FACULTY OF CHEMICAL ENGINEERING

UNIVERSITI TEKNOLOGI MARA

LESSON PLAN
CPE615
PROCESS SAFETY

1.0

1/8

COURSE INFORMATION

COURSE NAME
COURSE CODE
SEMESTER
CREDIT HOURS
CONTACT HOURS
COURSE STATUS
PRE-REQUISITE
2.0

PAGE

:
:
:
:
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PROCESS SAFETY
CPE615

6 (EH220\ EH221)
3
4
CORE
NIL

SYNOPSIS
This course offers a detailed study of safety and loss prevention covering concepts,
methods and application of techniques with emphasis on the control of hazards using
safety-engineering in process industry. The syllabus covers the national and
international safety and health regulatory provisions, and principles and techniques
for identifying, analyzing and controlling hazards which are required on any process
plant to ensure the safe and efficient operation. The course also emphasizes on risk
assessment, occupational safety and health management system, emergency planning
and case studies.

3.0

OBJECTIVES
Upon completion of this module, students should be able to:
1.
2.
3.
4.

4.0

Describe and explain the main principles of safety, health, accident prevention and
relevant safety and health legislation and regulations.
Compare and apply the various hazard identification and risk assessment
methodologies HAZOP, ETA and FTA, and QRA.
Describe and develop successful safety and health management system, and describe
the development of safety and health management system (OHSM) in Malaysia and
other countries.
Apply the knowledge on safety and health in addressing causes, consequences,
control, preventive measures and management system to prevent accidents in a
hypothetical plant.

METHODS OF INSTRUCTION
Lectures, Tutorials, Active-learning and Case Studies.

LESSON PLAN
CPE615
PROCESS SAFETY

5.0

FACULTY OF CHEMICAL ENGINEERING

UNIVERSITI TEKNOLOGI MARA
PAGE

2/8

LESSON PLAN

Week
1-2

Duration
2

Topics
1.0 Introduction to hazard and risk
1.1 Safety versus health
1.2 Engineers and safety
1.3 Inherently safe plant
1.4 Examples from past industrial accidents:
Bhopal, Flixborough, Piper Alpha and other
related accidents
1.5 Root causes of accident
1.6 Immediate causes of accident

Activities
Briefing of the course objectives and lesson plan.
Ask students to define safety and health.
Describe past industrial accidents in Malaysia and other
countries.
Read Crowl Chapter 1, Wentz p. 1-5, and Perrys
Chem. Eng. Handbook Chapter 23

2.0 Safety legislation and regulations

2.1 Definition of accidents
2.2 OSHA 1994 & Regulations
2.3 FMA 1967 and other related legislation
and regulation
2.4 Others safety related regulations

Look up DOSH Malaysia website.

Read on functions of DOSH.
Read OSHA 1994 and its regulations, FMA 1967,
Petroleum Act and EQA 1984.

4 -5

3.0 Hazards Identification

3.1 Definition
3.2 Types of hazards
3.3 Toxic hazard, fire hazard and explosion
hazard
3.4 Hazard reduction and control
3.5 Probit analysis Fire, thermal radiation
and explosion

Read Crowl Chapter 6, 7 and 12

Read Wentz Chapter 1,3, 5, 6, 7 and 10.
Read Perry Chapter 23
Look up web-site on CSDS.
Test 1

4.0 Hazard analysis

4.1 Hazard and Operability Studies
(HAZOP)
4.2 Fault Tree Analysis (FTA)
4.3 Event Tree Analysis (ETA)
4.4 Failure frequency analysis

Read Crowl Chapter 10 and 11, Wentz Chapter 2, and

Perry Chapter 23.
Class exercise on HAZOP/ETA/FMA study (Group)

5.0 Risk Assessment and Management

5.1 Definition of risk
5.2 Acceptability criteria
5.3 Qualitative and quantitative risk
assessment (QRA)
5.4 Fire radiation calculations API RP251
5.5 Explosion: TNO explosion analysis
methodology
5.6 Safe distances: dispersion calculations,
domino effects
5.7 Risk reduction and management

Read Crowl Chapter 11, Wentz Chapter 10, and Perry

Chapter 23.

6.0 Plant maintainability and reliability

6.1 Scope of industrial preventive or
predictive maintenance programs
6.2 Reliability and failure distributions

Read Wentz, p. 317-352

7.0 Emergency planning

7.1 On-site emergency planning
7.2 Off-site emergency planning

Read Wentz Chapter 9 and 14

Read Wells on emergency planning

10

8.0 Safety management system

8.1 Key elements for effective safety
management system

Read OSH MS 1722, OHSAS 18001, ILO OSH 2001

Discussion on OSH management.
Test 2

FACULTY OF CHEMICAL ENGINEERING

UNIVERSITI TEKNOLOGI MARA

LESSON PLAN
CPE615
PROCESS SAFETY

PAGE

3/8

8.2 Safety management audit, safety audit

8.3 Safety training, motivation and
incentives
13-14

6.0

9.0 Special topics related to the safety and

loss prevention in the chemical process
industries.

ASSESSMENTS
Final Examination:
Assignments and tests :

60%
40%

7.0

TEXTBOOK USED
Crowl, D. A. and Louvar, J. F. (2002). Chemical Process Safety. 2nd ed. Upper Saddle
River NJ: Prentice Hall International Series

8.0

REFERENCES
Wentz, C. A. (1998). Safety, Health and Environmental Protection. New York:
McGraw Hill.
Perry, R.H. and Green, D.W., (2007 ). Perry's Chemical Engineers' Handbook. 8th
Edition, New York: McGraw Hill.
Lees, F.J., (1994). Loss Prevention in the Process Industries Vols. 1, 2 and 3, London:
Butterworth & Company (Publ.) Ltd.
Wells, G. L., (1980). Safety in Process Plant Design, Rugby, UK: IChemE/Godwin
Wells, G. L., (1996). Hazard Identification and Risk Assessment, Rugby, UK:
IChemE/Godwin
Other references related to safety and loss prevention in process industries.

9.0

OTHER INFORMATION/DETAILS
a) Attendance is compulsory. Students who fail to comply with 80% of attendance
will be barred from sitting for the final examination. Absence from lectures,
tutorials, tests, or presentations must be supported with relevant documentation.
b) Marks will be deducted for late submission of assignment/report.
c) Consultation is by appointment only.
d) Any form of cheating and/or plagiarism in examinations, tests, reports and
assignment will be penalized.

PREPARED BY:
SIGNATURE:

APPROVED BY :
SIGNATURE :

________________________________
NAME : RAFEQAH BNITI RASLAN

_________________________________
NAME :
POSITION :
DATE : 5 MAC 2013

POSITION: Lecturer
DATE : 5 MAC 2013

FACULTY OF CHEMICAL ENGINEERING

UNIVERSITI TEKNOLOGI MARA

COURSE OUTLINE
CPE615
PROCESS SAFETY

Week

Discussed Topic

1-2

1.0 Introduction to hazard and risk

1.1 Safety versus health
1.2 Engineers and safety
1.3 Inherently safe plant
1.4 1.4 Examples from past industrial accidents:
Bhopal, Flixborough, Piper Alpha and other
related accidents
1.5 Root causes of accident
1.6 Immediate causes of accident

PO7, PO8, PO9

2.0 Safety legislation and regulations
2.1 Definition of accidents
2.2 OSHA 1994 and Regulations
2.3 FMA1967
2.4 Others safety related regulation

PO7, PO8, PO9

PAGE

Course Outcomes (Refer to

Bloom's Taxanomy Learning
Domain)
Course Outcome 1 (CO1)
Describe and explain the main
principles of safety, health,
accident prevention and
relevant safety and health
legislation and regulations

Course Learning Outcomes

The students should be

4/8

Delivery
Methods

Assessment

able to explain the definition of

safety and health,
able to explain the role of an
engineer in the aspect of safety,
able to list lessons learned from
past industrial accidents,
able to describe causes of
accidents
able to explain inherently safe
plant

Lectures, active
learning, case
study
Collaborative
learning
Class exercise

Examination or tests
or project

able to compare and contrast

safety related legislation and
regulations as applied in Malaysia
and other countries.
able to describe OSHA 1994 and
its regulations.
able to explain the definition of
industrial accidents
able to describe the requirements
and applications of the relevant
safety legislations and regulations
able to describe duties of
employers and employees in
ensuring safety and health at the
workplace.

Lectures, active
learning,
Collaborative
learning
Class exercise

Examination or tests
or project

FACULTY OF CHEMICAL ENGINEERING

UNIVERSITI TEKNOLOGI MARA

COURSE OUTLINE
CPE615
PROCESS SAFETY
4-5

3.0 Hazards Identification

3.1 Definition
3.2 Types of hazards
3.3 Toxic hazard, fire hazard and explosion
hazard
3.4 Hazard reduction and control
3.5 Probit analysis Fire, thermal radiation and
explosion
PO7, PO8, PO9
4.0 Hazard analysis
4.1 Hazard and Operability Studies (HAZOP)
4.2 Fault Tree Analysis (FTA)
4.3 Event Tree Analysis (ETA)
4.4 Failure frequency analysis

PO7, PO8, PO9

PAGE

5/8

Course Outcome 2 (CO2)

Compare and apply the
various hazard identification
and
risk
assessment
methodologies HAZOP, ETA
and FTA, and QRA.

able to identify hazards within a

plant design and operation
able to apply checklists to
significant plant designs and
operations to identify hazards.
able to prepare a professional
accident investigation report
evaluating the event and describe
the sociotechnical system

lectures, active
learning,
tutorials, group
work
Class exercise

Course Outcome 2 (CO2)

Compare and apply the
various hazard identification
and
risk
assessment
methodologies HAZOP, ETA
and FTA, and QRA.

able to identify potential initiating

events for chemical plant
operations,
able to determine the cause of the
accident,
able to estimate the consequence
and develop alternative designs or
operations that might have
prevented the accident and
reduced the risk,
able to apply Fault Tree Analysis
to determine all possible paths
leading to a specified Top Event,
able to apply and communicate
HAZOP to small sections of
chemical plant operations to
identify potential hazards and
operability problems

Lectures, active
learning,
tutorials, group
work
Class exercise

Examination or tests
or assignment
and/or case study
Test 1

Examination or test
or project

FACULTY OF CHEMICAL ENGINEERING

UNIVERSITI TEKNOLOGI MARA

COURSE OUTLINE
CPE615
PROCESS SAFETY
7

PAGE

5.0 Risk Assessment and Management

5.1 Definition of risk
5.2 Acceptability criteria
5.3 Qualitative and quantitative risk assessment
(QRA)
5.4 Fire radiation calculations API RP251
5.5 Explosion: TNO explosion analysis
methodology
5.6 Safe distances: dispersion calculations,
domino effects
5.7 Risk reduction and management

6/8

able to discuss the concept of

risk assessment, the acceptability
criteria and risk reduction
able to predict the range of values
of the consequences of an event
including, but not limited to, toxic
exposure, explosions, fires, and
spills using Probit analysis.
able to predict the probability of
occurrence of an event

Lectures, active
learning,
collaborative
learning, group
work and
tutorials

Examination or tests
or project

able to discuss the concepts of

maintainability and reliability,
able to describe maintenance
programs.

Lectures, active
learning and
tutorial
Class exercise

Examination or tests
or project

lectures, tutorial,
active learning
and group work

Examination or tests
or project

lectures,
tutorials, active
learning and
group work
Class exercise

Examination or tests
or project

PO7, PO8, PO9

8

6.0 Plant maintainability and reliability

6.1 Scope of industrial preventive or predictive
maintenance programs
6.2 Reliability and failure distributions

7.0 Emergency planning

7.1 On-site emergency planning
7.2 Off-site emergency planning

10

8.0 Safety management system

8.1 Key elements for effective safety
management system
8.2 Safety management audit, safety audit
8.3 Safety training, motivation and incentives
PO7, PO8, PO9

Course Outcome 3 (CO3)

Describe and develop
successful safety and health
management system, and
describe the development of
safety and health management
system (OHSM) in Malaysia
and other countries.

able to describe off-site and onsite emergency planning,

able to develop an emergency
plan,
able to communicate emergency
plan
able to list the key elements of
effective PSM,
able to explain the safety
management audit and safety
audit.
able to describe and compare and
contrast OHSM standards e.g.
ILO OSH 2001, OHSAS 18001,
OSH MS 1722

Test 2

FACULTY OF CHEMICAL ENGINEERING

UNIVERSITI TEKNOLOGI MARA

COURSE OUTLINE
CPE615
PROCESS SAFETY
11-14

9.0 Special topics related to the safety and loss

prevention in the chemical process industries.

PO7, PO8, PO9

PAGE
Course Outcome 4 (CO4)

Apply the knowledge on

safety and health in
addressing causes,
consequences, control,
preventive measures and
management system to
prevent accidents in a
hypothetical plant.

able to communicate and present

the outcomes of a case study.

7/8
Case study and
cooperative
learning

Oral presentation,
peer assessment and
report

LIST OF COURSE OUTCOMES:

CO1
CO2
CO3
CO4

Describe and explain the main principles of safety, health, accident prevention and relevant safety and health legislation and regulations.
Compare and apply the various hazard identification and risk assessment methodologies HAZOP, ETA and FTA, and QRA.
Describe and develop successful safety and health management system, and describe the development of safety and health management system (OHSM) in Malaysia
and other countries.
Apply the knowledge on safety and health in addressing causes, consequences, control, preventive measures and management system to prevent accidents in a
hypothetical plant.

LIST OF PROGRAMME OUTCOMES:

PO1
PO2
PO3
PO4
PO5
PO6
PO7
PO8
PO9
PO10
PO11
PO12

Ability to acquire and apply the knowledge of basic sciences, mathematics and engineering fundamentals to solve chemical engineering problems.
Ability to undertake problem identification, formulation and solution in engineering.
Ability to design and conduct experiments, as well as to analyze and interpret data.
Ability to utilize modern engineering tools, components and systems.
Ability to utilize systems approach and evaluate operational performance to design related plants.
Ability to acquire in-depth technical knowledge in chemical engineering principles.
Ability to communicate effectively, not only with engineers but also with the community at large.
Ability to apply the knowledge of safety, health, and the environment including sustainable development issues in chemical engineering scenarios.
Ability to function effectively as an individual and in a group with the capacity to be a leader or manager as well as an effective team member.
Ability to apply entrepreneurship skill in engineering related businesses.
Ability to integrate the importance of the social, cultural and global contemporary issues and professional ethics in engineering practice.
Ability to undertake lifelong learning.

FACULTY OF CHEMICAL ENGINEERING

UNIVERSITI TEKNOLOGI MARA

COURSE OUTLINE
CPE615
PROCESS SAFETY

PAGE

8/8

PO-CO MATRIX
PROGRAMME OUTCOMES
COURSE OUTCOMES

PO
1

PO
2

PO
3

PO
4

PO
5

PO
6

PO
7

PO
8

PO
9

PO
10

CO1. Describe and explain the main principles of

safety, health, accident prevention and
relevant safety and health legislation and
regulations.

PO
11

INSTRUCTIONAL
METHODS

ASSESSMENT

Lectures, tutorials, group

works

Examination or tests
or integrated project

PO
12

CO2. Compare and apply the various hazard

identification
and
risk
assessment
methodologies HAZOP, ETA and FTA, and
QRA.

Lectures, tutorials, group

works

Examination or tests

CO3. Describe and develop successful safety and

health management system, and describe
the development of safety and health
management system (OHSM) in Malaysia
and other countries.

lectures, tutorials, group

works

Examination or tests

CO4. Apply the knowledge on safety and health

in addressing causes, consequences,
control,
preventive
measures
and
management system to prevent accidents in
a hypothetical plant.

lectures, tutorials, group

works

Examination or tests
or integrated project

Numbers Indicator: 3 Strongly emphasized, 2 Moderately emphasized, 1 Slightly emphasized