS, an industrial technology alliance of the American Institute of Chemical Engineers (AIChE), has been at the forefront of documenting and sharing important process safety risk assessment methodologies for more than 35 years and has published over 100 books in its process safety guidelines and process safety concept book series. The EI’s Technical Work Program addresses the depth and breadth of the energy sector from fuels and fuels distribution to health and safety, sustainability and the environment. The EI program provides cost-effective, value-adding knowledge on key current and future international issues affecting those in the energy sector.