Robert Johnson (Unwin Co.)

This web-based instructional module contains about 100 web pages with extensive links, graphics, videos, and supplemental slides. It can be used either for classroom presentation or as a self-paced tutorial. The module is designed to supplement a junior or senior chemical engineering course by showing how uncontrolled chemical reactions in industry can lead to serious harm, and by introducing key concepts for avoiding unintended reactions and controlling intended reactions. The five main sections in the module cover (1) three major incidents that show the potential consequences of uncontrolled reactions; (2) how chemical reactions get out of control, including consideration of reaction path, heat generation and removal, and people/property/environmental response; (3) data and lab testing resources used to identify reactivity hazards, (4) four approaches to making a facility inherently safer with respect to chemical reactivity hazards; and (5) strategies for designing facilities both to prevent and to mitigate uncontrolled chemical reactions. The module concludes with a ten-question informative quiz. An extensive Glossary and Bibliography are directly accessible from any page.

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Ron Darby (Texas A&M University)

This Design Module covers the principles and procedures for sizing emergency relief systems for both single-phase (gas or liquid) and two-phase flow, including relief devices as well as inlet and discharge piping. The Homogeneous Direct Integration method for two-phase flow described herein is simpler, more general, and more rigorous than methods previously presented. The material is in a form which could be incorporated into courses on applied fluid mechanics, process safety, or process design, or it could be presented separately as a "stand alone" topic. It is assumed that the student has a familiarity and working knowledge of the macroscopic conservation laws for mass, energy, and momentum, and Newtonian fluid flow through pipes and fittings, including incompressible as well as compressible flow up to and including choked flow. Several worked examples are included which serve to illustrate applications of the procedures and equations, or which can be used for student exercises. A Power Point presentation is included, as are the spreadsheet calculations for the example problem solutions.

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Art Schwartz (Bayer Corp., retired)

Biohazards are agents that are biological in nature and have the capability to cause harm to biological organisms. This module is intended to provide a brief overview of the area of BioSafety. A Powerpoint presentation provides an introduction to types of Biohazards and discusses sources of biohazards, classifications of biohazards by risk group, and methods of reducing risk from biohazards. Also discussed are Waste Handling and Universal Precautions. The module is oriented towards dealing with biohazards in a laboratory or clinical setting. Included with the module are several examples of Biosafety Manuals that are typically used in corporate (BiosafetyManual.zip) or public health organizations such as the US Department of Health and Human Services (DHHS) and the World Health Organization (WHO).

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Ron Darby (Texas A&M University)

This module is an updated and revised version of the module entitled “A Unit Operations Laboratory Experiment for Runaway Reactions”, published by SACHE in 2001. The title has been changed to reflect the more general utility of the module for education, training and instruction of personnel in industrial, governmental or other laboratories who are concerned with the characterization and sizing of relief vents for runaway reactions, in addition to universities who would like to include this subject matter in lecture and/or laboratory courses concerned with process safety.

The Advanced Reactive Screening Tool (ARSST) is an easy to use and cost effective calorimeter that can be used to quickly and safely identify potential chemical reactivity hazards. It can also yield critical experimental data on the kinetic characteristics of runaway reactions that can be scaled up to full scale process conditions and can be used directly to estimate the size of a relief device that would be required to protect the reactor against the over-pressure that would result from a runaway reaction.

This instruction module describes the ARSST and its operation, and illustrates how this instrument can easily be used to experimentally determine the transient characteristics of runaway reactions, and how the resulting data can be analyzed and utilized to size the relief vent for such systems. It can also be easily incorporated into a Chemical Engineering Unit Operations Laboratory as an effective educational laboratory experiment utilizing a practical and physically realistic example reactive system.

Student access: All files are available to students logged into the site.

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Ed Kitchen (Digital Solutions Technology, Inc.)

The Mach II system is unique to any other relief system design software because it is custom designed specifically for speed, user-friendliness, flexibility, compatibility, API/ASME single-phase sizing, and DIERS two-phase methodology. In short the Mach II is easy to learn simple to use yet it is very comprehensive. The Mach II program will calculate the required capacity of each relief scenario not already input by the user, and will then calculate the required and standard orifice size and standard relief capacity. The program will then select the worst-case scenario, largest required orifice, as the basis for the design of the relief system to include the associated piping. The program also has a built-in piping program where the user can choose the number and type of fitting for both inlet and outlet piping. Mach II then calculates the piping resistance and pressure drop for this piping arrangement. Mach II is intuitive to use and the results are produced instantaneously by just clicking on the Generate Report tab after all input data has been entered. Mach II was designed based on the requirements as set forth in OSHA 29 CFR 1910.119a whereby relief system design and design-based calculations must be compiled and maintained for all processes involving highly hazardous chemicals.

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J. R. Welker and C. Springer (University of Arkansas)

"Safety, Health, and Loss Prevention in Chemical Processes - Problems for Undergraduate Engineering Curricula" Volume 1 was originally published by CCPS in 1990. Copies were given to universities and sold to industry. This was a very popular and valued product that is currently out of print. J. Wagner (Oklahoma State University) recently put this product in electronic format for distribution here. The problems are available via the Links menu on this site and to students logged into the site.

The 90 problems involve issues of safety, health, and loss prevention and provide students and new engineers with important insights to industrial processes. This material can also be used as a reference for industrial courses for new engineering employees. These safety problems and solutions further demonstrate that safety and health issues are handled with basic engineering principles and logic. Finally, through the use of this material, we hope to instill in students and engineers an increased recognition of the importance of chemical process safety and the recognition that they have the professional and ethical responsibility to provide safe chemical plants, processes and products.

The problems were designed to use in existing engineering courses, such as: stoichiometry, material balance, mass transfer, heat transfer, thermodynamics, process control, and design courses. The authors believe that it is important that students work on these problems while attending there undergraduate courses and throughout their education. This process should develop a safety culture within engineers that will help them throughout their careers.

Student access: Problem statements are available to students logged into the site.

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R. Willey (Northeastern University)
D. Crowl (Michigan Tech University)
R. Welker (University of Arkansas)
R. Darby (Texas A&M University)

"Safety, Health, and Loss Prevention in Chemical Processes - Volume 2" was originally published by CCPS in 2002 and distributed to SACHE University Members. This was a very popular and valued product that is now out of print. R. Willey recently put this volume in electronic form for distribution here. The problems are available on the Links menu on this site and to students logged into the site.

Like the Volume 1 problems, the 218 problems teach safety, health, and loss prevention. This solution set represents problems and solutions produced by SACHE in the period 1990 to 2000.

The problems were designed for use in existing engineering courses, such as: Stoichiometry, Thermodynamics, Fluid Mechanics, Kinetics, Heat Transfer, Process Dynamics and Control, Computer Solutions, and Mass Transfer. The authors believe that including these problems in a required undergraduate course helps engineering students develop a safety culture and mind set that will benefit them throughout their careers.

Student access: Problem statements are available to students logged into the site.

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Georges A. Melhem (ioMosaic, Inc.)

SuperChems is an advanced tool for pressure relief design, consequence analysis, and thermal hazards assessment. Developed by ioMosaic, SuperChems helps companies meet process safety design objectives and management needs. Its rigorous modeling capabilities enable companies to make technically sound decisions about key process design issues. SuperChems contains an extensive databank of more than 1200 components with equation-of-state based computer code and incorporates many features that add tremendous value to the quality of a detailed hazards analysis. It has been extensively validated against experimental data to ensure its accuracy.

ioXpress is a web-based enterprise knowledge management solution and is designed to help companies effectively manage their data and documents, enable knowledge sharing, and enhance communication. It serves as a knowledge manager for creating, editing, storing, and retrieving reusable documents within your organization. All documents are categorized, centralized, and managed through a secure database platform. As a web-based application, ioXpress Knowledge Manager allows users to share documents from any location. It can produce significant returns in the form of cost savings and productivity gains for small and large organizations.

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