CHEMICAL PROCESS SAFETY; CHEN 455

Transcription

1 CHEMICAL PROCESS SAFETY; CHEN 455 Instructor: Dr. Ray Mentzer, JEB 213 Phone: (979) Texas A&M University College Station, TX Class: 10:20 11:10 am; JEB 104 This course is concerned with all aspects of Chemical Process Safety and Loss Prevention. Process Safety differs from Personnel Safety (or Industrial Hygiene), in that it is concerned primarily with the identification of potential hazards and hazardous conditions associated with the processes and equipment involved in the Chemical Process Industries. It includes methods of predicting the possible severity of these hazards and preventing, controlling or mitigating them. As such, it is necessary to understand the operation of these processes and the equipment, and to apply sound engineering fundamentals to the analysis and prediction of performance, under adverse circumstances. Thus, the course emphasizes quantitative engineering analysis based upon the application of mass and energy balances, fluid mechanics of liquid, gas, and two-phase flow, heat transfer and the conservation of energy, mass transfer, diffusion and dispersion under highly variable conditions, reaction kinetics, process control, and statistics. Techniques for process hazard analysis, risk assessment, and accident investigations are also covered. In addition to applications of engineering principles, concepts of management and individual responsibility are stressed, as well as teamwork and the appreciation for orders of magnitude estimation and relative significance. The course topics follow those in the text: A. Crowl and Joseph F. Louvar, Chemical Process Safety: Fundamentals with Applications, Prentice Hall (2002). Homework assignments are taken primarily from the problems in the book (with occasional supplements). This material is supplemented and extended by student projects, which culminate in a report and class presentation. Prerequisites: Fundamentals of mass and energy balances, thermodynamics, fluid mechanics, heat and mass transfer operations. Course Learning Outcomes: 1. Recognize professional and ethical elements of an outstanding safety program. 2. Evaluate ethical issues that may occur in professional engineering practice. 3. Recognize ethical standards and professional codes of conduct for engineers, e.g., NSPE Code of Ethics for Engineers.

2 4. Identify government agencies, regulatory bodies, codes, and standards that govern the global, societal, and environmental impact of plant design projects. 5. Be able to list examples of how unsound science or unethical behavior had a negative impact on society. 6. Identify and apply OSHA PSM and EPA RMP in the chemical process industries. 7. Describe and apply the principles and approach of inherently safer design to reduce and eliminate hazards and thereby lower the risk of new or currently operating chemical systems. 8. Describe the operation of chemical processes and equipment and apply engineering fundamentals to the analysis and prediction of performance under adverse circumstances. 9. Perform quantitative engineering analysis based upon the applications of mass and energy balance, fluid mechanics of liquid, gas, and two-phase flows, heat transfer and the conservation of energy, mass transfer, diffusion and dispersion under highly variable conditions, reaction kinetics, process control, and statistics. 10. Perform PHA analysis of targeted chemical process industries and evaluate the safety performance. 11. Identify the potential hazards and hazardous conditions associated with the processes and equipment involved in the chemical process industries. 12. Work effectively in teams and develop problem solving skills. Prepare and present a professional project report. Teams: Students will be grouped into teams of 3 4, and work on the homework assignments and term project as a team effort. Students will submit homework assignments and the term paper as a group. The purpose of working in teams is NOT to spread the work around but to enhance the learning of all team members, who benefit from the knowledge and perspective of others. Team members will periodically evaluate each other in terms of their contribution to homework and a team project. Homework: Homework will generally be assigned every week. It is expected that all team members will participate in answering all homework problems, each signing the single solution submitted by the team. Late homework will not be accepted, except when prior approval has been obtained. Attendance: Class attendance is important for this course. Class participation is encouraged, material will be covered in class beyond the text, and there will be unannounced quizzes. Project: Each team will prepare a term project (selected from a list of topics provided), and the team will make a formal class presentation and submit a formal report on their project. Topics will be distributed on February 22, teams select top three topics on February 26, with final topic confirmed by the Instructor on March 1. The abstract is due on March 12 and the report due on April 19. Presentations will be on April 26 28, from 5:30 10 pm. All students are

3 expected to attend all presentations. Grading of the project is based on the abstract, written report, presentation, response to Q&As, and teammate evaluations. Exams: There will be three exams during the term. All exams will be closedbook in class. Exam I is scheduled on Wednesday, February 17; Exam II on Friday, March 26; with the Final at time assigned by University. Class Policy: All quizzes are closed-book, while exams are open book. Missing a quiz / exam results in a zero, unless arrangements were made with the instructor in advance. Homework is due a week after assigned in class. No texting, Blackberry or cell phone use during lectures. Grading Criteria: Homework 10% Project Report/Presentation 20% Quizzes 10% Hourly Exams 60% Grades: A B C D <60 F SUPPORT: - Dr. Mentzer (ray.mentzer@ch .tamu.edu) Monday s: 7:30 10:00 & 1:00 5:00 Wednesday s: 7:30 10:00; 4:00 5:00 Friday s: 7:30 9:00; 1:00 5:00 - TA Adam Georgeson (ageorgeson@neo.tamu.edu) - Graders Yogesh Koirala (yogesh1986@neo.tamu.edu) Daniel Thierry (dtennisman2006@tamu.edu)

4 Lecture Outline Hours I. Introduction - Process Safety Management 2 Failure Management Responsibility, Policy Hazard Identification Hazard Assessment Hazard Control Introduction to Process Safety Engineering, Loss Prevention Application of Fundamental Engineering Principles II. Toxic Materials - Introduction 1 Dose and Response Curves Threshold Limit Values and Permissible Exposure Levels Application of Engineering Principles - Problems III. Introduction to Hygiene 2 MSDS's Monitoring Volatile Toxicants, etc. Liquid Vaporization Rates - Exposure during vessel filling Ventilation IV. Source Models 5 Applications of Fluid Mechanics to Leakage of Liquid and Gas Through Holes, Pipes, and Fittings Evaporation, Flashing, and Boiling Two Phase Flow V. Toxic Release and Dispersion 5 Dispersion Models Pasquill-Gifford Plume and Puff Models Computer Applications VI. Fires and Explosions 2 Flammability of liquids and vapors Minimum Oxygen Concentration, Ignition Explosions - Detonations and Deflagrations Blast Damage VII. Fire and Explosion Protection and Prevention 3 Inerting, Purging Static Electricity Explosion Proof Equipment

5 Ventilation, Sprinklers VIII. Reliefs 1 Location, Types, Systems Knockout Drums Flares Scrubbers, Condensers IX. Relief Sizing 5 Spring Operated, Rupture Discs Design for Liquid, Vapor, Two-Phase Flow Venting for Dust and Vapor Thermal Expansion X. Hazard Identification 2 Checklists, DOW Fire and Explosion Index HAZOP Safety Reviews Application - Problems XI. Risk Assessment 3 Probability Theory Interactions between units Event Trees Fault Trees XII. Accident Investigations 2 Procedures Diagnosis Recommendations XIII. Term Project Presentations 6 Examinations 3 Total Hours: 42 ABET Credit Classification: Engineering Science - 1 ½ hour, Engineering Design 1 ½ hours

6 Relationship of course to program outcomes Course Outcomes 1. Recognize the professional and ethical elements of an outstanding safety program. 2. Evaluate ethical issues that may occur in professional engineering practice. 3. Recognize ethical standards and professional codes of conduct for engineers, e.g., NSPE Code of Ethics for Engineers. 4. Identify government agencies, regulatory bodies, codes, and standards that govern the global, societal, and environmental impact of plant design projects. 5. Be able to list examples of how unsound science or unethical behavior had a negative impact on society. 6. Understand and apply OSHA PSM and EPA RMP in the chemical process industries. 7. Understand and apply the principles and approach of inherently safer design to reduce and eliminate hazards and thereby lower the risk of new or currently operating chemical systems 8. Understand the operation of chemical processes and equipment and apply engineering fundamentals to the analysis and prediction of performance under adverse circumstances. 9. Perform quantitative engineering analysis based upon the applications of mass and energy balance, fluid mechanics of liquid, gas, and two-phase flows, heat transfer and the conservation of energy, mass transfer, diffusion and dispersion under highly variable conditions, reaction kinetics, process control, and statistics 10. Perform PHA analysis of targeted chemical process industries and evaluate the safety performance 11. Identify the potential hazards and hazardous conditions associated with the processes and equipment involved in the chemical process industries 12. Work effectively in teams and develop problem solving skills. Prepare and present a professional project report. ChE Program Outcomes 6, , 5, 6, 8, 11 1, 11 1, 5 4, 5, 7 9, 10, 11 4, 5, 7