CH5015 Process Safety


To train students in the practices prevailing in process industry on safetyTo train students in the theory behind the above practices prevailing in process  industry

Course Contents:

Course contentsSafety and Loss Prevention; safety, hazard and risk; accident and loss statistics; acceptable risk; nature of accident process; inherent safety; study of major accidents.Toxicology and Industrial Hygiene:Effect of toxicants on biological systems; models for dose and response curves; relative toxicity and threshold limits; Govt. Regulations for industrial safety – Indian and international scenario; MSDS; occupational health hazards and their control.Fires and Explosions:Fire Triangle; definitions; flammability characteristics of liquid and vapour; limiting oxygen concentration; flammability diagram; ignition energy; auto ignition and auto oxidation; adiabatic compression; ignition sources; sprays and mists; explosions; fire protection systems.Designs to prevent fires and explosions:Inerting; static electricity; controlling static electricity; explosion proof equipment and instruments; ventilation; sprinkler systems.Source Models:Flow of liquid from a hole in a tank and pipe; flow of liquid through pipes; flow of vapours through holes; flow of gases through pipes (adiabatic/isothermal); flashing liquids; liquid pool evaporation or boiling; guidelines for selecting process incidents.Accident Investigation:Incident causation theories; investigation methodologies; impact of human factors; building and leading accident investigation team; gathering and analyzing evidence; determining root cause; developing effective recommendations.Toxic Release and Dispersion models:Parameters affecting dispersion; neutrally buoyant dispersion models; dense gas dispersion; toxic effect criteria; effect of release momentum and buoyancy; release mitigation.Accident Case Histories:Lessons learnt through application of fundamentals of chemical process safety in following categories of accidents:System design; chemical reactivity; static electricity; procedures.  Asset Integrity Management:Definition; asset integrity risk management; Barrier models (Swiss Cheese/Bow Tie); Safety Critical Equipment; Risk Register; Project Health, Safety and Environment Review (PHSER); Process Safety Management (PSM); reliability management.Risk Assessment:Probability theory; event tress; fault trees; LOPA; QRA; practical application of QRA; software for QRA.

Text Books:

  1.  Chemical Process Safety Fundamentals with Applications by Daniel A. Crowl and Joseph F Louvar, Prentice Hall, 3rd editiion,2002.

Reference Books:

  1. Hazop & Hazan by Trevor A. Kletz., I.ChemE, 2nd edition, 2001