Introduction to Maintenance and

Process Safety

Dr. Waheed Miran

SCME, NUST

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 Course Information
COURSE CODE: CHE-425
COURSE NAME: Maintenance and Process Safety
CREDIT HOURS: Theory =3
Practical =0
Total =3
CONTACT HOURS: Theory = 48

Total = 48
PREREQUISITES: None
MODE OF TEACHING:
Instruction: Three hours of lecture per week 100%

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 Learning Outcomes
Learning
S. No. CLO PLO
level

Describe the key principles of process safety and

CLO-1 PLO 1 C-2
maintenance of industrial operations

Explain the practical application of safety and

CLO-2 PLO 1 C-2
risk management in process industry

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 Schedule
Week CLO Learning Level of
Topic
/Lecture No. Domain Learning
Types of maintenance; preventive, predictive,
and total productive maintenance.
1 1 Cognitive 2
Maintenance of rotary and stationery
equipment.
Inspection techniques, non-destructive testing
2 2 Cognitive 2
techniques
3-4 Lubrication and lubricants 1 Cognitive 2
Basic concepts: hazard, risk, hazard rules,
types of accidents their causes & effects. Risk
5-6 1,2 Cognitive 2
analysis methodologies, Evaluation of risk and
quantification
Hazard Identifications: HAZOP, HAZAN,
7-8 1 Cognitive 2
safety review and safety audit
Gas, vapor and dust explosion. Fire and
9-10 Explosion: The fire triangle and the factor 2 Cognitive 2
contributing to fire and explosion
Concept of Ignition, ignition energy. source of
ignition, auto ignition, auto oxidation,
11-12 adiabatic compression, role of fuel spray, 2 Cognitive 2
purging of equipment, ventilation of space, 4
control of static electricity
 Schedule
Week CLO Learning Level of
Topic
/Lecture No. Domain Learning
Safety equipment: firefighting and sprinkle
13 system, Runaway reactions: causes, 2 Cognitive 2
characterization, prevention, vent sizing
Atmospheric dispersion: factors affecting
14 2 Cognitive 2
dispersion and their modelling
Safety management: process safety
15 management, disaster control organization, 1 Cognitive 2
OSHA guidelines
Toxicology and industrial hygiene: Typical
toxins and their biological effects,
16 2 Cognitive 2
toxicological parameters, release and flow of
toxic gases
Environment impact assessment: cost and
benefits of EIA, EIA process, public
17 consultation and participation in EIA process, 2 Cognitive 2
EIA method & its techniques for impact
prediction and evaluation
18 End Semester Exam

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 Textbook and Reference Material
Textbook (s):
➢ Murphy, J. F., Chemical Process Safety, Fundamentals with Applications,
Fourth Edition By Daniel A. Crowl and Joseph F. Louvar , Pearson Education,
Inc, 628 pages, ISBN-13:978-0-13-485 777-0, ISBN-10-: 0:-13-485 777-1.
Process Safety Progress 2019, e12086.

➢ Pandya C.L, Hazards in Chemical Units, Oxford ISH 1991.

➢ Grimaldi J. H, Simonds, R.H., Safety Management. 5/e AITBS, Delhi,1990.

Reference (s):
➢ Roy E. Sandlers., Chemical Process Safety., Learning from Case Histories,
Butterworth. 1999.
➢ Marc J.Assael and Konstantinos E. Kakosimos, Fires, Explosion and Toxic Gas
Dispersion, CRC Press, 2010.
➢ Thomas A. Wester-Kamp, “Maintenance Manager’s Standard Manual,
Prentice-Hall.
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 PROGRAM LEARNING OUTCOMES (PLOs)
Twelve Programme Learning Outcomes (PLOs) given in the PEC accreditation
manual 2019 are adopted for the BE Chemical Programme.

Environment and
1 Engineering Knowledge:  7 ☐
Sustainability:
2 Problem Analysis: ☐ 8 Ethics: ☐
Design/Development of
3 ☐ 9 Individual and Teamwork: ☐
Solutions:
4 Investigation: ☐ 10 Communication: ☐
5 Modern Tool Usage: ☐ 11 Project Management: ☐
6 The Engineer and Society: ☐ 12 Lifelong Learning: ☐

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 ASSESMENT SYSTEM

No entry in exams < 75 % Attendance

Assignments/Presentations 10%
Quizzes 10%
Mid Semester Exam 30%
End Semester Exam 50%

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 Introduction to MPS
Primary role of a Chemical Engineer is to:

• Design and develop (or operate) processes that

convert raw materials into desired useful products
at industrial scale in a

✓ Safe and
✓ Economical way

The rationale of maintenance and process safety

mainly revolve around these aspects.
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Chemist vs Chemical Engineer

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 Chemist vs Chemical Engineer

The requirement of maintenance and process safety enormously

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increased at industrial scale
 Introduction to MPS

“ To know is to survive and to ignore fundamentals is to court

disaster.”

• Maintenance and Process Safety is must to achieve the desired

products in a safe and economical way.
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Maintenance

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Types of Maintenance

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Preventive Maintenance

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 Preventive Maintenance
In Preventive Maintenance focus is to:
•Locates weak spots of machinery and equipment's
•Provides them periodic/scheduled inspections and minor repairs
to reduce the danger of unanticipated breakdowns

ADVANTAGES
• Reduces break down and thereby down time
• Less odd-time repair and reduces over time of crews
• Greater safety of workers
• Lower maintenance and repair costs
• Less stand-by equipment and spare parts
• Better product quality and fewer reworks and scraps
• Increases plant life
• Increases chances to get production incentive bonus
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 Predictive (Condition-based) Maintenance
• In predictive maintenance, machinery conditions are
periodically monitored, and this enables the
maintenance crews to take timelyactions, such as
machine adjustment, repair or overhaul.
• It makes use of human sense and other sensitive
instruments, such as:
audio gauge, vibration analyzer, amplitude meter,
pressure, temperature and resistance strain gauges
etc.
✓ Unusual sounds coming out of a rotating equipment
predicts a trouble
✓ An excessively hot electric cable predicts a trouble
✓ Simple hand touch can point out many unusual equipment
conditions and thus predicts a trouble
• Predictive (Condition-based) maintenance
Benefits
One of the biggest reasons predictive maintenance is so valuable is
because it allows for maintenance to be performed only when
absolutely necessary—that is, just before equipment failure is
likely to occur. This means:
• Less money spent on preventive maintenance for a machine that
doesn’t need it

• Fewer production hours lost as a result of equipment failure

• A tenfold increase in ROI, and significant maintenance and
downtime reductions
 Breakdown or Corrective Maintenance
• Corrective or Breakdown maintenance implies that
repairs are made after the equipment is failed and can
not perform its normal function anymore

• Corrective maintenance can be defined as the

maintenance which is required when an item has failed
or worn out, to bring it back to working order.

• Corrective maintenance is carried out on all items where

the consequences of failure or wearing out are not
significant and the cost of this maintenance is much
greater than PREVENTIVE MAINTENANCE.
 Breakdown or Corrective Maintenance
Quite justified in small factories where:

• Down times are non-critical and repair costs

are less than other type of maintenance
• Financial justification for scheduling are not
felt
 Breakdown or Corrective Maintenance
Disadvantages of corrective maintenance
• Breakdown generally occurs inappropriate
times leading to poor and hurried maintenance
• Excessive delay in production & reduces output
• Faster plant deterioration
• Increases chances of accidents and less safety
for both workers and machines
• Direct loss of profit
• Can not be employed for equipment's regulated
by statutory provisions e.g. cranes, lift and hoists
etc
Maintenance Cost
Maintenance
Maintenance of Static and Rotating Equipments
Static Equipment: Equipment having no moving parts,
e.g., pressure vessels, drums, tanks, reactors etc.

• Comparatively more reliable

• Generally do not have a redundant/standby system.

Maintenance : Generally they are checked for wear and

tear, corrosion, and remaining life etc.
Maintenance of Static and Rotating Equipments
Rotating Equipment: Equipments having moving parts,
like shaft, impellers, pistons etc.

• Generally have a standby system

• Undergo regular maintenance

Maintenance: Mostly, they are pressure equipment, but

with shaft, impellers, vanes, seals etc. to move the liquid
and gases. Mostly checked for vibration, balancing, seal
leaks, wear and tear etc.
Maintenance of Static and Rotating Equipments
Overall equipment effectiveness
Inspection Techniques
Inspection Techniques