Contents

1. Piping and Instrumentation Diagram

2. Unit Operation / Process

3. Associated Hazards/ Controls, Precaution and Prevention in Unit Operations

4. Process Safety Measures across various industries

5. Sampling Techniques for toxic and Flammable Chemicals

6. Precaution in process & operation involving explosive, flammable toxic substance, dust gases, chemicals

• Components of P&ID

•Mechanical machinery named and listed numerically

•All valves and their identifications

•Process piping, sizes and identification

•Vents, drain, special fittings, sampling lines, reducers, increasers and swagger under miscellaneous items

•Permanent start-up, flush edges and flow directions

•Interconnections reference, control inputs, and output interlock

•Seismic category and annunciation inputs

•Computer control system input

•Vendor and contractor interfaces

•Identifications for outsourced components and subsystems

•The estimated physical sequence of the equipment and its rating or capability.

•Different symbols are used for different type of valve, equipment, piping, vessel ,Heat exchanger, pump, valve.

• Unit Process

In such processes, by combination (chemical reaction) of two or more chemicals, a new product (compound) is formed. It indicates a chemical change.

• Unit Operations

In such operations, there is no chemical reaction to form a new product. It indicates no chemical change but mechanical or physical change like distillation, cutting, heating, cooling, drying, mixing grinding, washing, packing, transferring, filtering, handling, radiation etc.

• Hazards associated with Unit Operations

Mechanical hazards

Reaction hazards

Environmental hazards

Toxicity and health effects

Flammability hazards due to explosive mixture

• Control of Unit Operations

Level Control

Pressure Control

Flow Control

Temperature Control

• Hierarchy of Safety Control in Operations

• Safety Precautions / Preventions in Unit Operations

• Primary hazards identified across various Industries

1. Safety Measures in Pesticide Industries

2. Safety Measures in Petrochemical Industry

3. Safety Measures in Pharmaceutical Industry

4. Safety Measures in Fertilizer Industry

   
   

   • Sampling techniques for toxic & flammable chemicals

Sampling can be done in three ways:-

a) Personal Air Sampling

b) Workplace Air Sampling

c) Ambient Air Sampling

There are two methods of sampling air borne particles :-

1) Filtrations Sampling

2) Use of Direct Reading Equipment

• Personal Dust Sampler

Types of filters & applications

Sampling Train

Sampling Procedure

• High Volume Sampler

Mechanism

Procedure

Calculations

• Precaution in process & operation involving explosive, flammable toxic substance, dust, gases, chemicals