Process Risk and Reliability Management

Process Risk and Reliability Management, 2nd Edition

Process Risk and Reliability Management, 2nd Edition,Ian Sutton,ISBN9780128016534


Gulf Professional Publishing




235 X 191

Practical guidance for the development and implementation of process safety management, operational integrity and operational excellence programs.

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Key Features

  • Learn how to develop a thorough and complete process safety management program.
  • Go beyond traditional hazards analysis and risk management programs to explore a company's entire range of procedures, processes and management issues.
  • Understand how to develop a culture of process safety and operational excellence that goes beyond simple rule compliance.
  • Develop process safety programs for both onshore facilities (EPA, OSHA) and offshore platforms and rigs (BSEE) and to meet Safety Case requirements.


In the last twenty years considerable progress has been made in process risk and reliability management, particularly in regard to regulatory compliance. Many companies are now looking to go beyond mere compliance; they are expanding their process safety management (PSM) programs to improve performance not just in safety, but also in environmental compliance, quality control and overall profitability. Techniques and principles are illustrated with numerous examples from chemical plants, refineries, transportation, pipelines and offshore oil and gas.

This book helps executives, managers and technical professionals achieve not only their current PSM goals, but also to make the transition to a broader operational integrity strategy. The book focuses on the energy and process industries- from refineries, to pipelines, chemical plants, transportation, energy and offshore facilities. The techniques described in the book can also be applied to a wide range of non-process industries.

The book is both thorough and practical. It discusses theoretical principles in a wide variety of areas such as management of change, risk analysis and incident investigation, and then goes on to show how these principles work in practice, either in the design office or in an operating facility. The second edition has been expanded, revised and updated and many new sections have been added including: The impact of resource limitations, a review of some recent major incidents, the value of story-telling as a means of conveying process safety values and principles, and the impact of the proposed changes to the OSHA PSM standard.


Managers and technical staff in the oil and gas industry: refineries, pipelines, transportation, offshore facilities. Managers and engineers in the process industries.

Ian Sutton

Ian Sutton is a chemical engineer with over thirty years of experience in the process industries. He has worked on the design and operation of chemical plants, offshore platforms, refineries, pipelines and mineral processing facilities. He has extensive experience in the development and implementation of process safety management and operational excellence programs.

Affiliations and Expertise

Principal, Sutton Technical Books

View additional works by Ian Sutton

Process Risk and Reliability Management, 2nd Edition

Chapter 1 - Risk Management
Chapter 2 - Compliance and Standards
Chapter 3 - Culture and Participation
Chapter 4 - Technical Information
Chapter 5 - Hazard Identification
Chapter 6 - Operating Procedures
Chapter 7 - Training and Competence
Chapter 8 - Prestartup Reviews
Chapter 9 - Asset Integrity
Chapter 10 - Management of Change
Chapter 11 - Incident Investigation and Root Cause Analysis
Chapter 12 - Emergency Management
Chapter 13 - Audits and Assessments
Chapter 14 - Consequence Analysis
Chapter 15 - Frequency Analysis
Chapter 16 - Reliability, Availability and Maintainability
Chapter 17 - Managing a Risk Program
Chapter 18 - Project Management
Chapter 19 - Contractors
Chapter 20 - The Risk Management Professional
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