Recognizing Catastrophic Incident Warning Signs in the Process Industries

List of Tables xix
<p>List of Figures xxi</p>
<p>Files on the Web Accompanying This Book xxii</p>
<p>Acknowledgements xxv</p>
<p>Foreword xxvii</p>
<p>Preface xxix</p>
<p>1. Introduction 1</p>
<p>1.1 Process safety management 3</p>
<p>1.2 Normalization of deviance 4</p>
<p>1.3 A strategy for response 5</p>
<p>1.4 Maintaining organizational memory and a healthy sense of vulnerability 7</p>
<p>1.5 Risk based process safety 8</p>
<p>1.6 Our target audience 11</p>
<p>1.7 How to use this book 12</p>
<p>1.8 Case study Toxic gas release in India 13</p>
<p>2. Incident Mechanics 17</p>
<p>2.1 Incidents do not just happen 17</p>
<p>2.2 Incident models 17</p>
<p>2.3 Case study Benzene plant explosion in China 27</p>
<p>3. Leadership and Culture 29</p>
<p>3.1 How does leadership affect culture? 29</p>
<p>3.2 The leadership and culture related warning signs 32</p>
<p>3.3 Case study Challenger space shuttle explosion in the US 46</p>
<p>4. Training and Competency 49</p>
<p>4.1 What is effective training and how is competency measured? 49</p>
<p>4.2 The training and competency related warning signs 51</p>
<p>4.3 Case study Gas plant vapor cloud explosion in Australia 62</p>
<p>5. Process Safety information 65</p>
<p>5.1 Critical information to identify hazards and manage risk 65</p>
<p>5.2 The process safety information related warning signs 66</p>
<p>5.3 Case study Batch still fire and explosion in the UK</p>
<p>6. Procedures 79</p>
<p>6.1 Safe and consistent operation 79</p>
<p>6.2 The procedure related warning signs 81</p>
<p>6.3 Case study Nuclear plant meltdown and explosion in the Ukraine 95</p>
<p>7. Asset Integrity 97</p>
<p>7.1 Systematic implementation 97</p>
<p>7.2 The asset integrity related warning signs 99</p>
<p>7.3 Case study Refinery naphtha fire in the US 114</p>
<p>8. Analyzing Risk and Managing Change 177</p>
<p>8.1 Risk management 117</p>
<p>8.2 The risk analysis and management of change related warning signs 121</p>
<p>8.3 Case study Cyclohexane explosion in the UK</p>
<p>9. Audits 139</p>
<p>9.1 Audits support operational excellence 139</p>
<p>9.2 The audit related warning signs 141</p>
<p>9.3 Case study Chemical warehouse fire in the UK</p>
<p>10. Learning From Experience 149</p>
<p>10.1 Methods for continuous improvement 149</p>
<p>10.2 The learning from experience warning signs 151</p>
<p>10.3 Case study Space shuttle Columbia incident in the US 159</p>
<p>11. Physical Warning Signs 163</p>
<p>11.1 The everyday things matter 163</p>
<p>11.2 The physical warning signs 164</p>
<p>11.3 Case study Resin plant dust explosion in the US 172</p>
<p>12. A Call to Action 175</p>
<p>12.1 Actions you can take now for each warning sign 176</p>
<p>12.2 A simple plan to consider for rigorous implementation and follow–up 177</p>
<p>12.3 Actions to consider 180</p>
<p>12.4 Summary 183</p>
<p>Appendix A. Incident Warning Sign Self Assessment Tool 187</p>
<p>Appendix B. Composite List of Catastrophic Incident Warning Signs 199</p>
<p>References &amp; Selected Regulations 205</p>
<p>Acronyms and Abbreviations 213</p>
<p>Glossary 215</p>
<p>Index 221&nbsp;</p>