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High Integrity Systems and Safety Management in Hazardous Industries
1st Edition - January 8, 2015
Author: J.R Thomson
Language: English
Paperback ISBN:9780128019962
9 7 8 - 0 - 1 2 - 8 0 1 9 9 6 - 2
eBook ISBN:9780128020340
9 7 8 - 0 - 1 2 - 8 0 2 0 3 4 - 0
This book is about the engineering management of hazardous industries, such as oil and gas production, hydrocarbon refining, nuclear power and the manufacture of chemicals and ph…Read more
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This book is about the engineering management of hazardous industries, such as oil and gas production, hydrocarbon refining, nuclear power and the manufacture of chemicals and pharmaceuticals. Its scope includes an overview of design standards and processes for high integrity systems,safety management processes as applied to hazardous industries and details best practices in design, operations, maintenance and regulation.
Selected case studies are used to show how the complex multidisciplinary enterprises to design and operate hazardous plant can sometimes fail. This includes the subtlety and fragility of the robust safety culture that is required.
It is aimed at professional engineers who design, build and operate these hazardous plants. This book is also written for business schools and university engineering departments where engineering management is studied.
An overview of design standards and processes for high integrity systems
An overview of safety management processes as applied to hazardous industries
Best practices in design, operations, maintenance and regulation
Chemical engineers, design engineers, safety practitioners, safety engineers.
Dedication
About the Author
Preface
Chapter 1: Introduction
Abstract
Hazardous industries, high-integrity systems and management processes
The structure of this book
Part 1: High-integrity Safety Instrumented Systems
Chapter 2: The Design of High-integrity Instrumentation and Control (I&C) Systems for Hazardous Plant Control and Protection
Abstract
The Safety Lifecycle for the Development of I&C Systems
Reliability Requirements for High-integrity Systems
The “software problem” and software quality management
Functional specifications, traceability, and the V-model
High-integrity software: Setting up a software project
Techniques and measures to produce high-integrity software
I&C failure analysis techniques
Common-mode failure
I&C architecture
The selection of logic elements and vendors for high-integrity industrial safety systems
Quality management of software suppliers
Chapter 3: Cyber Security, Cyber-attack and Cyber-espionage
Abstract
Stuxnet
APT1
Industrial control system architecture and cyber-attack
Chapter 4: The Human–Machine Interface
Abstract
Introduction
A note on pitot tubes
Birgenair 301, February 6, 1996
Aeroperu 603, October 2, 1996
A note on high-altitude upsets and angle of attack
Air France 447, June 1, 2009
Synthesis
Chapter 5: Some Case Studies of Software and Microprocessor Failures
Abstract
Introduction
Qantas flight 72: A serious incident involving smart devices with mixed control and protection
Discussion of Qantas 72 incident
Uljin Nuclear Power Plant, South Korea, 1999
Kashiwazaki-Kariwa Nuclear Power Plant, Japan, 2001
North sea pipe handling system fatal accident, 2008
Auto recalls for software faults
Chapter 6: Managing the Safety of Aging I&C Equipment
Abstract
Introduction: The problem of aging i&c equipment
Basic knowledge and understanding that must be retained by the plant operators
I&C lifecycle issues
Maintenance management
Maintenance planning
Procurement aspects
Key performance indicators (KPIs) for aging I&C equipment
Specific aging failure mechanisms
Case study: Buncefield 2005
Part 2: Historical Overviews of High-Integrity Technologies
Chapter 7: Learning from Ignorance: A Brief History of Pressure Vessel Integrity and Failures
Abstract
The sultana disaster, Tennessee, 1865
Boiler explosions and developments in boiler technology during the First Industrial Revolution
The Cockenzie steam drum failure, 1966
Modeling the fracture of pressure vessels
The accuracy and reliability of non-destructive examination
Dounreay, 1981 – safety valve testing on a steam drum
The SS Norway boiler explosion, Miami, 2003
Chapter 8: The Second Industrial Revolution – A Brief History of Computing
Abstract
Part 3: Safety Management
Chapter 9: Introduction: Organization and Safety Culture
Abstract
The Swiss cheese model
Royal air force nimrod crash, Afghanistan, September 2, 2006
The meaning of safety in a military environment
Chapter 10: Management Systems to Prevent or Mitigate Accidents
Abstract
The health, safety and environmental management system
Personnel recruitment and training
Safe working arrangements
Design engineering and safety functional requirements
Technical safety and technical risk assessments
Engineering changes and safety case changes
Accident and incident investigations
Emergency planning
Corrective action tracking
Synthesis
Chapter 11: The Human Factor
Abstract
Introduction
The Port of Ramsgate walkway accident, 1994
Saudia Flight 163: human behavior during crisis management
Conclusions
Chapter 12: Hydrocarbon Processing
Abstract
Pipeline rupture and fire, Washington State, USA, June 10, 1999
Equilon Anacortes refinery coking plant accident, November 25, 1998
Chapter 13: Offshore Oil and Gas: Piper Alpha and Mumbai High
Abstract
Piper Alpha accident and the Cullen report
Offshore safety training
Mumbai High, July 2005
Piper Alpha and Mumbai High: Common lessons?
Chapter 14: BP
Abstract
Introduction
BP Texas City refinery – prelude to the accident
The accident at BP Texas City
Aberdeen 2007 to 2009
The Macondo-Deepwater Horizon blowout, fire and oilspill, April to July 2010
The Macondo-Deepwater Horizon accident, April 20, 2010
So what went wrong?
Why did the blowout preventer fail to work?
Aftermath
Texas City and Macondo-Deepwater Horizon – Can any general conclusions be drawn about BP?
Chapter 15: Chernobyl and Fukushima
Abstract
Prelude: Tourism behind the Iron Curtain, 1984
Generic technical safety requirements for all nuclear reactors
Stability and predictability of nuclear reactor behavior
Nuclear reactor technology in the Soviet Union
The Chernobyl accident
Aftermath – Radiological and health consequences
Chernobyl: Indirect Causes of the Accident
The Great East Japan earthquake and tsunami, March 11, 2011
The accidents at Fukushima Daiichi
Major technical issues
Other Lessons Learned, cultural issues, and consequences for the nuclear industry elsewhere
Radiological and health consequences
Common threads between Chernobyl and Fukushima: National cultural issues and independent nuclear safety regulation
Chapter 16: Toxic Releases
Abstract
Introduction: Seveso, Bhopal, Mississauga, Sandoz
Toxic releases at DuPont Belle, West Virginia, January 22–23, 2010
Chapter 17: Tragedies of the Commons
Abstract
The Great Stink of 1858
The Great London Smog of 1952
World population in the twenty-first century
Global warming in the twenty-first century
Chapter 18: Conclusions
Abstract
Some key themes in safety instrumented systems
Some key themes in safety management
Final words
Further reading
Appendix 1: Experience and Judgment
Appendix 2: Roger Boisjoly, the Challenger Accident, and Whistle-Blowing
Index
No. of pages: 360
Language: English
Edition: 1
Published: January 8, 2015
Imprint: Butterworth-Heinemann
Paperback ISBN: 9780128019962
eBook ISBN: 9780128020340
JT
J.R Thomson
JR (Jim) Thomson, BSc(Eng), PhD, CEng, FIET, FIMechE, FNucI is an independent consultant, www.safetyinengineering.com, specializing in high integrity systems and safety management. He has worked in plant operations management, engineering management and safety management, and has previously held executive director posts in two international safety consultancies. He has been chair of two international conferences on high-integrity safety systems, and was awarded the Nuclear Institute’s Pinkerton Prize 2013
Affiliations and expertise
Independent consultant, www.safetyinengineering.com, specializing in high integrity systems and safety management.
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