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SAChE Products can be used and adopted to learning environments including students in many different fields (such as chemical and mechanical engineering as well as chemistry and materials science) and practicing engineers (such as in safety training programs). We attempt to put the materials in an easy to use format, and modifications can be made to the materials to fit the circumstances.



A Process Safety Management (PSM) Overview

Sponsors

Bruce K. Vaughen (Cabot Corporation)

Description

The objective of this product is to provide an overview of the basic elements of a Process Safety Management (PSM) system. An effective PSM system ensures the safety, health, and welfare of people, the community and the environment by understanding and controlling process hazards. The product defines PSM, Operational Discipline (OD) and Risk, and it describes an approach to process safety risk reduction as well as discussing basic concepts describing the PSM elements that comprise an effective system.

This product includes:

  • A two-part PowerPoint presentation
  • Lecture notes
  • Handouts

and can be used by faculty, industrial trainers, and students. Details or specific examples can be added to the PSM elements in the presentation.

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

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Conservation of Life: Application of Process Safety Management

Sponsors

J. Klein (DuPont)

Description

This SACHE product introduces “conservation of life” (COL) as a fundamental principle of chemical engineering design and practice, equivalent in importance to conservation of energy and mass. This presentation provides a good introduction to application of process safety and provides an overall structure for consideration of process safety by students.

COL principles that are discussed include:

  • Assess material/process hazards
  • Evaluate hazardous events
  • Manage process risks
  • Consider real-world operations
  • Ensure product sustainability.

Most of the presentation is spent on the first three principles, which are most important to chemical engineering design and education, but all principles are introduced. Important factors for assessment of toxicity, flammability, reactivity, and dust hazards are provided. Use of PHAs, layers of protection, inherently safer methodologies, and human factors for managing process risk are highlighted. The “Swiss Cheese Model” is also introduced to consider how layers of protection can fail, potentially leading to catastrophic incidents such as the Deepwater Horizon oil spill in 2010.

This product can be used in the university (introductory engineering, design, or kinetics courses) or for the introduction of process safety for new industrial employees. COL can be used by universities as a concept and unifying theme for increasing awareness, application, and integration of process and product safety throughout the chemical engineering curriculum and for meeting the revised ABET accreditation criteria.

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

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Fundamentals of Chemical Transportation with Case Histories

Sponsors

Ronald J. Willey (Northeastern University)

Description

Chemical engineering students typically receive little formal training in the transportation of materials beyond the flow of material within a pipe. Yet, our raw materials must arrive by some means, and our products need to be shipped. In hazard analysis, it is often vitally important that the chemical engineer consider the details of material transfer beyond the pipe. The engineer should be aware of the many regulations that cover the transfer of commercial materials. They should have some sense of the potential hazards of the various means of transportation based on past incidents. They should understand the signage on various transport vessels should an accident occur within the plant or neighborhood and they are called upon to offer expertise in clean up. This overview of transportation of chemical materials addresses these topics and includes several case histories. Review of the total package requires two to three hours. For a classroom presentation, portions can be shown within a 45 minute lecture with several memorable photos particularly in the section “why I lost my job today.”

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

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T2 Runaway Reaction and Explosion

Sponsors

Ronald J. Willey (Northeastern University)

Description

The main reason for the explosion at T2 Laboratories, Inc. was the lack of understanding of the hazards involved in dealing with a potential runaway reaction. This product emphasizes the following:

  • A runaway reaction is a reaction that can no longer be controlled in the existing equipment, and exothermic reactions can run away, especially when (potentially unknown) secondary exothermic reactions can occur at higher than expected temperatures (sometime termed temperatures of no return).
  • All major processes should have a complete hazard identification study completed beforehand and revisited regularly after the process is built.

The main source of information for this product is the T2 CSB report cited in the references. This product includes a PowerPoint presentation including lecture notes. An example problem based on this accident is available in the textbook by Scott Fogler entitled “Essentials of Chemical Reaction Engineering” (Prentice-Hall, 2011).

Student access: The slide summary with notes is available to students logged into the site.

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