J. Loss Prey. Process Ind. Vol. 8. No. 2, p.
133, 1995
S E U I T L t-~ W O R 1 t t Elsevier Science Ltd
I N [2 N'I A N N
Printed in Great Britain
0950-4230/95 $10.00 + 0.00
Book Reviews " L
Pilot Plant and Laboratory Safety
By Richard P. Palluzi .... r"
McGraw-Hill Inc, New York, 1994, 278 pages ISBN 007-048181--4 £44.95
This book is a companion volume to sis. Flammability basics are discussed oratories may also be affected in some
the author's previously published 'Pilot very briefly in Chapter 6, covering cases. NFPA 30, the Flammable and
Plant Design, Construction and Oper- flammability, flash point, auto-ignition Combustible Liquids Code, is reviewed
ation'. The author is a senior staff temperature, explosive limits, and the in Chapter 12, which discusses the
engineer at Exxon Research and Engin- NFPA classification of liquids. This following aspects of the code: tank
eering Company where he has been chapter could have been more detailed, storage, overfill protection, solvent stor-
involved in pilot plant and laboratory as this is a very important safety topic, age cabinets, and container and portable
safety for his entire career. He also but the author cites a number of relevant tank storage. In Chapter 13, relevant
teaches courses for AIChE on pilot references to enable the reader to learn aspects of NFPA 496 (Purged and
plants and safety in pilot plants and more about the subject. In Chapter 7, Pressurized Enclosures for Electrical
research operations. His expertise in the basics of safety systems (also called Equipment) are discussed, reviewing
these areas is amply demonstrated in safety shutdown systems, safety inter- the different types of purging systems,
this book. The book contains 16 chap- lock systems, protective systems, or purged enclosure design considerations,
ters, an appendix, a selected bibli- alarm systems) are presented. The chap- and control-room design consider-
ography, and a good index. ter does not attempt to make the reader ations. Chapter 14 is a succinct review
The first chapter is an introduction an expert in this complex area, but of NFPA 45 (Fire Protection for Lab-
explaining what topics the book covers does identify some of the most common oratories Using Chemicals).
and the differences between pilot plant/ and often overlooked concerns of inter- Some of the more common and
laboratory research operations and pro- est to pilot plant and laboratory research recurring specific safety concerns and
cess plant operations. Chapter 2 dis- facilities. It is a very good and inform- problems in pilot plants and research
cusses safety inspections, including ative chapter. work are discussed in Chapter 15.
types of safety inspections, housekeep- In Chapter 8, considerations for pilot Twenty-two different concerns and
ing inspections, procedure inspections, plant and laboratory space (types of problems are described, with a good
area or unit audits, and problems with housing) are reviewed from a safety number of diagrams included. These
safety inspections. The last topic is very perspective. The topics included are are very informative and useful. Safety
useful and discusses what should be separate buildings, containment cells, concerns about heated equipment, e.g.
done to maximize the effectiveness of open bays, laboratory areas, estimating electrical and fired heaters, in pilot
inspections while minimizing expendi- space requirements, interior versus plant operations are briefly discussed
ture. In Chapter 3, safety standards exterior locations, laboratory versus in Chapter 16. High-temperature pro-
are reviewed, discussing typical safety pilot plant areas, barricades versus other tection for heated equipment and safety
standards, problems with safety stan- measures, and barricade design and problems with heat tracing are
dards, and developing effective safety operational considerations. Chapter 9 reviewed. The Appendix deals with
standards. Chapter 4 describes the more reviews the various codes and standards testing for leaks in pilot plant and
commonly used research safety reviews. that must be complied with, and also laboratory equipment. Topics include
The discussion covers the overall con- lists the most commonly used ones maximum acceptable leak rate, prep-
cept of a safety review, regardless of and the organizations (NFPA, OSHA, aration for testing, preliminary tests,
the type. The types of safety reviews EPA, etc.) that are reponsible for section tests, and locating leaks.
and topics covered include conceptual issuing them. Gas-monitoring systems This is an outstanding book which
(preliminary) safety reviews, pre- are described in Chapter 10, reviewing will be of great use to chemical engin-
budget safety reviews, design safety the following topics: types of hazard, eers and chemists involved in the design
reviews, pre-start-up safety reviews, i.e. flammable/combustible gases, toxic and operation of pilot plants and
unit modification, control-of-change gases, and asphyxiating gases; types of research laboratories. It very nicely
or change-of-service reviews, decom- sensors; gas-monitoring system compo- complements the book by Marshall and
missioning safety reviews, recom- nents (sampling system, alarm module, Townsend 'Safety in Chemical Engin-
missioning safety reviews, common warning system and power supply); eering Research and Development',
problems with all safety reviews, and ensuring effective installations; portable which has been reviewed in this journal
ensuring that safety reviews meet their monitors; and common concerns with (1994, volume 6, page 270) and which
goals. regard to portable gas monitors. This presents the subject from a UK perspec-
Chapter 5 is a succinct but good chapter has very useful and practical tive.
review of safety analysis of pilot plants information. Chapter 11 is a review of
and research operations, covering the NFPA 70, the National Electrical Code,
types of hazard analyses (what-if, focusing on the most common areas of Stanley S. Grossel
HAZOP, etc.), hazard analysis docu- concern, namely pilot plants - larger Process Safety & Design lnc,
mentation, and successful hazard analy- laboratory equipment or specialized lab- Clifton, New Jersey, USA
J. Loss Prey. Process Ind., 1995, Volume 8, Number 2 133
