OSF353 Syllabus - Chemical Process Safety - 2021 Regulation - Open Elective | Anna University

OSF353 Syllabus - Chemical Process Safety - 2021 Regulation - Open Elective | Anna University

OSF353	CHEMICAL PROCESS SAFETY	L T P C

3003

COURSE OBJECTIVES:

• Teach the principles of safety applicable to the design, and operation of chemical process plants.
• Ensure that potential hazards are identified and mitigation measures are in place to prevent unwanted release of energy.
• Learn about the hazardous chemicals into locations that could expose employees and others to serious harm.
• Focuses on preventing incidents and accidents during large scale manufacturing of chemicals and pharmaceuticals.
• Ensure that the general design of the plant is capable of complying with the dose limits in force and with the radioactive releases

UNIT I	ISAFETY IN THE STORAGE AND HANDLING OF CHEMICALS AND GASES	9

Types of storage-general considerations for storage layouts- atmospheric venting, pressure and temperature relief - relief valve sizing calculations - storage and handling of hazardous chemicals and industrial gases, safe disposal methods, reaction with other chemicals, hazards during transportation - pipe line transport - safety in chemical laboratories.

UNIT II	CHEMICAL REACTION HAZARDS	9

Hazardous inorganic and organic reactions and processes, Reactivity as a process hazard, Detonations, Deflagrations, and Runaways, Assessment and Testing strategies, Self - heating hazards of solids, Explosive potential of chemicals, Structural groups and instability of chemicals, Thermochemical screening,

UNIT III	SAFETY IN THE DESIGN OF CHEMICAL PROCESS PLANTS	9

Design principles -Process design development -types of designs, feasibility survey, preliminary design, Flow diagrams, piping and instrumentation diagram, batch versus continuous operation, factors in equipment scale up and design, equipment specifications - reliability and safety in designing - inherent safety - engineered safety - safety during startup and shutdown - non destructive testing methods - pressure and leak testing - emergency safety devices - scrubbers and flares- new concepts in safety design and operation- Pressure vessel testing standards- Inspection techniques for boilers and reaction vessels.

UNIT IV	SAFETY IN THE OPERATION OF CHEMICAL PROCESS PLANTS	9

Properties of chemicals - Material Safety Data Sheets - the various properties and formats used - methods available for property determination. Operational activities and hazards -standards operating procedures - safe operation of pumps, compressors, heaters, column, reactors, pressure vessels, storage vessels, piping systems - effects of pressure, temperature, Flow rate and humidity on operations - corrosion and control measures- condition monitoring - control valves - safety valves - pressure reducing valves, drains, bypass valves, inert gases. Chemical splashes, eye irrigation and automatic showers.

UNIT V	SAFETY AND ANALYSIS	9

Safety vs reliability- quantification of basic events, system safety quantification, Human error analysis, Accident investigation and analysis, OSHAS 18001 and OSHMS.

TOTAL: 45 PERIODS

COURSE OUTCOMES: Students able to

CO1 Differentiate between inherent safety and engineered safety and recognize the importance of safety in the design of chemical process plants.
CO2 Develop thorough knowledge about safety in the operation of chemical plants.
CO3 Apply the principles of safety in the storage and handling of gases.
CO4 Identify the conditions that lead to reaction hazards and adopt measures to prevent them.
CO5 Develop thorough knowledge about

TEXT BOOKS:

1 David A Crowl & Joseph F Louvar,”Chemical Process safety”, Pearson publication, 3rd Edition,2014
2 Maurice Jones .A,”Fire Protection Systems,2nd edition, Jones & Bartlett Publishers,2015

REFERENCES:

1. Ralph King and Ron Hirst,”King´s safety in the process industries”, Arnold, London, 1998.
2. Industrial Environment and its Evolution and Control, NIOSH Publication, 1973.
3. National Safety Council,” Accident prevention manual for industrial operations”. Chicago, 1982.
4. Lewis, Richard. J., Sr,“Sax´s dangerous properties of materials”. (Ninth edition). Van Nostrand Reinhold, New York, 1996.
5. Roy E Sanders, ”Chemical Process Safety”,3rd Edition, Gulf professional publishing, 2006