Consulta de Guías Docentes



Academic Year/course: 2017/18

531 - Master's in Chemical Engineering

66215 - Safety and Risk Analysis in the Chemical Industry


Syllabus Information

Academic Year:
2017/18
Subject:
66215 - Safety and Risk Analysis in the Chemical Industry
Faculty / School:
110 - Escuela de Ingeniería y Arquitectura
Degree:
531 - Master's in Chemical Engineering
ECTS:
6.0
Year:
1
Semester:
Second semester
Subject Type:
Compulsory
Module:
---

5.1. Methodological overview

The methodology followed in this course is oriented towards achievement of the learning objectives. A wide range of teaching and learning tasks are implemented, such as

  • Theory sessions using the traditional blackboard and audiovisual media. 
  • Side by side with the theoretical concepts, problems arising from them will be proposed and solved in class for each topic. Students will be advised to work on them prior to their solving. Most cases will be “open” problems with different possible approaches that consciously can lead to discussion.
  • In every topic, different “case studies” coming from reports and analysis provided by institutions and professional associations worldwide will be suggested. This material will consist of cases involving real accidents in which hazardous substances have played a primary role. Case studies will be suggested by the lecturer, worked by the students on their own (individually or in small groups) and commented in class. 
  • At least one of the case studies will be written down by the students and later handed in to the lecturer, corrected and marked. This mark will constitute a significant part of the final one as is conveniently described in the corresponding issue.

5.2. Learning tasks

The course includes the following learning tasks: 

  • Lectures (30 hours). The theoretical aspects of the different topics will be provided. Besides, these sessions will be the scenario for proposing “model” problems related to the theoretical aspects shown in class.
  • Practice sessions (30 hours). In these sessions the lecturer will solve problems and case studies previously offered to the students to be worked on their own.  Likewise, students will be encouraged to take part in the solving process, proposing alternatives and/or doubts that have arisen along the autonomous solving process.  These problems or case studies will be related to the theoretical aspects exposed in the lectures.
  • Guided projects (20 hours). In groups or individually, students will do 2 or 3 activities proposed along the course that will be supervised by lecturers.
  • Autonomous work and study (50 hours). It is strongly recommended that students follow a personal study schedule from the very beginning until the end of the course.
  • Tutorials (10 hours).
  • Assessment (10 hours). A final global exam will be carried out at the end of the course where it will be evaluated the achievements of the student as much in theory as in practice. 

5.3. Syllabus

The course will address the following topics:

  1. 0. Safety and risk analysis. Introduction to safety and risk analysis. Concepts: Risk, danger and accident. Individual risk and societal risk. Individual risk maps. Risk in human activity: risk indexes. Risk acceptability. Loss prevention.  Mathematical losses expectation.

SECTION A. RISK ASSESSMENT AND HAZARD IDENTIFICATION

  1. A.1 Comparative methods for hazard identification. Historical analysis. Codes and standards. Checklists.
  2. A.2 Risk indexes. DOW's Fire & Explosion Index. DOW's chemical exposure index. PROCESO Index. Other risk indexes.
  3. A.3 Structured methods of risk analysis. Hazard and Operability analysis (HazOp). What If analysis.
  4. A.4 Quantitative methods of risk analysis. Fault tree analysis (FTA). Event tree analysis (ETA). Failure mode and event analysis (FMEA).
  5. A.5 Reliability engineering. Introduction. Failure rate. Reliability and availabilyty. Failure density function. Human reliability.

SECTION B. CONSEQUENCE ANALYSIS

  1. B.1 Loss of containment. Introduction. Classifications. Factors involved. Characterization of outcoming flow from a vessel.  Vapours and gases: flow through orifice.  Vapours and gases: flow through pipe + orifice.  Liquids: flow through orifice.  Liquids: flow through orifice + accessories.  Bernouilli’s theorem. Crow & Louvar’s equation for non-stationary liquid flow. Complex vessel geometry (horizontal cylinder and spherical). Two-phase flow. Flash fraction. Pool formation. Evaporation models according to the limiting property (heat or material convention).
  2. B.2 Explosions (Gas and Vapours). Introduction. Fire and explosion triangle. Explosion and flammability limits. Flammability diagrams. Autoignition temperature. Minimum ignition energy. Characteristic effects of explosions. Deflagration and Detonation. Differences between fire and explosion. Quantification of the effects of explosions. Pilling effect. Confined cloud explosions (CCE). Bursting of vessels (physical rupture). Emergency release devices: rupture discs and release valves. Unconfined Vapour Cloud Explosions (UVCE). Overpressure graphs. Characteristic parameters of an explosion: side pressure, dynamic pressure, positive and negative phase, arrival time. TNT equivalent model. TNO Multienergy model. TNT equivalent model applied to bursting of vessels.
  3. B.3 Dust explosions. Introduction. Dust deflagration index Kst. Quantification of effects. ATEX Norm. Zone classification. Case study analysis.
  4. B.4 Fires. Introduction. Classification. Poolfire model. Geometry of the fire: Thomas models. Emissive intensity. Atmospherical transmissivity. Geometric visión factor. Jetfire model. Flashfire model. Case studies.
  5. B.5 BLEVE Explosions. Introduction. Reid’s theory of massive nucleation. Geometry of fireballs. Quantification models. TNT equivalent model for BLEVEs. Case study analysis.
  6. B.6 Toxic clouds. Introduction. Convective movement in the atmosphere. Characteristics and atmospheric stability. Adiabatic Lapsus Rate. Wind direction, velocity and persistence: Wind rose, Pasquill-Guifford stability classes. Gaussian dispersion models. Continuous source. Instantenous source. Gaussian model limitations. Model corrections: size of the source, rugosity of the terrain, duration of the exposition. Case studies.
  7. B.7 Vulnerability Analysis.Introduction. Access to human organism. Toxicologic indexes. Population heterogeneity. PROBIT methodology. Vulnerability to persons and materials. Equations for predicting damage by overpressure. Equations for predicting damage by thermal radiation. Equations for predicting damage by toxic exposition. Refuge and evasive actions.
  8. B.8 Chemical reactivity. Reactivity identification. Theoretical methods: CHETAH index. Practical methods: adiabatic calorimetry. Runaway reactions. Semenov’s theory. On-set temperature. Maximum adiabatic temperature. Maximum self-heating rate.

SECTION C. NORMATIVE AND LEGISLATION

  1. C.1 Emergency planning. Internal emergency plan (IEP). External emergency plan (EEP). Coordination. Communication of major disasters.
  2. C.2 Normative and Spanish and EU legislation.

5.4. Course planning and calendar

Further information concerning the timetable, classroom, office hours, assessment dates and other details regarding this course, will be provided on the first day of class or please refer to the EINA website (http://eina.unizar.es).

5.5. Bibliography and recommended resources

 BB Crowl, Daniel A.. Chemical process safety : fundamentals with applications/ Daniel A. Crowl, Joseph F. Louvar . - 2nd ed. Upper Saddle River, New Jersey : Prentice Hall, cop. 2002
BB Guidelines for chemical process quantitative risk analysis / [prepared for] Center for Chemical Process Safety of the American Institute of Chemical Engineers . - 2nd ed. New York : The Center, cop. 2000
BB Mannan, S.. Lees' Loss Prevention in the Process Industries: Hazard Identification, Assessment and Control / S. Mannan Butterworth-Heinemann. 2004 
BB Santamaría Ramiro, J. M.. Análisis y reducción de riesgos en la industria química / J. M. Santamaría Ramiro, P. A. Braña Aísa . - 2ª ed. Madrid : MAPFRE, 1998
BB TNO YELLOW BOOK. Method for the Calculation of Physical Effects due to Release of Hazardous Materials (Liquids and Gases). CPR14E. Ministerie van Verkeer en Waterstaat. 2005.
BC Díaz Alonso, Fernando. Explosiones industriales : análisis de consecuencias y distancias de seguridad / Fernando Díaz Alonso Saarbrücken : Editorial Académica Española, cop. 2011
BC Nolan, D.P.. Safety and Security Review for the Process Industries. Application of HAZOP, PHA, What-If and SVA Reviews / Nolan, D.P. 3rd Edition Gulf Professional Publishing. ELSEVIER. 2012.
BC Seguridad industrial en atmósferas explosivas / editor, Javier García Torrent [Madrid] : Laboratorio Oficial José María Madariaga, D.L. 2003
BC Stapelberg, R.D.. Handbook of Reliability, Availability, Maintainability and Safety in Engineering Design / R. D. Stapelberg Springer. 2009
BC Storch de Gracia y Asensio, José María. Seguridad industrial en plantas químicas y energéticas : fundamentos, evaluación de riesgos y diseño / J. Mª Storch de Gracia y T. García Martín . - 2ª ed. Madrid : Díaz de Santos, D. L. 2008
 
LISTADO DE URLs:
 
  TNO GREEN BOOK. Method for the Calculation of Physical damage to people and objects resulting from release of hazardous materials. CPR16E. Ministerie van Verkeer en Waterstaat. 1992. TNO YELLOW BOOK. Method for the Calculation of Physical Effects due to Release of Hazardous Materials (Liquids and Gases). CPR14E. Ministerie van Verkeer en Waterstaat. 2005. - [https://www.tno.nl/en/focus-area/urbanisation/environment-sustainability/public-safety/the-coloured-books-yellow-green-purple-red/]