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BIRLA INSTITUTE OF TECHNOLOGY AND SCIENCE, Pilani

Pilani Campus
AUGS/ AGSR Division

SECOND SEMESTER 2018-19


COURSE HANDOUT

Date: 07.01.2019

In addition to part I (General Handout for all courses appended to the Time table) this portion gives further
specific details regarding the course.
Course No : CHE F413
Course Title : Process Plant Safety
Instructor-in-Charge : AMIT JAIN

1. Course Description:
Role of safety in society; Engineering aspects of process plant safety; Chemical hazards and worker safety;
Hazardous properties of chemicals; Safety aspects in site selection and plant layout; Design and inspection
of pressure vessels; Storage, handling and transportation of hazardous chemicals; Risk assessment methods;
Toxic release; Fire and Explosions; Safety audit; Emergency planning and disaster management; Case
studies.
2. Scope and Objective of the Course:
 This course deals with various safety aspects encountered in the chemical process industries.
 The primary objective of this course is teach important technical fundamentals for proper assessment of
the risks posed by hazardous chemicals and continuous care during their manufacturing, processing,
treatment, packaging, storage, transportation, use and sale.
 We will apply the concepts and principles learned in the course to analyze numerous cases of ‘real
world’ chemical process incidents/accidents.
 This course provides guidance for developing industrial safety procedures and equipment designs.

3. Text Book:
T1 Crowl D.A., and J.F. Louvar, “Chemical Process Safety: Fundamentals with Applications”, Prentice
Hall PTR, Englewood Cliffs, New Jersey, 3rd ed., 2012.

4. Reference Books:
R1 Trevor Kletz, “What went wrong? Case Histories of Process Plant Disasters”, 4 th edition, Gulf
Professional Publishing, 1999.
R2 Sanders R.E., “Chemical Process Safety: Learning from case Histories”, Butterworth-Heinemann,
Boston, 1999.
R3 Carson, P. and C. Mumford, "Hazardous Chemicals Handbook", Butterworth-Heinemann, Woburn,
2002.

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BIRLA INSTITUTE OF TECHNOLOGY AND SCIENCE, Pilani
Pilani Campus
AUGS/ AGSR Division

5. Course Plan:
Module Lecture Session Reference Learning Outcomes

1. Introduction L1.1 Introduction to safety in process 1.1 - 1.2, 1.8  Understand the
to chemical plant; Recent and historical cases of (T1) Examples importance of safety
process safety process accidents; from R1, R2 standards in chemical
and news
process industries.
articles.
 Internalize the
L.1.2 Role of safety programs in professional ethics and
industry;Safety audits procedures and standards in chemical
steps, Engineering ethics and professional industry.
standards;

L1.3Accident and loss statistics, T1: 1.3 - 1.7


acceptable risk; Public perceptions about
safety; Nature of accident process and
inherent safety

2. L2.1 Introduction to Toxicology; 2.1-2.4 (T1)  Understanding the


Toxicology Toxicological studies, Dose versus toxicology in biological
response organisms and
toxicology studies.
L2.2 Models of does: response curves, 2.5- 2.8 (T1)
 Analysis on the dose
relative toxicity; Threshold limit values
versus response models
for toxicants.

3. L3.1 Introduction to government http://labour.gov  Recognize government


Industrial regulations for worker safety .in/industrial- regulations.
hygiene and safety-health  Identify, anticipation,
Industrial Hygiene: anticipation and
personnel identification 3.1 (T1) and evaluation of
safety various safety aspects
L3.2 Industrial Hygiene: Evaluation 3.3 (T1) of industrial hygiene.

L3.3 Industrial Hygiene: Control 3.4 (T1)

4. Source L4.1 Introduction to source models; Flow 4.1-4.3 (T1);  Understand various
models of liquid through a hole; Flow of liquid Read Cases aspects of source
through a hole in a tank from : 13.1- models and cause of
13.2 (R1); accidents.
Chapter 2 (R2)  Develop source models

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BIRLA INSTITUTE OF TECHNOLOGY AND SCIENCE, Pilani
Pilani Campus
AUGS/ AGSR Division

L4.2 Flow of liquid through pipes; Pipe 4.4 (T1); forhazardous situations
failures 9.1 (R1) such as flowing liquid,
gas/vapor through
L4.3 Flow of gases or vapors through 4.5 (T1) holes from tanks, and
holes in pipes.
L4.4 Flow of gases or vapors through 4.6 (T1);  Identify the causes of
pipes; Pipe failures 9.1 (R1) pipe and tank failures,
and methods to
L4.5 Flash liquids; liquid pool mitigate those failures.
evaporation or boiling; Realistic and
worst-case releases; conservative analysis
4.7-4.10 (T1)
L4.6 Review and discussion of source
models

5. L5.1 Introduction to toxic release and 5.1-5.2 (case  Understanding the


Toxic Release dispersion models; Parameters affecting 10) (T1) release and dispersion
and Dispersion dispersion; Meteorological effects on of toxic material.
Models dispersion, Dispersion models: Chapter 7 (R1)
 Study various
dispersion models and
L5.2 Pasquill Gifford Model: assumption, 5.2 (case 11)-
parameters affecting
emission calculation;Toxic release 5.4 (T1); 5.3
dispersion.
mitigation. (T1); Chapter 7
 Application of the
(R1)
toxic release models to
mitigate consequences.

6. L6.1 Introduction to fires and explosions; 6.1-6.12 (T1),  Distinguishing between


Fires & Flammability characteristics; fires and explosions
Explosions 5.4, 6.1 13.3
 Understand the
(R1)
flammability
L6.2 LOC and inerting, Flammability 6.5-6.12 (T1) characteristics of
diagram, ignition energy, autoignition, liquids and vapors, gas
adiabatic compression, ignition sources, mixtures and the
sprays, and mists dependence on
temperature and
pressure.
 Understand various
L6.3 Explosions—Detonation and 6.13 (T1) factors effecting the
deflagration, confined explosions, Blast fires
from overpressure, TNT equivalency, 5.4, 6.1 13.3  Understand the details
TNO Multi-Energy Method (R1)
of explosions; their
causes, methods to

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BIRLA INSTITUTE OF TECHNOLOGY AND SCIENCE, Pilani
Pilani Campus
AUGS/ AGSR Division

L6.4 Explosions –Energy of chemical 6.13 (T1) measure the resulting


explosions, Energy of mechanical damage.
explosions, missile damage, blast damage 5.4, 6.1 13.3
to people, Vapor cloud explosions, (R1)
Boiling-liquid expanding vapor
explosions

L6.5 Review and discussion of Fires and L6.1-L6.4


Explosions

7. L7.1 Inerting: Purging 7.1 (T1)  Understanding various


Designs to concepts and strategies
prevent fires L7.2 Static Electricity 7.2 (T1)
to prevent fires and
and explosions L7.3 Controlling static electricity 7.3 (T1) explosions.
 Design of flare
L7.4 Explosion-proof equipment and 7.4-7.7 (T1) systems.
instruments; ventilation; sprinkler
systems; other concepts for prevention of
fires and explosions.

8. L8.1 Background of chemical reactivity; 8.1-8.2 (T1)  Understand the


Chemical Reactive chemical hazards identification background and case
reactivity and awareness Chapter 22
histories of chemical
(R1)
reactivity hazards
L8.2 Characterization of reactive chemical 8.3-8.4 (T1)  Understand the
hazards; controlling reactive hazards characterization of
Chapter 22 reactive chemical
(R1) hazards, and study the
design principles for
controlling these
hazards.

9. L9.1 Relief concepts and Definitions; 9.1-9.4 (T1)  Understand the concepts
Introduction to Location of reliefs; Relief types and of pressure relief systems
reliefs characteristics and their installation and
design criteria to prevent
L9.2 Relief scenarios; Data for reliefs 9.5-9.7 (T1)
or mitigate hazards
sizing; Relief systems

10. L10.1 Hazards Checklists, Hazard 11.1-11.2 (T1)  Understand the methods
Hazard Surveys; Fire & Explosion Index, of hazard identification
Identification using checklists and
L10.2 Hazard and Operability (HAZOP) 11.3-11.5 (T1)
surveys.
studies; Safety Reviews; Other methods
 Understand the HAZOP
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BIRLA INSTITUTE OF TECHNOLOGY AND SCIENCE, Pilani
Pilani Campus
AUGS/ AGSR Division

for hazard identification such as Human studies, safety reviews


Error, FMECA in a chemical process
 Familiarity with
concepts of human error
and FMECA methods
for hazard
identification.

11. L11.1-11.2 Review of Probability Theory: 12.1 (T1)  Review the probability
Risk Interactions between Process Units, mathematics and its
assessment Revealed and Unrevealed Failures, use in safety
Probability of Coincidence, Redundancy,  Understand two
Common Mode Failures probabilistic methods:
event trees and fault
L11.3 Event Trees: Theory and analysis, 12.2 (T1)
trees
examples
 Understand the
L11.4-11.5 Fault trees: Theory& 12.3 (T1) concepts of QRA and
quantitative analysis LOPA

L11.6 QRA and LOPA: Theory& Case 12.4 (T1)


studies

12. Storage, L.12.1 Classification and labelling of  Understand the art of


handling and chemicals, siting and design of storage identifying and labelling
transportation area, Lecture Notes
the hazardous chemicals
of hazardous (R3)& research
 Learn the standard
chemicals; L.12.2 Safety aspects in Transporting articles
practices in
Hazardous Materials
transportation of
hazardous materials.

13. Emergency L.13.1 Steps involved in disaster Open literature  Understanding the
planning and management & handling emergencies & research handling of
disaster planning articles emergencies.
management  Designing systems for
managing disasters.

14. L.14.1-14.2 Static electricity, Chemical 14.1 -14.4  Study major accidents
Case histories reactivity, System designs, procedures, (T1), cases and case histories, apply
and Major List of Major accidents (1970-1998) studies from knowledge gained from
accidents reference R1 the course to analyze
the cases.

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BIRLA INSTITUTE OF TECHNOLOGY AND SCIENCE, Pilani
Pilani Campus
AUGS/ AGSR Division

6. Evaluation Scheme:
Duration Date & Nature of component
Component Weightage (%)
(Minutes) Time (Close Book/ Open Book)
Assignments (3) One week 15% In class Take Home/OB
Project: Recent application
20 15% In class Take Home/OB
/field advancement
15/3 9:00
Mid-Semester Test 90 30% - 10:30 CB
AM
Comprehensive Exam 180 40% 10/5 FN CB

7. Chamber Consultation Hour: To be announced in the class.


8. Notices:All notices concerning this course will be displayed in Nalanda Portal ( http://nalanda.bits-
pilani.ac.in/) and on the Chemical Engineering Notice Board.
9. Make-up Policy:Make-up for any component of evaluation will be given only in genuine cases of
absence. Prior permission of the instructor -in-charge, before the examination, is necessary, if the absence is
anticipated.
10. Note (if any):None

Instructor-in-charge
Course No. CHE F413

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