Management Concepts and Ideas: Ian Sutton

Example 1: Process Flow

The first example shows a simple process involving the flow of liquid from a tank into a pressure vessel. It illustrates the principles and techniques of process hazard analysis.

Figure 1
Process Flow Example

Example 2:  Equipment

The second example concerns an equipment item widely used throughout the process industries: a shell and tube heat exchanger. It illustrates equipment failure analysis techniques, particularly Failure Modes and Effects Analysis (FMEA).

Figure 2
Heat Exchanger Example

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Example 3:  Operations

Figure 3 shows a forced-draft cooling tower. Warm water from the users enters at the top of the tower and then flows down the packing into the basin. The fans at the top of the tower pull air into the base of the tower. The air flows counter currently against the warm water. Some of the air evaporates, thus cooling the water. The cooled water is pumped to the users. Makeup water and treatment chemicals are added, as shown.

This example is used to illustrate the development of operating and maintenance procedures.

Figure 3
Cooling Tower Example

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Example 4:  Management Workflow

The fourth example illustrates the development and use of risk management systems.

Figure 4
Work Flow Example

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Example 5:  Significant Potential Incident

A cone-roof atmospheric storage tank stores a nonflammable, low-vapor pressure inorganic liquid. The vapor space above the chemical is air; the tank breathes in and out through a simple vent line, as shown in Figure 5. Also shown is a vehicle; one of the facility roads runs close to the tank. A fairly steady stream of vehicles uses the road. The fifth and final example illustrates the development and use of risk management systems.

The pump stopped operating, the check valve failed to hold and light hydrocarbons flowed backward into the tank. A layer of hydrocarbons formed on top of the inorganic liquid, as shown.

Figure 5
Reverse Flow Scenario

The hydrocarbons in the tank vaporized and then vented to the atmosphere, as shown. A hydrocarbon detector located about 100 meters from the tank detected the presence of flammable vapors.

The vapors did not light off. However, the potential for a serious event is high; the vapors could have ignited at a vehicle engine. The flame front could have entered the tank and caused the vapors to explode.

Table of Contents

Introduction
Example 1: Process Flow
Example 2: Equipment
Example 3: Operations
Example 4: Risk Management Workflow Plan
   External Standard
   Guidance
   Risk Analysis Plan
   Implement
   Audit / Deltas 
   Success / Continuous Improvement
Example 5: Significant Potential Incident
Index