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Process Plant Safety
CHE F413

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 CHE F413 Process Plant Safety 3 0 3

COURSE CONTENT

• Introduction
• Toxicology
• Industrial hygiene
• Source Models
• Toxic release and dispersion model
• Fire and explosions
• Designs to prevent fires and explosions
• Reliefs
• Hazards Identification
• Risk Assessment
• Accident Investigation
• Case histories
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Lec. No. Learning objectives Contents References
@
(Chapters)
1-2 Introduction Safety programs, statistics and disasters 1

3-4 Toxicology Toxicological studies, model for dose and response 2

curves, TLV

5-8 Industrial hygiene Identification, Evaluation and control 3

9-12 Source Models Flow of liquid, vapor, gases through a hole/pipe 4

13-17 Toxic release and Various dispersion Models and its toxic effect criteria 5
dispersion model
18-22 Fire and explosions Flammability, Autoignition, various types of explosion 6
23-27 Designs to prevent Inerting, Static Electricity, Explosion proof and 7
fires and explosions ventilation, sprinkler

28-31 Reliefs Introduction 8

32-35 Hazards Process Hazard, Hazard Survey, Safety Review 10

Identification
36-38 Risk Assessment Probability, Event, Fault tree analysis 11

39-40 Accident Investigation process and summary, Aids for 12

Investigation diagnosis and recommendations 6
41-42 Case histories Various chemical plant accidents 13
 Weightage %
EC Components
No Duration Date & Time Venue

1 Test-1 (Closed Book) 50 22

minutes 06.03.16 (Su 2)
8.30 - 9.20 am

2 Quiz-1 (Closed Book) 20 10

28.03.16 (M 1)

To be announced later
minutes
8.00 - 8.20 am

3 Test - 2 (Open Book*) 50 20

minutes 26.04.16 (T 2)
8.30 - 9.20 am

4 Assignment/Project 20 10 #R- I (18th Feb), R- II

minutes (24th Mar), R-III (14
Apr), R-IV (18th May)
5 Compre Exam (Closed 3 hours 40
Book) 29.05.16 (S) AN
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Safety →→→→→ Loss Prevention
•Safety or Loss
Prevention
•Hazard
•Risk
 Safety Program

The Ingredients of a successful Safety Program

Accidents and loss statistics

 OSHA incidence rate

Fatal Accident Rate (FAR)
and
Fatality rate or death per
person per year
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 Problems
1. An employee works in a plant with a FAR of 4. If this employee works a 4-
hr shift, 200 days per year, what is the expected deaths per person per
year?
2. Three process units are in a plant. The units have FARs of 0.5, 0.3, and
1.0, respectively.
1. What is the overall FAR for the plant, assuming worker exposure to all
three units simultaneously?
2. Assume now that the units are far enough apart that an accident in
one would not affect the workers in another. If a worker spends 20%
of his time in process area 1, 40% in process area 2, and 40% in
process area 3, what is his overall FAR?
3. Assuming that a car travels at an average speed of 50 miles per hour, how
many miles must be driven before a fatality is expected?

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The Accident Pyramid
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The nature of accident process

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Inherent Safety

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Significant Disasters
Flixborough
Bhopal
Seveso
Pasadena