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Safety & Health NewsAIChE SAFETY AND HEALTH AMERICAN INSTITUTE OF DIVISIONCHEMICAL ENGINEERS www.shdiv.aiche.org

A Supplement to Process Safety Progress Spring 2002

SAFETY FORUMINHERENT SAFETY REVISITED

"Green chemistry" has become a major focus fordevelopment of new chemical products andmanufacturing processes. While emphasis hasgenerally been placed on environmental issues,inherent product and process plant safety areimportant components of the concept. Aninherently safer plant relies on chemistry andphysics, that is, the quantity, properties, andconditions of use of the process materials toprevent injuries, environmental damage, andproperty damage, rather than control systems,interlocks, alarms, and procedures.

Inherently safer plants are often the most costeffective. Smaller equipment operating at lesssevere temperatures and pressures will becheaper and will have lower operating costs. Aprocess that does not require complex safetyinterlocks and elaborate procedures will besimpler, easier to operate, and more reliable.

Revisiting inherent safety was prompted by theexcellent discussions in the Special Supplementof the January 2002 Chemical EngineeringProgress entitled "An Evolution in ChemicalEngineering: The Journey Ahead." Of specialinterest here was the section written by Edward L.Cussler, David W. Savage, Anton P. J.Middelberg, and Matthias Kind with the title"Refocusing Chemical Engineering." The chemicalcommodity industry is now mature. The largededicated plants must be operated efficiently tomake a profit. Thus, process optimization andprocess control are important issues. Inherentsafety improves the cost effectiveness and can beconsidered in on-going plant processimprovements. However, the future of chemical engineeringmay well be in the manufacture of specialtychemicals such as pharmaceuticals, electronicmaterials, and biotechnology products. Being first

in the market place is the key to profitability. Thus,plant equipment is used for several differentproducts with batch and semi-batch processesdominating rather than large continuous systems.

It is not uncommon for the process equipmentto be larger scale versions of laboratory unitswhich are then operated in ways that closelyapproximate the laboratory methods. If chemicalengineers are not involved in the early stages ofproduct and process definition, opportunities willbe lost to apply the principles of inherent safetysince any retrofitting will be unlikely. Failure to actat an early stage will lead to considerations ofsafety as an "add-on" with resultant inefficienciesand less effective control of the hazards and risks.

As a refresher, here are the five approachesfor inherently safer plants:! Intensification: using smaller quantities of

hazardous materials;! Substitution: replacing a material with a less

hazardous substance;! Attenuation: using less hazardous process

conditions or a less hazardous form of amaterial;

! Limitations of effects: developing a processthat will minimize the release of hazardousmaterials; and

! Simplification: developing a process andequipment that will make operating errors lesslikely and that will be forgiving of errors thatare made.

The point here is that chemical engineers mustbecome much more actively involved in the earlystages of product and process development in thefuture in order for the principles of inherent safetyto be applied. Failure to do so will lead to a muchmore cumbersome approach to process safety. Sam West

2 Safety & Health News Spring 2002

Safety & Health News is published quarterly by the Safety and Health Division of the American Institute of Chemical Engineers (AIChE).It is distributed to members of the Division as a supplement to Process Safety Progress. Publication is funded by the Safety and Health Division,by the Center for Chemical Process Safety (CCPS) of AIChE, and by AIChE.

A. S. West, P.E., Editor3896 Sidney Road

Huntingdon Valley, PA 19006215-938-7181

e-mail: [email protected]

SAFETY AND HEALTH DIVISION 2002Walter L. Frank, Chair

ABS Consulting5301 Limestone Road, Suite 210

Wilmington, DE 19808302-239-0496

[email protected]

Kris Chatrathi, 1st Vice-ChairFike Corporation

704 South Tenth StreetBlue Springs, MO 64015

816-229-3405, [email protected]

Scott W. Ostrowski, 2nd Vice-ChairExxonMobil Chemical Company

Baton Rouge PlantP. O. Box 241

Baton Rouge, LA 70821-0241225-777-7400

[email protected]

John F. Murphy, Past-ChairU.S. Chemical Safety Board

2175 K Street, NWSuite 400

Washington, DC 20037-1809205-261-7622

[email protected] Albert I. Ness, Secretary/Treasurer

Rohm and Haas CompanyP. O. Box 584

Bristol, PA 19007215-785-7567

[email protected]

DIRECTORS

Henry L. Febo (2000-2002)FM Global

1151 Boston-Providence TurnpikeP.O. Box 9102

Norwood, MA 02062781-255-4771

[email protected]

Walter Silowka (2000-2002)Air Products & Chemicals, Inc.Corporate Engineering Dept.

7201 Hamilton BoulevardAllentown, PA 18195-1501

[email protected]

Gary Pilkington (2001-2003)

Abbott LaboratoriesDept. 05-SL, Bldg. AP52S

200 Abbott Park RoadAbbott Park, IL 60064-6212

[email protected]

Ronald J. Willey (2001-2003)Northeastern University

Dept. of Chemical Engineering360 Huntington Avenue

Boston, MA 02115617-373-3962

[email protected]

Susan R. Cyganiak (2002-2004)Pharmacia

4901 Searle ParkwaySkokie, IL 60077

847-982-4752 [email protected]

William F. Early (2002-2004)Early Consulting

12330 Lanny LaneHouston, TX 77077

[email protected]

PROGRAM COORDINATORS

John F. Murphy(see Past-Chair)

Ephraim A. ScheierBP Amoco Corporation

Room WL4-753P. O. Box 3092

Houston, TX 77253-3092 281-366-2573

[email protected]

AWARDS COMMITTEE

Joseph F. Louvar, ChairWayne State University

Department of Chemical Engineering5050 Anthony Wayne Drive

Detroit, MI 48202-9988313-577-9358

[email protected]

AIChE STAFF REPRESENTATIVE

Clare BennettAmerican Institute of Chemical Engineers

Center for Chemical Process Safety3 Park Avenue

New York, NY 10016-5991212-591-7319

[email protected]

MEMBERSHIP COMMITTEE

Walter L. Frank(see Chair)

John F. Murphy(see Past-Chair)

PUBLICATIONS COMMITTEE

Daniel A. Crowl, ChairMichiganTechnological University

Department of Chemical EngineeringHoughton, MI 49931

[email protected]

CONTINUING EDUCATION COMMITTEE

Dennis C. HendershotRohm and Haas CompanyEngineering Department

P. O. Box 584Bristol, PA 19007

215-785-7243 [email protected]

Peter N. LodalEastman Chemical Company

Building 18P. O. Box 511

Kingsport, TN 37662423-229-2675

[email protected]

Robert W. OrmsbyAir Products & Chemicals, Inc.

7201 Hamilton BoulevardAllentown, PA 18195-1501

[email protected]

GOVERNMENT RELATIONS

Randy Freeman281-877-6407

[email protected]

LIAISON TO BOARD OF DIRECTORS

Dennis C. Hendershot(see Continuing Education Committee)

EDITOR - PROCESS SAFETYPROGRESS

Theodore A. VentroneP. O. Box 669

Belle Mead, NJ 08502908-359-3392

WEBMASTER

Chaitanya BelwalMichigan Technological University

Department of Chemical EngineeringHoughton, MI 49931

[email protected]

Spring 2002 Safety & Health News 3

SAFETY AND HEALTH DIVISION UPDATEWalt Frank, Chair

I'd like to begin by welcoming the continuingmembers of the Division (I won't say oldmembers!) and welcoming aboard the newmembers. On behalf of the Executive Committeeof the AIChE Safety and Health Division, I offerthanks for your support of the Division, the Divisionjournal, and the profession.

I am Walt Frank, the 2002 Chair of theDivision. I am a Senior Consultant in the RiskConsulting Division of ABS Consulting. I haveworked for over 28 years in the chemical and alliedindustries, the last 14 years as a process safetyconsultant. Over 24 years were spent withDuPont, including 10 years in the Process Safetyand Fire Protection group of the DuPontEngineering Department. In addition to being aDivision officer, I am a current member of both theProgram Area 11a and 11b committees ( seeDivision Meetings below). I am also an activesupporter of the AIChE Center for ChemicalProcess Safety (CCPS), having had the privilegeto assist in the preparation of a number of thebooks in the excellent CCPS Guidelines series. Iam a Professional Engineer, licensed in Delaware,where I serve as an elected member of the statePE Licensing Board as well as the Chair of theLaw Enforcement and Ethics Committee.

But enough about me - let's talk about you.You are (most likely) a member of the Safety andHealth Division (or you wouldn't be receiving thisNewsletter). You are, more than likely, anemployee of a firm that has been downsized, re-engineered, or reorganized in a way that placed farmore responsibility on those of you who remained.You, or the part of you that performs the safetyrole for your organization, are probably regardedas an overhead cost, and you are constantlyseeking to justify your existence. And, aschallenging as you previously thought your job tobe, after 9/11/01 you found that it was even morechallenging than you imagined. I hope thatthrough your membership in the Division you canfind significant assistance in meeting at least aportion of the challenges that face you. Read ourjournal, Process Safety Progress, and stay abreastof advances in process safety technology. Cometo our Loss Prevention Symposiums and our Airand Ammonia Plant Symposiums - hobnob withsome of the leading thinkers in our profession -bring your talents and knowledge to contribute aswell. If you find we are not meeting your needs, orif you have suggestions for changes and

improvements, contact one of the Division Officersor Directors (see page 2). This is your Division!Help us to help you.Past-Chair: I would be remiss if I did notacknowledge our outgoing Division Chair, JohnMurphy, P.E. John will not have the opportunity torest on his laurels, however, since not only doeshe continue to serve on the Executive Committeefor one more year, but also is the Meeting Chair forthe 2003 Loss Prevention Symposium - out of thefrying pan into the fire. John, on behalf of theDivision, I thank you for your steady leadershipduring 2001.New Officers: The new Executive Committee ofthe Division is shown on page 2. Kris Chatrathi ofFike Corporation moves up to 1st Vice-Chair andScott Ostrowski of ExxonMobil takes his place asthe newly-elected 2nd Vice-Chair. We have twonewly elected Directors who will serve for the2002-2004 term: Susan R. Cyganiak (Pharmacia)and William F. Early (Early Consulting). I want torecognize and thank our two retiring Directors, Dr.Sam Mannon of the Mary Kay O'Connor ProcessSafety Center at Texas A&M, and Scott Ostrowskiwho, as previously noted, was unable to achieveescape velocity and will be serving as 2nd Vice-Chair. One last acknowledgement is in order.Alan E. Nelson, formerly a PhD candidate atMichigan Technological University, has decidedthat being an Assistant Professor at the Universityof Alberta would be more fun than continuing asthe Division Webmaster. Alan, congratulations forobtaining your PhD and thanks for your help. ChatBelwal of MTU is now our Webmaster.Safety and Health Division Website: Please finda moment and visit the Division website atwww.shdiv.aiche.org. You will find items aboutthe Division organization, programs, andpublications, as well as a number of useful links tosources of health, safety, environmental, and fireprotection information. If you have some favoritelinks that you find useful, please submit them tome and they will be added to the site. Perhapsone of the most useful tools on the website is thecomplete Table of Contents for all issues ofProcess Safety Progress (and its predecessorPlant/Operations Progress). Created andmaintained by Dennis Hendershot of Rohm andHaas, this database allows you to do keywordsearches by author or article title. It is a valuableresearch tool. (continued on page 4 - see UPDATE)

DIVISION ELECTIONIn the recently completed Safety and HealthDivision election for Officers and Directors, ScottOstrowski became 2nd Vice-Chair, starting theprogression to Chair. Susan Cyganiak andWilliam Early were elected as Directors for the2002-2004 term. Albert Ness of Rohm and Haaswas reelected as Secretary/Treasurer for a one-year term.

Walter L. Frank of ABS Consulting moved tothe Chair post and Kris Chatrathi, FikeCorporation, advanced to 1st Vice-Chair.

This was the first Division election conductedwith the option of voting electronically. About 20%of the members voted with a ratio of e-ballots topaper ballots of 2/1. The number of membersvoting was about the same as previous recentyears, but the cost of electronic voting issubstantially less than with paper ballots. The useof e-mail voting is definitely the procedure for thefuture.

Scott Ostrowski is not a new member of theExecutive Committee having served as Director forthe past three years, but he is now in a new post as2nd Vice-Chair. He is a Staff Engineer in theProcess Safety Engineering and ManufacturingServices Group with ExxonMobil Chemical. Hehold a BS degree from Texas A&M and earned anMS from the University of Southern California.

Susan Cyganiak is Manager of Safety andIndustrial Hygiene for Pharmacia. She obtained herBS degree from Virginia Tech.

William Early is President of Early Consulting,LC. He holds BS and MS degrees from theUniversity of Mississippi.

All of the Officers and Directors have hadsignificant leadership activities, both managerialand technical, in the Division.


UPDATE (continued from page 3)Division Meetings: About the time you receivethis Newsletter, you may be either contentedlyreflecting the good time you had at the 36thAnnual Loss Prevention Symposium (LPS) in NewOrleans or regretting the fact that you did not go.If you are in the latter category, despair no morebecause we are giving you another shot at the BigEasy. The 37th LPS will also be held in NewOrleans on March 31-April 2, 2003. You may benoting that the New Orleans venue in 2003interrupts the usual shuttling back and forthbetween Houston and New Orleans. The ProgramArea 11a Committee (the organizers of the LPS)had some very serious concerns about thelogistical issues that were encountered last yearin Houston which impacted on the overall quality ofthe meeting. Consequently, we requested, as didother groups, to change the venue for 2003 whileoptions for future years are being considered. TheCall-for-Papers for the 37th LPS is on page 9.

The Program Area 11b Committee, whichtends to be Houston oriented, has also agreed tohold its biennial Process Plant Safety Symposiumin New Orleans in parallel with the LPS. The Call-for-Papers will appear in the Summer 2002 issueof this Newsletter.

The 46th Annual Safety in Ammonia Plantsand Related Facilities Symposium, organized byProgram Area 11c, held its 2001 session,postponed because of the September 11 terroristattacks, in January of this year. The 47th AnnualSymposium is scheduled for September 16-19,2002, in San Diego.What's Ahead? Certainly, as a consequence of9/11, an important topic that many of us will belooking at over the coming months is that of plantsecurity. This issue includes physical security,information security, and security of electronicsystems. It is my hope that we can help keep youabreast of the developments in this area during thecoming year. In the meantime, you may want tomonitor Senate Bill S.1620, introduced by SenatorCorzine (D-NJ). This "Chemical Security Act of2001" has been proposed to ".... to prevent theftfrom and criminal attack on chemical sources andto reduce the harm such acts would produce by:(1) reducing usage and storage of chemicals bychanging production methods and processes; (2)employing inherently safer technologies in themanufacture, transport, and use of chemicals; (3)enhancing secondary containment and otherexisting mitigation measures such as providingbuffer zones; and (4) improving security.Obviously, there is significant potential impacthere.

Another issue that I will be writing about infuture Newsletters is the topic of professionalcertification for process safety practitioners. If yourbarber requires some sort of professionalcertification to cut your hair, wouldn't it seemreasonable to require suitable credentials for theperson designing your relief valves and emergencyvent systems. More on this later.And finally: I am looking forward to my year asDivision Chair. Please contact me with anycomments or suggestions at 302-239-0496 or [email protected].

Walt Frank, P.E.

NEW BOOK ON ARRESTERSA new CCPS book entitled "Deflagration andDetonation Arresters" has been published and willbe available for the first time at the AIChE SpringMeeting in New Orleans, March 10-14, 2002.Information about the book can be found on page11.

For further information about CCPS, contact:

Dr. Jack A. Weaver, DirectorCenter for Chemical Process SafetyAmerican Institute of Chemical Engineers3 Park AvenueNew York, NY 10016-5991

212-591-7404 e-mail: [email protected]


THE CCPS PAGECENTER FOR CHEMICAL PROCESS SAFETY

PROCESS SAFETY BEACONMessages for Plant Personnel

In this recent project, CCPS is bringing to thesponsor organizations a new product aimed atimproving safety awareness. The intent is toprovide materials for delivering important andtimely process safety messages for manufacturingpersonnel. The messages, with the title ProcessSafety Beacon, are one-page documentsdelivered electronically on a monthly basis. Eachmessage presents a real-life accidental event orpotential incident, describes the lessons learned,and provides practical means to prevent theaccident in your plant.

The Process Safety Beacon is sentelectronically on a monthly basis free of charge toone key contact in each of the CCPS sponsorcompanies. Each contact can then set up adistribution program within their organization,perhaps via an internal e-mail system, to get themessages to the hands-on people such as plantoperators, maintenance personnel, plant safetypeople, supervisors, and engineers.

During this current introductory period, theProcess Safety Beacon will be available free ofcharge to non-sponsor companies to promoteprocess safety awareness across the industry.Once the trial period is complete, the documentswill be available to non-sponsors by subscription.

To view the Process Safety Beacon issuescurrently available, refer to www.aiche.org/ccpsand click on "Process Safety for Operators." Ifyour organization is not a sponsor, but you wouldlike to subscribe, send a request via e-mail [email protected] with the following information:Name, Company, Street Address, City, State,Postal Zip Code, Country, Telephone, and e-mailAddress.

The first message was issued in November2001 with the title "Trace Quantities ofFlammables Can Cause an Event Like This!" Theprimary concern related to flammable vaporspaces in vessels containing only traces offlammable materials.

The December 2001 message covered "Snowand Ice Hazards - They Can Cause More ThanSlips and Falls." Snow and ice build-up onoutdoor equipment and on process buildings canbe hazardous.

The January 2001 message on "Explosions"discussed flammable ranges. O

REACTIVE CHEMICALSThe CCPS Reactive Hazards Subcommittee hasinitiated a recently approved project to create anew reactive hazards book that will expandsignificantly the earlier 10-page Safety Alert on thesubject. The new book will be of value to not onlychemical manufacturers, but also to chemicalformulators and warehousers.

The Safety Alert on "Reactive MaterialHazards" is available at www.aiche.org/ccps,click on "Process Safety Alerts." This booklet hassix sections: (1) Introduction; (2) HandlingReactive Materials; (3) Reactive Interactions; (4)Data Needed to Control Hazards; (5) Safeguardsto Control Hazards; and (6) Helpful References.

Previous pertinent CCPS Guidelines booksinclude Guidelines for Reactivity Evaluation andApplication to Process Design, Publ. G-13 (1995),and Guidelines for Safe Storage and Handling ofReactive Materials, Publ. G-45 (1995). O

PLANT SECURITYAt a meeting in early January in Ft. Lauderdale,FL, the CCPS Technical Steering Committeeformed a Security Subcommittee to develop toolsand to create a book on chemical process security.A six-hour workshop on security issues was heldduring the meeting which served as a focal point toinitiate the project. This is obviously an urgentissue. The book and related materials will be ofsignificant value. O

SAFETY COURSESThe following four process safety continuingeducation courses will be presented April 22-26,2002, in Baltimore, MD, at the Doubletree Inn atthe Colonnade.#173: Emergency Relief System Design UsingDIERS Technology, April 22-24, 2002.#295: Updating and Revalidating Process SafetyHazards, April 25-26, 2002.#300: Hazard Evaluation: Qualitative andQuantitative Methods of Reliability and RiskAssessment, April 22-26, 2002. #579: Preventing Human Error, April 25-26,2002.For further information, see www.aiche.org.


RISK AND RELIABILITYCONFERENCE

There is still time to submit proposals for papersfor the 17th Annual International Conference andWorkshop organized by CCPS which is scheduledfor October 8-11, 2002, in Jacksonville, FL, butyou must hurry. Abstracts can be submitted up toMarch 15, 2002. Abstracts should be e-mailed [email protected]. The abstract of 200 wordsor less may either be in the body of the messageor as a separate WORD document attached to thee-mail. Include contact information.

The theme is risk and reliability. Relatedtopics include the relationship of economic valueand EHS performance. Risk includes hazardidentification, consequence modeling, quantitativeand qualitative risk analysis, risk management,inherent safety, and facility security. Reliabilityincludes engineering programs that prevent therelease of hazardous materials, increase on-stream efficiency, and reduce reactivemaintenance costs.

The conference will consist of PlenarySessions and Workshops. Session themes willinclude the following:RISK: Risk is a measure of human injury,environmental damage, or economic loss in termsof both likelihood and magnitude. Areas includerisk analysis, risk assessment, risk management,and risk communication.FACILITY SECURITY: Recent events haveheightened security concerns. Although acomponent of traditional risk analysis, separatediscussions are warranted.INHERENT SAFETY: Experiences in applyinginherently safer design approaches to reduce oreliminate potential hazards associated with aprocess are included.RELIABILITY: Topics here include newdevelopments in plant equipment reliabilitydatabases and reliability-centered design andmaintenance. CONSEQUENCE MODELING: Developments forprediction of dispersion from multiphase (aerosol)and multi-component releases and experimentalvalidation of models are included in this area.TRANSPORTATION RISK ANALYSIS: Althoughtransportation risk analysis uses familiar tools andtechniques, distribution activities are often housedin separate organizations and responsibility isshared among several parties, and thus a separatediscussion is appropriate.

It is indeed not too early to put the conferencedates on your calendar now. O

SACHE NEWSThe Safety and Chemical Engineering Education(SACHE) program is sponsored by CCPS. Thereare now about 125 university members, including10 in Canada and 6 in other countries. TheFaculty Workshop scheduled for September 16-19,2001, at the BASF Corporation in Wyandotte, MI,has been rescheduled for the Spring of 2002. The2003 Faculty Workshop will be held at theExxonMobil Plant in Baton Rouge, LA. TheWorkshop teachers are industrial experts indesign, operation, and maintenance of plants withknowledge of process safety and experimentalsafety issues. These sessions provide excellentexperiences to support teaching of chemicalengineering. Industrial members of the Safety andHealth Division should encourage faculty membersto attend. O

PARTNERSHIP WITH DOEAIChE became the first professional organizationto enter into an Allied Partnership with the Office ofIndustrial Technologies (OIT) within theDepartment of Energy (DOE). As an AlliedPartner, AIChE will share information about OITresources with the chemical engineeringcommunity. Specifically, information on emergingindustrial technologies, research, and developmentactivities that improve industrial energy efficiencywill be shared with industrial manufacturers.

Outreach to companies will be the most visiblepart of this partnership, as the AIChE network ofmembers can help link decision makers toavailable resources and opportunities. In addition,training workshops will be developed by the AIChEEducational Services Department. O

SAFETY NOTES


! A new report from the Bureau of LaborStatistics of the U.S. Department of Laborindicates that even though the constructionworkplace is getting safer, it is still one of themost dangerous industries. In 2000, the rateof workplace injury and illness in the privateconstruction sector declined to 8.3 cases per100 workers, down from 8.6 in 1999. Thedecline may be due to safety awareness fromtraining programs and from owner safetyrequirements which often must be met beforecontracts are awarded. In 2000, the numberof incidents for all full-time workers dropped tolevels similar to the mid-1970s. Of allindustries, manufacturing reported the highestrate of injury and illness in 2000 with 9.0 casesper 100 workers.

! A program to generate basic toxicityinformation on industrial chemicals istriggering the release of significantamounts of unpublished data. Fewertests than initially thought to be neededare now required according to EPA inthe High Production Volume (HPV)Challenge Program. Chemicalmanufacturing companies aresearching the scientific literature to findpublished data and are searchingthrough their own files for unpublished studies.Under the HPV initiative, chemicalmanufacturers are voluntarily testing about2,800 commercial chemical substances madein the U.S.A. in quantities exceeding 1 millionlb/yr. The aim of the program is to fill ininformation gaps about the basic health andenvironmental effects of these substances,their environmental fate, and certainphysical/chemical properties. Thus far, 469companies and 187 consortia have agreed tosponsor testing of 2,155 HPV chemicals. EPAwill issue regulations requiring studies, andplans to issue one such rule by mid-2002 for37 substances not currently sponsored.

! Neutrally buoyant objects such as boats andpeople will sink in an aerated liquid. Often, lifepreservers are standard safety equipmentaround aeration tanks, e.g., at WastewaterTreatment Plants, but the more importantsafety feature is to provide for emergency

systems to stop the aeration blowers with, say,emergency stop buttons, in case a worker fallsinto a tank. Appropriate training of theoperating staff should also be includedwherever aerated tanks are in use.

! Increasing the use of animal cell lines forchemical toxicity safety testing couldimmediately reduce the number of necessarylaboratory rodents significantly according tothe National Institute of Environmental HealthSciences (NIESH). Two reports onalternatives to LD50 testing methods indicatethat new tests under development in the USAand in Europe require only 8 to 12 animals,instead of perhaps as many as 100 for pre-screening chemical toxicity.

! The National Toxicology Program (NTP)issues a periodic Report on Carcinogens

which identifies substances, mixtures, orexposure circumstances that are "known"or are "reasonably anticipated" to behuman carcinogens and to which asignificant number of Americans areexposed. The most recent report is the 9thEdition issued in May 2000. An addendumwas issued in 2001 changing the listing of2,3,7,8-tetrachlorodibenzo-p-dioxin (known

as TCDD and commonly called "dioxin") to a"known human carcinogen" from its previouslisting as "reasonably anticipated humancarcinogen."

! The 10th Edition of the Report on Carcinogenswill be issued in 2002. The group ofnominations for this edition includes berylliumand beryllium compounds, vinyl bromide, vinylfluoride, steroidal estrogens, metallic nickeland certain nickel alloys, trichloroethylene,broad spectrum UV radiation, and wood dust.Final decisions will be made by NTP followinga review of the recommendations from severalparticipating committees and from publiccomments. Scientific review of nominationsunder consideration for the 11th Edition hasnow been initiated.

! Do engineering students really think thatSpring Break is a metal fatigue problem? O

CERTIFIED SAFETYPROFESSIONALS

The Board of Certified Safety Professionals inSavoy, IL, announced the new officers for 2002.Stewart C. Burkhammer, CSP, PE, of BechtelCorporation, was elected President; David A.Herbert, CSP, a consultant, was elected Vice-President; and Curt L. Lewis, CSP, PE, ofAmerican Airlines, is the new Secretary/Treasurer.

The Board also announced the availability ofthe new Third Edition Safety Fundamentals andComprehensive Practice Self AssessmentExaminations. For more information, see:www.bcsp.org/assess.html.


RECURRING CHEMICALINCIDENTS

The Environmental Protection Agency and theOccupational Safety and Health Administrationhave investigated a number of recent significantincidents at petroleum refineries, chemicalmanufacturing facilities, tolling operations, andother types of similar facilities. According toJames C. Belke of EPA, there are recurringthemes and common causes of such incidents.The five common themes were: (1) inadequatehazard review; (2) inadequate management ofchange; (3) use of inappropriate equipment; (4)inadequate indications of process operatingconditions; and (5) poor attention to warnings.

In almost every accident investigated, someaspect of hazard review or process hazardsanalysis (PHA) was deficient. In some incidents,a PHA was performed but did not identify allprocess hazards. Material Safety Data Sheetswere looked upon as the primary source of hazardinformation. While MSDSs do provide substantialinformation on chemical hazards, they rarelyprovide significant information on process hazards.In other cases, no hazard review was undertakenon the process involved in the accident.

Several of the incidents investigated followedthe installation of devices to eliminate or reducevapor emissions. Each case involved a processchange made with the good intentions ofprotecting the environment. However, the fullimplications to personnel and process safety werenot considered. In short, a change was made, butit was not managed properly.

In several incidents, equipment was used fora task which was inappropriate or not inaccordance with current standards or goodpractices.

Another recurring theme was the fact that theprocess instrumentation did not provide theoperators with the necessary indications to identifyclearly that unsafe process conditions wereoccurring. Each of these accidents occurred orwas made more severe because theinstrumentation necessary to control the processsafely was not available.

The fifth recurring root cause was that priorwarnings were not heeded. Major accidents areoften preceded by a series of minor accidents,near-misses, or accident precursors. Failure tofollow-up or take sufficient corrective actions withthe less significant incidents and process upsetsled to major problems.

Lack of training leading to operator errors wasanother significant root cause. O

NOVEL GREEN CHEMISTRYThe National Risk Management ResearchLaboratory (NRMRL) of EPA, through itsSustainable Technology Division, is introducingnew scientific approaches to a persistenttechnological problem, that is, how to synthesizesafely commercially important chemicals withoutdepleting or damaging the environment. Currently,the chemical manufacturing industry generatesabout 1.5 billion tons of hazardous wastes and 9billion tons of non-hazardous wastes annually.Toxic releases are also a problem. Roughly half ofthe releases and transfers of chemicals reportedthrough the EPA Toxic Release Inventory are aresult of chemical manufacturing.

While emphasis is on environmental concerns,process safety issues go hand-in-hand. Fewerreleases, safer solvents, minimized inventories,and smaller reactors are all examples.

The initial effort will focus on alternativeoxidation technologies to address this challenge,since oxidation reactions are used to producenearly one-third of industrial chemicals in the USA,such as aldehydes, alcohols, ketones, andcarboxylic acids. Conventional oxidationprocesses are energy intensive, have low catalyticconversion efficiencies, and generate hazardouswastes and byproducts.

To develop a cleaner and safer alternativeprocess, the NRMRL researchers havesuccessfully tested the synthesis of chemicals byphotocatalytic oxidation of organic molecules usingan optically excited, specially prepared catalyst.The success of this technology could potentiallylead to a revolutionary use of sunlight andmolecular oxygen. O


CALL FOR PAPERS 37th Annual Loss Prevention Symposium New Orleans, Louisiana March 31- April 2, 2003

The Loss Prevention Symposium, organized by the Safety and Health Division Program Area 11a, has been held annually since 1967.The objective is to promote safety in the chemical process and allied industries by providing a forum for practitioners from industry,academia, and government to share experiences, technological advances, and new ideas. Accepted papers will be published in theSymposium Proceedings and may also be selected for publication in Process Safety Progress.

Symposium Chair Symposium Vice-ChairJohn F. Murphy Robert W. JohnsonU.S. Chem. Safety Board Unwin Corporation2175 K Street, NW 1920 Northwest BoulevardSuite 400 Suite 201Washington, DC 20037 Columbus, OH 43212202-261-7622 [email protected] [email protected]

1. ENGINEERING ISSUES IN SECURITY OF HIGH HAZARDFACILITIES - This session focuses on the engineeringmethods used to improve the security, reduce the facilityvulnerability to terrorist attack, and reduce the consequencesof a hazardous chemical release by improvements in thedesign, layout, and operation of equipment handling hazardouschemicals. Papers are solicited addressing these currentconcerns.

Chair Vice-ChairRandy Freeman Richard D. SiegelABS Consulting Foster Wheeler 16855 Northchase Drive Environmental Corp.Houston, TX 77060-6008 52A Charles River Road281-877-6407 Waltham, MA 02453-2402rfreeman@ 781-891-5655 absconsulting.com [email protected] 2. PROCESS SAFETY LEGAL/LIABILITY ISSUES - Civillitigation and criminal prosecution may result from processsafety incidents. Papers are invited discussing prevention andmitigation of losses that can result from these liability issues forcorporations and for individuals within those organizations.

Chair Vice-ChairDavid G. Clark Walter L. FrankDuPont Company ABS Consulting1007 Market Street 5301 Limestone Road, Ste.210Wilmington, DE 19898 Wilmington, DE 19808302-774-8044 302-239-0496david.g.clark@ [email protected] usa.dupont.com

3. FIRE, EXPLOSIONS, AND REACTIVITY HAZARDS - Theanalysis, prevention, and mitigation of fire and explosionhazards continue to be important issues to the Loss PreventionCommunity. Papers are invited that identify, analyze, or offerdesign guidance on fire, explosion, and reactivity hazards.

Chair Vice-ChairEphraim A. Scheier Christopher HanauskaBP Amoco Corporation Hughes Associates, Inc.P. O. Box 3092 3610 Commerce Drive, Ste. 817Houston, TX 77253-3092 Baltimore, MD 21227-1652281-366-2573 410-737-8677, [email protected] [email protected]

4. INTEGRATION OF SAFETY AND ENVIRONMENTALCONCEPTS - There is often a conflict between engineeringand design activities associated with implementation of safetyand environmental concepts. This session invites papersdealing with integration of safety and environmental conceptsduring all phases of the plant's life cycle.

Chair Vice-ChairM. Sam Mannan Dennis C. HendershotTexas A&M University Rohm and Haas Company337 Zachary Engineering Ctr. P. O. Box 584College Station, TX 77843 Bristol, PA 19007979-862-3985 [email protected]@rohmhaas.com

5. INCORPORATING PROCESS SAFETY IN MAINTENANCEAND NON-ROUTINE OPERATIONS - Papers are invited onrecommended strategies for identification, evaluation, andcontrol of process related hazards when the unit is in, or isbeing prepared for a non-routine operating mode, includingmaintenance operations.

Chair Vice-ChairScott W. Ostrowski Stanley S. GrosselExxonMobil Chemical Co. Process Safety & Design, Inc.P. O. Box 241 41 Sussex RoadBaton Rouge, LA 70821-0241 Clifton, NJ 07012-2017225-777-7400 973-779-8579scott.w.ostrowski@ [email protected] exxonmobil.com

6. CASE HISTORIES AND LESSONS LEARNED - Reviewsof process safety incidents and near misses provide valuablelearning opportunities. Papers detailing incidents, near misses,and lessons learned are requested.

Chair Vice-ChairErdem A. Ural Henry L. FeboFenwal Safety Systems FM Global90 Brook Street 1151 Boston-Providence Trpk.Holliston, MA 01746 Norwood, MA 02062508-429-3190 [email protected] [email protected]

TO PRESENT A PAPER - contact the appropriate SessionChair and submit a typed abstract of 150-200 words by June3, 2002. Include the names, addresses, telephone numbers,and affiliations of the authors. Electronic submissions by e-mail or computer disk are encouraged. Session Chairs willselect papers to be presented and contact the authors by July1, 2002. Authors of selected papers will need to complete aProposal-to-Present (PTP) form on the AIChE worldwide website by August 1, 2002. Final manuscripts for publication inthe Symposium Proceedings are due to Session Chairs byNovember 6, 2002.O

PAPERS, PAPERS, PAPERS


" A S t u d y o f S e l f -Accelerating DecompositionTemperature (SADT) UsingReaction Calorimetry,"

J.Sun, Y.Li, and K.Hasegawa, J.LossPrev.Proc.Ind. 14, No.5, 331-336 (September2001).

SADTs evaluated using ARC must be underthe assumption of zero order reaction kinetics andrequire extrapolation to lower temperatures. Usingthe Setaram C8OD apparatus, however, thereaction can easily be detected in the vicinity of theSADT for many reactive materials because of thehigher sensitivity of the apparatus. In the presentstudy, both the ARC and the C8OD were used toinvestigate the decomposition of an asphalt-saltsmixture which had caused a fire in a nuclear fuelfacility. The decomposition mechanism of thismixture was complex, but the greater sensitivity ofthe C8OD enabled it to be clarified. A reasonableestimate of the SADT was obtained. Theestimated SADT from the ARC experiments wasabout 70oC higher since the first two steps of thedecomposition went undetected.

"Checking Up on Rupture Disk Holders,"J.W.Reynolds, Chem.Eng. 108, No.11, 149-153(October 2001).

It is important for rupture disk users to performa thorough examination of the disk and its holderat preset time intervals to demonstrate properfunctioning. A principal source of potentialproblems is the holder. Almost any degradation inthe sealing surfaces or in the internal geometry willdecrease the performance level of a device. Thisdecrease is manifested in process fluid leakage atthe sealing surfaces and a decrease, orsometimes even an increase, in actual rupturepressure. This paper presents criteria to apply toa variety of holder designs to assure that a properinspection is performed.

"Caging the Shark - Bulk OperationsContainment," Chem. Health & Safety 8, No.5, 9-11 (September/October 2001).

A common industrial hygiene practice in thepharmaceutical industry is to develop a matrix thatdescribes particular types of controls for handlingactive ingredients. This type of system is referredto as containment handling or exposure banding.There are significant problems at a plant levelwhen using large quantities of substances in the

chemical processing. This paper describestechniques for appropriate equipment andprocedures in bulk handling particularly in batchand semi-batch processing, drawing an analogy tothe necessary protection when experts areobserving shark behavior safely.

"Thermal Runaway Conditions of a PartiallyDiluted Catalytic Reactor," M.M.J.Quina andR.M.Ferreira, Ind.Eng.Chem. Research 38, No.12,4615-4623 (1999).

The generalized parametric sensitivity criterionwas used to obtain runaway diagrams for one- andtwo-dimensional heterogeneous models and aone-dimensional pseudo-homogeneous model.The simulation work was based on the partialmethanol oxidation to formaldehyde in a fixed bedreactor with two distinct catalytic zones. At theinlet of the reactor, the catalyst was diluted withinert packing followed by a region of pure catalyst.The dilution of the catalyst bed led to anenlargement of the stable region of operation, anda gain in the critical methanol concentration.

"Avoid Process Engineering Mistakes,"I.Duguid, Chem.Eng. 108, No.12, 97-100(November 2001).

This paper presents a set of case studiesinvolving process engineering errors. Examplesinclude misuse of design standards, conservativedesign costs, wrong equipment choices, tunnelvision in ignoring alternatives, and failure to look atthe whole plant rather than a specific operatingunit. Process engineering errors can indeed leadto safety problems.

"HarsNet: A European Thematic Network,"J.Etchells and S.Waldram, IChemE SymposiumSeries, No.147, 277-285 (2000).

The organization and function of the thematicnetwork entitled "HarsNet" is discussed. HarsNetis concerned with the hazards of exothermicreactions in batch and semi-batch processes. It isa four-year European Community programinvolving 31 partners. Its purpose is to makeavailable to small and medium sized companiesthe best available advice for assessing andcontrolling the hazards of exothermic reactions.

"Use Software to Automate MSDSManagement," R.E.Lis, Chem.Eng. 108, No.12,89-92 and 111-112 (November 2001). O

BOOKS, BOOKS, BOOKS


Deflagration and Detonation Arresters, 148 pp,Publ. G-64, ISBN 0-8169-0791-9, AIChE/CCPS,New York, NY 10016 (2002), $89.00 (20%discount for members).

This book fosters effective application andoperation of deflagration and detonation arresters(DDAs) through treatment of their principles ofoperation, selection, installation, and maintenancemethods. The book is designed for chemicalengineers and other technical personnel involvedin the design, operation, and maintenance offacilities and equipment where DDAs may berequired.

The text covers a broad range of issuesconcerning DDAs, including: (1) an overview ofdeflagration and detonation prevention andprotection practices; (2) an overview of combustionand flame propagation phenomena related toDDAs; (3) deflagration and detonation technology;(4) installation in process systems; (5) regulations,codes, and standards; (6) illustrative examples,calculations, and guidelines for DDA selection; and(7) appendices, including a glossary, a flamearrester specification sheet for vendor quotation,and a listing of flame arrester manufacturers.

Making EHS An Integral Part of ProcessDesign, 160 pp, Publ. C-19, ISBN 0-8169-0848-6,AIChE/CWRT/CCPS, New York, NY 10016,(2001), $85.00 (20% discount for members).

This volume focuses on the MERITT(Maximizing EHS Returns by Integrating Tools andTalents) approach for enhancing processdevelopment through better integration ofenvironmental, health, and safety evaluations.MERITT draws upon components of inherentsafety, pollution prevention, green chemistry, andrelated paradigms through selective adoption andadaption of their existing tools, skills, andknowledge resources, and offers ways ofenhancing existing best practices.

Contents include: (1) staging and control; (2)EHS constraints and opportunities; (3) the five "C"fundamental principles of commitment,concurrency, communication, collaboration, andcontinuity; (4) the application of MERITT; (5) thenon-integrated EHS approach; and (6)implementation guidance. This unified approachoffers the flexibility to meet many differentdevelopmental needs, together with the capability

to evolve with changingbusiness Imperatives.

Green Engineering: EnvironmentallyConscious Design of Chemical Processes,D.T.Allen and D.R.Shonnard, 574 pp, ISBN 0-13-061908-6, Prentice-Hall, Upper Saddle River,NJ 07458 (2001), $65.00.

This is the first green engineering text book. Ithad its start in 1998 in the EPA Office of PollutionPrevention, Pesticides, and Toxic Substances,which claims to be the birthplace of the greenchemistry movement. It is designed for senior-level undergraduate and for graduate courses.Production of the book was coordinated by theEPA Green Chemistry Program. The bookprovides an introduction to major environmentalissues, regulations, and risk concepts. It describesrisk-based tools and approaches for assessing andimproving environmental performance as well assafety of chemical processes.

Fundamentals of Occupational Safety andHealth, 2nd Edition, M.A.Friend and J.P.Kohn,457 pp, ISBN 0-86587-709-2, ABS Consulting -Government Institutes, Rockville, MD 20850(2001), $79.00.

This revised edition provides safetyprofessionals with a thorough and up-to-dateoverview of the occupational safety and healthfield and the issues safety professionals facetoday. New chapters on behavioral safety andmulti-employer work sites are included. Also,there are updated discussions on systems safety,accident investigation, and ergonomics. Majortopics covered are safety legislation, safety-relatedbusiness laws, hazardous materials, andworkplace employee problems. This new bookexamines technology, management, andregulatory compliance issues. Occupational Safety and Health Lawbook,L.L.Byrum et al, 365 pp, ISBN 0-86587-640-1,ABS Consulting - Government Institutes,Rockville, MD 20850 (2001), $89.00.

This comprehensive new book, written by 18attorneys, provides managers, engineers, andsafety professionals with reliable and practicalguidance regarding occupational safety and healthlegal issues.

AND MORE BOOKS

CCPS BOOK PLANSDuring the second quarter of 2002, CCPS plans toissue the following two books:(1) Understanding Explosions, Publ. G-61, and(2) Wind Flow and Vapor Cloud Dispersion atIndustrial Urban Sites (with CD-ROM forcalculating a surface roughness parameter), Publ.G-75.


Naturally Dangerous: Surprising Facts AboutFood, Health, and the Environment,J.P.Collman, 270 pp, ISBN 1-891389-2,University Science Books, Herndon, VA 20172(2001), $29.00

Here is an intriguing book written in a no-nonsense style by James P. Collman who is aProfessor of Chemistry at Stanford University.Chemists and chemical engineers areknowledgeable about the hazards and risks ofhandling chemicals in the course of their normalwork. But this book supplies information for thegeneral public about the considerations of thehazards of substances encountered in daily living.The primary thrust is that natural does notnecessarily mean safe. The title describes thecontent. All human activities have risks. Thereader is encouraged to seek balance. As statedby Paracelsus (1493-1541), the dose makes thepoison. Collman, a scientist, now delivers thesame message in modern form for lay people.The book is organized in a logical fashion. Adiscussion on food and essential nutrients isfollowed by a review of health products such aspharmaceuticals and supplements of varioustypes. Then, diseases, cancer and theenvironment, and other environmental issues areexplained. While not comprehensive on thesematters, the reader

will benefit from the perspectives presented. Thebook is readable in the browsing mode.Technically trained people can learn from thestories presented and then will be better able toconvey information about risks of a variety ofchemically related activities to non-technicalassociates.

Sittig's Handbook of Toxic and HazardousChemicals and Carcinogens, 4th Edition,R.P.Pohanish, 2300 pp, William AndrewPub l ish ing , N o r w ich , NY (2001 ) ,www.williamandrew.com.

This is the recently issued fourth edition ofMarshall Sittig's well known toxic chemicalshandbook. O

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Send to: American Institute of Chemical Engineers Enclosed is a check payable to AIChE for theAttention: Customer Service Center annual dues including a subscription to Process3 Park Avenue Safety Progress. Print version is $39.00*, on-lineNew York, NY 10016-5991 version is $39.00, both versions are $62.00*. (*If1-800-242-4363 outside North America, add $38.00 for postage.)

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