Management of Safety in Chemical Plants

Learning Outcomes

Disciplinary Specific Learning Outcomes

Having successfully completed this module you will be able to:

• To critically evaluate and select control of hazard and control evaluation techniques applicable to different industrial processes. (Depth);
• To be able to perform a detailed design of HSE systems based on process analysis and dynamics. (Depth)

Knowledge and Understanding

Having successfully completed this module, you will be able to demonstrate knowledge and understanding of:

• Identify and describe the essential aspects of industrial safety management

Subject Specific Intellectual and Research Skills

Having successfully completed this module you will be able to:

• Draw on safety legislation and occupational safety literature to design a safe working practice (Depth)

Subject Specific Practical Skills

Having successfully completed this module you will be able to:

• Classify the types of risks present in chemical plants and present strategies for the mitigation of such risks (Depth);
• Employ standard hazard identification tools in the chemical industry (Depth) ;

Transferable and Generic Skills

Having successfully completed this module you will be able to:

• Evaluate the outcomes of case studies of industrial accidents (Breadth)

UNIT I - INDUSTRIAL SAFETY MANAGEMENT

Importance of Safety consciousness in Chemical Industries – Development of Industrial Health and Safety, Safety Organization –Polices-Culture -Planning- Promotion – Inspection –Rules- Responsibility – Supervision, Safety Committee –role of safety functionaries, Elements of work place Safety Program, Economic and Social Benefits from Safety Program- Effective Safety Education and Training – Communication at various levels of production and operation, Safety slogans

UNIT II - CHEMICAL PLANT SAFETY

Chemical process Industries - Sitting and Layout of a Chemical plant, Safety in transportation, storage and handling of hazardous chemicals, Chemical process hazards and their control - First degree and second degree hazards. Lines of defence - High pressure - High temperature operations – Case studies, Emergency preparation: On-site and Offsite , Safety aspects of maintenance in chemical plant -Effective steps to implement safety procedures-Periodic Advice and checking to follow safety procedures and rules- Safe guarding of Machines – Ergonomics -Proper selection and replacement of handling equipment –Safe handling and operation of materials and machineries

UNIT III - ACCIDENT AND THEIR PREVENTION

Definitions, H.W.Henrich, Frank bird & Multiple Causation theories of accident occurrences, Classification, Causes, Costs -Industrial accidents, Principles of Accident prevention, Accident prevention technique – Plant and Chemical job safety analysis, Accident proneness-vocational guidance, Safety performance measurement tools - FR. SR, (FSI), Safe-T-Score, Accident rate per 1000 workers, Disabling injury index, Accident Compensation Statutes, Accident Investigation reporting and Analysis - Case studies. Conditions -Fire triangle- Classification of fires, Common causes of industrial fires, Fire protection systems prevention- Case studies, Safety in Explosive

UNIT IV - HAZARD IDENTIFIATION TECHNIQUES

Safety Appraisal - Risk Assessment -Hazard identification techniques with examples such as FMEA, CMA, Fault Tree Analysis, Preliminary Hazard Analysis (PHA), Hazard and operability (HAZOP) study, Quantitative risk analysis-Out line of methodology, Consequences analysis (Calculation of release rates of liquids under ambient pressure and liquids under pressure, Calculation of dispersion of released gases and vapours and platting of equal concentration contours), Dow(Index) Fire and Explosion Index System of Risk Analysis, Safety Audit.

UNIT V - INDUSTRIAL HYGIENE AND OCCUPATIONAL HEALTH HAZARDS

Concepts - Industrial and Occupational health hazards, Housekeeping, human factors and error, stress at work, Personnel protective equipment’s, Role of trade unions in Industrial safety and health. mental health

Teaching and learning methods

Teaching is by a combination of formal lectures augmented by problem solving sessions and computer practical labs

Summative

This is how we’ll formally assess what you have learned in this module.