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Loss prevention engineering describes all activities intended to help organizations in any industry to prevent loss, whether it be through injury, fire, explosion, toxic release, natural disaster, terrorism or other security threats. Compared to process safety, which only focusses on preventing loss in the process industry, this is a much broader field.
Here is the only one-stop source for loss prevention principles, policies, practices, programs and methodology presented from an engineering vantage point. As such, this handbook discusses the engineering needs for manufacturing, construction, mining, defense, health care, transportation and quantification, covering the topics to a depth that allows for their functional use while providing additional references should more information be required. The reference nature of the book allows any engineers or other professionals in charge of safety concerns to find the information needed to complete their analysis, project, process, or design.
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Seitenzahl: 1841
Veröffentlichungsjahr: 2013
Table of Contents
Related Titles
Title Page
Copyright
Contents to Volume 1
Preface
List of Contributors
Part I: Engineering Management for Loss Prevention Engineering
Chapter 1: Management Systems – Loss Prevention Engineering Programs and Policy
1.1 Introduction – Understanding the Need for Management Systems
1.2 Management Systems – Definitions
1.3 Loss Prevention Engineering – Considerations
1.4 Management Systems – Loss Prevention Engineering
Appendix 1.A: BCN – NSHE Sample Drug and Alcohol Policy
Appendix 1.B: Behavior-Based Safety Supporting Tool
Appendix 1.C: Sample Internal Simple Inspection Checklist
References
Chapter 2: Resource Allocation and Effectiveness Measures for Loss Prevention
2.1 Introduction
2.2 What is Loss Prevention/Safety and Health Intervention?
2.3 Historical Perspective of Resource Allocation for Loss Prevention
2.4 Loss Prevention/Safety and Health Intervention Effectiveness Evaluation
2.5 Importance of Multiple Factors in Loss Prevention
2.6 Research Methodology in Resource Allocation for Loss Prevention
2.7 Experimental Method
2.8 Analysis and Results
2.9 Conclusion
References
Chapter 3: Engineering Systems and Engineering Economics of Loss Prevention
3.1 Introduction
3.2 Cost of Injuries
3.3 Return on Investment Versus Cost Savings Versus Productivity Savings
3.4 Engineering Economics
3.5 Engineering Economic Decision-Making
3.6 Net Present Value Comparison (Equipment Replacement)
3.7 Payback Period Comparison
3.8 Financial Considerations of a Loss Prevention Engineering Project
3.9 Conclusion
References
Chapter 4: Safety Management and Culture
4.1 What Is Organizational Culture?
4.2 How Does Culture Form?
4.3 Why is it Good Business to Improve Your Company's Culture?
4.4 Measuring Culture
4.5 How to Bring About Changes in Culture
References
Chapter 5: Leadership and Loss Prevention Engineering: Creating Conditions to Get Beyond Compliance to High Performance
5.1 Introduction
5.2 Management Theories
5.3 Moving Beyond Mechanistic Management
5.4 Humanistic Organizations
5.5 Case Studies of Humanistic Management
References
Part II: Design and Analysis of Protective Systems – General Loss Prevention Engineering
Chapter 6: General Loss Prevention Engineering Programs – Including Fire Loss Control
6.1 Background
6.2 Introduction
6.3 Elements of a Fire Loss Control Program
6.4 Fire Prevention Controls
Appendix A. Loss Prevention Survey
References
Chapter 7: Permit-to-Work Systems
7.1 Introduction
7.2 The Permit-to-Work Process
7.3 Regulations and Standards
7.4 Hot Work
7.5 Confined Space
7.6 Live Line Electrical Work
Chapter 8: Excavation and Trenching
8.1 Introduction
8.2 Hazard Identification and Federal OSHA Regulation
8.3 Soil Types
8.4 Basic Soil Mechanics Theory
8.5 Testing and Soil Classification Systems
8.6 Protective Systems
References
Chapter 9: Machine Safeguarding
9.1 Introduction
9.2 Regulations and Standards
9.3 Machine Motion Hazards
9.4 Human Factor Aspects of Machine Guarding
9.5 Machine Safeguarding Methodology
9.6 Basic Machine Guarding Principles
9.7 Types of Machine Safeguarding
9.8 Machine Controls
9.9 Responsibilities of the Machine Builder
9.10 Mechanical Power Presses
9.11 Power Press Brakes
9.12 Conveyors
9.13 Roll-Forming and Roll-Bending Machines
9.14 Shearing Machines
9.15 Laser Machining
9.16 Robots
9.17 Conclusion
References
Further Reading
Chapter 10: Boilers and Pressure Vessels: a Brief Look at General Safeguards
10.1 Water
10.2 Safeguards
10.3 Codes, Regulations, and Training
10.4 Types of Boilers
10.5 Operating Considerations
10.6 Boiler Feed Water
10.7 Chemical Handling
10.8 Steam
10.9 Special Considerations for Pressure Vessels
10.10 Fire Detection and Control
10.11 Incident Investigation
10.12 Closing Thoughts
References
Chapter 11: Welding and Cutting
11.1 Introduction
11.2 Basic Equipment for Welding Comfortably and Safely
11.3 The Welding Process
11.4 Cutting
11.5 Conclusion
References
Chapter 12: Power Tools
12.1 Introduction
12.2 Guards
12.3 Safety Switches
12.4 Electric Tools
12.5 Powered Abrasive Wheel Tools
12.6 Liquid Fuel Tools
12.7 Pneumatic Tools
12.8 Hydraulic Power Tools
12.9 Conclusion
References
Chapter 13: Personal Protective Equipment
13.1 Introduction
13.2 General Selection
13.3 Types
13.4 Conclusion
References
Chapter 14: Powered Industrial Trucks
14.1 Introduction
14.2 Lift Truck Accident Prevention: An Integrated Approach
14.3 Fork Truck Safety Observations
14.4 Making Safety Observations
14.5 Loading Dock Safety
14.6 Whole Body Vibration
14.7 Administrative Controls for Lift Truck Operator Strains and Sprain Prevention
14.8 Rack and Overhead Storage and Industrial Lift Truck Operations
14.9 Carbon Monoxide and Dilution Ventilation
14.10 MVR Program and Physical Requirements
14.11 Case Studies
14.12 Using Acceptable Safety Tolerances in Defining Preventive Maintenance
14.13 Industrial Lift Truck Accident Costs
14.14 Conclusions and Establishing Safe Behavior Observation Management Programs
References
Part III: Ergonomics and Human Factors Engineering
Chapter 15: Biomechanics and Physical Ergonomics
15.1 Introduction
15.2 Biomechanics
15.3 Applications of Biomechanics in Ergonomics
15.4 Conclusion
References
Chapter 16: Human Factors and Cognitive Engineering
16.1 Introduction
16.2 Models of Human Cognition
16.3 Applications to Process Engineering and Surface Transportation
16.4 Conclusions
References
Chapter 17: Virtual Working Environment
17.1 Methodological Assumptions
17.2 Elements of the Virtual Working Environment Structure
17.3 Engineering Approach to Loss Prevention Within the Life-Cycle of Technical Means
17.4 Methods and Tools Supporting the Creation of Elements of a Virtual Working Environment
17.5 Human Body Modeling
17.6 Anthropomorphic Test Dummies
17.7 Multi-Body Models of ATDs
17.8 Multi-Body Human Models
17.9 Finite Element Models of ATDs
17.10 Finite Element Human Models
17.11 Digital Human Models
17.12 Modeling of Phenomena
17.13 Conclusion
References
Chapter 18: Shaping of Working Conditions Using ICT Technology
18.1 Working Environment
18.2 Information and Communication Technologies
18.3 Computer-Aided Shaping of Working Conditions
18.4 Shaping of Work Organization Using ICT
18.5 Conclusion
References
Chapter 19: Safety-Oriented Virtual Prototyping of Mining Mechanical Systems
19.1 Introduction
19.2 Introduction to Polish Underground Coal Mine Working Conditions
19.3 Introduction to Technical Hazards
19.4 Graphical Methods of Technical Hazards Assessment in Underground Mechanical Systems
19.5 Virtual Prototyping of FOPS
19.6 Application of Computational Fluid Dynamics (CFD) Analyses in Virtual Prototyping of Mining Machines
19.7 Conclusion
References
Title Page
Contents to Volume 2
List of Contributors
Part IV: Process Safety Management and System Safety Engineering
Chapter 20: Process Safety Regulations Around the World
20.1 Introduction
20.2 Process Safety – Drivers
20.3 Differences and Commonalities
20.4 Non-Regulatory Approaches
20.5 Lessons Learned
20.6 Evolving Field
20.7 General Duty
20.8 Proposed Changes to Regulations
20.9 Summary
20.10 Future of Process Safety
Appendix 20.A: Process Safety Drivers
Appendix 20.B Process Safety Regulations Around the World.
Appendix 20.C Non−Regulatory Approaches
Appendix 20.D: Good Engineering Practices (GEPs) Listed in the OSHA NEP for Refineries (CPL 03-00-004)
Appendix 20.E: The Author's Suggestion for a Possible Outline for a Process Safety Management Program, Based on Concepts Derived from the Main Process Safety Drivers
Appendix 20.F: Abbreviations Used in the Appendices
References
Chapter 21: Analytical Methods in Process Safety Management and System Safety Engineering – Process Hazard Analysis
21.1 Introduction
21.2 Overview of PHA
21.3 PHA and Decision-Making
21.4 Stages and Steps in PHA
21.5 PHA Project Initiation
21.6 Hazard Identification
21.7 Selecting a PHA Method
21.8 Defining the Purpose, Scope, and Objectives of the Study
21.9 Selecting a Team
21.10 Collecting and Preparing Reference Information and Data
21.11 Estimating the Effort Involved and Scheduling Study Sessions
21.12 Briefing/Training Team Members
21.13 Arranging Required Facilities
21.14 Other Items
21.15 Subdividing the Process
21.16 Performing an Inherent Safety Review
21.17 First Session
21.18 Recording PHA Studies
21.19 Making Worksheet Entries
21.20 Special Topics
21.21 Revalidation
21.22 Report Preparation
21.23 Follow-Up
Acknowledgments
Appendix 21.A. Descriptions of PHA Methods
Appendix 21.B. Comparison of PHA Methods
References
Chapter 22: Safety Instrumented Systems
22.1 Introduction
22.2 Fundamentals
22.3 Planning and Management
22.4 Analysis Phase
22.5 Realization Phase
22.6 Operation Phase
22.7 Conclusion
References
Chapter 23: Analytical Methods in Process Safety Management and System Safety Engineering – Layers of Protection Analysis
23.1 Introduction
23.2 Overview of LOPA
23.3 Scenario Risk
23.4 Risk Tolerance Criteria
23.5 Stages and Steps in LOPA
23.6 Initiating a Project
23.7 Preparing for LOPA
23.8 Preparing for a Study
23.9 Conducting a Study
23.10 Limitations, Cautions, and Pitfalls
Acknowledgments
References
Chapter 24: Chemical Reaction Safety
24.1 Introduction
24.2 Chemical Reaction Hazards
24.3 Identifying Reaction Hazards
24.4 Determine the Worst-Case Consequences
24.5 Assessing Chemical Reaction Risks
24.6 Identifying Process Controls
24.7 Basis of Safety Selection
24.8 Conclusion
References
Chapter 25: Application of Systems Engineering to Safety and Risk Management: a Human–Systems Integration Perspective
25.1 Introduction
25.2 Systems Engineering
25.3 Human–Systems Integration
25.4 Systems Modeling Language
25.5 Human–Systems Integration Model Domains
References
Chapter 26: Management of Change
26.1 Introduction
26.2 What Is Management of Change (MOC)?
26.3 Why Is MOC Important
26.4 Developing a Formal MOC Program
26.5 Executing the Change
26.6 Scalable MOC
26.7 Pitfalls to Avoid
26.8 Success Stories
26.9 Conclusion
26.10 Tools and Resources
26.11 Accreditation Groups
References
Further Reading
Chapter 27: The Importance of Fostering a Strong Industrial Safety Culture and Change Management
27.1 Introduction
27.2 Process Description
27.3 Site Leadership Team Industrial Safety Culture Review
27.4 Change Management
27.5 Conclusion
References
Chapter 28: Contractor Safety Management
28.1 Introduction
28.2 Contractor Management
28.3 The Score: Questionnaires and Contractor Ranking Systems
28.4 Summary and Conclusion
Chapter 29: Emergency Preparedness and Response
References
Chapter 30: Security and Terrorism
30.1 Security and Terrorism
30.2 The Oklahoma City Bombing
30.3 The 9/11 Attacks
30.4 Lessons Learned from the Oklahoma City Bombing and 9/11
30.5 Bioterrorism
30.6 Cyber Terrorism
30.7 Conclusion
References
Part V: Occupational Health and Environmental Engineering
Chapter 31: Control of Chemical Hazards
31.1 Introduction
31.2 Considerations
31.3 Control Methods
31.4 Conclusion
References
Chapter 32: Control of Physical Hazards
32.1 Introduction
32.2 Considerations
32.3 Control Methods
32.4 Conclusion
References
Chapter 33: Control of Air Pollution
33.1 Introduction
33.2 History of Air Pollution Regulations
33.3 Benefits of the Clean Air Act and Amendments (CAAA) from 1990 to 2020
33.4 Atmospheric Factors
33.5 Air Pollution Types, Sources, and Effects
33.6 Indoor Air Quality
33.7 Air Pollution Control
33.8 Best Practices and Solutions
33.9 Conclusion
Acknowledgments
References
Chapter 34: Hazardous Waste Management and Engineering
34.1 Introduction
34.2 Impact of Hazardous Waste
34.3 Hazardous Waste Regulation
34.4 Hazardous Waste Management Strategies
34.5 Hazardous Waste Treatment
34.6 Hazardous Waste Minimization
34.7 Hazardous Waste Remediation
34.8 Hazardous Waste Technologies
34.9 Life-Cycle Assessment
34.10 Conclusion
References
Part VI: Incident Investigation and Root Cause Analysis Methodology and Management
Chapter 35: How to Conduct Effective Incident Investigations
35.1 Introduction
35.2 What is the Purpose of the Investigation?
35.3 Why Investigations Fail
35.4 The Basic Investigation Process
35.5 Investigation Resource Requirements
35.6 Using Teams to Conduct Investigations
35.7 Sources of Evidence
35.8 Minimizing the Erosion of Evidence
35.9 Finding the Root Causes of Incidents and Problems
35.10 How to Develop Effective Corrective Actions
35.11 Tips for Improving an Investigation Process
35.12 Conclusion
References
Chapter 36: Incident Investigations – Lessons Learned – Development and Communications
36.1 Introduction
36.2 Internal Lessons
36.3 Distribution
36.4 External Lessons
36.5 Collection of Data
36.6 Dissemination of Data
36.7 Industry and Discipline Participation
36.8 Regulatory Actions and Changes
36.9 Suppliers
36.10 In Review
36.11 Case Study – Lessons Learned
References
Chapter 37: Managing Records, Investigation and Recommendation Management and Closure
37.1 Introduction
37.2 Reporting
37.3 Storage and Protection
37.4 Retention
37.5 Confidentiality
37.6 Legal Issues
37.7 Regulatory Considerations
37.8 Types of Records
37.9 Recommendation Management and Closure
37.10 Escalation
37.11 Corrective Actions
37.12 Implementation, Verification, and Validation
37.13 In Review
References
Part VII: Fire Protection Engineering
Chapter 38: Fire Dynamics
38.1 Overview
38.2 Part A – Qualitative Description of Fire Dynamics
38.3 Part B: Predictive Methods
References
Chapter 39: Fire Prevention and Protection
39.1 Introduction
39.2 Basic Principles
39.3 Design Basics
39.4 Practical Design Considerations
39.5 Oil and Gas Facilities
39.6 Natural Gas Vehicle Fueling Stations
39.7 Hazard Versus Risk
39.8 Practical Operations Considerations
39.9 Floating Roof Tank Operation Considerations
39.10 Investigating and Reporting on Fire Losses
39.11 Fire Reporting
39.12 Example Root Cause Analysis Report of Fire
39.13 Fire Suppression Equipment
39.14 Roles and Responsibilities
39.15 Conclusion
References
Chapter 40: The Science and Engineering of Explosions
40.1 Introduction
40.2 Fundamentals of Explosions
40.3 Types of Explosions
40.4 Combustion and Chemistry of Explosions
40.5 Ignition
40.6 Blast Damage Due to Over-Pressurization
40.7 Blast Fragment Missile Damage
40.8 Evolution of Flammable Material
40.9 Dispersion and Possible Ignition of Released Material
40.10 Plume Distribution Calculations
40.11 Puff Distribution Calculations
40.12 Conclusion
References
Index
Related Titles
Reniers, G. L. L., Zamparini, L. (eds.)
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2012
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Reniers, G. L. L.
Multi-Plant Safety and Security Management in the Chemical and Process Industries
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CCPS
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The Editor
Joel M. Haight, Ph.D., P.E.
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Contents to Volume 1
Preface
Loss Prevention Engineering involves the engineering required to help us prevent accidental, undesired loss-producing incidents. It is a diverse application of engineering that can call upon every engineering discipline and many other scientific and social science disciplines as well as just about every aspect of industrial life. It is generally assumed that, by definition, we do not want to experience this type of loss. In response to that, the authors of this book seek to inform the engineering community about what must be considered when designing, operating and maintaining systems and processes so that accidental and undesired failures or loss-producing incidents (including human injury) are less likely to occur or, if they do, that they result in lesser consequences.
However, because loss prevention engineering is such a diverse and broadly demanding application of engineering and scientific principles and even if we limit the subject to preventing accidental loss incidents (such as automobile crashes, sporting accidents, etc.), we would still never be able to cover all the relevant and important topics that would be needed in just one book. So, we have chosen to cover the topics relating to engineering industrial processes to prevent or reduce loss from accidental and undesired incidents. It is the expectation of our authors to present to you, our readers, a thorough collection and summary of what is known in industry about preventing work related injuries and other undesired, accidental loss incidents. Some of our readers will already be well-versed in such fields as safety engineering, process safety management, fire protection engineering, industrial hygiene, or environmental engineering, but it is expected that not many engineers are well-versed in all of these fields. Therefore, with the input of nearly 40 authors, and since many find themselves to be in need of information on any and all of these topic areas, the book encompasses parts of all of them. The book is grouped into major topic areas of similar subject matter to lend cohesiveness to the information. Our authors present a number of case studies and exercises that will help our readers to put the principles and theories of loss prevention engineering into proper day-to-day perspective. It is also the expectation of the authors that our readers will find this book to be a necessity any time each of you are tasked with solving an engineering problem that could lead to a loss-producing incident, any time you find yourself assigned to a job in which loss prevention engineering is part of the defined responsibilities or any time you want to learn about loss prevention engineering as an occupation or field of study. This book provides you the information you will need in any or all of these cases. It is an excellent and thorough reference handbook that we hope you find useful in the everyday dispatch of your industrial duties.
A diverse and detailed publication like this would not be possible without the input of many people of a multitude of experiences, languages, countries of origin, and industrial backgrounds. Our authors hail from nine different countries, represent nearly 20 different industry categories, and have an average of about 20 years of experience in their fields. This book would not have been possible without them and I thank all of them for their significant and valuable contributions. I would also like to thank the reviewers of our chapters as it is an important aspect of this book to ensure that you, our readers, get more than just the opinions of one author. You will find that the material is widely accepted and is not just a “here's how we do things at our plant”-type book. All engineers are charged with a responsibility to protect people, equipment, facilities and operations and therefore, it is our hope that in reading this book you will learn something new and that you will enhance your organization's efforts to protect their operations and their people from injuries and other loss-producing incidents.
Pittsburgh
Joel M. Haight
January 2013
List of Contributors
Part I
Engineering Management for Loss Prevention Engineering
Chapter 1
Management Systems – Loss Prevention Engineering Programs and Policy
Shakirudeen Shakioye
Several industries around the world apply a multifaceted health, environmental, and safety (HES) program approach in reducing occupational HES incidents. Arguably, it is conventional wisdom within most industries that not a single safety or environmental or health process or tool has been proven to act independently to reduce or eliminate workplace incidents directly. To ensure that workplace incident prevention is achieved and sustained, an optimal mix of HES tools and processes needs to be implemented and managed (Shakioye and Haight, 2010). Regulatory requirements, company policies/procedures, and the sheer size of activities that support the operations across industries in the modern world introduce a degree of complexity. Such complexity requires a systemic management of implemented HES programs to ensure that the programs are sustained and continuous improvements in the form of learnings are captured and incorporated into existing practices.
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