Primer: Safety in Design
Purchasing Information
Price: $9.99 (U.S.)
No cost to paid subscribers at this substack through July 7, 2025.
The Primer Series
Information to do with other products in this series is available here.
Overview
The primer Safety in Design provides practical guidance on integrating safety principles into every stage of process facility design, from concept development through commissioning and decommissioning. Drawing on lessons from major incidents, current standards, and best engineering practices, this primer introduces foundational concepts such as inherently safer design, fail-safe systems, safe operating limits, and human factors.
Written for engineers, designers, and safety professionals, the primer emphasizes risk-based thinking, multidisciplinary collaboration, and lifecycle responsibility. It also highlights emerging trends, including digital twins, and climate resilience.
Whether you're involved in facility upgrades, new builds, or operational reviews, Safety in Design offers clear, actionable insights to strengthen the safety and integrity of your projects.
Table of Contents
Introduction
Core Concepts and Terminology
Inherent Safety
Hazard Elimination
Process Hazards Analysis
Safe Limits
Fail-Safe Design
RAGAGEP
Human Factors Engineering
Timing
Regulations and Standards
Potential Pitfalls
Emerging Trends
Knowledge Check: 10-Question Quiz
Questions
Answer Key
The Quiz
Choose the best answer for each of the following questions.
1) What is the primary goal of Safety in Design?
a) Increase production
b) Eliminate training needs
c) Reduce operational costs
d) Eliminate or control hazards before they occur
2) What diagram provides the most detailed view of process equipment and control logic?
a) BFD
b) PFD
c) P&ID
d) Loop diagram
3) Which standard governs safety instrumented systems in the process industry?
a) API 520
b) ASME Section VIII
c) NFPA 30
d) IEC 61511
4) Which of the following is NOT a principle of inherently safer design?
a) Substitute
b) Complicate
c) Minimize
d) Moderate
5) What is a common pitfall in process design?
a) Performing a HAZOP
b) Using current standards
c) Relying only on procedures to manage risk
d) Including multiple layers of protection
6) What federal regulation governs Process Safety Management in the U.S.?
a) 40 CFR Part 68
b) 29 CFR 1910.119
c) ASME B31.3
d) ISO 14001
7) What is a benefit of using digital twins in design?
a) They reduce permit costs
b) They simulate operating and emergency conditions
c) They replace documentation
d) They serve as legal compliance tools
8) In which phase should hazard identification begin?
a) After commissioning
b) During maintenance
c) During detailed design
d) Before conceptual design
9) What is the role of CCPS?
a) Enforce OSHA standards
b) Set environmental regulations
c) Provide guidance and best practices for process safety
d) Manufacture safety equipment
10) Which of the following would most likely appear on a P&ID?
a) Annual budget
b) Pressure vessel design margin
c) Relief valve and control loops
d) Feedstock cost projections
