According to Wikipedia, Chemical engineering is a branch of engineering that applies physical sciences (physics and chemistry), life sciences (microbiology and biochemistry), together with applied mathematics and economics to produce, transform, transport, and properly use chemicals, materials and energy. Chemical Engineers spend their life in making the world a better place to live. A chemical engineer designs large-scale processes that convert chemicals, raw materials, living cells, microorganisms and energy into useful forms and products.

What is the Difference between Chemical Engineer and a Chemist?

What’s the difference between a chemist and a chemical engineer?

At least $10k a year

There is a funny saying; And a meme also roll around.

Those who study Chemistry becomes Chemists. Chemists study the composition of matter and its properties. Chemists carefully describe the properties they study in terms of quantities, with detail on the level of molecules and their component atoms. They use this knowledge to learn the composition, and properties of unfamiliar substances, as well as to reproduce and synthesize large quantities of useful naturally occurring substances and create new artificial substances and useful processes.

Chemical engineers are involved in many aspects of plant design and operation, including safety and hazard assessments, process design and analysis, modeling, control engineering, chemical reaction engineering, nuclear engineering, biological engineering, construction specification, and operating instructions. They are involved in designing the process making the lab scale process into pilot plants and then commercialization to produce in large volumes in process plants by implementing chemical process principles and technology.

History of Chemical Engineering

The history of chemical engineering can be traced back to the early 1800s, when scientists and engineers began to study the processes involved in the production of chemicals. The first chemical engineering textbooks were published in the mid-1800s, and the first chemical engineering courses were offered at universities in the late 1800s.

The field of chemical engineering grew rapidly in the early 1900s, as the demand for chemicals increased. Chemical engineers played a key role in the development of new industries, such as the petroleum industry and the plastics industry.

Chemical engineering continued to grow in importance in the 20th century. Chemical engineers played a key role in the development of new technologies, such as nuclear power and biotechnology.

What are the concepts you study in Chemical Engineering?

Air Pollution Control Engineering

Chemical Engineering Economics and Plant Design

Chemical Process Industries

Reaction Engineering

Environmental Pollution Control and Safety Management

Fertilizer Technology

Fundamentals of Mass Transfer

Fundamentals of Heat Transfer

Instrumentation and Process Control

Introduction to Electrical and Electronics Circuits

Introduction to Numerical Analysis

Material Science

Molecular Cell Biology

Organic Chemistry

Pharmaceutical Technology

Process Equipment Design & Economics

Fluid Mechanics

How to become a Chemical Engineer?

1. Diploma – 3 year basic course for learning the fundamentals of chemical engineering

2. Under Graduate -Most of the colleges and universities offer 4 year under graduate degree courses and award B.E/ BS/ BSc/ B.Tech degree.

3. Post Graduate – They are offered as 2 year course after under graduation. In some of the institution’s it is offered as 5 years sandwich course where M.E/ MS/ MSc/ M.Tech is awarded upon course completion.

4. Doctor of Philosophy – phD is an academic degree awarded by universities to a candidate who has submitted a thesis or dissertation, based on extensive and original research in their chosen field.

5. Post Doctoral Fellow – A person professionally conducting research after the completion of their doctoral studies. Post Doctoral Fellow (PDF) degree is awarded after completion of research.

Recommended books for Chemical Engineering

Perry’s Chemical Engineers’ Handbook is the most authoritative source of reference for any Chemical Engineering graduate. Authored by Robert H. Perry & Don W. Green, this handbook is an ultimate choice for reading which covers almost all aspects of Chemical Engineering. 8^th edition of this handbook comes with more than 2700 pages and 25 chapters. A must read for Chemical Engineers!

Coulson & Richardson’s Chemical Engineering has 6 Volumes. 

Volume 1 – Fluid Flow, Heat Transfer and Mass Transfer

Volume 2 – Particle Technology and Separation Processes

Volume 3 – Chemical & Biochemical Reactors & Process Control

Volume 4 – Solutions to the Problems in Volume 1

Volume 5 – Solutions to Volume 2 & 3

Volume 6 – Chemical Engineering Design

It is a good one for reference to various problems related to Chemical Engineering. The final year academic project demands the Chemical Engineers to understand and apply the design concepts, for which Volume 6 – Chemical Engineering Design can be referred.

Unit Operations of Chemical Engineering is yet another book for Chemical Engineers published by McGraw Hill. The authors of the book are Warren L. McCabe, Julian C. Smith & Peter Harriott. This book is divided into 5 sections namely Introduction, Fluid Mechanics, Heat Transfer & its Applications, Mass Transfer & its Applications and Operations involving Particulate Solids. At the end of each chapter numerous problems are also available to practice and understand the chemical engineering concepts.

Other important books include Fluid Mechanics by FM White; Mass Transfer Operations by Treybal, Process Control books by Coughnour and Stephanopoulos, Heat Transfer book by Smith & Van ness, Transport Phenomena, Shreves Chemical Process Industries, Chemical Engineering Thermodynamics – Van Ness, Process Calculations – Himmelblau, Bhatt and Vora, Reaction Engineering by Octave Levenspiel, Fogler etc

Real life Applications of Chemical Engineering

1. Petroleum refining. Chemical engineers design and operate the refineries that turn crude oil into gasoline, diesel fuel, jet fuel, and other products.
2. Chemical manufacturing. Chemical engineers design and operate the plants that produce chemicals such as plastics, fertilizers, and pharmaceuticals.
3. Food processing. Chemical engineers design and operate the plants that process food products such as bread, milk, and juice.
4. Water treatment. Chemical engineers design and operate the plants that treat water for drinking, industrial, and agricultural use.
5. Wastewater treatment. Chemical engineers design and operate the plants that treat wastewater from homes, businesses, and industries.
6. Environmental remediation. Chemical engineers clean up contaminated sites, such as Superfund sites.
7. Energy production. Chemical engineers design and operate the plants that produce energy from fossil fuels, nuclear power, and renewable sources such as solar and wind power.
8. Materials science. Chemical engineers develop new materials with improved properties, such as strength, lightness, and durability.
9. Biotechnology. Chemical engineers use their knowledge of chemistry and engineering to develop new products and processes in the field of biotechnology, such as biofuels, pharmaceuticals, and medical devices.
10. Nanotechnology. Chemical engineers are at the forefront of the development of nanotechnology, which is the manipulation of matter at the atomic and molecular level.

Where do Chemical Engineers work?

Chemical Engineers making difference in quality of life. There are unlimited possibilities for Chemical Engineers. They find place in variety of fields and here is the part of the exhaustive list.

We hope this Mater guide to Chemical engineering helps you to understand various dimensions about Chemical Engineering and will help your to make better professional and career decisions. It you want to add value to this, please get in touch with us.

Professional bodies for Chemical Engineers & Key Benefits to members

Professional Development is one of the essential things for a Chemical Engineer to grow in career. Let us see about the Professional bodies available for Chemical Engineers and the key benefits of joining them.

What are the Professional bodies for Chemical Engineers?

Indian Institute of Chemical Engineers (IIChE) – IIChE was established in 1947 with Dr. Hira Lal Roy as founder president. Its activities are widespread across India through its 33 Regional Centres. IIChE is organizing an Annual sessions SCHEMCON for students and CHEMCON for Chemical Engineers.

American Institute of Chemical Engineers (AIChE) – In 1908, AIChE was founded. It is the world’s leading organization for chemical engineering professionals, with more than 50,000 members from over 100 countries. AIChE Annual Meeting, Annual Safety in Ammonia Plants and Related Facilities Symposium are a few noteworthy events.

Institution of Chemical Engineers (IChemE) – IChemE membership count exceeds 44,000 members from over 120 countries. IChemE Global Awards attract interest from all over the globe and are widely recognized as the world’s most prestigious chemical engineering awards. 

Pakistan Institute of Chemical Engineers (PIChE) –  In 1969, PIChE was founded. It provides technical support to its members by arranging seminars, functions, technical lectures and training sessions on various chemical engineering related topics.

European Federation of Chemical Engineering (EFCE) – EFCE has member societies who are European non-profit making professional scientific and technical societies whose activities embrace either wholly or partly the field of chemical engineering sciences.  It has European & Non- European Institutional members who are Institutions and corporate bodies whose activities relate to the field of chemical and biochemical engineering sciences. You may explore the list to find the professional body best suited to you.

Key benefits to members in a Professional body for Chemical Engineers

We have seen the list of professional bodies available for Chemical Engineers. One must think of getting a membership for professional accomplishment and also reap the following benefits.

• It gives personal prestige to be a part of the professional body.
• It also demonstrates professional commitment and enhances career prospects.
• Chemical Engineers get access to the Chemical Engineering Magazines published by the professional body. For example, becoming a member in AIChE gives free access to Chemical Engineering Progress magazine
• Professional body membership also provides the way to meet and network with the Chemical Engineering colleagues and helps you informed about what’s happening in your industry. Local sections or Chapters provides the opportunity to get in touch with the Chemical Engineers in your locale and also provides Volunteering opportunities to give back to society.
• Conference or Symposiums are also organized by most of the professional bodies and the membership offers the benefit of attending the program at the subsidized rates. For example, IIChE conducts four-day Annual Professional Meet called CHEMCON and the member gets a discount on the rate.
• It also gives the opportunity to attend Webinars, Courses and Training programs organized by the professional body at regular interval.
• Membership benefits also include a discounted price on books. For example, IChemE offers a discount on books for all its members.
• Conference or Symposiums are also organized by most of the professional bodies and the membership offers the benefit of attending the program at the subsidized rates. For example, IIChE conducts four-day Annual Professional Meet called CHEMCON and the member gets a discount on the rate.
• It also gives the opportunity to attend Webinars, Courses and Training programs organized by the professional body at regular interval.
• Membership benefits also include a discounted price on books. For example, IChemE offers a discount on books for all its members.

What are you thinking about now?

Yes! It is the right time to join any of the professional body to accomplish your career goals as a Chemical Engineer!

Is Chemical Engineering a dying Profession?

The truth is simple: Chemical engineering is not obsolete — it is evolving to meet the needs of the 21st century. From green hydrogen to advanced materials, from pharmaceutical breakthroughs to water sustainability, chemical engineers are leading the way. The next generation of chemical engineers will be both process experts and digital innovators. So, the next time someone says “chemical engineering is becoming obsolete”, remember — the world’s most urgent challenges can’t be solved without it.

In Conclusion, we hope this Master guide for Chemical Engineering will help you to appreciate the functions of Chemical Engineers. Similarly it will also aid to make better career decision. If you would like to add value please get in touch through email, we will enhance this article regularly.

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EPSC – EUROPEAN PROCESS SAFETY CENTRE, is an international not for profit organization. It is founded in 1992 and provides an active network for members to work together on process safety

The EPSC Learning Sheets are meant to stimulate discussion on important process safety topics at operational sites, to improve competency & awareness in a pleasant format. EPSC facilitates its members to evolve from a sharing organisation to a learning organisation. The Sheets are available in various different languages.

Similarly EPSC Learning Sheets are also helpful in creating awareness about process safety.

So far 82 learning sheets were published and here is the consolidated list and download link.

Get unlimited access to 5,000+ magazines, newspapers and curated premium stories at flat 55% off

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P&ID is the diagram which shows the interconnection of process equipment and the instrumentation used to control the process.

The uses of P&ID are as follows

• P&ID is the basis for developing the control systems in the chemical process.
• It helps in Equipment design and Piping design and also serves to estimate the capital cost.
• Hazard and Operability (HAZOP) Study is performed during the design stage with the help of P&I diagram.
• It will assist in preparing Commissioning procedure, Pre-Startup Safety Review, Standard Operating Procedures for Startup, Normal operation and Shutdown.
• It also assists in preparing Plant Operating manual
• Control narrative and Interlock narratives will be prepared by having P&ID as the basis.
• It will help to prepare the Instrument Index and other will serve as a reference for creating other datasheets.
• It acts as a beacon for newbie process engineer in a Chemical Industry.
• P& ID also helps in Incident investigations to find out What Went Wrong through root cause analysis.
• It helps in evolving maintenance procedures of equipment. It helps to visualize the interconnecting systems with the equipment and planning for proper isolation can be done.

What is the difference between P&ID and PFD?

Process Flow Diagram (PFD) is used for indicating the general flow of process and equipment. It helps to visualize the overall process of the in a chemical plant.

PFD will contain main process piping, Main equipment number, Equipment Name, Flow directions, Major bypass lines, Critical Control Valves that affects the process, Stream Number, Stream Designation, Process parameters like operating temperature, operating pressure, flow rate, Composition and heat duty of heat transfer equipment.

PFD will not contain Piping size and classification, Process control Instrumentation details like Transmitters, Control valves, Design Temperature and Pressure, Material of Construction of Equipment and piping, Mechanical Valves for isolation, Vents and Drains, Relief valves & Safety Valves.

P&ID will contain Equipment number, Equipment Name, Process and Utility piping, Piping size and classification, Instrumentation details like Transmitters, Control valves with their numbers, Control input and output, Annunciation input, SIS input, solenoid valves, On-off valves, Motorised valves, Relief valves, All Mechanical valves Miscellaneous items like strainers, Vents, drains, Silencers, standpipes etc, Vendor items and interfaces, Equipment design pressure, Temperature and Material of Construction, Free draining requirements etc. P&ID will also have general notes that will assist during Detailed Engineering, Erection and Commissioning phase. Though it is not an exhaustive list, Our P&ID Check list in the trailing part of this post will help you to explore in detail about Piping and Instrumentation Diagrams.

P&ID will not contain Operating parameters, Equipment elevation details, Elbows, MTO, etc. It is not drawn to scale and hence geometric accuracy can not be expected out of P&ID.

P&ID Symbols

The instrumentation symbols used in P&ID are as per ISA-S5.1 standard –  Instrumentation Symbols and Identification. For Symbols of chemical apparatus and equipment normally ISO, JIS, DIN or PIP standards are followed. 

What are the Softwares available to make P&ID?

There is some renowned P&ID software available that can be used online and offline. It saves time in creating a P&ID with the help of simple user-friendly tools available in them. Some of them are,

Autocad is one of the worlds leading design and drafting software used by many of the Chemical Process Design companies for preparing P&ID. 2D and 3D design drawings also can be made out of it.

MS-Visio is very useful offline software for Chemical Engineers to prepare PFD, P& ID and other diagrams in a simple way by just dragging and dropping the symbols.

Lucidchart is an online software for preparing P&I diagrams in a fast manner. Anyone can make the drawing with a drag and drop option. This simple and efficient software also has the functionality to import and export from MS- Visio.

P&ID Review Checklist

Chemical Engineer must review the P&ID before finalizing them for implementation. Our exhaustive Excel P&ID Review Checklist helps to review the P&ID to make it fit based on Safety, Erection, Commissioning and Operation aspects.

Download the P&ID Review Checklist as Excel file

If you find anything missing in our checklist, feel free to mail to us so that we will add them.

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Pump Affinity Laws

Q1 / Q2                =             N1 / N2

Flow Changes directly to the change in Speed

H1 / H2                =             (N1 / N2)²

Head Changes directly proportional to the Square of the change in Speed

BHP1 / BHP2    =             (N1/ N2)³

Brake Horse Power Changes directly proportional to the Cube of the change in Speed

For a fixed speed and varying impeller diameter pump affinity laws are as follows:

Q1 / Q2                   =            D1 / D2

H1 / H2                  =           (D1 / D2)²

BHP1 / BHP2       =           (D1 / D2)³    

Nomenclature:

Q1, Q2 – Volumetric Flow rate in m³/hr

H1, H2 – Head  in m

D1, D2 – Diameter of the impeller in mm

N1, N2 – Speed in rpm

BHP – Brake Horse Power in kW

The above two cost reduction techniques in Centrifugal pump may be analyzed using the Pump Affinity Laws before implementation of the project.

Pump Affinity Laws Calculator in Excel

To help the process engineers in Chemical Processing Industry, Pump Affinity laws are incorporated in Excel file and uploaded. You may download this template and use it for Pump Affinity law Calculations.

Excel Calculation File Available Here

Application of Pump Affinity Laws

The practical application of Centrifugal Pump Affinity laws is helpful in implementing energy savings in oversized pumps. In an industry process related pumps may be over sized because of various reasons or it may be underutilized based on the required operating conditions. This results in waste of energy. Pump affinity laws are helpful in implementing “VFD” and “Impeller Trim”.

Variable Frequency Drives are installed for the motor to vary the pump speed according to the requirement and it reduced power requirement.

“Impeller Trim” operation is carried out to reduce the impeller diameter of the pump to reduce the power consumption.

Centrifugal Pump Affinity Law Online Calculator

Simplify Pump Performance Calculations with Our Free Centrifugal Pump Affinity Law Calculator!

Are you a process or chemical engineer looking to quickly estimate pump performance changes with speed or impeller diameter variations?

Check out our easy-to-use online Pump Affinity Law Calculator! It helps you calculate new flow rate, head, and power based on the affinity laws — saving time and improving accuracy for pump scaling and selection.

Key Features:

Input mode for speed or diameter change

Instant calculation of new Q (flow), H (head), and P (power)

Export live formulas to Excel for further analysis

Supports a variety of units: m³/h, m, kW, and more

Perfect for energy savings, pump optimization, and troubleshooting

Try it now and streamline your pump performance calculations:

https://chemicalengineeringsite.in/centrifugal-pump-affinity-law-calculator/

Visit Chemical Engineering Online Calculators

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Let’s have a look at them in particular now.

Process Engineering Tools LITE

Air Cooler surface area and its fan power requirements, Power consumption of Compressor, Centrifugal pumps Hydraulic head, Hydraulic power and Power absorbed by motor. Alternatively you can also check the pump efficiency. This Android App also contains a navigation tree which helps us to choose the right thermodynamic package for the process simulation in Hysys which is a useful decision making tool for Chemical engineers in process simulation. Process Engineering Tools LITE remains one of the best Chemical Engineering Apps.

Download Process Engineering Tools LITE App here

Steam Hub

Steam Hub is Forbes Marshall’s android app for all steam related calculations.

Boilers section contains Boiler Efficiency calculation, Blowdown requirements, Fuel requirement calculation and few other things in it. Steam Distribution section contains an interesting components such as Steam trap selection and Valve selection based on the application. Pipe sizing also built in it which makes the calculations easier in a simple touch on the screen.

It is also possible for us to calculate the Flash steam generation quantity and percentage from the given inputs. It also contains Steam tables and Unit converter which makes it user friendly. Technical tools contain details about IP (Ingress Protection) ratings, Recommended Fluid Velocities in pipeline for various applications are also equipped in the Steam Hub app by Forbes Marshall.

Download Steam Hub App here

Unit Converter

Unit conversion in day to day life of an engineer is inevitable. This Unit converter App has more than 30 categories like Temperature, Pressure, Energy, Power etc. This elegant app has Currency converter also in it which makes your currency calculations simple during your travel to other countries and gives peaceful mind.

Download Unit Converter App here

Engineer Owl Jiffy

This Android App has major categories like Pumps, Compressor, Heat Exchangers, Pressure Vessel, Pressure Drop Calculation and Tools.  Under each Category there are few computational tools available like Shell and Tube Heat Exchanger Design, Pressure Vessel Design, Pump Specific Speed Calculation Compressor Power/ Outlet Temperature calculation as well as Saturated and Super heated Steam tables.

Download Engineer Owl Jiffy App here

Psychrometric

This app has features to input Dry bulb temperature and Wet bulb temperature or Relative humidity to find out the remaining. Relative Humidity or Wet bulb temperature, Humidity ratio, Dew point, Specific Volume and Enthalpy are the outputs. This Android App definitely helps to make Psychometric calculations simple.

Download Psychrometric App here

Similarly Chemical Engineering Apps like DWSIM Simulator, PID Loop Tuning Guide, DigiFlange  and Pressure Drop Calculator also available. Share this with your friends and If you come across any Android app that eases the tasks of Chemical Engineers, please share with us.

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PFD and P& ID Preparation in Visio

Process Flow Diagram (PFD) and Piping and Instrumentation diagram (P& ID) can be prepared with the help of this software easily. The available tools for creating the diagram is customized and made available as icons under the topics Equipments – General, Heat Exchangers, Pumps, Vessels, Instruments, Pipelines, valves & Fittings. Once can also use the search box to find out the needed equipment. Other simple customizations can be done like any other MS – Office software like Changing the color, Font size and Inserting symbols which is helpful in creating colorful PFD/ P& ID’s for presentation purpose. It is possible to save the diagrams as VISIO files or simple images. The other use is we can simply copy the equipments from VISIO and paste it as image wherever we need.

Other Applications of VISIO

Organization charts for the department or for an Industry can also be effectively created with the help of VISIO. Gantt Charts can be created by using MS – VISIO to schedule project tasks and communicate them visually to team members. Program Evaluation and Review Technique (PERT) chart can be prepared which is a useful tool for Project managers. Brainstorming diagrams available in MS-VISIO Swill help to conduct a brainstorming session in effectively capturing and organizing the ideas.

It also helps to prepare Plant layout and site layout. Cause and effect diagrams which is also known as fishbone or Ishikawa diagrams can be made using VISIO. This will Show factors and causal relationships in a given situation. Fault tree analysis diagrams show and analyzes faults in processes. Basic electrical diagrams, Circuits and logic diagrams, Industrial control systems diagrams will be helpful for creation of circuit diagrams and other Interlock diagrams. These will be very useful for Electrical engineers and Instruments Engineers also.

Hope this review will be helpful to understand the uses of MS- VISIO. If so, Share this with friends

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Basic Principles and Calculations in Chemical Engineering is divided into 5 parts namely,

1. Introduction

2. Material Balances

3. Gases, Vapors, Liquids and Solids

4. Energy Balances

5. Supplementary Material

The book starts with Introduction chapter where authors provided concise information about Dimensions, Units, Unit conversions, Moles, Density, Concentration, Temperature and Pressure. Each chapter in this book starts with the objectives where reader can clearly understand the benefits of studying that chapter. Example problems and solutions are also given in each chapter to understand the concepts in a better manner. At the end of each Chapter, Supplementary Resources list which contain Books, Chemical Engineering Journals and Websites pertaining to that Chapter is listed.

The second part is dedicated for Material Balances. The concept of Material balance for Various systems like Steady state and unsteady state, Batch and Semi batch process etc. Separate chapters are incorporated for Material Balance in Single Units, Multiple Units, Material Balance for units involving Chemical Reactions and Material balance for Industrial applications for Recycle, Bypass and purge. We learn to apply 10 step strategy, to solve Material balance in this chapter.

Next part is Gases, Vapors, Liquids and Solids. This contains details on equations of state, Vapor pressure, Condensation, Adsorption and saturation etc. Energy Balances is the fourth part of this book. Energy balance calculation for various systems and concepts like enthalpy change, heat of mixing are elaborated. Application of Humidity chart is explained in detail. The above chapters is helpful designing few of the industrial applications like Dryer, Air Conditioning Units, Cooling Towers etc. Finally Supplementary Material is contain guidance on solving material and energy balances using Chemical Process Simulators like Aspen Hysys.

Basic Principles and Calculations in Chemical Engineering  by Himmelblau is a great source for Chemical Engineering students to learn Chemical Process calculations.  It will also help Chemical engineers to refresh their basics.

Found Useful? Visit our Chemical Engineering Books review section.

Related Books:

Buy Basic Principles and Calculations in Chemical Engineering. David M. Himmelblau – Book

Buy Basic Principles and Calculations In Chemical Engineering- CD

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Chemenator is the column where recent research and developments in Chemical Engineering and associated fields are presented. Research study findings, Pilot plant study, process improvements are the main focus areas in this column. It helps the readers to update contemporary knowledge in Chemical Engineering field.

Chemical Engineering articles are categorized into four namely processing and Handling, Business & Economics, Environment, Health & Safety, Automation & Control and published. Cover story is elaborated article which details the nook and corner of the topic in various dimensions. Apart from the editors contributing editors from various Chemical Industry and Organizations also share the articles of greater use in Chemical Engineering Magazine. Business and Economics section also provides details on chemical plant cost index, mergers and acquisitions, expansion and new facilities etc.

Events and announcement section unveils Chemical Engineering related conferences details. It also has got place for who’s who where top management changes in Chemical Industry are given.

New Products and services page provides details and the availability of products and services related to chemical engineering which finds greater use by Industry professional.

Career tools is a division where articles on Presentation and communication skills, project planning, Opportunities for recent graduates, Book review professional development.

Facts at your finger steps section collects the data from various resources done on a specific topic and presented in this section.

Chemical Engineering Magazine Subscription

Chemical Engineering Magazine is available in digital media. For US users print version is also available. Subscription to chemical engineering magazine has got two options. One is Silver where only for current edition of the magazine can be accessed online. Gold option allows the subscribers to have access over 25 years of past achieves.  Back issues of the Chemical Engineering magazine can be accessed here

More Information

Website: www.chemengonline.com

Visit here for Chemical Engineering Magazine LinkedIn Group

Publisher: Michael Grossman

Editors: Dorothy Lozowski, Gerald Ondrey, Scott Jenkins, Mary Page Bailey

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About Trevor Kletz:

Trevor Kletz (1922-2013) is the author of Still Going Wrong. He was also the author of the book what went wrong? Kletz is a graduate in Chemistry. He joined ICI as a Research chemist and later he became Technical Safety Advisor. Still going wrong was published in 2003 which was his last book in his lifetime as sole author.

Still going wrong – A Readers Review

Nomenclature: In the beginning lines Kletz quoted about the nomenclature which is followed in US & UK. List of Engineering terms is given for both UK & US for common purpose. This will help the readers to understand about the systems discussed in the book and also to know about the industrial practices in various countries. For example in US it is stack, in UK it is called chimney.

Maintenance: The preparation for maintenance is an important task in Chemical Industries which involves lot of risk. Kletz gives case histories for isolation, dismantling, commissioning, dead end and other hidden hazards that may arise during maintenance of the equipment & piping.

Entry into Confined Spaces: Kletz gave examples for incidents involving incomplete isolation, Hazardous material introduction, inadequate PPE and Poor atmosphere testing.   At the end of the chapter avoiding the need for entry in various jobs is depicted which is worth considering. This reminds the recent PETROBOT project by shell & EU for development of robot for online inspection in confined spaces.

Changes to Process Plants & in Organization:  Plant modifications and scaling up activity and equipment modification will also pose threat to chemical process safety; an interesting example in still going wrong is the Valve is insulated to save energy. This resulted in the expansion of bolts due to heat and explosive gas leaked to atmosphere and fire occurred. Even Insulation has got the power to destroy the plant! Changes in organization like multi skilling, de – manning and outsourcing also has got potential hazards which are to be addressed with care.

Changes in procedures instead of designs: Simple procedure changes instead of change in design was also resulted in untoward incidents and various examples were given given by Kletz.

Material of construction & Operating Methods: The selection of improper material of construction for various applications poses high risks of accidents. Erroneous Operating methods also cause incidents and discussed with case histories in still going wrong.

Still going wrong also discusses case histories associated with Explosions, Poor Communication, Inadequate training, Process control malfunctions, Leaks and Reactions. Accidents in Other Industries like coal mine, Marine facilities also gives us a picture on what not to do. Authors view on Accident investigation and tips for it also informative sections for process safety professionals.

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Process Safety Beacon – Messages for Manufacturing Personnel

Process Safety Beacon is an Industrial Safety tool for conveying One Page Safety message for manufacturing personnel every month.  First Edition was published in 2001. And now it is available in about 30 Languages including Indian Languages like Tamil, Telugu & Hindi. This regional language support will help the industry personnel to train the contract labor also. Process safety beacon analyses industrial safety issues in detail to avoid the accidents to happen again.

Every Process safety beacon analyses the safety incident for 5 W’s.

Who is it about?

What happened?

When did it take place?

Where did it take place?

Why did it happen?

The Industrial accidents are analyzed for the root causes and gives solutions for the manufacturing personnel to avert such incidents in future. Every issue comes with a solution – What you can do? It is really a worth tip to have and follow in carrying out the jobs safely in any Industry.

All the issues of Process Safety beacon are available online in PDF formats for free. You can use it for educating your Industry personnel to make them sound in Process Safety. Archives can be accessed here. The back issues from year 2001 till 2022 are available for download.

Website

http://www.sache.org/beacon/products.asp

The EPSC Learning Sheets are meant to stimulate discussion on important process safety topics at operational sites, to improve competency & awareness in a pleasant format.

Share this wealth with Your Friends!

Related Books:

Buy What Went Wrong?: Case Studies of Process Plant Disasters By Kletz from Flipkart.com

Buy Process Safety and Loss Prevention By Mohanad El-harbawi from Flipkart.com

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