Process Safety Management provides comprehensive, practical guidance for developing and implementing process safety programs in the design, operation, and maintenance of industrial facilities. Drawing on clear definitions, real-world examples, historical context, and case studies, the book explains how process safety management (PSM) principles can be applied across the process and energy industries.
A successor to Sutton’s earlier work Process Risk and Reliability Management, this volume reflects current industry practice and incorporates new developments in regulations, technology, and operational risk management. Across twenty-one chapters, it addresses the core elements of process safety, including hazards analysis, incident investigation, operating procedures, training, and audits. The discussion highlights how process safety improves not only safety performance but also operational integrity, equipment reliability, and system availability.
The book reviews major process safety regulations and standards and outlines proposed updates by agencies such as OSHA and the EPA. It also considers emerging topics, including the role of generative AI in PSM and the implications of net-zero initiatives for process safety programs and sustainable operations.
Process Safety Management is intended for graduate students in chemical, industrial, and process engineering, as well as for practicing engineers in design firms, consultancies, and operating companies. It also serves as a reference for professionals in regulatory organizations such as the CSB, OSHA, API, NFPA, and the US EPA who evaluate or oversee industrial safety programs.
1. Title of Book - p. i 2. Cover image - p. i 3. Title page - p. ii 4. Table of Contents - p. iii 5. Copyright - p. iv 6. Preface - p. xxix 7. Chapter 1. The Process Safety Discipline - p. 1 8. Chapter 2. Risk Analysis and Management - p. 51 9. Chapter 3. Regulations and Standards - p. 81 10. Chapter 4. Process Safety Culture - p. 99 11. Chapter 5. Process Safety Information - p. 119 12. Chapter 6. Hazards Analysis - p. 141 13. Regulations - p. 142 14. Hazards Analysis Process - p. 145 15. Types of Hazard Analysis - p. 147 16. Organization of a Hazards Analysis - p. 150 17. The Team - p. 159 18. The Hazard and Operability Method (HAZOP) - p. 168 19. HAZID/Major Hazards Screening - p. 178 20. Checklists - p. 179 21. The What-If Method - p. 179 22. Failure Modes and Effects Analysis (FMEA) - p. 189 23. Qualitative Fault Tree Analysis - p. 197 24. LOPA - p. 197 25. Bow-Tie Analysis - p. 202 26. Cause and Effect Charts - p. 204 27. Revalidation Hazards Analyses - p. 204 28. Results of the Analysis - p. 206 29. The Hazards Analysis Report - p. 210 30. Publishing the Report - p. 219 31. Legal Issues - p. 224 32. Special Types of Hazards Analysis - p. 227 33. Benefits of Hazard Analyses - p. 231 34. Limitations and Concerns - p. 232 35. OSHA Updates - p. 239 36. Chapter 7. Consequence Analysis - p. 257 37. Chapter 8. Frequency Analysis - p. 283 38. Chapter 9. Operating Procedures - p. 347 39. Chapter 10. Training and Human Factors - p. 437 40. Chapter 11. Contractor Management - p. 461 41. Chapter 12. Asset Integrity and Maintenance - p. 477 42. Chapter 13. Operational Readiness - p. 491 43. Chapter 14. Management of Change - p. 501 44. Chapter 15. Incident Investigation and Analysis - p. 541 45. Chapter 16. Emergency Response - p. 617 46. Chapter 17. Audits and Reviews - p. 633 47. Chapter 18. Reliability, Availability, and Maintainability - p. 675 48. Chapter 19. Safety in Design - p. 691 49. Chapter 20. Managing a Process Safety Program - p. 715 50. Chapter 21. The Process Safety Professional - p. 749 51. Index - p. 775
Process Safety Management provides comprehensive, practical guidance for developing and implementing process safety programs in the design, operation, and maintenance of industrial facilities. Drawing on clear definitions, real-world examples, historical context, and case studies, the book explains how process safety management (PSM) principles can be applied across the process and energy industries.
A successor to Sutton’s earlier work Process Risk and Reliability Management, this volume reflects current industry practice and incorporates new developments in regulations, technology, and operational risk management. Across twenty-one chapters, it addresses the core elements of process safety, including hazards analysis, incident investigation, operating procedures, training, and audits. The discussion highlights how process safety improves not only safety performance but also operational integrity, equipment reliability, and system availability.
The book reviews major process safety regulations and standards and outlines proposed updates by agencies such as OSHA and the EPA. It also considers emerging topics, including the role of generative AI in PSM and the implications of net-zero initiatives for process safety programs and sustainable operations.
Process Safety Management is intended for graduate students in chemical, industrial, and process engineering, as well as for practicing engineers in design firms, consultancies, and operating companies. It also serves as a reference for professionals in regulatory organizations such as the CSB, OSHA, API, NFPA, and the US EPA who evaluate or oversee industrial safety programs.
1. Title of Book - p. i 2. Cover image - p. i 3. Title page - p. ii 4. Table of Contents - p. iii 5. Copyright - p. iv 6. Preface - p. xxix 7. Chapter 1. The Process Safety Discipline - p. 1 8. Chapter 2. Risk Analysis and Management - p. 51 9. Chapter 3. Regulations and Standards - p. 81 10. Chapter 4. Process Safety Culture - p. 99 11. Chapter 5. Process Safety Information - p. 119 12. Chapter 6. Hazards Analysis - p. 141 13. Regulations - p. 142 14. Hazards Analysis Process - p. 145 15. Types of Hazard Analysis - p. 147 16. Organization of a Hazards Analysis - p. 150 17. The Team - p. 159 18. The Hazard and Operability Method (HAZOP) - p. 168 19. HAZID/Major Hazards Screening - p. 178 20. Checklists - p. 179 21. The What-If Method - p. 179 22. Failure Modes and Effects Analysis (FMEA) - p. 189 23. Qualitative Fault Tree Analysis - p. 197 24. LOPA - p. 197 25. Bow-Tie Analysis - p. 202 26. Cause and Effect Charts - p. 204 27. Revalidation Hazards Analyses - p. 204 28. Results of the Analysis - p. 206 29. The Hazards Analysis Report - p. 210 30. Publishing the Report - p. 219 31. Legal Issues - p. 224 32. Special Types of Hazards Analysis - p. 227 33. Benefits of Hazard Analyses - p. 231 34. Limitations and Concerns - p. 232 35. OSHA Updates - p. 239 36. Chapter 7. Consequence Analysis - p. 257 37. Chapter 8. Frequency Analysis - p. 283 38. Chapter 9. Operating Procedures - p. 347 39. Chapter 10. Training and Human Factors - p. 437 40. Chapter 11. Contractor Management - p. 461 41. Chapter 12. Asset Integrity and Maintenance - p. 477 42. Chapter 13. Operational Readiness - p. 491 43. Chapter 14. Management of Change - p. 501 44. Chapter 15. Incident Investigation and Analysis - p. 541 45. Chapter 16. Emergency Response - p. 617 46. Chapter 17. Audits and Reviews - p. 633 47. Chapter 18. Reliability, Availability, and Maintainability - p. 675 48. Chapter 19. Safety in Design - p. 691 49. Chapter 20. Managing a Process Safety Program - p. 715 50. Chapter 21. The Process Safety Professional - p. 749 51. Index - p. 775
