Design Safety detailed syllabus for Chemical Engineering (CE) for 2021 regulation curriculum has been taken from the Anna Universities official website and presented for the CE students. For course code, course name, number of credits for a course and other scheme related information, do visit full semester subjects post given below.
For Chemical Engineering 6th Sem scheme and its subjects, do visit CE 6th Sem 2021 regulation scheme. For Professional Elective-VI scheme and its subjects refer to CE Professional Elective-VI syllabus scheme. The detailed syllabus of design safety is as follows.
Course Objectives:
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Unit I
SAFETY SYSTEMS 9
Safety systems: Deployment of sensors (Toxic, HC and Thermal) at critical locations, Fire network including elevated fire monitors, Egress system, Escape route and Assembly point, Water curtain, eye wash requirement, Clean and cooler water supply ;Dovetail Early Event Detections system to forecast and forewarn on ‘unsafe’ conditions emerging in process units, Cause & Effect diagram, Alarm rationalization, Partial or Total Plant Trips review; Setting up IOW (Integrity Operating Window), Utility stations at strategic locations in process units (for supply of LP steam, Nitrogen, Industrial Air, Service water), Fire Proofing of structures, ROVs (Remote Operated Valves), EIVs (Emergency Isolation Valves), Redundancy in trips (1 oo 1; 2 oo 3) and avoidance of spurious trips ;SIL (Safety Integrity Level) in process safety, HIPS (High Integrity Protection System),Shutdown system reset – Field or Controlled room, Centralized Vs Decentralized Control centre, Need of Chemical filter in Control Room Air conditioning, Cyber-attack prevention, Mutual aid plan. Case Studies – From Peer Industries on Performance Benchmark, Process safety Management, Safety Culture, Asset Integrity, Litigations, Safety & Environmental Incidents, etc.
Unit II
ELECTRICAL SYSTEMS 9
Power systems – KV level, 3 phase and single phase, LT, HT generation and distribution network systems, MCC / PCC (motor control centre and power control centre) substations, Electrical Energy Audits, Exergy analysis, Cogen design aspects ; Emergency Power needs based on process criticalities (including power back up for fire water and plant safe shut down), Load shedding, Essential and Non- essential power load Uninterrupted Power System (UPS), Load assessment for UPS, Battery bank ;Earth pit design and maintenance aspects, Earth – Neutral Differential & impacts of stray voltage, Fault Level and its relevance in industry, Start-up load, Power from two independent Sources, Relay / Fuse Coordination. Electrical load distribution and its influence on safety relief / flare load in an industrial complex, Interphase with DCS (Distributed Control System), PLCs (programmable logic controls), I/P (Current to Pneumatic transmission) convertor failures ;An overview on electrical failures viz. cable fault, over load, over voltage due to surges, lightning strokes, aging of conductor, internal & external stresses on the conductors, spike in power banks, etc., Case Studies – Industries experiences on Steam – Power balance for efficiency enhancement, smart debottlenecking to minimize cable routing & MCC / PCC use, Safety & Environmental Incidents, etc.
Unit III
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Unit IV
RISK MITIGATION MEASURES 9
HAZOP (Hazard and Operability Study), HAZID (Hazard identification), HAZAN (Hazard Analysis), EERA (Emergency escape route analysis), SIL (Safety Integrity levels) study, QrA (Quantitative Risk Assessment)and Dispersion studies ;Trip reset (Field and Control Room) and MSDS (Material Safety Data Sheet) for all streams being handled, Bow Tie Analysis, Risk Evaluation using 8 x 8 Matrix, FMEA (Failure Modes And Effects Analysis),Insurance premium assessment and measures to minimize ;Best practices – Updated documentation, SOPs (Standard Operating Procedures),
SMPs (Standard Maintenance Procedures), PSM audits, Competency mapping and enhancement, employee loyalty programme, etc. Business risk – Risk in transportation of feed and products especially in sea routes (marine pollution); HSE norms non-compliance; Act of force majeure; etc. Case Studies – Industries experiences such as Trouble shooting, Efficiency / Effectiveness tracking, Debottlenecking, Design tips, Safety & Environmental Incidents, etc.
Unit V
PROCESS CONTROL & INSTRUMENTATION 9
Pneumatic (analogue controls) to DCS journey, Single loop Vs Multi loop controls, I/O cards, Graphic design & grouping to minimize user latency in process control ;Designed for safety through redundancy right from dedicated impulse lines to card level, PLC (Programmable Logic Controls), Cascaded Control, Process Historian, Online reporting by exception, Inferential predictions ;Use of AI / ML in controlling plant within best operating zone, QMIs (Quality Measuring Instruments), Alarm rationalization, Operator Fatigue ;Functional designs in delayed (by a few seconds) trip, Machine monitoring viz. signature analysis (vibration and axial displacement), surge control with differing mol wt of process gas, tribology analysis ;Emphasis on lab instrumentation to get “tell-tale” indications on existence of unsafe conditions, hand held instrumentations to work in confined space, communication system (field & control room, etc.) etc. CCTV at select places to monitor and alert well in advance. Centralized fire control panel for the whole premises by way of wired network of safety sensors. Case Studies – From Industries on operations & maintenance aspects viz. Trouble shooting, Efficiency / Effectiveness tracking, Debottlenecking, Design tips, Safety & Environmental Incidents, etc.
Course Outcomes:
On completion of the course, the students will be able to
- learn the safety systems both to prevent incident & to minimize loss
- understand the safety in electrical systems
- knowledge on flare systems and their safety
- get thorough knowledge on risk analysis and mitigation
- knowledge on the control systems and their safety usage in different process industries
Text Books:
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Reference Books:
- Chemical Process Safety – Aarti Kashyap
- Process Safety – Klein James A and Bruce K Vaughan
For detailed syllabus of all the other subjects of Chemical Engineering 6th Sem, visit CE 6th Sem subject syllabuses for 2021 regulation.
For all Chemical Engineering results, visit Anna University CE all semester results direct link.