Safety and Hazard Management in Chemical Industry 3340505

GUJARAT TECHNOLOGICAL UNIVERSITY, AHMEDABAD, GUJARAT

COURSE CURRICULUM
COURSE TITLE: SAFETY AND HAZARD MANAGEMENT IN CHEMICAL
INDUSTRY
(Code: 3340505)

Diploma Programme in which this course is offered Semester in which offered

Chemical Engineering 4th Semester

1. RATIONALE
Chemical Industries are known as the most dangerous and hazardous industries since long.
Varieties of conditions are present in chemical industries which may lead to different type of
industrial accidents. Bhopal MIC leak accident is a world famous industrial accident which
also happened in a chemical plant of Union Carbide Company in which thousands died and
many got different diseases. Most of the industrial accidents are due to the human error or
ignorance and responsible for the major losses to the industries and humanity. Use and
handling of certain chemicals is also found to be dangerous as it may lead to health hazards. It
is therefore essential for the technician to know about hazards, accidents, safe handling of
chemicals, and operation of plant equipment and transportation of chemicals. Hence the
course has been designed to develop this competency and its associated cognitive, practical
and affective domain learning outcomes.

2. COMPETENCY
The course should be taught and curriculum should be implemented with the aim to develop
required skills so that students are able to acquire following competency:

 Handle chemicals and operate chemical plant safely

3. COURSE OUTCOME
The theory should be taught and practical should be carried out in such a manner that students
are able to acquire required learning out comes in cognitive, psychomotor and affective
domain to demonstrate following course outcomes.
i. Explain Indian and International Safety standards.
ii. Identify the causes of accident and explain various engineering control methods
iii. Explain storage, handling and transportation of hazardous materials.
iv. Classify fire extinguishing agents and methods
v. Explain risk assessment methods.
4. TEACHING AND EXAMINATION SCHEME

Examination Scheme
Teaching Scheme Total Credits
Total
(In Hours) (L+T+P) Theory Marks Practical Marks
Marks
L T P C ESE PA ESE PA
150
3 0 2 5 70 30 20 30
Legends: L - Lecture; T - Tutorial/Teacher Guided Student Activity; P - Practical; C - Credit; ESE - End
Semester Examination; PA - Progressive Assessment

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Safety and Hazard Management in Chemical Industry 3340505

5. COURSE DETAILS
Major Learning
Unit Outcomes Topics and Sub-topics
(in cognitive domain)
Unit – I 1a. Describe importance
1.1 Importance of Industrial Safety
Introduction of safety in Industry
to Industrial 1.2 Types of hazard
Safety and (a) Chemical hazard
Hazards (b) Thermal hazard
(c) Electrical hazard
1b. Classify the hazards
(d) Mechanical hazard
(e) Vibrational hazard
(f) Biological hazard
(g) Radioactive hazard
1c. Explain Indian and 1.3 Safety and health Standards
International safety 1.3.1 Indian Standards & codes for safety &
standards health
1.3.2 International standard: OHSAS 18001
Unit – II 2a. Classify chemical 2.1 Classification of Chemical Hazards and their
Chemical hazards & their control
hazards control 2.2 Chemicals as a cause of occupational
and Their 2b. Explain occupational diseases and poisoning
Control diseases and 2.3 Prevention of diseases due to chemical effect
poisoning
2c. Apply preventive
measures of diseases
2d. Describe safety 2.4 Safety aspects in plant layout, Ventilation
aspects in plant layout and
2e. Identify different lighting
colour codes for 2.5 Color codes and symbols for safety in
chemical plants chemical plants
(a) Classification of Color codes and
symbols
(b) Color codes for gas cylinders
(c) Color codes for pipelines
2f. Classify Personal 2.6 Personal Protective Devices (PPDs)
Protective Devices (a) Non respiratory
2g. List Personal (b) Respiratory
Protective Devices in
each
Unit – III 3a. Discuss 3.1 Important characteristics and chemical
Safe characteristics of reaction of
Handling of hazardous chemicals 3.2 hazardous chemicals like
Hazardous (a) Chlorine
Chemicals (b) Nitric Acid
(c) Ammonia
(d) Carbon Monoxide
(e) Caustic Soda
(f) Phosphoric Acid

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Safety and Hazard Management in Chemical Industry 3340505

Major Learning
Unit Outcomes Topics and Sub-topics
(in cognitive domain)
(g) Sulfuric Acid
(h) HCl

3b. Handle hazardous 3.2 Storage, Handling & Transportation of

chemicals for Storage, hazardous chemicals
Handling &
Transportation
Unit – IV 4a. Describe Fire 4.1.Fire hazards & their causes
Fire hazards
Hazards 4a1. List the causes
and their of Fire hazards
Prevention 4b. Explain fire triangle 4.2.Fire Triangle
4c. Describe Classes of
4.3.Classes of fire
fire
4d. Describe fire 4.4. Fire extinguishers
extinguishers 4.4.1 Classes of fire & types of extinguishers
4e. List types of 4.4.2 Construction and working of fire
extinguishers extinguishers
4f. Describe 4.4.3 Methods of their applications
Construction and
working of fire
extinguishers
4g. Describe Methods of
their applications for
fire extinguishers

Unit – V 5.1 Hazard identification methods :

5a. Explain hazard
Hazard a) Hazard Operability study (HAZOP),
Identificatio identification methods
b) Hazard Analysis (HAZAN)
n and Risk 5b. List risk assessment 5.2 Risk Assessment methods:
Assessment methods a) Failure mode and effect analysis ( FMEA)
5b1Explain risk b) Fault Tree analysis (FTA)
assessment methods c) Event Tree analysis (ETA)

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Safety and Hazard Management in Chemical Industry 3340505

6. SUGGESTED SPECIFICATION TABLE WITH HOURS & MARKS (THEORY)

Distribution of Theory Marks

Unit Unit Title Teaching R U A Total
Hours Level Level Level Marks
I Introduction to Industrial
06 4 4 2 10
Safety and Hazards
II Chemical hazards and
14 10 8 6 24
Their Control
III Safe Handling of
06 4 4 2 10
Hazardous Chemicals
IV Fire Hazards and their
06 4 4 2 10
Prevention
V Hazard Identification And
10 8 6 2 16
Risk Assessment
Total 42 30 26 14 70
Legends: R = Remember; U = Understand; A = Apply and above levels (Bloom’s revised taxonomy)
Note: This specification table shall be treated as only a general guideline for students and
teachers. The actual distribution of marks in the question paper may vary from above table.

7. SUGGESTED LIST OF EXERCISES/PRACTICAL

The practical/exercises should be properly designed and implemented with an attempt to

develop different types of skills (outcomes in psychomotor and affective domain) so that
students are able to acquire the competencies/programme outcomes. Following is the list of
practical exercises for guidance.

Note: Here only outcomes in psychomotor domain are listed as practical/exercises. However,
if these practical/exercises are completed appropriately, they would also lead to development
of certain outcomes in affective domain which would in turn lead to development of Course
Outcomes related to affective domain. Thus over all development of Programme Outcomes
(as given in a common list at the beginning of curriculum document for this programme)
would be assured.

Faculty should refer to that common list and should ensure that students also acquire
outcomes in affective domain which are required for overall achievement of Programme
Outcomes/Course Outcomes.

Apprx.
Practical/Exercise
Sr.No. Unit No. Hrs.
(Outcomes’ in Psychomotor Domain)
Required
1 I Prepare a chart of Indian safety standards 02
2 I Identify different hazards in a given chemical plant 02
3 II Identify different chemical hazards in a given chemical plant 02
4 II Identify colour codes for pipelines 02
5 II Identify colour codes for gas cylinders 02
6 II Identify different safety symbols for chemical industry 02
7 II Demonstrate Personal Protective Devices 02
Prepare a handouts of safe handling practices for hazardous
8 III 04
chemicals

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Safety and Hazard Management in Chemical Industry 3340505

Apprx.
Practical/Exercise
Sr.No. Unit No. Hrs.
(Outcomes’ in Psychomotor Domain)
Required
1 I Prepare a chart of Indian safety standards 02
2 I Identify different hazards in a given chemical plant 02
9 IV Demonstrate Fire triangle and classes of fire 02
Demonstrate construction and working of different fire
10 IV 04
extinguishers
11 V Apply HAZOP method using a case study 02
12 V Apply Risk Assessment method for a chemical plant 02
Total Hrs 28

8. SUGGESTED LIST OF STUDENT ACTIVITIES

Following is the list of proposed student activities:
i. Study of Fire extinguishers / Visit of a nearby fire station
ii. Study of personal protective equipments / visit to nearby industry
iii. Preparation of Material Safety Data Sheet of hazardous materials
iv. Visit to websites of reputed fire and safety equipment suppliers and study of
features of their equipment/instruments/tools.

9. SPECIAL INSTRUCTIONAL STRATEGY ( IF ANY)

i. Show different video/Animated films about functioning of different safety
equipment/fire prevention equipment
ii. Discuss case studies of major industrial disasters/accidents and cause for them.

10. SUGGESTED LEARNING RESOURCES

A. List of Books
Sr.
Title of Books Author Publication
No.
D.Venkateswarlu, Chemical Engineering
Manual of Chemical
1 K.R.Upadrashta, Education Development
Technology, Chemtech-I
K.D. Chandrasekaran Centre, IIT, Madras, 1975
Fundamentals of Industrial Siddharth Prakashan,
2 Dr. K. U. Mistry
Safety & Health Ahmadabad
Chemical Process Safety: Daniel A. Crowl, 3rd Edition, 2011, Prentice
3
Fundamentals with application Joshef F. Louvar Hall, USA,
N. K. Tarafdar, Dhanpatrai and Co.Ltd.,
4 Industrial Safety Management
K. J. Tarafdar New-Delhi, 1st Edition, 2012
Tata McGraw Hill, New
5 Industrial safety management L M Deshmukh
Delhi, 2006
Industrial Safety, Health & Sunil S. Rao, R.K. Khanna Publishers, New
6
Environment management Jain Delhi, 2006

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Safety and Hazard Management in Chemical Industry 3340505

B. List of Major Equipment/Materials

i. Fire Extinguishers
– CO2 type, A, B, C type, Dry chemical powder type
Foam type- 9 litre, operation-inverted, ISS-933, Class B fire
ii. Water type-CO2 gas pressure, 9 litre, operation-upright, ISS-940, Class A fire
iii. DCP type- 1,2,5 or 10 Kg, operation-upright, ISS-2171, Class B and C fire
iv. Soda acid type-9 litre, operation-inverted or upright, ISS-934, Class B and C fire
v. Respiratory & Non-respiratory personal protective devices:
vi. Safety goggles, face screens, Industrial safety helmets, hairnets and fire fighters
helmets, Earplugs, earmuffs, Gloves, Safety boots and shoes with protective
toecaps and penetration-resistant, Apron, Chemical suit
C List of Software/Learning Websites
i. https://www.osha.gov
ii. https://www.iso.org
iii. https://www.bis.org.in
iv. http://www.iffco.nic.in/applications/brihaspat.nsf
v. http://sp.ehs.cornell.edu/lab-research-safety/laboratory-safety-
manual/Pages/ch8.aspx

11. COURSE CURRICULUM DEVELOPMENT COMMITTEE

Faculty Members from Polytechnics

 Prof. Mukesh B. Dhangar, Lecturer in Chemical Engineering, Shri N. G. Patel
Polytechnic, Isroli – Afwa.
 Prof. Manish R. Nasit, Lecturer in Chemical Engineering, Shri N. G. Patel
Polytechnic, Isroli – Afwa
 Prof. Nitin N. Hansalia, Lecturer in Chemical Engineering, G. P. Rajkot

Coordinator and Faculty Members from NITTTR Bhopal

 Dr. Abhilash Thakur, Associate Professor, Department of Applied Sciences
 Dr. Bashirullah Shaikh, Assistant Professor, Department of Applied Sciences

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