Process Utilities and Safety

Introduction to Process Utilities: Importance and Role of Utilities in Chemical Industries, Classification of Utilities: Primary and Secondary, Economics of Utilities: Cost estimation, energy efficiency, conservation, Design Considerations and Selection Criteria, Integration of Utilities with Process Operations.

Industrial Safety Fundamentals: Types of Hazards in Chemical Plants: Physical, Chemical, Biological, and Ergonomic Hazards, Hazard Identification and Risk Assessment (HIRA), Fire and Explosion Hazards: Fire triangle, Fire classes, Extinguishers, and Suppression systems, Personal Protective Equipment (PPE) and Safety Signage, Occupational Health and First Aid process in industries

Water, Air, and Refrigeration Systems: Water as a Utility: Water Treatment Methods (Softening, Demineralization, Boiler Feed Water specifications), Cooling Water Systems and their safety aspects, Safety aspects of Compressed air and vacuum systems (Compressors, blowers and vacuum pumps) and their limitations, Air Drying systems, Filtration systems, Refrigeration systems and Chilling Systems and their key safety aspects. Importance of insulation for meeting the process requirement, insulation materials and their effect on various material of equipment piping, fitting and valves etc. insulation for high, intermediate, low and subzero temperatures, including cryogenic insulation

Steam and Power: Properties and Generation of Steam: Types of Boilers and boiler safety, Boiler Accessories and Mountings and Personal safety (PPE, Awareness of steam leaks, burns, and pressure hazards, Lock-out/tag-out (LOTO) procedures during maintenance), Steam distribution system and steam line safety, and Power Generation in Process Industries: Types of Power generation, Energy Integration and Electrical Utilities their safety measures,

Process Safety and Regulations: Process Hazard Analysis (PHA) Techniques: HAZOP, FMEA, Fault Tree Analysis, Relief and Flare Systems: Pressure Relief Valves, Rupture Discs, Design of Flare Systems, Safety Instrumented Systems (SIS) and Interlocks, Environmental and Safety Legislations: Factories Act, Environmental Protection Act, OSHA norms, Case Studies on Major Industrial Accidents (Bhopal, Flixborough etc). Total 40