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Purdue Process Safety & Assurance Center

’P2SAC’

Dr.RayA.Mentzer

SchoolofChemicalEngineeringPurdueUniversity

PROCESSSAFETYVS.

PERSONNELSAFETY??

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Bhopal,India–1984;+2,000fataliLes

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WestPharmaceuLcals–2003;6fataliLes

ImperialSugar,Georgia–2008;14fataliLes

BPTexasCity,2005;15fataliLes

DuPontInsecLcidePlant,TX–2014;4fataliLes

4TexasTechUniversity;ChemLab–2010

Tianjin,China,2015;173fataliLes

SpaceShuYleChallenger–1986;7fataliLes

CSB*IncidentInvesLgaLons‘98–`15-88invesLgaLons/171fataliLes-

#IncidentsperIndustry

ChemPlant(23)Refining(15)Manufacturing(9)Processingnon-O&G(9)Agriculture/Food(7)Storage/Blending(5)O&GProd(4)Other(14)

Other–hazardouswaste&wastewatertreatment,medical/pharmaceuLcal,laboratories,gaspipeline,railcarloading,…*USChemicalSafetyBoard

FataliLesperIndustry

ChemPlant(27) Refining(35)

Manufacturing(25) Processingnon-O&G(14)

Agriculture/Food(24) Storage/Blending(4)

O&GProd(20) Other(22)

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5 7 5 3 2 0 0 0 1 0 0 1 1

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INCIDENTFREQUENCYVS.#FATALITIES

CSBIncidentInvesLgaLons–cont’d•  37stateshadatleastoneincident

–  13incidentswereinTX–  11totalinINplusneighboringstatesofIL,KY&OH

•  FataliLesdominatedbyTXCity(15);Macondo(11);ImperialSugar(14)&West(14)–  laYertwoinAgriculture/Foodcategory

•  Chemicalplantincidentsmostcommon–  CSBinvesLgated6dustexplosionsresulLngin36fataliLes;studied281USincidentsfrom‘80–’05resulLngin119fataliLes

–  CSBinvesLgated11reacLvechemicalincidentsresulLngin29fataliLes;studied167reacLvechemicalincidents’80-’01resulLngin108fataliLes

•  9companieshad2ormoreincidentsinvesLgatedbyCSB–  2coswith4incidentsinvesLgated–  3coswith3incidentsovershortperiodsofLme

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P2SACFormedin2014•  ConductprocesssafetyrelatedresearchfocusingonfundamentalsciencebasedonexperimentaldataandtheoreLcalmodeling

•  TeachprocesssafetycoursesandinsLllProcessSafetyManagement(PSM)consideraLonsincorecapstonedesignprojects

•  SourceofexperLseforindustryandotherstakeholdersregardingprocesssafetyrelatedstandards&bestpracLces

•  Focusonoil&gasindustry,chemicals,pharmaceuLcals,andtechnologyincludingconsumerproductsandmanufacturing

•  Researchprojectssolicitedfromindustrysponsors,aswellasotherstakeholderssuchasgovernmentresearchlabsandacademia

•  EnhanceeducaLonexperienceofallPurdueChemicalEngineeringgraduates 7

MulLpleChemicalEngineeringFacultyEngagedinProcessSafetyRelatedResearch

Op5malplacementofgasdetectorsusingdispersionsimula5onsandstochas5cprogramming

Faulttolerantcontrolforsafeplantopera5on

SynthesisofsolidLewisacidsforsafercataly5coxida5onreac5onsinvolvinghydrogenperoxide

Advancedsepara5ontechniquesforefficientuseofsafesolvents

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CHEN420-ChemicalProcessSafety–coreUGcourse

Personnelvs.ProcessSafety&MetricsApplicableregulaLons:OSHAPSM,EPARMP,etcToxicants&IndustrialHygieneSourceTermModelingHazardsIdenLficaLon(HAZOP,..)RiskAssessment(Matrix,QRA,..)Fire&ExplosionProtecLonChemicalReacLvityToxic/FlammableGasReleaseDispersionModelingReliefSystemDesignAccidentInvesLgaLons

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T-2 Laboratories, FL – ’09; 4 fatalities

P2SACFallConference-Nov10;draqagenda

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7:45-8:00ProfOsmanBasaran:Welcome,statusofP2SAC,andagenda8:00-8:50PrasadGoteL(Honeywell):LOPA(LayersofProtecLonAnalysis)8:50-9:40ProfCarlLaird:OpLmalplacementofgasdetectorsinprocessfaciliLes:Bringing

opLmizaLon-basedgasdetectorplacementintopracLce9:40-9:55Refreshmentbreak9:55-10:45ProfRajGounder:SynthesisofsolidLewisacidsforsaferoxidaLonreacLons10:45-11:35GeorgeHarrioY(AirProducts):RecentadvancesinleakdetecLonongas

pipelines11:35-12:25EdwardMarszal(President,Kenexis):Gasdetectorscenariocoveragemapping

usingcomputaLonalfluiddynamicsdispersionmodeling12:25-1:15Cateredlunch1:15-2:00ProfRayMentzer:OverviewofcorePurdueChEundergraduateprocesssafetycourse2:00-2:45JonathanBach(NIOSH):PrevenLonthroughDesign2:45-3:30ProfsLindaWangandVilasPol:UpcyclingofplasLcstofuelsandtheirseparaLons3:30-3:45Refreshmentbreak3:45-4:30ProfZoltanNagy:FaulttolerantcontrolforsafeplantoperaLon4:30-6:00Heldforadd’lpresentaLonsbyselectparLcipants&discussionofpossiblefuture

centerprojects7:00-9:00ParLcipantdinner

BenefitsfromJoiningP2SAC•  Directengagementinprocesssafetyresearchprojects,theirselecLonandprogress.

•  AYendanceatbiannualmeeLngstoreviewresearchprogressandlearnfromoutsideexpertsfrompresentaLonsorshortcourses.

•  ContactwithstudentsastheydevelopprocesssafetyexperLseandenhancethescience.

•  AroleinenhancingtheprocesssafetyrelatedskillsofallPurdueChemicalEngineeringstudents.

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CurrentSponsors

AdvisoryBoardalsoincludesAirProducts&NaLonalInsLtuteforOccupaLonalSafety&Health(NIOSH)

RoomforMore…

longlistofpoten5alresearchprojects&opentosuggestedprojectsfromSponsors 12

Wrapup

•  Scopeofchemicalprocesssafetynotwidelyrecognized

•  AchallengingquanLtaLve/technicaldiscipline•  Applicabletomanyindustries:oil&gas,chemicals,pharmaceuLcals,agriculture,…

•  AbundantopportuniLesforexperimental&modelingresearchtoenhanceunderstandingandsavelives

•  PurdueposiLonedtoplaykeyroleviaP2SAC•  TypicalSponsoragreementis$25k/yearfor3years

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