Module Details

Module Code: CHEP8023
Title: Chemical Process Safety
Long Title: Chemical Process Safety
NFQ Level: Advanced
Valid From: Semester 2 - 2023/24 ( January 2024 )
Duration: 1 Semester
Credits: 5
Field of Study: 5240 - Chemical & Process Eng
Module Delivered in: 2 programme(s)
Module Description: The module is designed to give students a thorough grounding in the issues that must be addressed when assessing the hazards arising from the processing of chemicals on an industrial level.
 
Learning Outcomes
On successful completion of this module the learner will be able to:
# Learning Outcome Description
LO1 Identify and assess the hazards arising from existing chemical processes and activities.
LO2 Determine the risks arising from a hazard analysis.
LO3 Identify workplace controls required to reduce or eliminate workplace risks.
LO4 Assess chemical process safety management systems and introduce improvements where necessary.
LO5 Perform a chemical process safety analysis on a proposed process.
Dependencies
Module Recommendations

This is prior learning (or a practical skill) that is strongly recommended before enrolment in this module. You may enrol in this module if you have not acquired the recommended learning but you will have considerable difficulty in passing (i.e. achieving the learning outcomes of) the module. While the prior learning is expressed as named MTU module(s) it also allows for learning (in another module or modules) which is equivalent to the learning specified in the named module(s).
Incompatible Modules
These are modules which have learning outcomes that are too similar to the learning outcomes of this module. You may not earn additional credit for the same learning and therefore you may not enrol in this module if you have successfully completed any modules in the incompatible list.
No incompatible modules listed
Co-requisite Modules
No Co-requisite modules listed
Requirements

This is prior learning (or a practical skill) that is mandatory before enrolment in this module is allowed. You may not enrol on this module if you have not acquired the learning specified in this section.
No requirements listed
 
Indicative Content
Legislation
Irish and European Safety Law The Safety, Health and Welfare at Work Act (2005). The Construction Regulations, 2006, The General Applications Regulations 2007 HSA guidance documents on Safety Management Systems, The Safety Statement, HSA Codes of Practice. Safe Systems of Work
Safety Theory
Legal, Moral/ Ethical and Economic reasons for safe operation. Safety Statistics, Safety Management Systems. Definitions of Hazard, Risk, Control measures. Sustainability in Chemical Process Safety
Safety Statements
Elements of the safety statement. Health and safety policy. Hazard identification. Examples of hazards. Carrying out a risk assessment. Precautions. Findings. Review and update of safety statements.
Control of Hazards in the Workplace
Hierarchy of controls, design, replacement, isolation, local ventilation, general ventilation, good housekeeping and hygiene, limited exposure, personal protective equipment. Selection of PPE.
Quantitative and Qualitative risk assessment techniques.
Definitions, Procedure, Preparation, Meetings, Follow up, Recording. HAZOP, FTA, FMEA, SIL, LOPA.
Control of Major Accident Hazards
Chemicals Act (Control Of Major Accident Hazards Involving Dangerous Substances) Regulations 2015 (S.I. No. 209 of 2015) Definition of "SEVESO" Sites. Calculation methods to determine tier. Requirements of different tier sites.
Fire and Explosion Prevention and Response
Definitions (combustion, ignition, autoignition, auto ignition temperature, flash point, flammable or explosive limits, explosion, deflagration, detonation, confined explosion, unconfined explosion, boiling liquid, expanding vapour explosion (BLEVE), effect of temperature and pressure on flammability, flammability characteristics, minimum oxygen concentration, minimum ignition energy, adiabatic compression). Parameters effecting the behavior of an explosion. Vapour explosions. Dust explosions: deflagration indices, hybrid mixtures, dust explosion prevention. Static Electricity: generation, hazards and control. Design of fire detection systems fire extinguishment. Types of fire.
Chemical Reaction Safety
Storage of Chemicals, Incompatibilities, Safety Data Sheets, Reaction Assessment Systems, Sources of Data, Case Studies.
Pressure Systems
Safety, Health and Welfare at Work (General Application) (Amendment) Regulations 2012 (S.I. No. 445 of 2012) Definitions. Pressure relief assessment, including type, development of relief scenarios, data collection and sizing of relief devices. Integrity of pressurised equipment. Failure modes.
Management of Change/ Permit to Work
Maintenance and modification of operating plant. Permit to work system. Planning maintenance. Types of permit. Modification of processes.
Electrical Equipment
Safety, Health and Welfare at Work (General Application) Regulations 2007 (S.I. No. 299 of 2007), Codes of Practice, ATEX Regulations, Hazardous area classification, Extent of hazardous area. Classification of gases and vapours for the purposes of equipment design. Prevention of gas ignition by electrical apparatus.
Module Content & Assessment
Assessment Breakdown%
Coursework50.00%
End of Module Formal Examination50.00%

Assessments

Coursework
Assessment Type Essay % of Total Mark 5
Timing Week 1 Learning Outcomes 1,3,4
Assessment Description
Identify key Safety Issues in Process Safety in an existing Facility
Assessment Type Project % of Total Mark 25
Timing Week 5 Learning Outcomes 1,2,3,4,5
Assessment Description
Perform a critical Process Hazard Assessments (PHA) on a given process.
Assessment Type Project % of Total Mark 20
Timing Week 9 Learning Outcomes 1,2,3,4
Assessment Description
Perform a critical analysis on an existing Safety Management System
End of Module Formal Examination
Assessment Type Formal Exam % of Total Mark 50
Timing End-of-Semester Learning Outcomes 1,2,3,4,5
Assessment Description
End-of-Semester Final Examination
Reassessment Requirement
Repeat examination
Reassessment of this module will consist of a repeat examination. It is possible that there will also be a requirement to be reassessed in a coursework element.

The University reserves the right to alter the nature and timings of assessment

 

Module Workload

Workload: Full Time
Workload Type Contact Type Workload Description Frequency Average Weekly Learner Workload Hours
Lecture Contact Topics covered as per Indicative Content Every Week 4.00 4
Independent Learning Non Contact Project work and further study of class content Every Week 3.00 3
Total Hours 7.00
Total Weekly Learner Workload 7.00
Total Weekly Contact Hours 4.00
Workload: Part Time
Workload Type Contact Type Workload Description Frequency Average Weekly Learner Workload Hours
Lecture Contact Topics covered as per Indicative Content Every Week 4.00 4
Independent Learning Non Contact Project work and further study of class content Every Week 3.00 3
Total Hours 7.00
Total Weekly Learner Workload 7.00
Total Weekly Contact Hours 4.00
 
Module Resources
Recommended Book Resources
  • Daniel A. Crowl, Joseph F. Louvar. (2019), Chemical Process Safety, 4th Edition. Prentice Hall, [ISBN: 978-0-13-485777-0].
  • John Barton, Richard Rogers. (1997), Chemical Reaction Hazards, 2nd Edition. The Institution of Chemical Engineers, [ISBN: 0852953410].
  • Institution of Chemical Engineers. (2003), Explosion Protection: Practical Understanding of Recent Standards and New Legislation in Process Safety, IChemE, p.110, [ISBN: 0852954565].
  • Lees' loss prevention in the process industries : hazard identification, assessment and control, 4th Edition. [ISBN: 9780123971890].
Recommended Article/Paper Resources
  • Oireachtas Na hEireann. S.I. No. 299 of 2007 Safety, Health and Welfare at Work (General Application) Regulations 2007.
  • Oireachtas na h-Éireann. The Safety, Health and Welfare at Work Act(2005).
  • Oireachtas na h-Éireann. (2006), The Construction Regulations, 2006.
  • Oireachtas na Éireann. (2015), The Chemicals Act (Control of Major Accident Hazards involving Dangerous Substances) Regulations 2015 (S.I. No. 209 of 2015 ).
  • Institution of Chemical Engineers. Loss Prevention Bulletin, [ISSN: 0260-9576],
    http://www.icheme.org/resources/lpb.asp
  • Oireachtas na Éireann. (2012), Safety, Health and Welfare at Work (General Application)(Amendment) Regulations 2012 (S.I. No. 445 of 2012) Pressure Systems.
  • Oireachtas na Éireann. (2007), S.I. No. 299 of 2007 Safety, Health and Welfare at Work (General Application) Regulations 2007 (ATEX Regulations).
Other Resources
 
Module Delivered in
Programme Code Programme Semester Delivery
CR_ECPEN_8 Bachelor of Engineering (Honours) in Chemical and Biopharmaceutical Engineering 6 Mandatory
CR_ECPRS_8 Certificate in Chemical Process Safety 1 Mandatory