CE400/CE500: Process Safety Management

Fall 2021 - Lecture

Registration number: 21562/21563

Prerequisites: Approved Chemical Engineering Majors Only

Credits: 3

Instructor: Dr. David Courtemanche, Furnas Hall 203A, 645-3316, djcourte@buffalo.edu

Lectures: Monday, Wednesday, Friday at 10:20--11:10 am in Cooke 127A.

Office hours: Mondays and Wednesdays at 1:00 pm--2:00 pm, or by arrangement- Contact me via email to arrange a meeting

OPEN DOOR POLICY - djc will be happy to answer questions at ANY time; students should feel free to contact me via email or knock on door at ANY time Monday through Friday

Course description: Process Safety Management is a core responsibility of a Chemical Engineer. This course will focus on the fundamental aspects of a safety management program including Hazards Analysis and many basic calculations involved in assuring safe operation of a chemical process.

Required textbook: Crowl, Daniel A. & Louvar, Joseph F. 2011. Chemical Process Safety: Fundamentals with Applications, 3rd ed. Prentice Hall, Upper Saddle River, NJ.

Lectures - TENTATIVE SCHEDULE

Lect. Date Description Pertinent are...
Text Notes
L01 08/30
Mon
Introduction to course and textbook, Safety Culture
pp.23-30 Course Intro
L02 09/01
Wed
The Need for Process Safety Management and Safety Culture
Elements of a Process Safety Management Program
OSHA 14 point program
pp.71-73 Elements of PSM
L03 09/03
Fri
Elements of a Process Safety Management Program, continued
pp.71-73 Elements of PSM, continued
L04 09/08
Wed
Hazards of Common Chemicals
- Hazards of Common Chemicals I
L05 09/10
Fri
Hazards of Common Chemicals II
- Hazards of Common Chemicals II
L06 09/13
Mon
Toxicology
pp.37-60, 84-88 Toxicology
L07 09/15
Wed
Industrial Hygiene - Estimating Exposure
pp. 91-99
Industrial Hygiene - Estimating Exposure
L08 09/17
Fri
Fires and Explosions - Fire Triangle - Fire vs Explosion
pp. 65-110
pp. 245-262
Fires and Explosions - I
L09 09/20
Mon
Fires and Explosions - Ignition
pp. 270-304 Fires and Explosions - II
L10 09/22
Wed
Source Models for Toxic and Flammable Releases
pp. 119-233 Source Models
L11 09/24
Fri
Prevention of Fire and Explosions
pp. 317-332, 363-374
Prevention of Fires and Explosions
L12 09/27
Mon
Hazardous Material Dispersion
pp. 185-244 Hazardous Material Dispersion I
L13 09/29
Wed
Hazardous Material Dispersion
pp. 185-244 Hazardous Material Dispersion II
L14 10/01
Fri
Static Electricity
pp. 333-363 Static Electricity
L15 10/04
Mon
Combustible Dust and Deflagration Indices
Imperial Sugar Video
pp.248, 277-287, 481-488, 617, 643-644 Combustible Dust
L16 10/06
Wed
Chemical Reactivity
pp. 381-418
Chemical Reactivity
L17 10/08
Fri
Process Hazards Analysis
-
Process Hazards Analysis I
L18 10/11
Mon
Process Hazards Analysis
-
Process Hazards Analysis II
Exam 01 10/13
Wed
Exam 01 Covers Lectures 01-11
-
L19 10/15
Fri
Risk Assessment
Hazard Identification Methods
pp. 524-538
Risk Assessment I
L20 10/18
Mon
Risk Assessment
Hazard Identification Methods
pp. 524-538
Risk Assessment II
L21 10/20
Mon
Risk Assessment Class Exercise
-
Risk Assessment Class Exercise
Hazards Analysis Spreadsheet
L22 10/22
Wed
Probability and Statistics
-
Probability and Statistics I
L23 10/25
Fri
Probability and Statistics II
-
Probability and Statistics
L24 10/27
Wed
Determining Frequency of Events
pp. 549-576 Determining Frequency of Events I
L25 10/29
Fri
Determining Frequency of Events
pp. 549-576 Determining Frequency of Events II
L26 11/01
Mon
Risk Mitigation Strategies
604-617 Risk Mitigation Methods
L27 11/03
Wed
Process Safety in Design
604-617 Process Safety in Design I
L28 11/05
Fri
LOPA, Part I
pp. 576-588 LOPA
L29 11/08
Mon
LOPA Part II
- LOPA II
L30 10/10
Wed
LOPA & SIL
LOPA & SIL I
L31 11/12
Fri
LOPA & SIL
LOPA & SIL II
L32 11/15
Mon
Relief Devices - I
pp. 429-452 Relief Devices - I
L33 11/17
Wed
Relief Devices - II
pp. 459-496 Relief Devices II
Exam 02 11/19
Fri
Exam 02 Covers Lectures 12-29
-
L34 11/22
Mon
Relief Devices - III
pp. 459-496 Relief Devices III
L35 11/29
Mon
Facilities Siting
- Facilities Siting
L36 12/01
Wed
Safety Procedures/Alarm Management pp. 597-603 Safety Procedures/Alarm Management
L37 12/03
Fri
Black Swans pp. 597-603 Black Swans
L38 12/06
Mon
Take Home Exam Instructions
- Instructions
L39 12/08
Wed
Human Factors/Incident Investigations
- Human Factors/Incident Investigations
L40 12/10
Fri
Course Review Regarding BP Texas City Incident
- Course Review Regarding BP Texas City Incident

Learning outcomes: Click here for statement of learning outcomes

Composition of grade:
Homework 30%
Two midterm exams @ 20% each 40%
Final Project 30%

Assignment of grade: Final grades for all students will be determined by establishing an optimal correlation between total points earned over the course (computed according to the preceding table and scaled from 0 to 1000; essentially continuously distributed data) and grade points (4.00 for A, 3.67 for A-, 3.33 for B+, ..., 1.33 for D+, 1.00 for D; quantized results). An effort will be made to position grade lines at gaps in the distribution of course totals. Click here to see a hypothetical example of this procedure.

Professionalism: Students are expected to turn in homework that is neat, clear and well organized. Significant point penalties will be imposed for messy, disorganized, confusing or otherwise unclear work. Although allowances will be made for the effects of time pressure on exams, points will also be deducted for messy, disorganized, confusing or otherwise unclear solutions of exam problems.

UB Portfolio: If you are completing this course as part of your UB Curriculum requirements, please select an ‘artifact’ from this course that is representative of your learning and upload it to your UBPortfolio account. Templates have been created for this purpose. Artifacts include homework assignments, exams, research papers, projects, lab reports, presentations, and other course materials. Your final UB Curriculum requirement, UBC 399: UB Curriculum Capstone, will require you to submit these ‘artifacts’ as you process and reflect on your achievement and growth through the UB Curriculum. For more information, see the UB Curriculum Capstone website: https://www.buffalo.edu/ubcurriculum/capstone.html.

Academic integrity: All students must fully familiarize themselves with University policy on academic integrity. Acceptable and unacceptable conduct will be reviewed on the first day of class. Acts of academic dishonesty, such as plagiarism or other infractions, will not be tolerated. As discussed on the first day of class, the concept of plagiarism applies not only to text per se, but also to mathematical derivations and computer programs. Students will be required to take responsibility for acts of academic dishonesty by bearing penalties resulting from these acts. Suspected instants of academic dishonesty will be investigated thoroughly in accordance with Steps 1-3 of the University’s Consultative Resolution process. If an act of academic dishonesty is substantiated, then a point penalty will be imposed at the first instance, and failure in the course will be imposed at any subsequent instance. Being allowed to continue the course with a point penalty is contingent on offering a reasonable explanation of the infraction. The instructor will be happy to answer questions about what does and does not constitute allowed behavior at any time. The instructors will cooperate fully with any investigation resulting from an appeal of a finding of academic dishonesty. Click here for examples of academically honest and dishonest behavior.

Reproduction of course material is prohibited without the author’s consent. Any student that posts any course materials without permission is violating the copyright.

Course Piracy:
All materials prepared and/or assigned by the course instructors are for the students' educational benefit. Other than for permitted collaborative work, students may not photograph, record, reproduce, transmit, distribute, upload, sell, or exchange course materials without prior written permission of the instructors. "Course materials" include, but are not limited to, all instructor-prepared and assigned materials (such as lectures, lecture notes, discussion prompts, study aids, tests, and assignments), presentation materials (such as Power Point slides, Prezi slides, etc), and course packets or handouts. Public distribution of such materials may also constitute copyright infringement in violation of federal or state law. Violation of this policy may additionally subject a student to a finding of "academic dishonesty" under the Academic Integrity Policy and/or disciplinary charges under the Student Code of Conduct.

Conduct: Students are required to treat all UB faculty, staff, visitors and fellow students with professionalism and respect. All students are expected to abide by the Obstruction or Disruption in the Classroom Policy. Any instance of disruptive, disrespectful or aggressive conduct in this course will result in the instructor following the steps outlined in this policy. Instructors will consult with the Department, the School, and the Office of Student Conduct and Advocacy as needed. The instructor will cooperate fully with any investigation or disciplinary process resulting from a violation of this policy or the campus Code of Conduct. Disrespectful, unprofessional or otherwise inappropriate conduct toward the instructor or a TA can result in a suspension of office hour privileges.

Accommodations for physical and learning disabilities: Students are encouraged to request reasonable accommodations for equal access to this course because of a physical or learning disability. To do so they must register with UB's Accessibility Resources Office (60 Capen Hall, 645-2608, http://www.buffalo.edu/studentlife/who-we-are/departments/accessibility.html). The instructors will fully support students in receiving approved accommodations, e.g., by bringing exams in advance to Accessibility Resources for students entitled to take exams there with extra time, or taking other actions requested the Office.

Support for victims of sexual violence: UB is committed to providing an environment free of all forms of discrimination and sexual harassment, including sexual assault, domestic and dating violence and stalking. If you have experienced gender-based violence (intimate partner violence, attempted or completed sexual assault, harassment, coercion, stalking, etc.), UB has resources to help. This includes academic accommodations, health and counseling services, housing accommodations, helping with legal protective orders, and assistance with reporting the incident to police or other UB officials if you so choose. Please be aware that in some situations, UB employees may be required reporters. This means that if you tell me about a situation, the information may need to be reported to the Office of Equity, Diversity and Inclusion. Regardless of whether the information must be reported, you will still have options about how the situation will be handled, including whether or not you wish to pursue a formal complaint. Please know that if you do not wish to have UB proceed with an investigation, your request will be honored unless UB's failure to act does not adequately mitigate the risk of harm to you or other members of the University community. You also have the option of speaking with trained counselors who can maintain complete confidentiality. UB’s Options for Confidentially Disclosing Sexual Violence provides a full explanation of the resources available, as well as contact information. You may call UB’s Office of Equity, Diversity and Inclusion at (716) 645-2266 for more information, and you have the option of calling that office anonymously if you would prefer not to disclose your identity. The instructors will fully support victims of sexual violence, e.g., by allowing extra time to turn in assignments, or making other accommodations in consultation with the Office of Equity, Diversity and Inclusion, and Counseling Services, in the interest of providing the best possible support and outcome for the student.


Grateful thanks to Johannes M. Nitsche for use of website template