B.E. (Chemical Engineering) Chemical Plant Safety and Hazards Syllabus - Mumbai University 2026

Module 1: Introduction: History and development of safety movement, Safety printed in the syllabus as Module Course Contents

• programs, Need for safety, Engineering ethics, accident and loss statistics, acceptable risk, The nature of accident process, Identifying the causative and initiating factors of Industrial accidents, Accident prevention and control techniques, Plant safety inspections, Major Industrial Disasters (Case Studies) Bhopal disaster (1984), Chernobyl Disaster, Fukushima Daiichi Disaster etc. Case studies. Industrial Hygiene: Definition of Industrial Hygiene, Phases of industrial hygiene, Industrial Hygiene: Control Methods, Substitution, Changing the process, isolation, wet method, local exhaust ventilation, personal hygiene, housekeeping and maintenance, waste disposal, special control measures, Government Regulations, Anticipation and identification, MSDS, Evaluation workers exposure to Volatile toxicants, dust, noise, toxic vapors, Industrial Hygiene : Control

Module 2: Fire and Explosions printed in the syllabus as Module Course Contents

• Fire: Fire triangle, Classification of fires, Flammability characteristics of liquids and gases, Limiting oxygen concentration, ignition energy, auto ignition, autoxidation, adiabatic compression. Ignition sources, spray and mist. Common causes of industrial fires. Explosion: Detonation, Deflagration, Confined explosion, unconfined explosion, VCE, BLEVE, Problems on energy of chemical explosion.

Module 3: Concept to Prevent Fire and Explosion (Fire and Explosion printed in the syllabus as Module Course Contents

• prevention methods and Introduction to Reliefs) and Introduction to Reliefs Inerting: vacuum and pressure purging, combined purging, Controlling Static electricity: Bonding and grounding, dip pipes, Explosion-proof equipment instruments, ventilation. Sprinklers systems. Fire-fighting systems: Different types of portable fire extinguishers, their installation, periodic inspection and operation, Replacement of Halon with safer substitutes, Fire hydrant system, Fire monitors, sprinkler system and deluge system, Carbon-dioxide flooding system, Foam Pourer system Relief concept: Principle of pressure system, Pressure, Hazards of steam, Mechanism of Steam explosion, key components and safety features of pressure system, Failure of pressure system, Hazards of overpressure and over temperature in pressure system, location of reliefs and types of relief.

Module 4: Chemical Reactivity and Safety In Plant Operation And printed in the syllabus as Module Course Contents

Module 5: Hazard Identification and Risk Assessment printed in the syllabus as Module Course Contents

• Hazard Identification: Hazard identification and risk control approaches and techniques, Reactive approach-Incident recall technique (after-the- event approach), Proactive approaches: Critical incident review technique (before-the-event approach), Deductive technique, Inductive technique Process hazards checklists, survey, Hazard and Operability Studies (HAZOP), Maximum Credible Accident Analysis (MCAA)/Quantitative Risk Assessment (QRA), Safety review. Risk assessment: Cause/consequence finding techniques What-if, Fishbone, Why-Why, Root Cause Analysis (RCA), Event tree analysis, Fault tree analysis, Maximum Credible Accident Analysis (MCAA)/Quantitative Risk Assessment (QRA) and LOPA.

Module 6: Safety Procedures and Design printed in the syllabus as Module Course Contents

• Process safety Hierarchy, managing safety, best practices, procedure for safety review and accident investigation, design for process safety, runway reactions, Job safety Analysis (JSA) and investigation of accidents, First aid, Financial costs-direct and indirect, social costs of accidents, Dust explosion, factors of pentagon, causes of dust explosions and controls, handling dusts and Miscellaneous designs for fire and explosions. Course Outcome

Recommended Books

• 1 Crowl, D. A. and Louvar, J. P.; Chemical Process Safety: Fundamentals with Applications;
• 2 K. S. N. Raju, Chemical Process Industry Safety, McGraw Hill Education
• 3 Roy E. Sanders, Chemical Process Safety: Learning from Case Histories, Butterworth-
• 4 H.W. Heinrich, Dan Petersen, and Nestor Roos, McGraw-Hill Book Company,
• 5 A.K.Gupta, Industrial Safety and Environment, McGraw-Hill Book Co. Ltd., New York,
• 6 K.T. Kulkarni, Industrial Safety: Concepts and Practices , Pune Vidyarthi Griha Prakashan,
• 7 Accident Prevention Manual for Industrial Operations (ISBN: 978-08-7-912024-5), National
• 8 H.W. Heinrich, Dan Petersen, and Nestor Roos , Industrial Accident Prevention, McGraw-
• 9 K.U. Mistry, A Course in Industrial Safety, NKM Publishers, Ahmedabad