Abstract
Safety considerations are of critical importance in process design. Companies have a legal and moral obligation to ensure that chemical plants are designed, built, and operated in a way that does not endanger employees or the general public. An overview of key safety legislation pertinent to chemicals manufacture is given. Hazards inherent to chemical plants are discussed, including materials hazards such as toxicity, flammability, reactivity (materials incompatibility), and radiation and process hazards such as pressure, temperature deviations, noise, loss of containment, fires, explosions, and human error. Methods for analysis of process hazards are introduced, including HAZAN, HAZOP, safety checklists, layer of protection analysis, failure mode effect analysis (FMEA), use of indices such as the Dow fire and explosion index or Mond Fire explosion and toxicity index, quantitative analysis of fault trees, and IEC 61511 methods for ensuring a safety instrumented system achieves a designed safety integrity level (SIL). The design and sizing of relief valves and of relief discharge systems are explained.
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