trevor kletz, ,still going wrong? case histories of process plant disasters and how they could have...

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0957–5820/04/$30.00+0.00 # 2004 Institution of Chemical Engineers www.ingentaselect.com=titles=09575820.htm Trans IChemE, Part B, May 2004 Process Safety and Environmental Protection, 82(B3): 256 BOOK REVIEW Still Going Wrong? Case Histories of Process Plant Disasters and How They Could Have Been Avoided Trevor Kletz Gulf Professional Publishing, 2003 230 pp, £29.95, ISBN 0 7506 7709 0 Reviewed by Nick Spencer (General Manager and Director, ConocoPhillips Ltd Humber Refinery, UK) Trevor Kletz has helped to educate many people in industry to the hazards that they are confronted with on a regular basis, especially those in the chemical, oil and process industries. Still Going Wrong is his eleventh book, and most people can learn something from it, whether they are involved in production, maintenance or design. This latest book complements his earlier book What Went Wrong? It contains many very recent events as well as identifying new causes of incidents, and sadly some of the now well-known causes. The book describes incidents that could occur in many types of plant. Virtually every incident could be avoided. The book contains much advice for those who operate process plants, but also for those who design them. A high price has been paid for this valuable information, and it should be used. The learnings can be used as safety topics, part of an engineer’s training programme, and as a way to keep the personnel in a plant talking about process safety. As Kletz comments on many occasions, Safety Manage- ment Systems are important, but equally as important or perhaps more so, is what actually happens in the field. The tendency to overly complicate design, or not design out traps, clearly is a significant source of incidents. The need to keep systems as simple as possible comes through as a theme. He has some very good advice for incident investi- gators, looking for the true cause of an accident and not just who to blame. The book is arranged into chapters covering different types of equipment as well as procedures and maintenance. It emphasizes the multiple causes of accidents, and wherever possible the underlying weaknesses in the management systems are discussed. However, in many cases there is not enough information to delve into the latent causes and the reports describe only the immediate technical causes. Although human error is not discussed as a particular topic, it is clearly included throughout the book. Most incidents have an element of human error. Someone has to decide what to do, how to do it or who has to do it. All may make errors. The book distinguishes errors into four groups— Mistakes, Violation or Non-Compliance, Mismatches, and finally Slips and Lapses of Attention. For those who want to explore this area in more detail, Kletz’s book An Engineer’s View of Human Error (IChemE, 2001) is very useful. Another theme that comes through clearly in the book is the failure of industry to learn from past accidents. Every chapter shows that organizations have limited memory. There must be something seriously wrong with safety education when so many accidents repeat themselves so often. Kletz has some practical advice about how to improve this situation. Still Going Wrong? is very aptly titled. All process industries have a tremendous amount to learn. The pressure for improving safety standards is relentless, as it should be. This book will help build awareness of the diverse causes of accidents. It will not prevent them unless the reader is committed to thinking about the lessons and applying them appropriately in their own area of responsibility. If lessons in this book prevent one incident in each reader’s plant, the cost of the human suffering incurred in the book will not have been wasted. Without a doubt I recommend this book for anyone involved with management, design, operation, health and safety, or maintenance, in the process industries. This book is available via IChemE’s Virtual Bookshop: www.icheme.org/shop (IChemE members receive 10% discount) 256

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Page 1: Trevor Kletz, ,Still Going Wrong? Case Histories of Process Plant Disasters and How They Could Have Been Avoided (2003) Gulf Professional Publishing 0 7506 7709 0 230 pp, £29.95

0957–5820/04/$30.00+0.00# 2004 Institution of Chemical Engineers

www.ingentaselect.com=titles=09575820.htm Trans IChemE, Part B, May 2004Process Safety and Environmental Protection, 82(B3): 256

BOOK REVIEW

Still Going Wrong?Case Histories of Process Plant Disasters and HowThey Could Have Been AvoidedTrevor KletzGulf Professional Publishing, 2003230 pp, £29.95, ISBN 0 7506 7709 0

Reviewed by Nick Spencer(General Manager and Director, ConocoPhillips Ltd HumberRefinery, UK)

Trevor Kletz has helped to educate many people in industryto the hazards that they are confronted with on a regularbasis, especially those in the chemical, oil and processindustries. Still Going Wrong is his eleventh book, andmost people can learn something from it, whether they areinvolved in production, maintenance or design.

This latest book complements his earlier book What WentWrong? It contains many very recent events as well asidentifying new causes of incidents, and sadly some of thenow well-known causes.

The book describes incidents that could occur in manytypes of plant. Virtually every incident could be avoided.The book contains much advice for those who operateprocess plants, but also for those who design them. Ahigh price has been paid for this valuable information, andit should be used. The learnings can be used as safety topics,part of an engineer’s training programme, and as a way tokeep the personnel in a plant talking about process safety.

As Kletz comments on many occasions, Safety Manage-ment Systems are important, but equally as important orperhaps more so, is what actually happens in the field. Thetendency to overly complicate design, or not design outtraps, clearly is a significant source of incidents. The need tokeep systems as simple as possible comes through as atheme. He has some very good advice for incident investi-gators, looking for the true cause of an accident and not justwho to blame.

The book is arranged into chapters covering differenttypes of equipment as well as procedures and maintenance.

It emphasizes the multiple causes of accidents, and whereverpossible the underlying weaknesses in the managementsystems are discussed. However, in many cases there isnot enough information to delve into the latent causes andthe reports describe only the immediate technical causes.Although human error is not discussed as a particular topic,it is clearly included throughout the book. Most incidentshave an element of human error. Someone has to decidewhat to do, how to do it or who has to do it. All may makeerrors. The book distinguishes errors into four groups—Mistakes, Violation or Non-Compliance, Mismatches, andfinally Slips and Lapses of Attention. For those who want toexplore this area in more detail, Kletz’s book An Engineer’sView of Human Error (IChemE, 2001) is very useful.

Another theme that comes through clearly in the book isthe failure of industry to learn from past accidents. Everychapter shows that organizations have limited memory.There must be something seriously wrong with safetyeducation when so many accidents repeat themselves sooften. Kletz has some practical advice about how to improvethis situation.

Still Going Wrong? is very aptly titled. All processindustries have a tremendous amount to learn. The pressurefor improving safety standards is relentless, as it should be.This book will help build awareness of the diverse causes ofaccidents. It will not prevent them unless the reader iscommitted to thinking about the lessons and applyingthem appropriately in their own area of responsibility. Iflessons in this book prevent one incident in each reader’splant, the cost of the human suffering incurred in the bookwill not have been wasted.

Without a doubt I recommend this book for anyoneinvolved with management, design, operation, health andsafety, or maintenance, in the process industries.

This book is available via IChemE’s Virtual Bookshop:www.icheme.org/shop (IChemE members receive 10%discount)

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