Handbook of Loss Prevention Engineering

Contents to Volume 1

PREFACE

PART I: Engineering Management for Loss Prevention Engineering

MANAGEMENT SYSTEMS - LOSS PREVENTION ENGINEERING PROGRAMS ANDPOLICY
Introduction - Understanding the Need for Management Systems
Management Systems - Definitions
Loss Prevention Engineering - Considerations
Management Systems - Loss Prevention Engineering

RESOURCE ALLOCATION AND EFFECTIVENESS MEASURES FOR LOSS PREVENTION
Introduction
What Is Loss Prevention/Safety and Health Intervention?
Historical Perspective of Resource Allocation for Loss Prevention
Loss Prevention/Safety and Health Intervention Effectiveness Evaluation
Importance of Multiple Factors in Loss Prevention
Research Methodology in Resource Allocation for Loss Prevention
Experimental Method
Analysis and Results
Conclusion

ENGINEERING SYSTEMS AND ENGINEERING ECONOMICS OF LOSS PREVENTION
Introduction

Cost of Injuries
Return on Investment Versus Cost Savings Versus Productivity Savings
Engineering Economics
Engineering Economic Decision-Making
Net Present Value Comparison (Equipment Replacement)
Payback Period Comparison
Financial Considerations of a Loss Prevention Engineering Project
Conclusion

SAFETY MANAGEMENT AND CULTURE
What Is Organizational Culture?
How Does Culture Form?
Why Is It Good Business to Improve Your Company's Culture?
Measuring Culture
How to Bring About Changes in Culture

LEADERSHIP AND LOSS PREVENTION ENGINEERING: CREATING CONDITIONS TO GET BEYOND COMPLIANCE TO HIGH PERFORMANCE
Introduction
Management Theories
Moving Beyond Mechanistic Management
Humanistic Organizations
Case Studies of Humanistic Management

PART II: Design and Analysis of Protective Systems - General Loss Prevention Engineering

GENERAL LOSS PREVENTION ENGINEERING PROGRAMS - INCLUDING FIRE LOSS CONTROL
Background
Introduction
Elements of a Fire Loss Control Program
Fire Prevention Controls

PERMIT-TO-WORK SYSTEMS
Introduction
The Permit-to-Work Process
Regulations and Standards
Hot Work
Confined Space
Live Line Electrical Work

EXCAVATION AND TRENCHING
Introduction
Hazard Identification and Federal OSHA Regulation
Soil Types
Basic Soil Mechanics Theory
Testing and Soil Classification Systems
Protective Systems

MACHINE SAFEGUARDING
Introduction
Regulations and Standards
Machine Motion Hazards
Human Factor Aspects of Machine Guarding
Machine Safeguarding Methodology
Basic Machine Guarding Principles
Types of Machine Safeguarding
Machine Controls
Responsibilities of the Machine Builder
Mechanical Power Presses
Power Press Brakes
Conveyors
Roll-Forming and Roll-Bending Machines
Shearing Machines
Laser Machining
Robots
Conclusion

BOILERS AND PRESSURE VESSELS: A BRIEF LOOK AT GENERAL SAFEGUARDS
Water
Safeguards
Codes, Regulations, and Training
Types of Boilers
Operating Considerations
Boiler Feed Water
Chemical Handling
Steam
Special Considerations for Pressure Vessels
Fire Detection and Control
Incident Investigation
Closing Thoughts

WELDING AND CUTTING
Introduction
Basic Equipment for Welding Comfortably and Safely
The Welding Process
Cutting
Conclusion

POWER TOOLS
Introduction
Guards
Safety Switches
Electric Tools
Powered Abrasive Wheel Tools
Liquid Fuel Tools
Pneumatic Tools
Hydraulic Power Tools
Conclusion

PERSONAL PROTECTIVE EQUIPMENT
Introduction
General Selection
Types
Conclusion

POWERED INDUSTRIAL TRUCKS
Introduction
Lift Truck Accident Prevention: An Integrated Approach
Fork Truck Safety Observations
Making Safety Observations
Loading Dock Safety
Whole Body Vibration
Administrative Controls for Lift Truck Operator Strains and Sprain Prevention
Rack and Overhead Storage and Industrial Lift Truck Operations
Carbon Monoxide and Dilution Ventilation
MVR Program and Physical Requirements
Case Studies
Using Acceptable Safety Tolerances in Defining Preventive Maintenance
Industrial Lift Truck Accident Costs
Conclusions and Establishing Safe Behavior Observation Management Programs

PART III: Ergonomics and Human Factors Engineering

BIOMECHANICS AND PHYSICAL ERGONOMICS
Introduction
Biomechanics
Applications of Biomechanics in Ergonomics
Conclusion

HUMAN FACTORS AND COGNITIVE ENGINEERING
Introduction
Models of Human Cognition
Applications to Process Engineering and Surface Transportation
Conclusions

VIRTUAL WORKING ENVIRONMENT
Methodological Assumptions
Elements of the Virtual Working Environment Structure
Engineering Approach to Loss Prevention Within the Life-Cycle of Technical Means
Methods and Tools Supporting the Creation of Elements of a Virtual Working Environment
Human Body Modeling
Anthropomorphic Test Dummies
Multi-Body Models of ATDs
Multi-Body Human Models
Finite Element Models of ATDs
Finite Element Human Models
Digital Human Models
Modeling of Phenomena
Conclusion

SHAPING OF WORKING CONDITIONS USING ICT TECHNOLOGY
Working Environment
Information and Communication Technologies
Computer-Aided Shaping of Working Conditions
Shaping of Work Organization Using ICT
Conclusion

SAFETY-ORIENTED VIRTUAL PROTOTYPING OF MINING MECHANICAL SYSTEMS
Introduction
Introduction to Polish Underground Coal Mine Working Conditions
Introduction to Technical Hazards
Graphical Methods of Technical Hazards Assessment in Underground Mechanical Systems
Virtual Prototyping of FOPS
Application of Computational Fluid Dynamics (CFD) Analyses in Virtual Prototyping of Mining Machines
Conclusion

Contents to Volume 2

PART IV: Process Safety Management and System Safety Engineering

PROCESS SAFETY REGULATIONS AROUND THE WORLD
Introduction
Process Safety - Drivers
Differences and Commonalities
Non-Regulatory Approaches
Lessons Learned
Evolving Field
General Duty
Proposed Changes to Regulations
Summary
Future of Process Safety

ANALYTICAL METHODS IN PROCESS SAFETY MANAGEMENT AND SYSTEM SAFETY ENGINEERING - PROCESS HAZARD ANALYSIS
Introduction
Overview of PHA
PHA and Decision-Making
Stages and Steps in PHA
PHA Project Initiation
Hazard Identification
Selecting a PHA Method
Defining the Purpose, Scope, and Objectives of the Study
Selecting a Team
Collecting and Preparing Reference Information and Data
Estimating the Effort Involved and Scheduling Study Sessions
Briefing/Training Team Members
Arranging Required Facilities
Other Items
Subdividing the Process
Performing an Inherent Safety Review
First Session
Recording PHA Studies
Making Worksheet Entries
Special Topics
Revalidation
Report Preparation
Follow-up

SAFETY INSTRUMENTED SYSTEMS
Introduction
Fundamentals
Planning and Management
Analysis Phase
Realization Phase
Operation Phase
Conclusion

ANALYTICAL METHODS IN PROCESS SAFETY MANAGEMENT AND SYSTEM SAFETY ENGINEERING - LAYERS OF PROTECTION ANALYSIS
Introduction
Overview of LOPA
Scenario Risk
Risk Tolerance Criteria
Stages and Steps in LOPA
Initiating a Project
Preparing for LOPA
Preparing for a Study
Conducting a Study
Limitations, Cautions, and Pitfalls

CHEMICAL REACTION SAFETY
Introduction
Chemical Reaction Hazards
Identifying Reaction Hazards
Determine the Worst-Case Consequences
Assessing Chemical Reaction Risks
Identifying Process Controls
Basis of Safety Selection
Conclusion

APPLICATION OF SYSTEMS ENGINEERING TO SAFETY AND RISK MANAGEMENT: A HUMAN - SYSTEMS INTEGRATION PERSPECTIVE
Systems Engineering
Human - Systems Integration
Systems Modeling Language
Human - Systems Integration Model Domains

MANAGEMENT OF CHANGE
Introduction
What Is Management of Change (MOC)?
Why Is MOC Important
Developing a Formal MOC Program
Executing the Change
Scalable MOC
Pitfalls to Avoid
Success Stories
Conclusion
Tools and Resources
Accreditation Groups

THE IMPORTANCE OF FOSTERING A STRONG INDUSTRIAL SAFETY CULTURE AND CHANGE MANAGEMENT
Introduction
Process Description
Site Leadership Team Industrial Safety Culture Review
Change Management
Conclusion

CONTRACTOR SAFETY MANAGEMENT
Introduction
Contractor Management
The Score: Questionnaires and Contractor Ranking Systems
Summary and Conclusion

EMERGENCY PREPAREDNESS AND RESPONSE

SECURITY AND TERRORISM
Security and Terrorism
The Oklahoma City Bombing
The 9/11 Attacks
Lessons Learned from the Oklahoma City Bombing and 9/11
Bioterrorism
Cyber Terrorism
Conclusion

PART V: Occupational Health and Environmental Engineering

CONTROL OF CHEMICAL HAZARDS
Introduction
Considerations
Control Methods
Conclusion

CONTROL OF PHYSICAL HAZARDS
Introduction
Considerations
Control Methods
Conclusion

CONTROL OF AIR POLLUTION
Introduction
History of Air Pollution Regulations
Benefits of the Clean Air Act and Amendments (CAAA) from 1990 to 2020
Atmospheric Factors
Air Pollution Types, Sources, and Effects
Indoor Air Quality
Air Pollution Control
Best Practices and Solutions
Conclusion

HAZARDOUS WASTE MANAGEMENT AND ENGINEERING
Introduction
Impact of Hazardous Waste
Hazardous Waste Regulation
Hazardous Waste Management Strategies
Hazardous Waste Treatment
Hazardous Waste Minimization
Hazardous Waste Remediation
Hazardous Waste Technologies
Life-Cycle Assessment
Conclusion

PART VI: Incident Investigation and Root Cause Analysis Methodology and Management

HOW TO CONDUCT EFFECTIVE INCIDENT INVESTIGATIONS
Introduction
What Is the Purpose of the Investigation?
Why Investigations Fail
The Basic Investigation Process
Investigation Resource Requirements
Using Teams to Conduct Investigations
Sources of Evidence
Minimizing the Erosion of Evidence
Finding the Root Causes of Incidents and Problems
How to Develop Effective Corrective Actions
Tips for Improving an Investigation Process
Conclusion

INCIDENT INVESTIGATIONS - LESSONS LEARNED - DEVELOPMENT AND COMMUNICATIONS
Introduction
Internal Lessons
Distribution
External Lessons
Collection of Data
Dissemination of Data
Industry and Discipline Participation
Regulatory Actions and Changes
Suppliers
In Review
Case Study - Lessons Learned

MANAGING RECORDS, INVESTIGATION AND RECOMMENDATION MANAGEMENT AND CLOSURE
Introduction
Reporting
Storage and Protection
Retention
Confidentiality
Legal Issues
Regulatory Considerations
Types of Records
Recommendation Management and Closure
Escalation
Corrective Actions
Implementation, Verification, and Validation
In Review

PART VII: Fire Protection Engineering

FIRE DYNAMICS
Overview
Part A: Qualitative Description of Fire Dynamics
Part B: Predictive Methods

FIRE PREVENTION AND PROTECTION
Introduction
Basic Principles
Design Basics
Practical Design Considerations
Oil and Gas Facilities
Natural Gas Vehicle Fueling Stations
Hazard Versus Risk
Practical Operations Considerations
Floating Roof Tank Operation Considerations
Investigating and Reporting on Fire Losses
Fire Reporting
Example Root Cause Analysis Report of Fire
Fire Suppression Equipment
Roles and Responsibilities
Conclusion

THE SCIENCE AND ENGINEERING OF EXPLOSIONS
Introduction
Fundamentals of Explosions
Types of Explosions
Combustion and Chemistry of Explosions
Ignition
Blast Damage Due to Over-Pressurization
Blast Fragment Missile Damage
Evolution of Flammable Material
Dispersion and Possible Ignition of Released Material
Plume Distribution Calculations
Puff Distribution Calculations
Conclusion

INDEX