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Student Name: Manukumar Balaraman Module Name: Process Safety 101 A. Module Summary The objective of this module is to introduce the basic concept related to process safety. In the first part of this module explain various process descriptions drawings which included block diagrams and piping and instrumentation diagrams etc, these were described in this section to get a basic understand the chemical processes and its various functions. The next part of the section introduced us to the elements of process safety management. In this section explain various elements of process safety management like Occupational Safety and Health Administration (OSHA) and its requirement for all employees and employers and also this section give a basic introduce to the various important features of the safety control systems. The next half part of the module included information regarding the flammability that is the characteristics of flammable mixtures and how we can handle it safe way and what are the precaution we had to take care etc. This section also give a small introduction to valves for example relief valves and their functions and its safety concern etc after that this section introduce different types of corrosion and how it effects in the industry etc. All this information was presented in a single PDF file which was linked to various other online sources. The last part of this module consisted of a fifty question quiz which tested the ability and the understanding level of the students. B. What are at least 3 of the most important concepts from this module? Why are they important? In this Module of Process safety there are several concepts were introduced among that I think the first very important concept is the understanding of the descriptive drawing of the chemical processes. This is an important concept in the process safety because with out knowing what exactly is occurring in a chemical process talking about the safety is worthless . From the process description drawing people get the big picture about the plant and the process and the equipments etc. With out understanding the plant equipment and its function it is very difficult to identify the problems and understand safety concern. After an engineer identifies for the problems and its location in the process is very important so reading and developing a descriptive drawing is very important. The second important concept in this module is the Process safety management. I think this part is the core of this module because by following the instructions and requirements, especially the ones set by OSHA (Occupational Safety and Health Administration ) , safety can be guaranteed to a certain extent. Understanding and following these requirements precisely can prevent a lot of accidents and other safety issues and hence make industry a safer place The third important concept I think is Mechanical Integrity this is because regular inspection and testing performed on the equipments is very important. Any equipment malfunction and Team: A2
deficiencies outside the acceptable limit can be easily find out and corrected with this regular checkups. After inspection, we can decided whether to replace some parts or leave them for some more time. This will increase the machine life time reduce the hazards materials and increase the safety. C. Describe at least two items of information in the module that surprise, concern, or worry you, and why they surprise, concern, or worry you. The first thing surprise me in this module is the process safety management. Previously I worked in a pharmaceutical company in India as an operator and there were safety engineers they were always goes to inspect for the plant and they were always comes to us the operation and gave us courses in safety and always plan new safety rules for employees and I thought on that time this is not necessary and they were just waste their times. But after going through this section, I just realize how it is so important for running any plant and how you should find the best way to protect you and your coworker and the plant itself. In the Second section of the module while am reading through flammability I surprised know that an explosion can occur because of a small electrostatic discharge when it goes into contact with a hybrid mixture this is totally new knowledge for me. In this section also give a wide understanding of the various hybrid mixtures and its flammability percentage limit etc, and am concern about these chemicals when am try to design an equipment dealing with these chemicals I have to take account of these safety concern. And nowadays these chemical are widely used in the industry. D. Describe at least 2 instances of especially effective instruction in the module, and why you found them effective. One effective instruction in this module is the 2003 AIChE Faculty Workshop Presentation. In the presentation there are so many diagrams and pictures shown that help get the clear idea and understanding the process control and its functions Another effective part is that sources were made easily accessible even after the certificate is gotten since most of them are not connected to the AIChE website. That also makes the sources accessible for people who didnt do the module. E. Make at least 2 suggestions to improvement the teaching effectiveness of the module and why your suggestion would improve the effectiveness. Process Safety Module is very brief and contained very less information and many links provided in the pdf file actually direct to Wikipedia. Although the source has much information, but the Wikipedia is academically less reliable source. I think for improving this module one effective way is to include more video tutorial that improve the leaning and teaching skill, nowadays for reading all pdf file time consuming and boring. Easy way to understand the concept in this morden world is by seeing something ,there are lot of scientific study prove this factor. Also I think they should provide some animation video about the process from inside the industry to make the student be aware about what equipment, the control room where it control the process plant, and any part of the industry that it seems very important to learn.
B. What are at least 3 of the most important concepts from this module? Why are they important? There are so many important concepts were introduced in this module about the inherent safety , First and most important concept is the process safety , as a chemical engineering student, I should aware about the four strategies of process safety, which they are inherent, passive, active, and procedural. Knowing these four strategies may minimize the hazards or I can eliminate these hazards. This is also important because it makes the employee feel much safer ,and one can work without worrying about safety. The second important concept is identification the chemical reaction hazard and reactive material hazards and one can understand which are the hazards material are using the plant, then decide how likely they can react and how serious their consequences would be. By knowing all these factor we can avoid any explosions or big fires to protect people and environment. The third and last concept is how we present the information and its function to the operators. It is so important to show the right information to the operator in order to avoid any accident that might appear to the process. By showing the information to the operator clearly explain the problem and their effective solution, so he can react quickly to the problem and do the right things
C. Describe at least two items of information in the module that surprise, concern, or worry you, and why they surprise, concern, or worry you Thing that I surprises in this module is the importance of having a very detailed study about the possible hazards that can occur in a process and the plant. So this need a good communication and coordination between different departments in the plant. Otherwise, without knowing what a possible hazard in a given process and plant, an inherent safer design becomes worthless. The second things I was surprised when reading this module that inherently safer design is a subset of green engineering. I never know this ,I always think green engineering some thing related to pollution controlling or global warming. And the things that worry me is spending my future life in a dangers field. I need to be a good in my major and in the safety plan that I will work in to avoid any hazards may affect people, environment, or me. D. Describe at least 2 instances of especially effective instruction in the module, and why you found them effective. I think one effective technique in this module is sources and examples that were provided . sources contain some industry related study and some research article it also include some real-life examples that would clarify explain the idea behind an inherently safer design. The second effective technique was the four method for achieving inherently safer design are very simplified to an extent that they can be understood and grasped by the people who are not well educated because it does not contain confused technical term and principle so very one in the plant can understand and do the necessary step when it needed. E. Make at least 2 suggestions to improvement the teaching effectiveness of the module and why your suggestion would improve the effectiveness. I Think it is better to include some picture and video file instead of downloading the lengthy pdf file and if the explanation contain some animation about the causes of the some industrial accident then the student will understand the concept of inherent safety very well. And the second thing need of to improve the source is distributed among 15 different pdf file that is too lengthy and very time consuming for arrange and read all these file so I practice skim reading and go all these file but my suggestion is that need to put all these file in one place for example like a web page and put all PDF file in some hierarchy structure.
it will affect lot of innocent people nowadays plant is bigger and storage capacity much higher numbers. D. Describe at least 2 instances of especially effective instruction in the module, and why you found them effective. While reading through this module I found lot of example given all are taken from real world incident I think this is the effective instruction in this module . The examples given are real life examples, and they touch every human beings emotions. This would not only let engineers who design plants pay extra care and attention on the safety of a plant, but will also make them innovative and creative in avoiding such hazards. The second thing I notice in this module is there are lot of pictures and chart provided . Pictures and chart helps the designers to get good imagination and better understanding about the incident and come up with better designs. E. Make at least 2 suggestions to improvement the teaching effectiveness of the module and why your suggestion would improve the effectiveness I think if the module include some animation about the explosion it is good idea to understand the concept of this module.I dont know if there is a video to explain how the explosions and disasters mentioned in this module occurred, but through the animation it would be definitely better to show how big an explosion could be. Second thing I suggest to improve the teaching is put some power point slides rater than PDF file.powerpoint give audience to point to point understanding about the incident so the audience get more understanding rather than reading and listening the audio.
to read the file with out internet connection. So one can reopen it in any location without signing in to the website. E. Make at least 2 suggestions to improvement the teaching effectiveness of the module and why your suggestion would improve the effectiveness This module didnt have enough visuals, that is it does not contain video or picture etc. So my first suggestion is to present the information in a more visual way including some animation or some video file ,The organization of this module is not good as what we see in other modules so for better understanding and we can also put all information in to a website and PDF file provided are then organized well in that website.