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CHEP8023 - Chemical Process Safety

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Title:Chemical Process Safety
Long Title:Chemical Process Safety
Module Code:CHEP8023
 
Credits: 5
NFQ Level:Advanced
Field of Study: Chemical & Process Eng
Valid From: Semester 1 - 2016/17 ( September 2016 )
Module Delivered in 2 programme(s)
Module Coordinator: MICHAEL J O MAHONY
Module Author: Patrick Kennedy
Module Description: The Module is designed to give students a thorough grounding in the issues that must be addressed when assessing the hazards arising from the processing of Chemicals on an industrial level.
Learning Outcomes
On successful completion of this module the learner will be able to:
LO1 Identify and assess the hazards arising from existing Chemical Processes and activities.
LO2 Determine the risks arising from a hazard analysis
LO3 Identify workplace controls required to reduce or eliminate workplace risks
LO4 Assess Chemical Process Safety Management systems and introduce improvements where necessary.
LO5 Perform a Chemical Process Safety Analysis on a proposed process
Pre-requisite learning
Module Recommendations
This is prior learning (or a practical skill) that is strongly recommended before enrolment in this module. You may enrol in this module if you have not acquired the recommended learning but you will have considerable difficulty in passing (i.e. achieving the learning outcomes of) the module. While the prior learning is expressed as named CIT module(s) it also allows for learning (in another module or modules) which is equivalent to the learning specified in the named module(s).
No recommendations listed
Incompatible Modules
These are modules which have learning outcomes that are too similar to the learning outcomes of this module. You may not earn additional credit for the same learning and therefore you may not enrol in this module if you have successfully completed any modules in the incompatible list.
No incompatible modules listed
Co-requisite Modules
No Co-requisite modules listed
Requirements

This is prior learning (or a practical skill) that is mandatory before enrolment in this module is allowed. You may not enrol on this module if you have not acquired the learning specified in this section.

No requirements listed
Co-requisites
No Co Requisites listed
 

Module Content & Assessment

Indicative Content
Legislation
Irish and European Safety Law The Safety, Health and Welfare at Work Act(2005). The Construction Regulations, 2006, The General Applications Regulations 2007 HSA guidance documents on Safety Management Systems, The Safety Statement, HSA Codes of Practice. Safe Systems of Work
Safety Theory
Legal, Moral and Economic reasons for safe operation. Safety Statistics, Safety Management Systems. Definitions of Hazard, Risk, Control measures.
Safety Statements
Elements of the safety statement. Health and safety policy. Hazard identification. Examples of hazards. Carrying out a risk assessment. Precautions. Findings. Review and update of safety statements
Control of Hazards in the Workplace
Hierarchy of controls, design, replacement, isolation, local ventilation, general ventilation, good housekeeping and hygiene, limited exposure, personal protective equipment. Selection of PPE.
Quantitative and Qualitative risk assessment techniques.
Definitions, Procedure, Preparation, Meetings, Follow up, Recording. HAZOP, FTA, FMEA, SIL, LOPA.
Fire and Explosion Prevention and Response
Definitions (Combustion, ignition, autoignition, auto ignition temperature, flash point, flammable or explosive limits, explosion, deflagration, detonation, confined explosion, unconfined explosion, boiling liquid, expanding vapour explosion, effect of temperature and pressure on flammability, flammability characteristics, minimum oxygen concentration, minimum ignition energy, adiabatic compression). Parameters effecting the behavior of an explosion. Vapour explosions. Dust explosions: The cubic law, deflagration indices, hybrid mixtures, dust explosion prevention. Static Electricity: Generation, hazards and control Design of fire detection systems Fire extinguishment Types of fire.
Chemical Reaction Safety
Storage of Chemicals, Incompatibilities, Safety Data Sheets Reaction Assessment Systems Sources of Data Case Studies.
Pressure Systems
S.I. No. 445 of 2012 Safety,Health and Welfare at Work (General Application)(Amendment) Regulations 2012 (Pressure Equipment Directive) Definitions. Need for pressure relief. Pressure relief types. Development of relief scenarios. Data collection. Size relief. Integrity of pressurised equipment. Failure modes
Management of Change
Maintenance and modification of operating plant. Permit to work system. Planning maintenance. Types of permit. Modification of Processes
Control of Major Accident Hazards
The Chemicals Act (Control of Major Accident Hazards involving Dangerous Substances) Regulations 2015 (S.I. No. 209 of 2015 ) Definition of "SEVESO" Sites. Calculation methods to determine tier. Requirements of different tier sites.
Electrical Equipment
S.I. No. 299 of 2007 Safety, Health and Welfare at Work (General Application) Regulations 2007 (ATEX Regulations) Hazardous area classification, Extent of hazardous area. Classification of gases and vapours for the purposes of equipment design. Prevention of gas ignition by electrical apparatus.
Assessment Breakdown%
Course Work70.00%
End of Module Formal Examination30.00%
Course Work
Assessment Type Assessment Description Outcome addressed % of total Assessment Date
Essay Identify key Safety Issues in Process Safety in an existing Facility 1,3,4 5.0 Week 1
Project Perform a critical analysis of selected literature on Process Hazard Assessments. 1,2,4 10.0 Week 3
Project Perform calculations on the Consequences of a chemical Process Incident. 1,2 15.0 Week 5
Essay Describe how a selected Process Hazard Assessment Technique is carried out. 2,3,4,5 15.0 Week 5
Project Perform a critical analysis on an existing Safety Management System 3,4 25.0 Week 8
End of Module Formal Examination
Assessment Type Assessment Description Outcome addressed % of total Assessment Date
Formal Exam End-of-Semester Final Examination 1,2,3,4,5 30.0 End-of-Semester
Reassessment Requirement
Repeat examination
Reassessment of this module will consist of a repeat examination. It is possible that there will also be a requirement to be reassessed in a coursework element.

The institute reserves the right to alter the nature and timings of assessment

 

Module Workload

Workload: Full Time
Workload Type Workload Description Hours Frequency Average Weekly Learner Workload
Lecture Topics covered as per Indicative Content 4.0 Every Week 4.00
Independent Learning Project work and further study of class content 3.0 Every Week 3.00
Total Hours 7.00
Total Weekly Learner Workload 7.00
Total Weekly Contact Hours 4.00
Workload: Part Time
Workload Type Workload Description Hours Frequency Average Weekly Learner Workload
Lecture topics covered as per "Indicative Content 4.0 Every Week 4.00
Independent Learning Project work and further study of class content. 3.0 Every Week 3.00
Total Hours 7.00
Total Weekly Learner Workload 7.00
Total Weekly Contact Hours 4.00
 

Module Resources

Recommended Book Resources
  • Daniel A. Crowl, Joseph F. Louvar, 2011, Chemical Process Safety: Fundamentals with Applications, Prentice Hall New Jersey [ISBN: 9780131382268]
  • Health and Safety Authority 2005, Guide to Safety, Health and Welfare at Work Act 2005, Dublin [ISBN: 1-84496-028-5]
  • Health and Safety Authority 2006, Guidelines on Risk Assessments and Safety Statements, HSA Dublin [ISBN: 1-84496-032-3]
  • Association of the British Pharmaceutical Industry, Guidelines for Chemical Reaction Hazard Evaluation, Association of the British Pharmaceutical Industry London
  • Barton and Rogers 2004, Chemical Reaction Hazards, Institution of Chemical Engineers [ISBN: 9780852954645]
  • European Process Safety Centre 2003, Explosion protection, Institution of Chemical Engineers Rugby [ISBN: 9780852954560]
  • Health and Safety Authority 2013, Guide to the Safety, Health and Welfare at Work (General Application)(Amendment) Regulations 2012 (S.I. No. 445 of 2012) Pressure Systems, Health and Safety Authority Dublin [ISBN: 978-1-84496-173-3]
  • Health and Safety Authority 2007, Guide to the Safety, Health and Welfare at Work (General Application) Regulations 2007, Health and Safety Authority Dublin
  • Mannan, Lees (eds) 2012, Lees' Loss Prevention in the Process Industries, 4 Ed., Elsevier Texas [ISBN: 978-0-12-3971]
Recommended Article/Paper Resources
  • Oireachtas Na hEireann S.I. No. 299 of 2007 Safety, Health and Welfare at Work (General Application) Regulations 2007
  • Oireachtas na h-Éireann The Safety, Health and Welfare at Work Act(2005)
  • Oireachtas na h-Éireann 2006, The Construction Regulations, 2006
  • Oireachtas na Éireann 2015, The Chemicals Act (Control of Major Accident Hazards involving Dangerous Substances) Regulations 2015 (S.I. No. 209 of 2015 )
  • Institution of Chemical Engineers Loss Prevention Bulletin [ISSN: 0260-9576]
  • Oireachtas na Éireann 2012, Safety, Health and Welfare at Work (General Application)(Amendment) Regulations 2012 (S.I. No. 445 of 2012) Pressure Systems
  • Oireachtas na Éireann 2007, S.I. No. 299 of 2007 Safety, Health and Welfare at Work (General Application) Regulations 2007 (ATEX Regulations)
Other Resources
 

Module Delivered in

Programme Code Programme Semester Delivery
CR_ECPEN_8 Bachelor of Engineering (Honours) in Chemical and Biopharmaceutical Engineering 6 Mandatory
CR_ECPRS_8 Certificate in Chemical Process Safety 1 Mandatory

Cork Institute of Technology
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Email: help@cit.edu.ie