Process Risk and Reliability Management

2nd Edition

Authors: Ian Sutton
Hardcover ISBN: 9780128016534
eBook ISBN: 9780128017968
Imprint: Gulf Professional Publishing
Published Date: 11th September 2014
Page Count: 798
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In the last twenty years considerable progress has been made in process risk and reliability management, particularly in regard to regulatory compliance. Many companies are now looking to go beyond mere compliance; they are expanding their process safety management (PSM) programs to improve performance not just in safety, but also in environmental compliance, quality control and overall profitability. Techniques and principles are illustrated with numerous examples from chemical plants, refineries, transportation, pipelines and offshore oil and gas.

This book helps executives, managers and technical professionals achieve not only their current PSM goals, but also to make the transition to a broader operational integrity strategy. The book focuses on the energy and process industries- from refineries, to pipelines, chemical plants, transportation, energy and offshore facilities. The techniques described in the book can also be applied to a wide range of non-process industries.

The book is both thorough and practical. It discusses theoretical principles in a wide variety of areas such as management of change, risk analysis and incident investigation, and then goes on to show how these principles work in practice, either in the design office or in an operating facility. The second edition has been expanded, revised and updated and many new sections have been added including: The impact of resource limitations, a review of some recent major incidents, the value of story-telling as a means of conveying process safety values and principles, and the impact of the proposed changes to the OSHA PSM standard.

Key Features

  • Learn how to develop a thorough and complete process safety management program.
  • Go beyond traditional hazards analysis and risk management programs to explore a company's entire range of procedures, processes and management issues.
  • Understand how to develop a culture of process safety and operational excellence that goes beyond simple rule compliance.
  • Develop process safety programs for both onshore facilities (EPA, OSHA) and offshore platforms and rigs (BSEE) and to meet Safety Case requirements.


Managers and technical staff in the oil and gas industry: refineries, pipelines, transportation, offshore facilities. Managers and engineers in the process industries.

Table of Contents

  • Preface
  • Chapter 1. Risk Management
    • Introduction
    • Technical, Process, and Occupational Safety
    • Historical Development
    • Major Events
    • Health, Safety, and Environmental Programs
    • Prescriptive/Nonprescriptive
    • Process Safety Management
    • Environment
    • Quality Management
    • Risk
    • Components of Risk
    • Common Cause Events
    • Subjective Nature of Risk
    • Quantification of Risk
    • Acceptable Risk
    • Risk Matrices
    • Black Swan Events
    • Different Industries
    • Examples
  • Chapter 2. Compliance and Standards
    • Introduction
    • Regulations
    • Codes and Standards
    • Company Standards
    • Industry Information
    • Commercial Information
    • Analysis
    • United States Federal Regulations
    • The Occupational Safety & Health Administration
    • The OSHA PSM Standard
    • The EPA
    • The EPA Risk Management Program—40 CFR 68
    • BSEE
    • State Regulations
    • The Safety Case Regime
    • International Agencies
    • Elements of PSM
  • Chapter 3. Culture and Participation
    • Introduction
    • Regulations and Standards
    • Warning Flags over Your Organization
    • Thinking Backward
    • Imagination
    • Culture Matrices
    • Measurement
    • Key Performance Indicators
    • Lagging and Leading Indicators
    • API RP 754
    • Selection of KPIs
    • Surveys
    • Creating a Strong Culture
    • Behavior-Based Safety
    • Employee Participation
    • Stakeholder Outreach
  • Chapter 4. Technical Information
    • Introduction
    • Process Description
    • Flowsheets
    • Materials of Construction Table
    • MSDS or Safety Data Sheet
    • Global Harmonization System
    • The Safety Diamond
  • <li


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About the Author

Ian Sutton

rIan Sutton is a chemical engineer with over thirty years of experience in the process industries. He has worked on the design and operation of chemical plants, offshore platforms, refineries, pipelines and mineral processing facilities. He has extensive experience in the development and implementation of process safety management and operational excellence programs. He has published multiple books including Process Risk and Reliability Management, 2nd Edition and Offshore Safety Management, 2nd Edition, both published by Elsevier.

Affiliations and Expertise

Principal, Sutton Technical Books