lesson plan + course outline september 2013

LESSON PLAN CPE615

PROCESS SAFETY

FACULTY OF CHEMICAL ENGINEERINGUNIVERSITI TEKNOLOGI MARA

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1.0 COURSE INFORMATION

COURSE NAME : PROCESS SAFETY COURSE CODE : CPE615SEMESTER : 6 (EH220\ EH221)CREDIT HOURS : 3CONTACT HOURS : 4COURSE STATUS : COREPRE-REQUISITE : NIL

2.0 SYNOPSIS

This course offers a detailed study of safety and loss prevention covering concepts, methods and application of techniques with emphasis on the control of hazards using safety-engineering in process industry. The syllabus covers the national and international safety and health regulatory provisions, and principles and techniques for identifying, analyzing and controlling hazards which are required on any process plant to ensure the safe and efficient operation. The course also emphasizes on risk assessment, occupational safety and health management system, emergency planning and case studies.

3.0 OBJECTIVES

Upon completion of this module, students should be able to:1. Describe and explain the main principles of safety, health, accident prevention and

relevant safety and health legislation and regulations. 2. Compare and apply the various hazard identification and risk assessment

methodologies HAZOP, ETA and FTA, and QRA. 3. Describe and develop successful safety and health management system, and describe

the development of safety and health management system (OHSM) in Malaysia and other countries.

4. Apply the knowledge on safety and health in addressing causes, consequences, control, preventive measures and management system to prevent accidents in a hypothetical plant.

4.0 METHODS OF INSTRUCTIONLectures, Tutorials, Active-learning and Case Studies.

LESSON PLAN CPE615

PROCESS SAFETY


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5.0 LESSON PLAN

Week Duration Topics Activities1-2 2 1.0 Introduction to hazard and risk

1.1 Safety versus health1.2 Engineers and safety1.3 Inherently safe plant1.4 Examples from past industrial accidents: Bhopal, Flixborough, Piper Alpha and other related accidents 1.5 Root causes of accident1.6 Immediate causes of accident

Briefing of the course objectives and lesson plan. Ask students to define safety and health.Describe past industrial accidents in Malaysia and other countries.Read Crowl Chapter 1, Wentz p. 1-5, and Perry’s Chem. Eng. Handbook Chapter 23

3 1 2.0 Safety legislation and regulations2.1 Definition of accidents2.2 OSHA 1994 & Regulations2.3 FMA 1967 and other related legislation and regulation2.4 Others safety related regulations

Look up DOSH Malaysia website.Read on functions of DOSH.Read OSHA 1994 and its regulations, FMA 1967, Petroleum Act and EQA 1984.

4 -5 2 3.0 Hazards Identification3.1 Definition3.2 Types of hazards3.3 Toxic hazard, fire hazard and explosion hazard3.4 Hazard reduction and control3.5 Probit analysis – Fire, thermal radiation and explosion

Read Crowl Chapter 6, 7 and 12Read Wentz Chapter 1,3, 5, 6, 7 and 10.Read Perry Chapter 23Look up web-site on CSDS.Test 1

6 2 4.0 Hazard analysis4.1 Hazard and Operability Studies (HAZOP)4.2 Fault Tree Analysis (FTA)4.3 Event Tree Analysis (ETA)4.4 Failure frequency analysis

Read Crowl Chapter 10 and 11, Wentz Chapter 2, and Perry Chapter 23.Class exercise on HAZOP/ETA/FMA study (Group)

7 2 5.0 Risk Assessment and Management5.1 Definition of risk5.2 Acceptability criteria5.3 Qualitative and quantitative risk assessment (QRA)5.4 Fire radiation calculations API RP2515.5 Explosion: TNO explosion analysis methodology5.6 Safe distances: dispersion calculations, domino effects5.7 Risk reduction and management

Read Crowl Chapter 11, Wentz Chapter 10, and Perry Chapter 23.

8 1 6.0 Plant maintainability and reliability6.1 Scope of industrial preventive or predictive maintenance programs6.2 Reliability and failure distributions

Read Wentz, p. 317-352

9 1 7.0 Emergency planning7.1 On-site emergency planning7.2 Off-site emergency planning

Read Wentz Chapter 9 and 14 Read Wells on emergency planning

10 2 8.0 Safety management system8.1 Key elements for effective safety management system

Read OSH MS 1722, OHSAS 18001, ILO OSH 2001 Discussion on OSH management. Test 2

LESSON PLAN CPE615

PROCESS SAFETY


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8.2 Safety management audit, safety audit8.3 Safety training, motivation and incentives

13-14 2 9.0 Special topics related to the safety and loss prevention in the chemical process industries.

6.0 ASSESSMENTSFinal Examination: 60%Assignments and tests : 40%

7.0 TEXTBOOK USEDCrowl, D. A. and Louvar, J. F. (2002). Chemical Process Safety. 2nd ed. Upper Saddle River NJ: Prentice Hall International Series

8.0 REFERENCESWentz, C. A. (1998). Safety, Health and Environmental Protection. New York: McGraw Hill.Perry, R.H. and Green, D.W., (2007). Perry's Chemical Engineers' Handbook. 8th

Edition, New York: McGraw Hill.Lees, F.J., (1994). Loss Prevention in the Process Industries Vols. 1, 2 and 3, London: Butterworth & Company (Publ.) Ltd.Wells, G. L., (1980). Safety in Process Plant Design, Rugby, UK: IChemE/GodwinWells, G. L., (1996). Hazard Identification and Risk Assessment, Rugby, UK: IChemE/GodwinOther references related to safety and loss prevention in process industries.

9.0 OTHER INFORMATION/DETAILS

a) Attendance is compulsory. Students who fail to comply with 80% of attendance will be barred from sitting for the final examination. Absence from lectures, tutorials, tests, or presentations must be supported with relevant documentation.

b) Marks will be deducted for late submission of assignment/report. c) Consultation is by appointment only.d) Any form of cheating and/or plagiarism in examinations, tests, reports and

assignment will be penalized.

PREPARED BY: APPROVED BY :SIGNATURE:

________________________________NAME : RAFEQAH BNITI RASLANPOSITION: Lecturer

DATE : 5 MAC 2013

SIGNATURE :

_________________________________NAME : POSITION : DATE : 5 MAC 2013

COURSE OUTLINE CPE615

PROCESS SAFETY


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Week Discussed Topic Course Outcomes (Refer to Bloom's Taxanomy Learning Domain)

Course Learning Outcomes The students should be

Delivery Methods

Assessment

1-2 1.0 Introduction to hazard and risk1.1 Safety versus health1.2 Engineers and safety1.3 Inherently safe plant 1.4 1.4 Examples from past industrial accidents: Bhopal, Flixborough, Piper Alpha and other related accidents1.5 Root causes of accident1.6 Immediate causes of accident

PO7, PO8, PO9

Course Outcome 1 (CO1)Describe and explain the main principles of safety, health, accident prevention and relevant safety and health legislation and regulations

able to explain the definition of safety and health, able to explain the role of an engineer in the aspect of safety, able to list lessons learned from past industrial accidents,able to describe causes of accidents able to explain inherently safe plant

Lectures, active learning, case

studyCollaborative

learningClass exercise

Examination or tests or project

3 2.0 Safety legislation and regulations2.1 Definition of accidents2.2 OSHA 1994 and Regulations2.3 FMA19672.4 Others safety related regulation

PO7, PO8, PO9

able to compare and contrast safety related legislation and regulations as applied in Malaysia and other countries.able to describe OSHA 1994 and its regulations. able to explain the definition of industrial accidents able to describe the requirements and applications of the relevant safety legislations and regulations able to describe duties of employers and employees in ensuring safety and health at the workplace.

Lectures, active learning,

Collaborative learning

Class exercise



PROCESS SAFETY


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4 - 5 3.0 Hazards Identification3.1 Definition3.2 Types of hazards3.3 Toxic hazard, fire hazard and explosion hazard3.4 Hazard reduction and control3.5 Probit analysis – Fire, thermal radiation and explosion

PO7, PO8, PO9

Course Outcome 2 (CO2)Compare and apply the various hazard identification and risk assessment methodologies HAZOP, ETA and FTA, and QRA.

able to identify hazards within a plant design and operation able to apply checklists to significant plant designs and operations to identify hazards. able to prepare a professional accident investigation report evaluating the event and describe the sociotechnical system

lectures, active learning,

tutorials, group work

Class exercise

Examination or tests or assignment and/or case study

Test 1

6 4.0 Hazard analysis4.1 Hazard and Operability Studies (HAZOP)4.2 Fault Tree Analysis (FTA)4.3 Event Tree Analysis (ETA)4.4 Failure frequency analysis

PO7, PO8, PO9

Course Outcome 2 (CO2)Compare and apply the various hazard identification and risk assessment methodologies HAZOP, ETA and FTA, and QRA.

able to identify potential initiating events for chemical plant operations, able to determine the cause of the accident, able to estimate the consequence and develop alternative designs or operations that might have prevented the accident and reduced the risk, able to apply Fault Tree Analysis to determine all possible paths leading to a specified Top Event, able to apply and communicate HAZOP to small sections of chemical plant operations to identify potential hazards and operability problems


tutorials, group work

Class exercise

Examination or test or project


PROCESS SAFETY


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7 5.0 Risk Assessment and Management5.1 Definition of risk5.2 Acceptability criteria5.3 Qualitative and quantitative risk assessment (QRA)5.4 Fire radiation calculations API RP2515.5 Explosion: TNO explosion analysis methodology5.6 Safe distances: dispersion calculations, domino effects5.7 Risk reduction and management

PO7, PO8, PO9

able to discuss the concept of risk assessment, the acceptability criteria and risk reduction able to predict the range of values of the consequences of an event including, but not limited to, toxic exposure, explosions, fires, and spills using Probit analysis. able to predict the probability of occurrence of an event


collaborative learning, group

work and tutorials


8 6.0 Plant maintainability and reliability6.1 Scope of industrial preventive or predictive maintenance programs6.2 Reliability and failure distributions

able to discuss the concepts of maintainability and reliability, able to describe maintenance programs.

Lectures, active learning and

tutorialClass exercise


9 7.0 Emergency planning7.1 On-site emergency planning7.2 Off-site emergency planning

Course Outcome 3 (CO3)Describe and develop successful safety and health management system, and describe the development of safety and health management system (OHSM) in Malaysia and other countries.

able to describe off-site and on-site emergency planning, able to develop an emergency plan, able to communicate emergency plan

lectures, tutorial, active learning and group work


10 8.0 Safety management system8.1 Key elements for effective safety management system8.2 Safety management audit, safety audit8.3 Safety training, motivation and incentives

PO7, PO8, PO9

able to list the key elements of effective PSM, able to explain the safety management audit and safety audit. able to describe and compare and contrast OHSM standards e.g. ILO OSH 2001, OHSAS 18001, OSH MS 1722

lectures, tutorials, active

learning and group work

Class exercise


Test 2


PROCESS SAFETY


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11-14 9.0 Special topics related to the safety and loss prevention in the chemical process industries.

PO7, PO8, PO9

Course Outcome 4 (CO4)Apply the knowledge on safety and health in addressing causes, consequences, control, preventive measures and management system to prevent accidents in a hypothetical plant.

able to communicate and present the outcomes of a case study.

Case study and cooperative

learning

Oral presentation, peer assessment and report

LIST OF COURSE OUTCOMES:

CO1 Describe and explain the main principles of safety, health, accident prevention and relevant safety and health legislation and regulations. CO2 Compare and apply the various hazard identification and risk assessment methodologies HAZOP, ETA and FTA, and QRA. CO3 Describe and develop successful safety and health management system, and describe the development of safety and health management system (OHSM) in Malaysia

and other countries. CO4 Apply the knowledge on safety and health in addressing causes, consequences, control, preventive measures and management system to prevent accidents in a

hypothetical plant.

LIST OF PROGRAMME OUTCOMES:

PO1 Ability to acquire and apply the knowledge of basic sciences, mathematics and engineering fundamentals to solve chemical engineering problems.PO2 Ability to undertake problem identification, formulation and solution in engineering.PO3 Ability to design and conduct experiments, as well as to analyze and interpret data.PO4 Ability to utilize modern engineering tools, components and systems.PO5 Ability to utilize systems approach and evaluate operational performance to design related plants.PO6 Ability to acquire in-depth technical knowledge in chemical engineering principles.PO7 Ability to communicate effectively, not only with engineers but also with the community at large.PO8 Ability to apply the knowledge of safety, health, and the environment including sustainable development issues in chemical engineering scenarios.PO9 Ability to function effectively as an individual and in a group with the capacity to be a leader or manager as well as an effective team member.PO10 Ability to apply entrepreneurship skill in engineering related businesses.PO11 Ability to integrate the importance of the social, cultural and global contemporary issues and professional ethics in engineering practice.PO12 Ability to undertake lifelong learning.


PROCESS SAFETY


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PO-CO MATRIX

COURSE OUTCOMES

PROGRAMME OUTCOMES INSTRUCTIONAL METHODS

ASSESSMENT

PO 1

PO 2

PO 3

PO 4

PO 5

PO 6

PO 7

PO 8

PO 9

PO 10

PO 11

PO 12

CO1. Describe and explain the main principles of safety, health, accident prevention and relevant safety and health legislation and regulations.

3 Lectures, tutorials, group works

Examination or tests or integrated project

CO2. Compare and apply the various hazard identification and risk assessment methodologies HAZOP, ETA and FTA, and QRA.

2 3 2 Lectures, tutorials, group works

Examination or tests

CO3. Describe and develop successful safety and health management system, and describe the development of safety and health management system (OHSM) in Malaysia and other countries.

2 3 2 lectures, tutorials, group works

Examination or tests

CO4. Apply the knowledge on safety and health in addressing causes, consequences, control, preventive measures and management system to prevent accidents in a hypothetical plant.

3 2 3 lectures, tutorials, group works

Examination or tests or integrated project

Numbers Indicator: 3 – Strongly emphasized, 2 – Moderately emphasized, 1 – Slightly emphasized

lesson plan + course outline september 2013

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