This Chemical Processing eHandbook examines some of today’s Process Safety challenges for chemical manufacturers and some of the best practices that can be implemented to make your operations safer.
Download this Chemical Processing eHandbook for insights and strategies including:
- Walk the Line: Company-wide initiative eliminates operator line-up errors. Learn the steps to recognize the errors and implement the solutions.
- Succeed at Process Safety Management: Follow ten rules to ensure an effective long-term program to make your operations safer.
- Properly Pump Condensable Vapors: Each system has benefits and limitations as well as special considerations for handling hazards mixtures. Find out what you need to know!.
Combustible dust explosions are a known hazard in chemical processing,and metal dusts pose a unique danger. Learn why this concern is growing in urgency and the steps industry regulators and technology leaders are taking to improve risk mitigation. Download the whitepaper now.06/28/2016
How do we make safety in our processes second nature? The concept of inherent safety goes beyond simply not having materials that potentially could damage the pipes, vessels and equipment that make up manufacturing facilities. We need to understand all the ways those materials can be involved in incidents that harm people, the environment and our facilities.
Without a thorough understanding of those scenarios and how they can occur, we can’t properly evaluate the risks posed by different technological approaches and effectively apply inherently safer technologies.
In this Chemical Processing Process Safety eHandbook, we delve in to what it means to embrace the concept of inherent safety and provide tips for safer processing including:
- A variety of strategies that can eliminate hazards from operations
- Improving alarm management – how adopting a pragmatic approach can achieve significant benefits
- A rational approach to combustible dust explosion protection
For chemical processors industrial safety is a top concern. Industrial accidents can lead to lost production, injury and in some cases even death. This special report examines how organizations can reduce risk, prevent incidents and ensure safety and compliance in hazardous environments with improved processes. Topics covered include:
- How to Achieve Effective Process Safety Management (PSM) -- Senior managers play an important role in improving PSM. Their efforts should be visible and their leadership felt to ensure success.
- Getting To The Root Of Accidents -- Accident investigations usually focus on operator error or technical failures. However, applying systems thinking may provide greater insights on underlying causes and, in the long run, prevent more incidents.
- Optimizing Safety and Efficiency Through Modern Design-- This ignition protection method helps ensure accuracy, safety and compliance in hazardous environments
Process Safety Management (PSM), driven by the OSHA 1910.119 standard, aims to prevent the unwanted release of hazardous chemicals. This whitepaper presents an overview of PSM, explains the requirements of a Mechanical Integrity (MI) program, and illustrates how PSM and MI can be established within an asset management framework.04/21/2015
Eastman Chemicals, one of the world’s largest chemical companies, recently decided to strengthen their information security and reliability, as well as develop a path forward to lower software maintenance costs. This Case Study shows how Eastman achieved their goals by globally standardizing on Bentley's ProjectWise software in order to replace an aging, but critical, in-house records management system. The ProjectWise solution has enabled Eastman to significantly reduce their IT costs, and is helping them achieve greater security of their vital plant information while providing a modern data-centric environment to move beyond engineering records into asset performance improvement.04/14/2015
For chemical processors, assuring safe operations is always top of mind. In this Chemical Processing Special Report we take a look at three distinct areas of operations and steps to insure best safety practices in each.
- HIPS for Reactive Processes – how this safety-instrumented systems offer advantages over pressure relief valves
- HART DIAGNOSTICS - in safety instrumented system (SIS) field devices have been used for many years by several different SIS vendors. HART diagnostics provide much more information on the health of a field device than can be determined from a standard 4–20 mA signal.
- Proof testing - how this modern method improves efficiency, reduces errors, and meets compliance requirements
Process design and process safety are critical considerations in chemical production and processing. With design and safety paramount at the outset of any new development or equipment retrofit, firms can minimize risk exposure, maximize productivity and position themselves to remain compliant and competitive. Whether retrofit or new, chemical processing is continually challenged by combustible dust. Combustible dust can pose a hidden hazard when accumulation occurs in unseen locations such as in mechanical spaces, above false ceiling, ventilation systems and dust collection systems. In this Chemical Processing Powder eHandbook, we take a look at strategies and solutions for mitigating combustible dust hazards including:
- Identifying hidden hazards - a case study outlining how a facility finds danger from accumulated dust and effectively addresses it
- Powder flowability - how new measurement methods now make it easier to evaluate flow
- Process safety - properly designed weigh model can optimize safety and improve efficiency
- A multivariate approach to powder processing - an overview of several methods that can help determine which powder properties have the greatest influence on performance
Learn how to preclude powder problems. Download your copy of this Chemical Processing Powder eHandbook now.11/11/2014
Systems are becoming more complex. This complexity is changing the nature of the accidents and losses we are experiencing. Process design and process safety are critical considerations in chemical production and processing. With design and safety paramount at the outset of any new development or equipment retrofit, firms can minimize risk exposure, maximize productivity and position themselves to remain compliant and competitive. Advanced automation technologies continue to drive productivity improvements. In this Chemical Processing Improve Plant Safety eHandbook, we provide tips for safer processing including:
- The role of senior management including six important steps senior management should take to insure safer processing
- Optimizing process safety and efficiency through modern weighing design
- The fundamentals of blast-resistant building
Download your copy of this Chemical Processing Improve Plant Safety eHandbook now.10/22/2014
Sponsored By: Parker
Chemical plants vary widely in size and complexity yet share common goals for maximizing efficiency safely and cost effectively. This Chemical Processing Special Report tackles two areas in chemical processing - compressed air systems and powder handling - where gains can be achieved for improving efficiency. We also address the concerns of safety as it relates to drying compressed air in hazardous atmospheres.
- Whether compressed air systems are centrifugal, rotary screw, reciprocating compressors or a combination, this Special Report provides and understanding of what’s involved in getting a suitable supply of compressed air.
- Efficient powder handling can be achieved through optimized humidity management.
- Safe drying practices in hazardous air locations
In the decade before Stuxnet attacked process control systems in Iran, there were just five known supervisory control and data acquisition (SCADA) vulnerabilities for all control systems in the world, according to the U.S. Department of Homeland Security’s Industrial Control Systems Cyber Emergency Response Team (ICS-CERT). In 2011, the year after Stuxnet, that vulnerability count jumped to more than 215. Last year, it reached 248 (Figure 1). No surprise then that Chemical makers are increasingly focusing on protecting their process control systems from intrusion both from the inside and outside. In this Chemical Processing Special Report: Secure plan(t), we take a look at:
How to better protect your control system - “Defense in depth” is crucial, and new and maturing technologies may help
Cyber Security Challenges – learn about countermeasures to protect control systems
Case Study: A vulnerability assessment reveals critical gaps in the security of a natural gas pipeline
How to mitigate security risks in legacy process control systems - several steps can help protect against threats and extend the life of legacy equipment
Learn how to secure your process control systems – and your plant. Download your copy of this Chemical Processing Special Report: Secure plan(t) now.12/17/2013
Major accidents with multiple fatalities continue to occur worldwide in theprocess industries, causing distress to those involved and massive costs to companies. Almost daily, facilities in the process industries face a number of specific major accident hazard scenarios depending upon the nature of the substances they handle and their processing activities. These are caused by known initiating events such as failure of hardware or control systems, or errors by operating or maintenance staff. In this Chemical Processing Process Safety eHandbook, we provide tips for safer processing including:
>> The role of senior management including six important steps senior management should take to insure safer processing
>> Process safety documentation – strategies for ensuring that your documentation is up-to-date and readily accessible09/19/2013
Effectively mixing liquids and solids to create an optimal slurry is one of the perpetual challenges in the chemical industry. This case study demonstrates how an eductor-based mixing system can effectively handle a wide range of materials, utilizing the least amount of floor space, energy and human resources to achieve an optimized process. In addition, the eductor mixing system offers increased efficiencies over a conventional system of mixing by allowing solutions and slurries to be made on demand – as opposed to pre-mixed in large holding tanks. Another important benefit is the system limits exposure to operators, and mitigates issues of delivering solid material in a large vapor space. The design flexibility of an educator-based mixing system offers a high level of customization.05/14/2013
Flexible Intermediate Bulk Containers (FIBCs) have found their niche in the worldwide transportation of powdered, flaked and granulated products. FIBCs are typically made of woven plastic with some type of liner insert and are often referred to as super sacks, big bags or bulk bags in industry. During filling and emptying of FIBCs there is a steady accumulation of static charge that can result in electrostatic discharges from the FIBC. This may in turn provide sufficient energy for ignition of combustible particulate solids or flammable vapors, not to mention unsettling shocks to nearby personnel. In this white paper we review the NFPA 654 Standard for the Prevention of Fire and Dust Explosions from Combustible Particulate Solids and the importance of why identifying the Minimum Ignition Energy (MIE) of your combustible dust or flammable vapor is a necessary component for selecting the correct FIBC Type for your application. Download now.10/22/2012
Combustible dust explosions are a risk in many areas, but one of the most common locations is the dust collector. This white paper reviews OSHA and NFPA standards, how to identify hazards, and the types of equipment used for explosion protection. It also examines common shortfalls to compliance.09/25/2012
Patching process control system software to remove security vulnerabilities is fraught with risk. System issues can be the result of installing a patch, but a system is also vulnerable without patching. Fortunately, virtual patching can improve the process and raise the system’s security at the same time.09/21/2012
As companies and industries increasingly rely on technology, security risks become greater. With growing numbers of Windows machines and increased scarcity of skilled technical resources, a “perfect storm” of cyber threats in production facilities is looming.09/21/2012
As the security threat landscape continues to evolve, so must your response. With increasing numbers of attempted intrusions, cautionary tales of security breaches and the potential for resulting damages at your site, application whitelisting can be an important addition to your security arsenal.09/21/2012
The U.S. Occupational Safety and Health Administration’s Process Safety Management (PSM) Standard [29 CFR 1910.119(j)] require plant management to identify and address hazards. Further challenging plant management, the mechanical integrity (MI) element of the PSM has been difficult for many facilities to implement. In fact, PSM audits by OSHA have consistently demonstrated that MI accounts for a large number of citations at most facilities. In this Chemical Processing Special Report, we take a look at how to effectively implement strategies to comply with PSM standards including:
- Common piping, hoses and valves hazards – what PHA (Process Handling Analysis) teams should look for to improve the quality of the hazard evaluation
- MI element of PSM – an in-depth look at the stated MI requirements, the perceived interpretation of these requirements and further considerations for identifying your plant’s compliance strategy
- MI implications – the impact MI has on plant’s written procedures, training, inspection & testing, and how equipment deficiencies and quality assurance programs are managed
As the Department of Homeland Security (DHS) moves forward with the Chemical Facility Anti-Terrorism Standards (CFATS), the program continues to evolve. This white paper describes the ongoing CFATS compliance process (which is a combination of technical, procedural, and personnel security) and also provides insight regarding how to develop or revise a comprehensive Site Security Plan (SSP) and prepare for a CFATS Authorization Inspection (AI). Recommendations are relevant to SSPs for all tier levels and should be considered for a facility's initial SSP submission and/or any required SSP resubmission. Download this white paper now: Tips for Inspection and Resubmission.07/25/2012