BITS, PILANI- KK BIRLA GOA CAMPUS

INSTRUCTION DIVISION-SECOND SEMESTER 2018-2019

Course Handout
Date: 08/01/2019
Course No. : CHE F413
Course Title : Process Plant Safety
Instructor in Charge : Prof. Saroj Sundar Baral

Course Description:
Role of safety in society; Engineering aspects of process plant safety; Chemical hazards and
worker safety; Industrial Hygiene: Potential hazard identification, evaluation and control
methods; Source models: how the materials are discharged. Toxic Release and Dispersion
models; Safety aspects in site selection and plant layout. Storage, handling and transportation of
hazardous chemicals. Risk assessment methods: Event tree and Fault tree analysis. Fire and
Explosions models –Design to prevent; Safety audit. Hazard Identification: HAZOP studies and
Fire and Explosion index; Case studies.

Scope and Objective:

This course deals with different safety aspects encountered in the chemical process industries.
The primary objective of this course is to encapsulate the 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.

Text Books:
T1: Crowl D.A., and Louvar J.F., “Chemical Process Safety: Fundamentals with
Applications”, Pearson Education, Indian Edition, 3rd ed., 2014.
T2: Fulekar M.H., “Industrial Hygiene and Chemical Safety”, I.K. International, New Delhi,
2006.

Reference Books:
R1: Sanders R.E., “Chemical Process Safety: Learning from case Histories”, Butterworth-
Heinemann, An imprint of Elsevier, Boston, 2007.
R2 : Bhaskara Rao and Jain, R,K, “ Safety in chemical plants/industry and its management”,
Khanna Publishers, 2012
R3 : K.S.N.Raju, “Chemical process industry Safety”, McGraw-Hill, 2014

Course Plan:

Lecture Learning objectives Topics to be covered Reference

No. Chap/Sec. #
(Book)
1-2 Introduction Role of safety, Accident and loss statistics 1.1 – 1.3 (T1)
3-4 Toxicology Different way toxicant enters, effects and 2.1-2.8 (T1)
elimination. Dose vs Response, Dose
Limit.
5-6 Industrial Hygiene Chemical Hazards and worker safety, 3.2-3.3 (T1)
Identification, Evaluation of occupational
conditions
7-8 Industrial Hygiene Problems and Control of occupational 3.4 (T1)
conditions, Ventilations
9-10 Source Models Flow of liquids through a hole, a hole in a 4.1-4.3(T1)
tank
 11-13 Source Models Flow through pipes and Chart 2K method. 4.4-4.8(T1)
Flow of vapors through holes, Flashing
liquids, Evaporation.
14-16 Toxic release and Parameters affecting Dispersion, 5.1-5.2 (T1)
Dispersion Models Neutrally buoyant dispersion models
17-18 Toxic release and Pasquill-Gifford model 5.2 (T1)
Dispersion Models
19-21 Fires & Explosions Flammability of Liq and vapors, Fire 6.1-6.6 (T1)
triangle, flammability diagram

22-23 Fires & Explosions VCE, BLEVE, Blast damage due to 6.7-6.12 (T1),
overpressure, Detonation and deflagration
24-26 Designs to Prevent Purging, Static electricity, explosion- 7.1-7.7 (T1)
Fires and Explosions proof equipments, Sprinkler systems
27-28 Introduction to Reliefs Relief concepts, Relief types, Relief 9.1, 9.2, 9.4, 9.7
systems (T1)
29-30 Hazard Identification Checklists, F & EI 11.1-11.2 (T1),
17 (T2)
31-32 Hazard Identification HAZOP, Safety reviews 11.3-11.4 (T1),
17 (T2)
33-34 Risk Assessment Probability theory 12.1-12.3(T1),
16 (T2)
35-36 Risk Assessment Event and Fault trees 12.2-12.3(T1),
16 (T2)
37-38 Plant Location Safety aspects of site selection, plant 10 (T2)
layout and unit plot planning
39-41 Hazards in Chemical Material Handling and transportation of 11, 12 & 15 (T2),
Operations Hazards. Onsite and Off-site emergency 18 & 19 (T2),
and Safety Audit 13 (T1)
Self- Case Histories and Personal protective devices ,Static Chap 9 (T2)
Study Major Accidents electricity, Chemical reactivity, System 13.1 -13.4 (T1),
designs procedures, Case study of Major Appendix (T1)
Accidents

Evaluation Scheme:

EC No. Evaluation Duration Weightage Date & Time Nature of

Component (min) Exam
2. Mid-Semester 90 30 11th March 2019 OB
Examination (9:00-10:30 AM)
3. Attendance and Surprise 30 OB
Quizzes/Assignments
4. Comprehensive 180 40 1st May 2019 (FN) OB/CB
examination

Chamber Consultation Hour: Friday Afternoon between 4-5PM.

Make-up policy: Make-up will be granted only when one attends more than 75% classes and
has genuine reasons not to appear in the regular test.

IC –CHE F413