BIRLA INSTITUTE OF TECHNOLOGY AND SCIENCE, Pilani

Pilani Campus
Instruction Division

Course Handout (Part-II)

Date: 02/08/2017

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 : BHANU VARDHAN REDDY KUNCHARAM

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:

 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. Prescribed Text Book:

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

4. Reference Book:

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.
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5. Course Plan

Module Lecture Session Reference Learning Outcomes

1. L1.1 Introduction and discussion of 1.8 (T1)  Understand the

Introduction the course content; Recent and importance of
historical cases of process Examples
to chemical from R1, R2 safety standards in
accidents; role of safety programs
process and news chemical process
in industry; engineering ethics and
safety professional standards; articles. industries.
 Internalize the
1.1 - 1.2
(T1) professional ethics
and standards in
L1.2 Accident and loss statistics, 1.3 - 1.7 chemical industry.
acceptable risk; public perceptions (T1)
about safety; Natural 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
response biological
organisms and
L2.2 Models of does: response 2.5- 2.8 (T1)
toxicology studies.
curves, relative toxicity; Threshold
 Understand the
limit values
dose versus
response models
for toxicants.

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

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

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L3.3 Industrial Hygiene: Control 3.4 (T1) industrial hygiene.

4. L4.1 Introduction to source 4.1-4.3 (T1);  Understand

Source models; Flow of liquid through a Read Cases various aspects of
models hole; Flow of liquid through a hole from : 13.1- source models for
in a tank 13.2 (R1); cause of
Chapter 2 accidents.
(R2)  Understand the
safety aspects in
L4.2 Flow of liquid through pipes; 4.4 (T1);
flowing liquid,
Pipe failures 9.1 (R1)
gas/vapor
L4.3 Flow of gases or vapors 4.5 (T1) through holes
through holes from tanks, and in
pipes.
L4.4 Flow of gases or vapors 4.6 (T1);  Identify the
through pipes; Pipe failures 9.1 (R1) causes of pipe and
tank failures, and
L4.5 Flash liquids; liquid pool 4.7-4.10
methods to
evaporation or boiling; Realistic (T1)
mitigate those
and worst-case releases;
failures.
conservative analysis

L4.6 Review and discussion of L4.1-L4.5

source models

5. L5.1 Introduction to toxic release 5.1-5.2  Understanding

Toxic Release and dispersion models; Parameters (case 10) the release and
and affecting dispersion; Neutrally (T1) dispersion of toxic
Dispersion Buoyant Dispersion models (Cases material.
Chapter 7
Models 1-10)  Study various
(R1)
dispersion models
L5.2 Pasquill-Gifford Model, (Cases 5.2 (case and parameters
11-15); dense gas dispersion 11)-5.4 (T1); affecting
5.3 (T1) dispersion.
 Apply the toxic
Chapter 7 release models to
(R1) mitigate

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L5.3 Dense gas transition to 5.5-5.7 (T1) consequences.

neutrally buoyant gas; Toxic effect
Chapter 7
criteria; effect of release
(R1)
momentum and buoyancy, release
mitigation

L5.4 Review and discussion of L5.1-L5.3

Dispersion Models

6. L6.1 Introduction to fires and 6.1-6.12  Distinguish

Fires & explosions; Flammability (T1), between fires and
Explosions characteristics; explosions
5.4, 6.1 13.3
 Understand the
(R1)
flammability
L6.2 LOC and inerting, 6.5-6.12 characteristics of
Flammability diagram, ignition (T1) liquids and
energy, autoignition, adiabatic vapors, gas
compression, ignition sources, mixtures and the
sprays, and mists dependence on
temperature and
L6.3 Explosions—Detonation and 6.13 (T1) pressure.
deflagration, confined explosions,  Understand
5.4, 6.1 13.3 various factors
Blast from overpressure, TNT
(R1) effecting the fires
equivalency, TNO Multi-Energy
Method  Understand the
details of
L6.4 Explosions –Energy of 6.13 (T1) explosions; their
chemical explosions, Energy of causes, methods
5.4, 6.1 13.3 to measure the
mechanical explosions, missile
(R1) resulting damage.
damage, blast damage to people,
Vapor cloud explosions, Boiling-
liquid expanding vapor explosions

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

and Explosions

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

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

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

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

9. L9.1 Relief concepts and 9.1-9.4 (T1)  Understand the

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

10. L10.1 Hazards Checklists, Hazard 11.1-11.2  Understand the

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Hazard Surveys; Fire & Explosion Index, (T1) methods of hazard

Identification identification using
L10.2 Hazard and Operability 11.3-11.5
checklists and
(HAZOP) studies; Safety Reviews; (T1)
surveys.
Other methods for hazard
 Understand the
identification such as Human Error,
HAZOP studies,
FMECA
safety reviews in a
chemical process
 Familiarity with
concepts of human
error and FMECA
methods for
hazard
identification.

11. L11.1 Review of Probability Theory 12.1 (T1)  Review the

Risk probability
L11.2 Event Trees 12.2 (T1)
assessment mathematics and
L11.3 Fault trees: Theory 12.3 (T1) its use in safety
 Understand two
L11.4 Fault trees: case study 12.3 (T1) probabilistic
methods: event
L11.5 QRA and LOPA: Theory 12.4 (T1)
trees and fault
L11.6 QRA and LOPA: case study 12.4 (T1) trees
 Understand the
L11.7 Review and discussion of L11.1-L11.6
concepts of QRA
Risk Assessment
and LOPA

12. Static electricity, Chemical 14.1 -14.4  Study major

reactivity, System designs, (T1), accidents and case
Self-Study:
procedures, List of Major accidents histories, apply
Case cases
(1970-1998) knowledge gained
histories and studies
from the course to
Major from
analyze the cases.
accidents reference
R1

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6. Evaluation Scheme:

EC No. Component Duration Weighta Date & Time Remarks

(Minutes) ge (%)
1. Assignments (6) One week 10% Take Home
2. Class Project report 30 15%
and Presentation
3. Class Quizzes* (6) 15 5% CB
4. Mid-Semester Test 90 30% 12/10 9:00 - 10:30 CB + OB
AM
5. Comprehensive Exam 180 40% 8/12 FN CB

*date will be announced in the class

Overall Course Learning Outcomes:

After completing this course, students should be able to

 Recognize technical elements of a successful chemical process safety program.

 Identify and analyze potential hazards and hazardous conditions of equipment used in
chemical industries.
 Understand hazard identification procedures, methods to predict the severity of the
hazardous conditions in chemical equipment and develop strategies to control or mitigate
them.
 Understand the risk assessments: probabilistic methods, quantitative and qualitative risk
analysis.
 Study and analyze numerous real-world cases of chemical process incidents/accidents.
 Work individually or in a team to analyze safety in chemical process, and communicate the
analysis effectively as a written report and presentation.

Course Policy:

 Mid Semester Test and Comprehensive Examination are according to the Evaluation
Scheme given in the Course Handout.
 If the student is unable to appear for the Regular Test/Examination due to genuine
exigencies, the student must refer to the procedure for applying for Make-up
Test/Examination (see Academic Regulations-2015). The request for the make-ups must be
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made in writing with a proper and reason. Instructor may grant Make-up for only genuine
cases. The decision of the instructor-in- charge in all matters of make-up shall be final (Sec.
4.07, Academic Regulations-2015)

Assignments are due by 5 PM on the deadline. Late submissions are not allowed.

Quizzes will be conducted during the lectures. There are no make-ups for quizzes.

Project reports and Presentation:

 The deadline for the report and date of presentations: to be announced in the class.
 Further guidance will be provided during the lectures.

Guidelines for Project reports:

 Team of 3 (or 4) students will be formed, randomly selected through a draw.

 Each team selects a case study of process incident/accident.
 Each team discusses with instructor an outline of their case study and submits a 250-word
abstract.
 Each team will apply the concepts, principles, and facts learned in this course to conduct a
thorough analysis of their case study.
 Each team will write a maximum of 10 page report (including figures and references) on or
before the deadline. Late submissions of reports are not allowed.
 Each team will present their report in 30 minutes on the presentation date.

Three objectives of working in team:

 To gain experience in working with others (a common mode of operation in industries).

 To learn from each other and expand each other perspectives of the course material.
 To benefit from insights, analysis, and evaluation of each member with dynamic
interaction, communication, and leadership.

Success and most learning in this course can be achieved by consistently keeping up with lectures,
assigned homework and reading. The course has been designed to be interactive; questions and
discussion of the topics, participation in the class is highly encouraged.

Closed Book Test:

No reference material of any kind will be permitted inside the exam hall.

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Open Book Exam:

Use of any printed / written reference material (books and notebooks) will be permitted inside the
exam hall. Loose sheets of paper will not be permitted. Computers, smartphones, tablets or
devices of any kind will not be allowed inside the exam hall. Use of calculators will be allowed in all
exams. No exchange of any material will be allowed.

Chamber Consultation Hour: To be announced in the class

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.

Instructor-in-charge
CHE F413

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