IS4204 Safety in Process Industries Syllabus:
IS4204 Safety in Process Industries Syllabus – Anna University PG Syllabus Regulation 2021
OBJECTIVES:
To provide knowledge on design features for a process industry and safety in the operation of various equipment in industry.
To understand the various hazards and prevention in commissioning stage of industry.
To recognise and identify the safe operation of equipment in process industry.
To plan and trained for emergency planning in a process industry.
To get fundamental knowledge on safe storage of chemicals.
UNIT I SAFETY IN PROCESS DESIGN AND PRESSURE SYSTEM DESIGN
Design process, conceptual design and detail design, assessment, inherently safer design- chemical reactor , types, batch reactors, reaction hazard evaluation, assessment, reactor safety, operating conditions, unit operations and equipments, utilities.
Pressure system, pressure vessel design, standards and codes- pipe works and valves- heat exchangers- process machinery- over pressure protection, pressure relief devices and design, fire relief, vacuum and thermal relief, special situations, disposal- flare and vent systems- failures in pressure system.
UNIT II PLANT COMMISSIONING AND INSPECTION
Commissioning phases and organization, pre-commissioning documents, process commissioning, commissioning problems, post commissioning documentation Plant inspection, pressure vessel, pressure piping system, non destructive testing, pressure testing, leak testing and monitoring- plant monitoring, performance monitoring, condition, vibration, corrosion, acoustic emission-pipe line inspection.
UNIT III PLANT OPERATIONS
Operating discipline, operating procedure and inspection, format, emergency procedures- hand over and permit system- start up and shut down operation, refinery units- operation of fired heaters, driers, storage- operating activities and hazards- trip systems- exposure of personnel
UNIT IV PLANT MAINTENANCE, MODIFICATION AND EMERGENCY PLANNING
Management of maintenance, hazards- preparation for maintenance, isolation, purging, cleaning, confined spaces, permit system- maintenance equipment- hot works- tank cleaning, repair and demolition- online repairs- maintenance of protective devices- modification of plant, problems controls of modifications. Emergency planning, disaster planning, onsite emergency- offsite emergency, APELL
UNIT V STORAGES
General consideration, petroleum product storages, storage tanks and vessel- storages layout segregation, separating distance, secondary containment- venting and relief, atmospheric vent, pressure, vacuum valves, flame arrestors, fire relief- fire prevention and protection- LPG storages, pressure storages, layout, instrumentation, vapourizer, refrigerated storages- LNG storages, hydrogen storages, toxic storages, chlorine storages, ammonia storages, other chemical storages- underground storages- loading and unloading facilities- drum and cylinder storage- ware house, storage hazard assessment of LPG and LNG
TOTAL: 45 PERIODS
OUTCOMES:
This course would make familiar of safe design of equipment which are the essential to chemical industry and leads to design of entire process industries.
Course would be helpful to understand the design of pressure systems.
Students would understand the problems and find innovative solutions while industries facing Problems in commissioning and maintenance stages.
Students can prepare the emergency planning for chemical industry problems
Students would be able to create safe storage systems.
REFERENCES
1. “Accident Prevention Manual for Industrial Operations” NSC, Chicago, 1982.
2. “Quantitative Risk Assessment in Chemical Process Industries” American Institute of Chemical Industries, Centre for Chemical Process safety.
3. Carbide of Calcium Rules, Government of India.
4. Fawcett, H.h. and Wood, “Safety and Accident Prevention in Chemical Operations” Wiley inters, Second Edition.
5. GREEN, A.E., “High Risk Safety Technology”, John Wiley and Sons,. 1984.
6. Lees, F.P. “Loss Prevention in Process Industries” Butterworths and Company, 1996
7. Petroleum Act and Rules, Government of India.