Study safety in chemical processing
170
Sub Topics
478
MCQs
292
MCOs
378
True/False
213
Fill Blanks
84
Rearrange
193
Matching
118
Comprehensions
204
Flashcard Decks
Curriculum
What You'll Learn
01 Introduction to Chemical Process Safety 3 topics
1 Historical Development of Process Safety
- Major Industrial Accidents and Their Impact
- Evolution of Safety Regulations
2 Safety Culture and Management Systems
- Elements of a Safety Culture
- Safety Leadership
- Employee Involvement
3 Economic and Business Case for Process Safety
- Cost of Incidents vs. Prevention
- Sustainability and Corporate Responsibility
02 Toxicology and Industrial Hygiene 3 topics
1 Fundamentals of Toxicology
- Dose-Response Relationships
- Routes of Exposure
- Acute vs. Chronic Effects
2 Industrial Hygiene Principles
- Workplace Exposure Limits
- Sampling and Monitoring Methods
- Hierarchy of Controls
3 Personal Protective Equipment
- Selection and Limitations
- Respiratory Protection
- Chemical Protective Clothing
03 Source Models and Hazardous Release 3 topics
1 Fluid Flow Through Holes and Pipes
- Liquid Release Models
- Gas Release Models
- Two-Phase Releases
2 Pool Evaporation and Boiling
- Evaporation from Spills
- Pool Spreading Models
3 Vapor Cloud Formation and Dispersion
- Gaussian Dispersion Models
- Dense Gas Dispersion
- Computational Fluid Dynamics Approaches
04 Fire and Explosion Fundamentals 4 topics
1 Fire Chemistry and Physics
- Fire Triangle/Tetrahedron
- Flammability Limits
- Autoignition and Flash Points
2 Types of Fires in the Process Industry
- Pool Fires
- Jet Fires
- Flash Fires
- Fireballs
3 Explosions
- Deflagration vs. Detonation
- Vapor Cloud Explosions
- Dust Explosions
- BLEVE (Boiling Liquid Expanding Vapor Explosion)
4 Explosion Effects
- Blast Waves
- Overpressure Effects
- Structural Damage Assessment
05 Chemical Reactivity Hazards 4 topics
1 Fundamentals of Chemical Reactivity
- Exothermic and Endothermic Reactions
- Reaction Kinetics and Thermodynamics
2 Reactive Chemical Hazards
- Self-Reactive Materials
- Pyrophoric Substances
- Water-Reactive Materials
- Peroxide-Forming Compounds
3 Runaway Reactions
- Thermal Runaway Theory
- Critical Temperature and Time to Maximum Rate
- Adiabatic Calorimetry Methods
4 Chemical Compatibility
- Compatibility Charts
- Storage Guidelines
- Mixing Hazards
06 Hazard Identification and Risk Assessment 3 topics
1 Process Hazard Analysis Methods
- HAZOP (Hazard and Operability Study)
- What-If Analysis
- FMEA (Failure Modes and Effects Analysis)
- Fault Tree Analysis
- Event Tree Analysis
2 Risk Assessment Techniques
- Qualitative Risk Assessment
- Semi-Quantitative Risk Assessment
- Quantitative Risk Assessment (QRA)
3 Consequence Modeling
- Impact Criteria
- Vulnerability Models
- Individual and Societal Risk
07 Inherently Safer Design 3 topics
1 Principles of Inherently Safer Design
- Minimize
- Substitute
- Moderate
- Simplify
2 Process Intensification
- Reduced Inventories
- Alternative Reaction Pathways
- Continuous vs. Batch Processing
3 Implementation Strategies
- Design Stage Opportunities
- Retrofit Considerations
- Economic Evaluation
08 Reliability Engineering and Equipment Safety 3 topics
1 Reliability Fundamentals
- Failure Rates and Distributions
- Mean Time Between Failures
- Availability and Maintainability
2 Equipment Reliability
- Pressure Vessels
- Storage Tanks
- Piping Systems
- Pumps and Compressors
- Heat Exchangers
3 Materials of Construction
- Corrosion Mechanisms
- Material Selection
- Mechanical Integrity Programs
09 Process Controls and Safety Instrumentation 3 topics
1 Process Control Fundamentals
- Feedback Control
- Feedforward Control
- Cascade Control
2 Safety Instrumented Systems (SIS)
- Safety Integrity Levels (SIL)
- SIL Determination and Verification
- SIS Design and Implementation
3 Alarm Management
- Alarm Philosophy
- Alarm Rationalization
- Human Factors in Alarm Response
10 Relief and Flare Systems 3 topics
1 Relief System Design Fundamentals
- Relief Scenarios
- Required Relief Capacity
- Discharge Coefficient
2 Relief Devices
- Pressure Safety Valves
- Rupture Discs
- Pressure/Vacuum Relief Valves
- Relief Valve Stability
3 Flare Systems
- Flare Headers and Networks
- Knockout Drums
- Flare Tips and Ignition Systems
- Radiation Effects
11 Human Factors in Process Safety 3 topics
1 Human Error Analysis
- Error Types and Mechanisms
- Performance Shaping Factors
- Human Reliability Assessment
2 Ergonomic Design
- Control Room Design
- Field Operations
- Accessibility and Maintainability
3 Training and Competency
- Operator Training
- Emergency Response Training
- Competency Assessment
12 Process Safety Management Systems 3 topics
1 Regulatory Frameworks
- OSHA PSM Regulation
- EPA RMP Rule
- Seveso Directive
- International Standards
2 PSM Elements
- Process Safety Information
- Process Hazard Analysis
- Operating Procedures
- Management of Change
- Pre-Startup Safety Review
- Mechanical Integrity
- Contractor Safety
- Incident Investigation
3 Performance Measurement
- Leading and Lagging Indicators
- Safety Performance Metrics
- Benchmarking
13 Emergency Planning and Response 3 topics
1 Emergency Planning
- Emergency Response Plans
- Evacuation Planning
- Community Notification
2 Emergency Response
- Incident Command System
- Emergency Operations Centers
- First Responder Considerations
3 Crisis Management
- Crisis Communications
- Business Continuity
- Recovery Operations
14 Case Studies and Lessons Learned 3 topics
1 Historical Major Accidents
- Flixborough (1974)
- Seveso (1976)
- Bhopal (1984)
- Texas City (2005)
- Deepwater Horizon (2010)
- West, Texas (2013)
2 Root Cause Analysis
- Investigation Methodologies
- Systemic Factors
- Organizational Learning
3 Industry-Specific Hazards
- Refining
- Petrochemicals
- Specialty Chemicals
- Pharmaceuticals
- Mining and Metals
15 Emerging Trends in Process Safety 3 topics
1 Digitalization and Industry 4.0
- Big Data Analytics
- Digital Twins
- Predictive Maintenance
2 Sustainability and Green Chemistry
- Alternative Feedstocks
- Circular Economy
- Energy Efficiency
3 Global Harmonization
- International Standards
- Cross-Border Safety Management
- Global Best Practices
16 Process Safety in Facility Lifecycle 4 topics
1 Safety in Design
- Front-End Engineering Design (FEED)
- Design Reviews
- 3D Modeling and Simulation
2 Construction and Commissioning
- Construction Safety
- Pre-Startup Safety Review
- Operational Readiness
3 Operations and Maintenance
- Safe Work Practices
- Permit to Work Systems
- Turnarounds and Shutdowns
4 Decommissioning and Demolition
- Decontamination
- Hazardous Materials Handling
- Site Remediation
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Chemical Process Safety
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