SEMESTER – VIII
PM6802 Safety and Risk Management
Elective -II
PRACTICALS
PM6811 Project Work
PM6801
PROCESS ENGINEERING ECONOMICS
OBJECTIVE: The objective of this course is to teach principles of cost estimation, feasibility analysis, management, organization and quality control that will enable the students to perform as efficient managers.
UNIT I
ENGINEERING FLOW DIAGRAMS AND SAFETY ASPECTS
Process Design Diagrams / Documents: Introduction to block, process flow, Logic, Information flow diagrams. Preparation of PID, trip and interlock systems, MOC and valve selection, color code of pipeline, Equipment datasheets, Layout engineering (Plot Plan) Safety In Process and Plant Design: Intrinsic / extrinsic safety, Safety of personnel, equipment and plant classification of plant areas, Fire protection systems, Flare systems, Safety relief valves, Flame arrestors, rupture disc and explosion venting etc., Health , Safety and Environmental hazards, Loss Prevention: Hazard Assessment Techniques: HAZOP, HAZAN, Fault Tree Analysis, etc
UNIT II
PROJECT ENGINEERING
Project Management and Statutory Regulations: Site Layout, Plant Layout, Battery Limits and Off Site Facilities, Stages of project, Use of Milestone chart / GANT chart/BAR chart, PERT and CPM techniques for project monitoring and control, Preparation of project reports (Feasibility Reports), Annual report of a company.
UNIT III
OVERVIEW OF PROCESS ECONOMICS
Economic decision making in the CPI, Process plant components, elements of costing and principles of accounting, Total cost components, Types and methods of cost estimation, Cost estimation for equipment and plant, Direct / indirect manufacturing costs.
UNIT IV
MANUFACTURING COST ESTIMATION
Various cost indices, William’s sixth tenth rule, methods of estimation of fixed capital, product cost estimation, Financing, Interest and investment cost, present worth and discount annuities, Source of capital, Depreciation, Taxes and Insurances, Balance Sheets, Perpetuity, Inflation.
UNIT V
PROFITABILITY: ALTERNATIVE INVESTMENTS AND REPLACEMENTS Alternative investments and replacements, profitability standards, discounted cash flow, rate of return, capitalized cost, payment period, alternative investments, analysis with small investments, increments and replacements, Break Even Analysis.
OUTCOME: Students gain the knowledge on cost and asset accounting, time value of money, profitability, alternative investments, minimum attractive rate of return, sensitivity and risk analysis.
TEXT BOOKS: 1. M.S. Peters and K. D. Timmerhaus, “Plant Design and Economics for Chemical Engineers”, Fourth Edition, McGraw Hill International Book Co., 1991
2. James R. Cooper, “Process Engineering Economics”, Marcel Delkker Inc, New York, 2003
3. Coulson, J.M., Richardson J.E. and Sinnott R.K., “Chemical Engineering”, Vol. VI, Pergamon Press, 1991.
4. R. Turton, R. C. Bailie, W. B. Whiting, and J. A. Shaeiwitz, “ Analysis, Synthesis, and Design of Chemical Processes”, Prentice Hall, Upper Saddle River, New Jersey, 1998.
5. L. S. Srinath, “PERT and CPM, Principles and Applications”, Third Edition, East-West Press,
PM6802 SAFETY AND RISK MANAGEMENT
OBJECTIVE: Students learn about implementation of safety procedures, risk analysis and assessment, hazard identification
UNIT I INDUSTRIAL SAFETY
Concepts of safety – Hazard classification chemical, physical, mechanical, ergonomics, biological and noise hazards – Hazards from utilities like air, water, steam.
UNIT II HAZARD IDENTIFICATION AND CONTROL
HAZOP, job safety analysis – Fault tree analysis – Event tree analysis – Failure modes and effect analysis and relative ranking techniques – Safety audit – Plant inspection – Past accident analysis.
UNIT III RISK MANAGEMENT
Overall risk analysis – Chapains model, E and FI model– Methods for determining consequences effects: Effect of fire, Effect of explosion and toxic effect – Disaster management plan – Emergency planning – Onsite and offsite emergency planning – Risk management – Gas processing complex, refinery – First aids.
UNIT IV SAFETY PROCEDURES
Safety in plant design and layout – Safety provisions in the factory act 1948 – Indian explosive act 1884 – ESI act 1948 – Advantages of adopting safety laws. UNIT V SAFETY IN HANDLING AND STORAGE OF CHEMICALS Safety measures in handling and storage of chemicals – Fire chemistry and its control – Personnel protection – Safety color codes of chemicals.
OUTCOME: Students get acquainted with risk assessment, process safety auditing and management systems in the petrochemical Industry
TEXT BOOKS: 1. Blake, R.P., “Industrial Safety”, Prentice Hall, 1953. 2. Lees, F.P., “Loss Prevention in Process Industries”, 2nd Edition, Butterworth Heinemann, 1996. REFERENCES: 1. Geoff Wells, “Hazard Identification and Risk Assessment”, I.ChE. 2. John Ridley and John Channing, “Safety at Work”, 6th Edition. Butterworth-Heinemann, 2003. 3. Raghavan, K.V. and Khan, A.A., “Methodologies in Hazard Identification and Risk Assessment”, Manual by CLRI, 1990.
