Training Course Modules in the area of “Chemical Process Safety Management” available from IIT Bombay

The development and implementation of a Process Safety Management System (PSMS) is essential for anticipating and reducing, production, property and human losses due to process upsets and accidents. Six independent course modules are available from IIT Bombay (Course Instructor: Prof Sandip Roy, Department of Chemical Engineering) that addresses various components of a PSMS. These courses may be conducted in-house for individual organizations, with a relevant customization of the content.

The author also undertakes consulting assignments on Hazard and Risk Assessment for the Chemical Process Industries. A select list of clients for courses and consultancy assignments are provided (see OTHER INFORMATION).

The table below provides a brief summary of the course modules, while content details are presented in the rest of the document.

Module No / Training Module (Course) Title / Tentative Duration (days)
1 / Chemical Process Hazard, Risk & Loss Assessment / 3
2 / Loss Prevention in the Process Industries / 3
3 / Learning from Chemical Process Incident Investigations / 2
4 / Improving Process Safety through Hazard Evaluation / 3
5 / Designing for Chemical Process Safety / 2
6 / Pipeline Risk Assessment / 3

The above courses have been availed of by a large number of industrial organizations (see OTHER INFORMATION).

COURSE INSTRUCTOR:

Prof. Sandip Roy

Department of Chemical Engineering

IIT Bombay 400 076

Tel: 022 - 25767024 (O) / 7249 (O) / 8249 (R)

Cell: 9819293590

Fax: 2572 6895

Email: ,

COURSE MODULE – I

TITLE: CHEMICAL PROCESS HAZARD, RISK & LOSS ASSESSMENT

DURATION: 3-DAYS

CONTENTS:

1. Overview of Process Hazard & Risk Management

  • Technical and Economic Issues in Process Risk Management
  • Current National/International Regulatory Trends
  • Overview of Review Hazard Identification Methodologies
  • Review of HAZOP Methodology: Case Studies on Continuous and Batch processes

2. Principles of Analysis of Accident Consequence

  • Methods for Assessing Consequences of Fires, Explosions, and Atmospheric Release of Toxic Substance
  • Estimation of Probability and Scale of Accident Effects: Probit Analysis

3. Accident Frequency Estimation Methods

  • Estimation of Equipment and Process System Failures Probabilities: Reliability analysis, Quantitative Fault and Event Tree Analysis
  • Techniques for using Fault-tree and Event-Tree Analysis for Improving Reliability of Engineering Systems

4. Principles of Risk Analysis

  • Identification of Individual and Societal Risk Contours around Chemical Process Facilities; Risk Acceptance Criterion
  • Risk Analysis and Accident Mitigation/Emergency Planning

5. Case Studies

  • Case Studies in Consequence Analysis for Accidental Release of Toxic, Flammable and Explosive Substances
  • Case Studies in Risk Analysis for Process Plants of Various Configuration handling Toxic, Flammable and Explosive Substances
  • Case studies on Loss/Damage Assessment
  • Demonstration of Software for Evaluating Hazard/Risk from Fires, Explosions, and Toxic Releases
COURSE MODULE – II

TITLE: LOSS PREVENTION IN PROCESS INDUSTRIES

DURATION: 3-DAYS

CONTENTS
  • Review of Common Causes for Chemical Process Accidents; Various Modes of “Loss of Containment” of Hazardous Chemicals
  • Using Hazard Evaluation Techniques Optimally for Loss Reduction
  • Carrying out Safety Audits
  • Concepts of Inherent Chemical Process Safety
  • Chemical Plant Design Strategies for Safe Operation
  • Techniques for Prevention of Chemical Process Accidents; Techniques for Detection of Leaks of Hazardous Substances
  • Techniques for Mitigation of Consequences of Chemical Process Accidents
  • Understanding Human Errors; Methodologies for Reduction of Human Errors
  • Managing Changes in Process Design and Operation
  • Emergency Planning: Identification of Credible Incidents for Emergency Planning; Overall Emergency Plan, Required Physical Facilities and Systems; Response Equipment and Supplies; Evaluating Process Risks for Emergency Planning
  • Decontamination of Accident Site and Response Team
  • Developing Process Safety Management Systems
COURSE MODULE – III

TITLE: LEARNING FROM CHEMICAL PROCESS INCIDENT INVESTIGATIONS

DURATION: 2/3 DAYS

CONTENTS
  • Case Histories of Select Major Accidents in the Process Industry
  • Lessons from Analysis of Major Process Accidents
  • Case Histories of Select Small-scale Accidents in the Process Industry
  • Investigating Process Upsets and Accidents: Evolving a Structured Approach
  • Predicting Consequence and Impacts of Accidents involving Hazardous Substances
  • Selection of Realistic and Worst Case Accident Scenarios for Consequence Estimation
  • Case Studies in Accident Consequence Analysis for Release of Toxic, Flammable and Explosive Substances
  • Software for Prediction of Accident Consequences and Impacts
  • Common Modes of Failures of Various Process Equipments
  • Common Causes for Loss of Containment from Process Equipments
  • Using Quantitative Techniques for Accident Investigation
  • Case Studies in Process Accident Investigation
  • Accident Consequence Analysis and Emergency Planning
  • Estimating Process Accident Costs
COURSE MODULE – IV

TITLE: IMPROVING PROCESS SAFETY THROUGH HAZARD EVALUATION

DURATION: 3-DAYS

CONTENTS:

  • Detailed Illustration of Hazard Evaluation Techniques: Preliminary Hazard Analysis, Checklists/Relative Ranking/HAZOP/Failure Modes and Effect Analysis/Fault and Event Tree/ Cause Consequence Analysis
  • Case Studies in application of Hazard Evaluation Techniques
  • Illustration of Special Applications of HAZOP through case studies
  • Criteria for selecting an appropriate HE technique
  • Deciding on when and where to apply each HE technique
  • Necessary information, knowledge and skill requirements
  • Preparation, execution and documentation of a HE study
  • Types of results of each HE technique
  • Factors responsible for successful HE study
  • Implementation and monitoring of HE recommendations for improving safety performance and loss prevention

COURSE MODULE – V

TITLE: DESIGNING FOR CHEMICAL PROCESS SAFETY

DURATION: 2/3 DAYS

CONTENTS

  • Design of Inerting/Purging of Process Vessels
  • Fundamentals of Static Charge Generation
  • Controlling Static Electricity
  • Design Methods to Prevent Electrostatic Ignitions
  • Ventilation Design
  • Sprinkler Systems Design
  • Relief Design Considerations
  • Rupture Disc Reliefs in Liquid/Vapour/Gas Service
  • Deflagration Venting for Dust and Vapor Explosions
  • Runaway Reaction Relief Design
  • Venting for Fires External to Process Vessels
  • Reliefs for Thermal Expansion of Process Fluids
  • Design Principles of Inherent Process Safety
  • Quantifying Inherent Process Safety

COURSE MODULE – VI

TITLE: PIPELINE RISK ASSESSMENT

DURATION: 3 DAYS

CONTENTS

  • Assessment of requirements on safety management systems in international regulations for the control of major hazard pipelines
  • International initiatives on the control of major accident hazards arising from pipelines
  • Statistical analysis of world-wide accidents on gas pipelines
  • Comparative study of onshore transmission accidents
  • Generalized Risk assessment methodology for pipeline systems
  • Critical aspects of risk assessment for hazardous pipelines containing flammable substances
  • Environmental Quantitative Assessment for Pipelines
  • Calculating the consequences of a pipeline rupture
  • Models for the release rate of hazardous gas from a hole on high-pressure pipelines
  • Transient outflow models for pipeline puncture
  • Thermal interaction analysis in pipeline systems
  • Cost-Benefit analysis for pipeline safety

OTHER INFORMATION

Select Client Organizations which have availed of Courses/Consultancy on Chemical Process Hazardand Risk Analysis from IIT Bombay

Corporate Organizations: Reliance Petrochemicals, Reliance Engineering Associates, NOCIL, Bharat Petroleum Corporation, Hindustan Petroleum Corporation, Kochi Refineries, Indian Oil Corporation, Deepak Fertilizers & Petrochemicals, Tata Chemicals, Tata Honeywell, Tata Consulting Engineers, Rallis India, Monsanto India, Lupin Labs India, Bayer India, CIBA, Grasim Industries, Kvaerner Powergas, Hikal, TATA-AIG Insurance, CIPLA, United India Assurance, Deepak Nitrite, Bombay Dyeing, Excel India, ICICI Lombard, Cholamandalam Insurance, etc.

Government Organizations: Central Labour Institute, Atomic Energy Regulatory Board

Organizations for which in-house courses have been conducted: Reliance Industries, L&T (Mumbai), Disaster Management Institute (Bhopal), National Safety Council (Mumbai), ONGC, IPCL, Haldia Petrochemcials, Garware Polyesters, Chambal Fertilizers and Chemicals

COURSE INSTRUCTOR

Prof. Sandip Roy

Department of Chemical Engineering

IIT Bombay 400 076

Tel: 25767024 / 7249 (O) / 8249 (R)

Cell: 9819293590

Fax: 2572 6895

Email:

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