Process Risk and Reliability Management

Book: Process Risk and Reliability Management

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This book can be ordered directly from the publisher, Elsevier (imprint Gulf Professional Publishing). Individual chapters are available as ebooks.


This book provides comprehensive and practical guidance for the development and implementation of process safety management (PSM), operational integrity and operational excellence programs. It covers design and operations, and shows how to improve not only safety but also reliability, environmental performance, quality and profitability. Techniques and principles are illustrated with numerous examples, chemical plants, refineries, transportation, pipelines, and offshore oil and gas.

The information provided will help executives, managers and technical professionals achieve not only their current PSM goals but also to make the transition to a broader operational integrity strategy. The book focuses on the energy and process industries from refineries to pipelines, chemical plants, transportation, energy and offshore facilities. The techniques described in the book can also be applied to a wide range of non-process industries.

The book is both thorough and practical. It discusses theoretical principles in a wide variety of areas such as management of change, risk analysis, and incident investigation, and then goes on to show how these principles work in practice, either in the design office or in an operating facility. The OSHA Process Safety Management (PSM) and BSEE Safety and Environmental Management Systems (SEMS) rules are covered in detail. 

The second edition has been expanded, revised and updated and many new sections have been added including: the impact of resource limitations, a review of some recent major incidents, the value of story-telling as a means of conveying process safety values and principles, and the impact of the proposed changes to the OSHA PSM standard.


The book has 20 chapters and 770 pages. (Details to do with each of the chapters are provided at the bottom of this page.)

  1. Risk Management
  2. Compliance and Standards
  3. Culture and Participation
  4. Technical Information
  5. Hazard Identification
  6. Operating Procedures
  7. Training and Competence
  8. Prestartup Reviews
  9. Asset Integrity
  10. Management of Change
  11. Incident Investigation and Root Cause Analysis
  12. Emergency Management
  13. Audits and Assessments
  14. Consequence Analysis
  15. Frequency Analysis
  16. Reliability, Availability and Maintainability
  17. Managing a Risk and Reliability Program
  18. Project Management
  19. Contractors
  20. The Risk Management Professional


. . . Sutton says, "the best way of ensuring that a facility is safe and productive is to design it correctly in the first place, but, regardless of the quality of the design, it has to be operated by real people. This book," he goes on, "seeks to help both designers and operators."

And so it does. There's a wealth of very practical advice in this book, and if you implement the strategies Sutton suggests, you will have a safe, productive, and sustainable plant. 

Walter Boyes, Editor in Chief Control Global

This unique book is to safety what Perry's is to Chemical Engineering. Fully of practical facts and advice and invaluable to the novice or seasoned professional; and a comprehensive reference. Since acquiring my copy I have used it frequently and it has provided the answers I needed. I highly recommend it. 

Clive Wilby

In my opinion, the author has produced an excellent book, replete with much useful and practical information, figures, and tables. Many of the references are also very recent (some as late as 2009 and 2010). It is a practical guide and roadmap to making the shift from Process Safety Management programs to Operational Integrity regimes that focus on increasing performance not just in safety, but also in environmental compliance, quality control, and overall profitability.

Stanley Grossel

Ian provides comprehensive guidance on the development, implementation and evaluation of process risk and process safety programs.

Charles Gillard

Copyright © Ian Sutton. 2018. All Rights Reserved.

Ian Sutton



Chapter 1 Risk Management

Chapter 2 Compliance and Standards

Chapter 3 Culture and Participation

Chapter 4 Technical Information

Chapter 5 Hazard Identification

Chapter 6 Operating Procedures

Chapter 7 Training and Competence

Chapter 8 Prestartup Reviews

Chapter 9 Asset Integrity

Chapter 10 Management of Change

Chapter 11 Incident Investigation and Root Cause Analysis

Chapter 12 Emergency Management

Chapter 13 Audits and Assessments

Chapter 14 Consequence Analysis

Chapter 15 Frequency Analysis

Chapter 16 Reliability, Availability and Maintainability

Chapter 17 Managing a Risk and Reliability Program

Chapter 18 - Project Management

Phase / Gate System 
Hazards Analysis on Projects
Phase I - Concept Selection
   Hazards Analysis
Phase II - Preliminary Design (FEED) 
   Hazards Analysis
Phase III - Detailed Engineering
   Hazards Analysis
Phase IV - Fabrication and Construction
   Transfer of Care, Custody and Control
      Turnover Packages
   Hazards Analysis
Phase V - Commissioning and Start-Up
   Operational Readiness Review
   Startup and Line Out
      Start-Up Procedures 
      Acceptance Test
   Hazards Analysis
Project Organization 

Chapter 19 - Contractors

Regulations and Standards
   OSHA PSM Standard
   OSHA PSM Guidance
      Employer Responsibilities
   API RP 76 
Types of Contractor 
   Contract Companies 
      Selecting a Contract Company 
      Contractor inherent-safety Program 
   Design Companies 
   Contract Workers 
   Maintenance Contractors 
   Visitor / Consultant 
Bridging Documents 
   Operator/Contractor Bridging Document 
   Bridging through a Regulation
Contractor Management 
   Contractor Selection 
   Record Keeping 
   Contractor Training 
   Safety Meetings
   Contractor Training 
   Safety Meetings 
   Contractor Evaluation

Chapter 20 - The Risk Management Professional 

The Risk Management Professional
   Education and Certification
   Technical Knowledge 
   Communication Skills
   Industrial Experience
   Knowledge of Past Events
   Professional Involvement
   The Resume / CV 
      Level of Detail
      Gaps / Negative Facts
      Multiple Resumes 
      Declining Experience
   Professional Engineer
      True Expertise 
      The Consultant as Outsider 
      Consultants - Not Doers 
      Quick Study 
      Role of the Client 
      Response to Criticism
Communicating with Management/Clients
Report Writing 
   Draft Report 
   Language of the Report 
   Completeness / Thoroughness 
   Personal Information 
   Writing Style 
      Non-Emotional Language 
      Minimalist Writing - Make Every Word Tell 
      Omit Needless Words 
      Short, Simple Words 
      Minimize "Soft" Materials
      Eschew Obfuscation 
      Develop a Theme 
      No Typos 
      Date Format 
      Active/Passive Voice
      He / She 
      You / I 
      Choice of Words 
      Use of Humor 
   Responsible Document Creation 
   Elements of a Story
Communicating with the Public
   The Community 
   Other Businesses
   The Media 
   Regulators / Non-Governmental Organizations (NGOs) 
   Types of Public Communication
   Developing a Risk Communication Program 
   Communicating New Paradigms
Trade Secrets (OSHA) 
Litigation Support 
   Use of Legal Services 
   Types of Litigation
   The Participants
   Timeline / Story Line
   The Discovery Process
   Witnesses to Fact 
The Expert Witness 
   Acceptance by the Court 
   Daubert and Frye Rules
   Prior Testimony 
   Timeline / Story Line 
   The Report 
   Attributes of an Expert Witness
      To Thine Own Self Be True
      Be Prepared
      Be a True Expert 
      Be a Teacher 
      "Reasonable" Risk




Gulf Professional Publishing