CH010 805 G04: SAFETY IN CHEMICAL INDUSTRIES

Teaching Scheme Credits: 4

2 hours lecture and 2 hour tutorial per week
Objectives
To impart the basic concepts of industrial safety.
To develop understanding about safety practices in industries and emergency
Procedures.

MODULE I (12 hours)

Introduction to safety: Concept and importance of industrial safety. safety in erection and
commissioning of chemical plants, Safety in the design process of chemical plants Fundamental
safety Tenets. Safety in the site selection and lay out. Location and design parameters for
chimney, Flares rupture discs, location of boiler houses, storage of hazardous chemicals etc.
Safety in Operations and processes. Work permit system. Confined space safety practices.

MODULE II (12 hours)

Chemical hazards classification, hazards due to fire, explosion, toxic chemicals and radiation.
Reduction of Process hazards by plant condition monitoring. Electrical exposures. Guarding Live
electrical elements. Electrical wiring switches and fuses. Grounding. Ground Fault Interrupter.
Classification of atmospheric contaminants.

MODULE III (12hours)

TLV Contamination reduction or removal methods. Handling and storage of Hazardous
chemicals. Pressurized lines and containers (LPG, Compressed air, gases or fluids). Extreme
temperatures hot and cold.

MODULE IV (12 hours)

Risk assessment - hazard vs risk, techniques for risk assessment, qualitative, reconnoitery, rapid
and comprehensive risk assessment techniques: checklists, indices, HAZOP, maximum credible
accident analysis, fault tree analysis, past accident analysis, FMEA (Failure mode and effect
analysis), quantitative risk assessment, domino effect and its assessment.
.
MODULE V (12 hours)
Emergency Preparedness: Fire and Explosion. Fire hazards. Fire pyramid. Types of fires. Types
of fire extinguishers and its handling. Types of built in extinguishing systems. Fixed Fire
protection systems. Fire fighting techniques. BLEVE and Runaway Reaction. Emergency
procedures. Types of alarm systems. Study of fire protection systems and Emergency procedure
of a leading chemical industry (preferably refinery/petrochemical)

TEXT BOOKS
1. Lees, F.P., Loss Prevention in Process Industries, Butterworths, NewDelhi, 3rd Edn.,
2005. Vol.1 , 2,3

UNIVERSITY EXAMINATION PATTERN: Question Paper consists of Part A, Part B and

Part C. Part A is for 15 marks and comprises of 5 compulsory short answer questions, each
carrying 3marks, covering the entire syllabus. Part B is for 25 marks, comprises of 5
compulsory questions from each module. And Part C is for 60 marks candidate has to answer
one full question of 12 marks from each module.
REFERENCE:
1. Accident Prevention Manual for Industrial Operations, NSC, Chicago, 1982.
2. Wells, G. L., Safety in process plant design, George Godwin Ltd, London
3. Encyclopedia of Occupational Health & Safety, International labour Office, Geneva
4. Grialdi, J. V., and Simonds, R.H., Safety Management, AITBS Publishers & Distributors,
New Delhi
5. Slote, L., Handbook of occupational safety & Health, John Wiley & Sons, New York.
6. Kumar, A., Chemical Process Synthetics and Engineering Design, Tata McGraw Hill,
NewDelhi
7. Buschmann, Loss Prevention and Safety Promotion in the Process Industries, Elsevier
Scientific, New York
8. K.V. Raghavan and A.A.Khan: Methodologies in Hazard Identification and
AssessmentManual by CLRI, December 1990.
9. V.C Marshal : Major Chemical Hazards Ellis Harwood Ltd., Chichester, U.K. 1987.
10. Frank P. Leis: Loss Prevention in Process Industries Vol 1 &2: Butterworth London
1980.
11. undamentals with
Prentice Hall, Inc.
12. Safety in Chemical Process Industries: 0. P. Kharbanda