Kletz

Kletz, T. A., Cheaper, Safer Plants, IChemE Hazard Workshop, 2d., IChemE, Rugby, U.K., 1984. 

T. Kletz, Plant Design for Safety, A UserFriendly Approach, Hemisphere Publishing, New York, 1991. 

Daniel A. Crowl, Stanley Grossel, W. G. High, Trevor A. Kletz, Robert W. Ormsby,... 

Trevor A. Kletz, D.Sc., Senior Visiting Research Fellow, Department of Chemical Engineering, Loughborough University, U.K. Fellow, American Institute of Chemical Engineers, Royal Academy of Engineers (U.K.), Institution of Chemical Engineers (U.K.), and Royal Society of Chemistry (U.K.) (Section 26, Process Safety)... 

The principle ways of designing inherently safer plants and other ways or makiug plants user-friendly are summarized as follows, with examples (Kletz, Plant De.sign for Safety—A U.ser-Friendly Approach, Hemisphere, 1991). 

When one modification leads to another, and then another (Kletz, Plant/Operations Progress 5, 1986, p. 136). 

References are available which provide FAR estimates for various occupations, modes of transportation, and other activities (Kletz, The Risk Equations—What Risk Should We Run , New Scientist, May 12, pp. 320-325, 1977). 

Shared equipment Design to avoid or minimize use of (e.g. auxiliary process- common equipment for incompatible ing scrubbers ). Pos- materials sihility of incompatible, Implement proper cleaning procedure materials coming between incompatible uses to prevent together. cross contamination Prescrub or treat process streams before transfer to common equipment API RP 750 CCPS G-11 CCPS G-22 Kletz 1991 Lees 1996 NFPA-91... 

Shared transfer Avoid the use of incompatible materials in systems. shared transfer systems Ensure cleaning procedures are followed Avoid pockets in lines Install dedicated transfer system API RP 750 Kletz 1991 Lees 1996 NFPA-91... 

When the steam was shut off and, 15 minutes later, the agitator was switched off, heat transferred from the hot wall above the liquid level to the top part of the liquid, which became hot enough for a runaway reaction to start. This resulted in a release of TCDD (dioxin), which killed a number of nearby animals, caused dermatitis (chloracne) in about 250 people, damaged vegetation near the site, and required the evacuation of about 600 people (Kletz 1994). 

ASME VIII CCPS G-7 CCPS G-11 CCPS G-22 CCPS G-29 CCPS G-56 Kletz 1991 Lees 1996... 

CCPS G-22 CCPS G-23 CCPS G-29 Kletz 1991 NFPA 30 NFPA 70... 

T. A. Kletz, Hazard Analysis-A Review of Criteria, Reliability Engineering, 3, 325-38, 1982. 

Table 12.5 summarizes the applieation of these prineiples (after Kletz - see Bibliography). Where this approaeh is not feasible, external features of plant must ensure the minimization of unwanted eonsequenees. 

Kletz, T.A. (1999) HAZOP and HAZAN Identifying and Assessing Process Industry Hazards, 4th edn. Institutional Chemical Engineers, Rugby. 

Kletz, T.A. (1989) What Went Wrong Case Histories of Process Plant Disasters, Gulf Publishing, Houston. 

Kletz, T.A. (1998) Process Plants A Handbook of Inherently Safer Design, Taylor and Francis Inc. 

Kletz, T.A. (1984) Cheaper, Safer Plants or Wealth and Safety at Work Notes on Inherently Safer and Simpler Plants, Institution of Chemical Engineers Loss Prevention Information Exchange Scheme - Hazard Workshop Module. 

Kletz, T., Hazop and Kazan—Identifying and Assessing Proeess Industry Hazards, 4th ed., IChemE, 1999. 

On December 14, 1977, Trevor Kletz, who was at that time safety advisor for the ICI Petrochemicals Division, presented the annual Jubilee Lecture to the Society of Chemical Industry in Widnes, England. His topic was What you don t have, can t leak, and this lecture was the first clear and concise discussion of the concept of inherently safer chemical processes and plants. 

Kletz repeated the Jubilee Lecture twice in early 1978, and it was subsequently published (Kletz, 1978). In 1985 Kletz brought the concept of inherent safety to North America. His paper, Inherently Safer Plants (Kletz, 1985), won the Bill Doyle Award for the best... 

Inherently safer design is a fundamentally different way of thinking about the design of chemical processes and plants. It focuses on the elimination or reduction of the hazards, rather than on management and control. This approach should result in safer and more robust processes, and it is likely that these inherently safer processes will also be more economical in the long run (Kletz, 1984, 1991b). 

Approaches to the design of inherently safer processes and plants have been grouped into four major strategies by IChemE and IPSG (1995) and Kletz (1984, 1991b) ... 

A few examples of process minimization will be presented here. Kletz (1984,1991b), Englund (1990, 1991a,b, 1993), IChemE and IPSG (1995), Lutz (1995a, b) and CCPS (1993a) provide many more examples. 

The insecticide carbaryl can be produced by several routes, some of which do not use methyl isocyanate, or which generate only small quantities of this toxic material as an in-process intermediate (Kletz, 1991b). One company has developed a proprietary process for manufacture of carbamate insecticides which generates methyl isocyanate as an in-situ intermediate. Total methyl isocyanate inventory in the process is no more than 10 kilograms (Kharbanda and Stallworthy, 1988 Manzer, 1994). 

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