Published by Pearson (6 November 2026) © 2027
Currently unavailable
Currently unavailable
Currently unavailable
The #1 Process Safety Guide Worldwide, Reorganized for Today's Learners and Expanded to Address Emerging Hazards
Process safety continues to evolve as a critical, interdisciplinary field focused on preventing large-scale industrial accidents and ensuring the integrity of systems handling hazardous substances. Chemical Process Safety, Fifth Edition, builds on its legacy as the definitive guide by introducing a powerful new framework that helps students and practicing engineers connect hazards, risk, and decision-making in real-world settings
This extensively revised edition reorganizes core concepts around six essential process safety questions, enabling a clearer, more flexible approach to teaching and learning. New and expanded coverage includes biological hazards and their management, broadening the scope of process safety for today’s diverse engineering environments.
Maintaining its hallmark balance of theory and application, the book integrates equations, calculations, case studies, and homework problems to help readers not only understand concepts but apply them effectively in practice.
Readers will gain practical insight into
Serving both as a primary textbook and a professional reference, this edition supports a wide range of learning and application needs, from introductory courses to advanced engineering practice.
Preface xiv
About the Authors xvii
Nomenclature xx
Chapter 1: Introduction 1
1-1 Case Histories 3
1-2 Definitions 10
1-3 Engineering Ethics 15
1-4 Myths About Process Safety 16
1-5 Individual Risk, Societal Risk, and Risk Populations 20
1-6 Voluntary and Involuntary Risk 20
1-7 Risk Perception 21
1-8 Accident and Loss Statistics 21
Chapter 2: Process Safety Overview 31
2-1 Professional Organizations 35
2-2 Hazards 36
2-3 Safety Culture 39
2-4 Safety Metrics 41
2-5 Codes, Standards, and Regulations 43
2-6 Safeguards and Layers of Protection 45
2-7 Inherently Safer Design 52
2-8 Risk Tolerance/Acceptance and Risk Matrix 56
2-9 Safe Work Practices 60
2-10 Designing for Process Safety 63
2-11 Safety Reviews 69
Chapter 3: The 20 Elements of Risk-Based Process Safety (RBPS) 77
3-1 Element 1: Process Safety Culture 85
3-2 Element 2: Compliance with Standards 86
3-3 Element 3: Process Safety Competency 87
3-4 Element 4: Workforce Involvement 88
3-5 Element 5: Stakeholder Outreach 88
3-6 Element 6: Process Knowledge Management 89
3-7 Element 7: Hazard Identification and Risk Analysis 90
3-8 Element 8: Operating Procedures 91
3-9 Element 9: Safe Work Practices 92
3-10 Element 10: Asset Integrity and Reliability 93
3-11 Element 11: Contractor Management 94
3-12 Element 12: Training and Performance Assurance 95
3-13 Element 13: Management of Change 96
3-14 Element 14: Operational Readiness 97
3-15 Element 15: Conduct of Operations 98
3-16 Element 16: Emergency Management 99
3-17 Element 17: Incident Investigation 101
3-18 Element 18: Measurements and Metrics 102
3-19 Element 19: Auditing 103
3-20 Element 20: Management Review and Continuous Improvement 104
3-21 Summary 105
Chapter 4: The Multi-Purpose Pilot Plant Vessel (PPV) 109
4-1 Pilot Plant Protocols 116
4-2 Material Compatibility 117
4-3 Pilot Plant Vessel Specifications 117
Chapter 5: Toxicology 129
5-1 Toxicology, Toxicity, and Toxic Hazard 130
5-2 Toxic Hazards 131
5-3 Toxicological Studies 138
5-4 Threshold Limit Values 151
5-5 Downwind Emergency Response Values 154
Chapter 6: Industrial Hygiene 163
6-1 Anticipating and Identifying Hazardous Workplace Exposures 165
6-2 Globally Harmonized System 168
6-3 National Fire Protection Association Diamond 175
6-4 Evaluate the Magnitude of Exposures and Responses 176
6-5 Develop and Evaluate Control Techniques to Prevent Exposures 194
Chapter 7: Source Models 209
7-1 Introduction to Source Models 210
7-2 Flow of Liquid Through a Hole 214
7-3 Flow of Liquid Through a Hole in a Tank 217
7-4 Flow of Liquids Through Pipes 221
7-5 Flow of Gases or Vapors Through Holes 232
7-6 Flow of Gases or Vapors Through Pipes 237
7-7 Flashing Liquids 256
7-8 Liquid Pool Evaporation or Boiling 262
7-9 Realistic and Worst-Case Releases 263
7-10 Conservative Analysis 265
Chapter 8: Hazardous Material Dispersion 275
8-1 Parameters Affecting Dispersion 277
8-2 Neutrally Buoyant Dispersion Models 281
8-3 Pasquill–Gifford Model 282
8-4 Dense Gas Dispersion 296
8-5 Release Prevention and Mitigation 297
Chapter 9: Fires and Explosions 307
9-1 The Fire Triangle 308
9-2 Distinction Between Fires and Explosions 310
9-3 Definitions 310
9-4 Flammability Characteristics of Liquids and Vapors 313
9-5 Mists and Sprays 338
9-6 Fire Types 339
9-7 Flammability Characteristics of Dusts 345
9-8 Ignition Energy 346
9-9 Ignition Sources 348
9-10 Experimental Characterization of Gas/Vapor and Dust Explosions 349
9-11 Explosions 357
Chapter 10: Concepts to Prevent Fires and Explosions 383
10-1 Inerting 384
10-2 Static Electricity 399
10-3 Controlling Static Electricity 416
10-4 Explosion-Proof Equipment and Instruments 425
10-5 Ventilation 427
10-6 Sprinkler Systems 431
10-7 Designs for Process Safety 434
10-8 Hot Work 438
10-9 Industry's Fire and Explosion Protection Strategy 439
Chapter 11: Chemical Reactivity 447
11-1 Background Understanding 448
11-2 Commitment, Awareness, and Identification of Reactive Chemical Hazards 451
11-3 Characterization of Reactive Chemical Hazards Using Calorimeters 458
11-4 Designs for Chemical Reactions 485
Chapter 12: Introduction to Reliefs 493
12-1 Relief Concepts 495
12-2 Definitions 496
12-3 Code Requirements 498
12-4 Relief System Design 502
12-5 Relief Types and Characteristics 507
12-6 Relief Installation Practices 517
12-7 Relief Effluent Handling 519
Chapter 13: Relief Sizing 529
13-1 Set Pressure and Accumulation Limits for Reliefs 532
13-2 Relief Sizing for Liquid Service 534
13-3 Relief Sizing for Vapor and Gas Service 541
13-4 Omega Method for Two-Phase Reactive Relief 548
13-5 Deflagration Venting for Dust and Vapor Explosions 558
13-6 Venting for Fires External to Process Vessels 564
13-7 Reliefs for Thermal Expansion of Process Fluids 568
Chapter 14: Hazards Identification and Evaluation 577
14-1 Introduction to Hazard Identification/Evaluation and Risk Analysis 580
14-2 Non-Scenario-Based Hazard Identification/Evaluation Methods 588
14-3 Scenario-Based Hazard Identification/Evaluation Methods 596
14-4 Documentation and Actions Required for Hazard Identification and
Chapter 15: Risk Analysis and Assessment 615
15-1 Probability Theory for Equipment Failures 617
15-2 Event Trees 630
15-3 Fault Trees 635
15-4 Bow-Tie Diagrams 642
15-5 Quantitative Risk Analysis 644
15-6 Layer of Protection Analysis 644
15-7 Risk Assessment 656
Appendix A: Unit Conversion Constants 665
Appendix B: Flammability Data for Selected Hydrocarbons 669
Appendix C: Saturation Vapor Pressure Data 675
Appendix D: Special Types of Reactive Chemicals 677
Appendix E: Hazardous Chemicals Data for a Variety of Chemical Substances 683
Appendix F: Process Diagrams 697
Appendix G: Process Development Area (PDA) General Specifications 701
Appendix H: Specifications for the 100 Gallon (378.5 L) Multi-Purpose Pilot Plant Vessel (PPV) 709
Appendix I: Personal Protective Equipment (PPE) Usage Guidelines for the Process Development Area (PDA) 715
Index 719
All in one place. Pearson+ offers instant access to eTextbooks, videos and study tools in one intuitive interface. Students choose how they learn best with enhanced search, audio and flashcards. The Pearson+ app lets them read where life takes them, no wi-fi needed. Students can access Pearson+ through a subscription or their MyLab or Mastering course.