Safety Module Summary and Critique

Student Name: Manukumar Balaraman Module Name: Process Safety 101 A. Module Summary The objective of this module is to introduce the basic concept related to process safety. In the first part of this module explain various process descriptions drawings which included block diagrams and piping and instrumentation diagrams etc, these were described in this section to get a basic understand the chemical processes and its various functions. The next part of the section introduced us to the elements of process safety management. In this section explain various elements of process safety management like Occupational Safety and Health Administration (OSHA) and its requirement for all employees and employers and also this section give a basic introduce to the various important features of the safety control systems. The next half part of the module included information regarding the flammability that is the characteristics of flammable mixtures and how we can handle it safe way and what are the precaution we had to take care etc. This section also give a small introduction to valves for example relief valves and their functions and its safety concern etc after that this section introduce different types of corrosion and how it effects in the industry etc. All this information was presented in a single PDF file which was linked to various other online sources. The last part of this module consisted of a fifty question quiz which tested the ability and the understanding level of the students. B. What are at least 3 of the most important concepts from this module? Why are they important? In this Module of Process safety there are several concepts were introduced among that I think the first very important concept is the understanding of the descriptive drawing of the chemical processes. This is an important concept in the process safety because with out knowing what exactly is occurring in a chemical process talking about the safety is worthless . From the process description drawing people get the big picture about the plant and the process and the equipments etc. With out understanding the plant equipment and its function it is very difficult to identify the problems and understand safety concern. After an engineer identifies for the problems and its location in the process is very important so reading and developing a descriptive drawing is very important. The second important concept in this module is the Process safety management. I think this part is the core of this module because by following the instructions and requirements, especially the ones set by OSHA (Occupational Safety and Health Administration ) , safety can be guaranteed to a certain extent. Understanding and following these requirements precisely can prevent a lot of accidents and other safety issues and hence make industry a safer place The third important concept I think is Mechanical Integrity this is because regular inspection and testing performed on the equipments is very important. Any equipment malfunction and Team: A2

deficiencies outside the acceptable limit can be easily find out and corrected with this regular checkups. After inspection, we can decided whether to replace some parts or leave them for some more time. This will increase the machine life time reduce the hazards materials and increase the safety. C. Describe at least two items of information in the module that surprise, concern, or worry you, and why they surprise, concern, or worry you. The first thing surprise me in this module is the process safety management. Previously I worked in a pharmaceutical company in India as an operator and there were safety engineers they were always goes to inspect for the plant and they were always comes to us the operation and gave us courses in safety and always plan new safety rules for employees and I thought on that time this is not necessary and they were just waste their times. But after going through this section, I just realize how it is so important for running any plant and how you should find the best way to protect you and your coworker and the plant itself. In the Second section of the module while am reading through flammability I surprised know that an explosion can occur because of a small electrostatic discharge when it goes into contact with a hybrid mixture this is totally new knowledge for me. In this section also give a wide understanding of the various hybrid mixtures and its flammability percentage limit etc, and am concern about these chemicals when am try to design an equipment dealing with these chemicals I have to take account of these safety concern. And nowadays these chemical are widely used in the industry. D. Describe at least 2 instances of especially effective instruction in the module, and why you found them effective. One effective instruction in this module is the 2003 AIChE Faculty Workshop Presentation. In the presentation there are so many diagrams and pictures shown that help get the clear idea and understanding the process control and its functions Another effective part is that sources were made easily accessible even after the certificate is gotten since most of them are not connected to the AIChE website. That also makes the sources accessible for people who didnt do the module. E. Make at least 2 suggestions to improvement the teaching effectiveness of the module and why your suggestion would improve the effectiveness. Process Safety Module is very brief and contained very less information and many links provided in the pdf file actually direct to Wikipedia. Although the source has much information, but the Wikipedia is academically less reliable source. I think for improving this module one effective way is to include more video tutorial that improve the leaning and teaching skill, nowadays for reading all pdf file time consuming and boring. Easy way to understand the concept in this morden world is by seeing something ,there are lot of scientific study prove this factor. Also I think they should provide some animation video about the process from inside the industry to make the student be aware about what equipment, the control room where it control the process plant, and any part of the industry that it seems very important to learn.

Safety Module Summary and Critique

Student Name: Manukumar Balaraman Module Name: Inherently Safer Design A. Module Summary The objective of this module is to introduce inherently safer design and how it can and is being used to eliminated and minimize the hazards.This method used in industry in order to develop, to manufacture, or even to use the chemical in safer way. This method basically concern about the issues in the design and operation for any processes in industry.This method is first used in Flixborough, England by hydrocarbon vapor cloud explosion. The definition of inherently safer design is something that inherent if it exists, which means that safety is built into the process and not added on. And hazards are eliminated and not controlled. The chemical process safety strategies can be divided into four groups: inherent, passive, active, and procedural. The inherent strategy is to eliminate the hazards by replacing the process to use material is not hazardous. Passive is to minimize the hazards by using the process that lower either the frequency or the consequence of an occurrence without the active operative of any device. Active strategy is used to include the process control system, safety system, and automatic incident justification system to extinguish a fire. Procedural strategy is including the standard operating procedures, safety rules, operator training, and management system. This module also includes various examples from everyday life and how inherently safer design effects our daily lives. Team: A2

B. What are at least 3 of the most important concepts from this module? Why are they important? There are so many important concepts were introduced in this module about the inherent safety , First and most important concept is the process safety , as a chemical engineering student, I should aware about the four strategies of process safety, which they are inherent, passive, active, and procedural. Knowing these four strategies may minimize the hazards or I can eliminate these hazards. This is also important because it makes the employee feel much safer ,and one can work without worrying about safety. The second important concept is identification the chemical reaction hazard and reactive material hazards and one can understand which are the hazards material are using the plant, then decide how likely they can react and how serious their consequences would be. By knowing all these factor we can avoid any explosions or big fires to protect people and environment. The third and last concept is how we present the information and its function to the operators. It is so important to show the right information to the operator in order to avoid any accident that might appear to the process. By showing the information to the operator clearly explain the problem and their effective solution, so he can react quickly to the problem and do the right things

C. Describe at least two items of information in the module that surprise, concern, or worry you, and why they surprise, concern, or worry you Thing that I surprises in this module is the importance of having a very detailed study about the possible hazards that can occur in a process and the plant. So this need a good communication and coordination between different departments in the plant. Otherwise, without knowing what a possible hazard in a given process and plant, an inherent safer design becomes worthless. The second things I was surprised when reading this module that inherently safer design is a subset of green engineering. I never know this ,I always think green engineering some thing related to pollution controlling or global warming. And the things that worry me is spending my future life in a dangers field. I need to be a good in my major and in the safety plan that I will work in to avoid any hazards may affect people, environment, or me. D. Describe at least 2 instances of especially effective instruction in the module, and why you found them effective. I think one effective technique in this module is sources and examples that were provided . sources contain some industry related study and some research article it also include some real-life examples that would clarify explain the idea behind an inherently safer design. The second effective technique was the four method for achieving inherently safer design are very simplified to an extent that they can be understood and grasped by the people who are not well educated because it does not contain confused technical term and principle so very one in the plant can understand and do the necessary step when it needed. E. Make at least 2 suggestions to improvement the teaching effectiveness of the module and why your suggestion would improve the effectiveness. I Think it is better to include some picture and video file instead of downloading the lengthy pdf file and if the explanation contain some animation about the causes of the some industrial accident then the student will understand the concept of inherent safety very well. And the second thing need of to improve the source is distributed among 15 different pdf file that is too lengthy and very time consuming for arrange and read all these file so I practice skim reading and go all these file but my suggestion is that need to put all these file in one place for example like a web page and put all PDF file in some hierarchy structure.

Safety Module Summary and Critique

Student Name: Manukumar Balaraman Module Name: Process Safety Lessons Taught from Experience A. Module Summary The Process safety lessons Taught from Experience module is a safety module that teaches how to learn from previous experiences. This module includes the case study of different chemical industry incidents and also the process safety related to these accidents. For that we have to study and investigate the the pros and cons accident then come with different solution for preventing the accident in the future .This module involves safety procedure and some examples of disasters that occurred in the chemical industries, such as what happened in India the union carbide explosion . These explosion kill thousand of people and lost billion dollars , an engineer is taught to study what actually happened, and then to avoid the mistakes that were done, the ones which lead such a disaster to occur. Such incidences are studied and investigated in a fair amount of detail. B. What are at least 3 of the most important concepts from this module? Why are they important? There are many concepts were introduced to in this Process Safety Lessons Taught from Experience module. Among those I think most important concept is the investigation. As an engineer to one should learn from previous mistakes, if we make the mistake we need to take extra time to figure out where went wrong so he has to know what exactly happened. This requires some investigation that would clarify the scene. In the investigation, an engineer has to identify where exactly the mistake happened. While investigating the incident, another concept comes, which is documentation. A well documented investigation give a good example for the accident prevention .A well constructed technical documentation provides a lot of information about the scene around the plant at which the disaster occurred etc. Also, it shows many plants and diagrams and information in detail. This help a lot in investigation because it is a pure source of information that just need to be filtered and connected. While documenting an incident, another important concept comes in the picture , which is the effects of a disaster. Knowing the effects of a disaster show what happened to people, and everything around the plant at which the disaster occurred. Effect disaster is important because it would not only investigate what happened in the incident, and also help in making later decisions, such as the location of a future plant etc. C. Describe at least two items of information in the module that surprise, concern, or worry you, and why they surprise, concern, or worry you While reading through this module I surprised that there are number of people are killed or injured every day through out the world because of of the plant operate with not enough safety. There are so many example are discussed in this module. Among this Bhopal India disaster is important there are more than 500,000 people are exposed by methyl isocyanides gas which lead to a death of 2000 and more injuries and property damages happened. And I am also concern about the there were lot plant around my place if any one has safety problem Team: A2

it will affect lot of innocent people nowadays plant is bigger and storage capacity much higher numbers. D. Describe at least 2 instances of especially effective instruction in the module, and why you found them effective. While reading through this module I found lot of example given all are taken from real world incident I think this is the effective instruction in this module . The examples given are real life examples, and they touch every human beings emotions. This would not only let engineers who design plants pay extra care and attention on the safety of a plant, but will also make them innovative and creative in avoiding such hazards. The second thing I notice in this module is there are lot of pictures and chart provided . Pictures and chart helps the designers to get good imagination and better understanding about the incident and come up with better designs. E. Make at least 2 suggestions to improvement the teaching effectiveness of the module and why your suggestion would improve the effectiveness I think if the module include some animation about the explosion it is good idea to understand the concept of this module.I dont know if there is a video to explain how the explosions and disasters mentioned in this module occurred, but through the animation it would be definitely better to show how big an explosion could be. Second thing I suggest to improve the teaching is put some power point slides rater than PDF file.powerpoint give audience to point to point understanding about the incident so the audience get more understanding rather than reading and listening the audio.

Safety Module Summary and Critique

Student Name: Manukumar Balaraman Module Name: Risk Assessment A. Module Summary The objective of the Risk Assessment is to provide a working knowledge of risk assessment, and reduction as applied to chemical plants. This module explain the examples of successful risk management programs and how we can apply this program and how to make this program economically feasible. In addition, this explain some other methods for identifying and analyzing risk are shown. It also explain some other kinds of analysis are also included, such as Failure Modes and Effects Analysis (FMEA), Hazard and Operability Studies (HAZOPS), what-if analysis, and even more. B. What are at least 3 of the most important concepts from this module? Why are they important? There are several important concepts were introduced to in to this module , among this three concept was important. First concept is to understand that there will not a zero risk in any plant we can minimized but it never come to zero. Installing the safeguards does not guarantee zero accidents . The zero accident come under the Risk management plan this is an important concept because it contain four other concept like operations, maintenance, inspection, testing and change control these five factor are used to reduce the risk factor .Hazards can occur any time because of many reasons, and there is always a chance that an employees and workers do the mistakes. So need up to date understanding and study about the hazards in the plant. Also understanding the properties of different materials is very important and that can help in designing systems that can prevent accidents. C. Describe at least two items of information in the module that surprise, concern, or worry you, and why they surprise, concern, or worry you While reading through this section in I surprised that adopting zero risk policy is not the solution to eliminating accidents, it explain that there is no such zero risk policy because accident can happen any times, because breaking one rule in thousands of policies can still lead an accident and lead to the deaths of many people. Another thing that I concern more about when I come to know that HAZOPS has worked hard for years; however, hazards and unexpected incidents always occur. D. Describe at least 2 instances of especially effective instruction in the module, and why you found them effective. This module is consist of both audio and PDF file available this is effective for me to get a clear understand of the concept with going through all pdf file reading is much more difficult for me so I prefer the audio sequence . The Second effective thing about this module is that it is in form of slides which are available online all the pdf file are downloadable so it very easy Team:A2

to read the file with out internet connection. So one can reopen it in any location without signing in to the website. E. Make at least 2 suggestions to improvement the teaching effectiveness of the module and why your suggestion would improve the effectiveness This module didnt have enough visuals, that is it does not contain video or picture etc. So my first suggestion is to present the information in a more visual way including some animation or some video file ,The organization of this module is not good as what we see in other modules so for better understanding and we can also put all information in to a website and PDF file provided are then organized well in that website.