CHEMICAL

PROCESS
SAFETY
 DESIGN PRINCIPLES
Principle 1:
Persons with Control – persons who make decisions
affecting the design of products, facilities or processes
are able to promote health and safety at the source.
 DESIGN PRINCIPLE
Principle 2: Cont’d…
Product Lifecycle – safe design applies to every
stage in the lifecycle. It involves eliminating hazards
or minimizing risks as early in the lifecycle as
possible.
 DESIGN PRINCIPLE
Principle 3:
Cont’d…
Systematic Risk Management – the application of
hazard identification, risk assessment and risk control
processes to achieve safe design.
 DESIGN PRINCIPLE
Principle 4: Cont’d…
Safe Design Knowledge and Capability – should be
either demonstrated or acquired by persons with
control over design and should reflect the knowledge
that a competent designer would be expected to have.
 DESIGN PRINCIPLE
Principle 5:
Cont’d…
Information Transfer- effective communication and
documentation of design and risk control information
between all persons involved in the phases of the
lifecycle is essential for the safe design approach.
Polymerization of
styrene
Styrene Polystyrene
` Catalyst: Benzoyl peroxide
Temperature: 70-750 C
SAFETY DESIGNS
Concept Design : feasibility or option studies.
Functional Design: Preliminary design.
Detailed Design: This includes full documentation
to allow construction to commence and should include
consideration of the procurement, construction, start
up and ongoing operation and maintenance of the
project.
Concept Design
Requirements:- Identification of critical
health and safety related risks that may
affect the viability of the project.
CONCEPT
Effectiveness: An alternate approach
lies in the notion of exchanger
effectiveness, E.
E = actual heat transfer/maximum
possible heat transfer
Eg: Site geology-soft soils
Functional Design
Requirements: Identification of
reasonably foreseeable safety risks with a
design project associated with the
construction/manufacture, installation,
commission/use, maintenance and disposal.
Eg: Redundancy , Specification of materials
with high durability and low maintenance
requirements .
Detailed Design
Detailed Design: Focusing on ways in which a
design can be modified to eliminate or reduce issues
that may affect the ongoing safety of persons involved
in constructing, using, maintaining or demolishing the
design product.
Eg: Inclusion of construction access into building
fabric e.g. removable panels
- Lifting lugs installed to facilitate the movement of
heavy items
 Feasibility Study
Feasibility study is an analysis of the viability of an
idea.
Evaluation and analysis of the potential of a proposed
project which is based on extensive investigation and
research to support the process of decision making.
 Preliminary Design
Use fewer hazardous substances and small quantities
( Minimize)
Use substances that are less hazardous ( Substitute)
Use moderate operating condition ( Moderate)
Use simple plant design ( Simplify)
Flow Diagrams
Three levels of Diagram

- Block Flow Diagram

- Process Flow Diagram
- Piping and Instrumentation Diagram.

P&ID Diagram is more complex but it is more

conceptual.
Block Flow
Diagrams(BFD)
Block or rectangles used
operation.
represent a unit

Blocks are connected by straight lines which

represent the process flow streams which flow
between the units.
Process flow streams may be mixtures of liquids,
gases and solids flowing in pipes or ducts, or solids
being carried on a conveyor belt.
Block flow diagrams a number of rules
should be followed:
-
unit operations such as mixers, separators,
reactors, distillation columns and heat
exchangers are usually denoted by a simple
BFD Cont’d…
- the direction of flow of each of the process flow
streams must be clearly indicated by arrows.
- unit operations (i.e., blocks) should be labeled.
Process Flow Diagram(PFD)( QP
2009)
Process flow diagram or system flow diagram(SFD).
Shows the relationships between the major
components in the system.
PFD also tabulate process design values for the
components in different operating modes, typical
minimum, normal and maximum.
A PFD should include:
- Process Piping
- Major equipment symbols, names and identification
numbers
- Control, valves and valves that affect operation of the
system
PFD Cont’d…
System Flow Diagrams should not include:
- pipe class- pipe line numbers- minor bypass lines-
isolation and shutoff valves- maintenance vents and
drains- relief and safety valve- code class information.
 Piping & Instrumentation
Diagram(P&ID)-(QP- 2014,2009)
The P&ID shows the flows in a plant (in the chemical or
process industry) and the corresponding sensors.
P&ID gives a name ("tag") to each sensor, along with
additional parameters.
P & I should be included with
– All process equipment identified by equipment
number.
– All pipes identified by a line number. Pipe size
and material of construction should be shown.
– All valves with an identification no. along with
their type &size should be shown.
– Ancillary fittings that are part of piping system
P & ID Cont’d…
P&ID Cont’d…
Batch Vs Continuous
The batch process has the following advantages
versus the continuous process:
• Flexibility when the feed quality changes
• System recovery can be maximized batch by batch
• Cleaning is easily implemented
• Simple automatic controls
• Quality can be controlled by termination of the
process
• Quality can be improved by total or partial second-
pass treatment
• Expansion is rather easy
• Lower investment costs
Batch Vs Continuous
The disadvantages are:
Cont’d…
• No continuous flow
• No constant quality
• Large feed tank required
• Larger power consumption
• Longer residence time.
• Higher total running costs.
Equipment
Specification
Equipment specification will define the performance
requirements of the equipment, materials of
construction, fabrication methods and procedures, test
and inspection requirements, etc.
Equipment specifications should be as short and
concise as possible and still achieve the required
results.
Eqpt. Spec Cont’d…
A typical specification is divided into the following
sections:

1. Scope

2. Standards, Codes and Specifications

3. Definitions and Terminology

4. Materials of Construction

5. Design Basis

6. Mechanical
Eqpt. Spec. Cont’d…
Scope: The scope of the specification may
include any or all of the following: design,
supply of material, fabrication, shop testing,
painting, delivery, erection, field services,
commissioning, etc. The scope may also
include a general description of the application
or service in which the equipment will be
placed.
Eqpt. Spec. Cont’d…
Definition & Terminology: Specifications provide a
means of communicating the purchaser’s
requirements for a piece of equipment. Terms such as
‘shall’, ‘should’ and ‘may’ must be used
appropriately to avoid confusion as to what
requirements are mandatory, recommended or
optional.
Shall indicates requirements that are mandatory.
Should indicates requirements that are
recommended but not mandatory.
May indicates requirements that are optional and,
consequently, are at the discretion of the designer.
Eqpt. Spec. Cont’d…
Materials of construction: The materials that will
be used for the fabrication of the equipment need to
be specified clearly so that the equipment performs
properly from a mechanical and corrosion point of
view.
Design Basis:
Process conditions (i.e. flows, temperature,
concentrations, pressures, etc.)
Site conditions (i.e. ambient temperatures,
barometric pressure, seismic zone, precipitation, etc.)
Continuous or intermittent operation
Noise limitations
Utilities (i.e. steam, compressed air, water, cooling
Eqpt. Spec. Cont’d…
Mechanical: Specific mechanical and fabrication
details or procedures should be specified if required to
ensure the quality of the equipment being supplied.
Guarantees: The specification and purchase of
equipment generally includes for some form of
guarantee of quality or performance. Any mechanical
equipment should be guaranteed against defective
design, material, workmanship, etc. for the period of
time specified in the purchase order agreement.
Testing & Inspection: Testing and inspection of the
equipment is required to ensure that the equipment
will meet its design intent. The requirement for
testing and inspection increases the cost of the
equipment and extends the fabrication schedule.
Eqpt. Spec. Cont’d…

Documentation: Equipment purchased from a vendor should

come with a set of documentation which allows the purchaser to
operate and maintain the equipment.
A complete document package may include the following:
• Completed inspection and test reports
• As built drawings
• Operating and maintenance manuals
• Weld procedures, qualifications weld maps.
• Material certificates.
Eqpt. Spec. Cont’d…
Shipping: After completion of the equipment in the
fabricator’s facilities it must be prepared for
shipment. The requirements for shipment will depend
on the specifics of the equipment (i.e. size, shape,
weight, etc.), the destination, mode of transport,
expected storage time and environmental conditions
at the site.
Reliability and Safety in
Designing ( QP 2011)

Reliability is the probability that a product will continue to

work normally over a specified interval of time, under
specified conditions.
Eg: The mouse on your computer might have a reliability of
0.990 (or 99%) over the next 1000 hours. It has a 99%
chance of working normally during this time, which is
obviously the same as saying it has a 1% chance of being
faulty.
Safety Critical Design(Reliability)
Product reliability and safety are related. There are
several
approaches to minimizing the risk.
- Over-specification: For product applications in the
building and construction industry, it is standard
practice to include a ‘x5’ safety factor in all material
strength calculations.
-
Redundancy (parallel): Multiple identical
components are used simultaneously, any one of
which would be capable of supporting normal
product function.
-
For example, a passenger lift has 4 cables carrying
the lift cabin, all sharing the load. Any one cable
would be capable of carrying the full passenger lift
Safety Critical Design(Reliability)
Cont’d…
Redundancy (standby): A back-up system is held in
reserve and comes into operation only when the main
system fails, for example stand-by generators in
hospitals.
Fail-safe design: Assumes an inherent risk of failure
for which the cost of any of the above three strategies
would be prohibitively high. The product or system is
designed to drop into a safe condition in the event of
partial or total failure.
Eg: Railway train brakes are released by vacuum, and
applied by
admitting air. If a brake pipe bursts, the admitted air
automatically applies the train brakes.
Inherent Safety-(QP APRIL
2014,2009,2011,2010)
Inherent Safety
Cont’d…

Bhopal Disaster: The Bhopal disaster was the worst

ever chemical disaster in the world. It resulted from
the release of a very toxic gas Methyl-iso-Cyanate
(MIC), which is a reaction intermediate in the
formation of Carbaryl. Here is the associated reaction,
where methylamine (1) reacts with phosgene (2) to
form methyl isocyanate (MIC) (3). MIC then reacts
with 1-naphthol (4) to give Carbaryl (5):
Due to what happened in Bhopal, the reaction to form
Carbaryl has now been replaced with a new safer
Engineered
Safety
It is necessary to design protective devices to
(QP
ensureAPRIL
either that the design conditions cannot
be exceeded or that the excessive condition is
2014)
relieved before it can do any harm.
Examples of such devices may include:
-
Pressure safety relief valve
-
High and Low temperature and pressure
alarms.
-
Fire detection and fighting systems.
-
Toxic gas alarms.
Pressure relief devices must be vent to a safe area and
if the substance being vented are themselves
Safety during startup and
shutdown
Startup is defined as “setting in operation of an
affected source or portion of an affected source for any
purpose”. Startup is what you do when you start your
process equipment.
Shutdown is defined as “the cessation of operation of
an affected source or portion of an affected source for
any purpose”. Shutdown is what you do when you turn
your process equipment off.
Safety during startup and
shutdown Cont’d…
Personnel Safety: All personnel present in the plant
(outside the control room or buildings) during startup or
shutdown shall wear personal protective equipment (PPE) as
required by site policies or regulations.
PPE should include:
– safety glasses with rigid side shields;
– hard hats;
– flame resistant clothing (FRC);
– hearing protection;
– safety shoes;
– gloves; and
– portable personal gas monitors.
Safety during startup and
shutdown Cont’d…
Emergency Response: Prior to
the startup or shutdown of the
unit, the following emergency
response requirements shall be
met:
- availability of site-specific
emergency response procedures;
- adequate training of
personnel in emergency
response procedures;
- availability of firefighting
equipment that has been tested
and confirmed ready for use
Safety during startup and
shutdown Cont’d…
Process safety: For a
startup or shutdown, the
following process safety
factors shall be
considered:
– training and competency
of plant personnel to
perform the startup or
shutdown procedures;
– staffing levels adequate
to ensure a safe startup or
shutdown;
– limiting the number of
individuals present in the
Safety during startup and
shutdown Cont’d…
Communication: Proper -critical local process
communication is needed instrumentation;
with the customers and
- testing and proper
organizations that are
operation of safety
connected with the
devices;
particular unit.
- temporary connections
Recommended
management;
operating procedures:
Site-specific operating - mechanical equipment
procedures should exist to handling;
address applicable utility
and auxiliary systems,
including the following:
– process analyzers
Safety during startup and
shutdown Cont’d…
Materials and equipment: The following supplies
should be available prior to startup and shutdown:
– portable analytical equipment and accessories;
– certified hoses;
– task-specific tools;
– burner ignition equipment;
– safety equipment
– breathing air equipment for-
confined vessel entry.
Safety during startup and
shutdown Cont’d…
On-line furnace inspections: Throughout startup
and shutdown periods, frequent visual observations of
the furnace interior shall be made through the
inspection ports.
Non Destructive
Testing
Non-destructive Testing is one
function of Quality Control.
part of the

Non-destructive testing is the testing of

materials, for surface or internal flaws or
metallurgical condition, without interfering in
any way with the integrity of the material or
its suitability for service.
The technique can be applied on a sampling
basis for individual investigation or may be
used for 100% checking of material in a
production quality control system.
NDT Cont’d…
Non-destructive Testing is not just a method for rejecting
substandard material; it is also an assurance that the
supposedly good is good.

The methods covered are:

• Radiography
• Magnetic Particle Crack Detection
• Dye Penetrant Testing
• Ultrasonic Flaw Detection
• Eddy Current and Electro-magnetic Testing
NDT Cont’d…
Introduction to Radiography: This technique is
suitable for the detection of internal defects in ferrous
and non ferrous metals and other