PLANT MAINTENANCE, INDUSTRIAL SAFETY AND POLLUTION CONTROL 6TH SEMESTER DIPLOMA CHEMICAL ENGINEERING

 

DIPLOMA IN CHEMICAL ENGINEERING

CLASS                        :  VI SEMESTER

SUBJECT                   :  plant maintenance, Industrial safety and

                                       POLLUTION CONTROL                           

SUBJECT CODE       : 9CH63         

 

SL. NO

 

SECTIONS

 

TOPICS

HOURS

ALLOTTED

 

1

 

Section-I

 

Plant MAINTENANCE

 

18

 

2

 

Section-II

 

industrial SAFETY

 

22

 

3

 

Section-III

 

POLLUTION CONTROL

 

 

18

 

4

 

 

 

Tests/Revision

 

06

 

 

 

Total

 

64

 

 

 

 

 

 

 

SYLLABUS

SUBJECT       : PLANT MAINTENANCE, INDUSTRIAL SAFETY and                       POLLUTION CONTROL        

SECTION - I

Plant MAINTENANCE:

Need for maintenance – Feature of break down – Schedules – corrective, Preventive and Productive  maintenance – Procedures effect of maintenance on out put and quality – Maintenance of schedules – Cost of maintenance – Co-ordination of maintenance department with others – Spare parts control – Equipment replacement analysis. Preparing  equipments for  maintenance – vessel entry – lubrication – types of lubricants – purposes of lubrication – properties of lubricants – Maintenance of  equipments on stream – fittings, pipes and lines, valves , Boilers, heat exchangers – High Pressure vessels, batch reactors, Air compressors, Centrifugal pumps.

Environmental concerns & innovative methods to reduce energy consumption, for recovery & reuse of valuable materials in the above.

 

SECTION – II

industrial SAFETY:

SAFETY MANAGEMENT

Safety in process industries - needs and importance - Role of safety organization – Role of management – Role of supervisors – Safety programme – Education – Enforcement – Engineering measures – Motivation for safety – Safety performance – Unsafe acts – Unsafe conditions – Safety inspection – Type of inspection – Safety survey.

PROCESS SAFETY

Hazard study – Types of industrial hazard – Chemical and Physical job analysis –Emergency planning – needs and importance – On-site Emergency plan – Off-site Emergency plan .Work permit system –Types of permit – Hot work – Vessel  entry –Excavation –Electrical work –Acid area work – Personal  safety –Head and Face protection – Eye  and  Ear protection – Hand and Arm protection – Foot and Leg protection.

ACCIDENTS

Industrial accidents – Accidents sequence – Accident proneness – Cost of accidents – Identification and Analysis of causes of injury to men and machinery – Accident prevention – Fire prevention and protection – Failure analysis – Case study – Bhopal accident.

SECTION – III

POLLUTION CONTROL Air pollution – Primary pollutant – Secondary pollutant – Ozone depletion and its effects – Acid rain and its effects – Global warming and its effects - Control measures.Effluent treatment – definition of BOD and COD- Equalization – Neutralization – Physical treatment – Sedimentation and Flotation – Chemical treatment – Coagulation – Biological treatment – Activated sludge process – Trickling filter – Stabilization pond. Pollution  problems and their treatment in sugar, fertilizer, refinery, pulp and paper ,tanneries, and in cement industries.

TEXT BOOKS:

1.                  Hand Book of "Industrial Safety and Health, Trade and Technical Press Ltd., Morden,       U.K. 1980

2.       William Handley, Industrial Safety Hand Book, McGraw-Hill Book Company

      2nd    Edition, 1969.                                 

  1. Fawatt, H.H. and Wood, W.S. Safety and Accident Prevention in Chemical Operation,       Interscience, 1965.

2.      S.P.Mahajan, "Pollution Control in Process Industries" Tata McGraw Hill, New Delhi 1985.

3.      S.C. Bhatia  Environmental pollution and control in Chemical process Industries  

4.      K .A.  Gavhane. Plant Engineering. Nirali Prakashan

5.      Handbook of Fire Technology by Barendra Mohan Sen.

6.      Book of Industrial Safety  Khanna Publishers.

7.      Industrial Hazards and plant safety  by Sanjoy Banerjee.

8.      Books and Manuals of National Safety Council, India.

9.      A Handbook of Fire Technology by R S Guptha, Orient Blackswan

REFERENCES:

1.   Heinrich,H.W. Dan Peterson, P.E. and Nester Rood Industrial Accident Prevention,

      McGraw-Hill Book Co., 1980

2.   Perry’s "Chemical Engineer's Hand Book", Seventh edition, McGraw Hill, Newyork

3,  Plant Maintenance Manual by Clement and Harrington charles and

    Tuttle  publishers 15 edogowa – cho, Bunkyo-ku, Tokyo - Japan.

SUBJECT       : plant maintenance, INDUSTRIAL SAFETY and  pollution Control

General Objectives :

            On completion of the subject the student will be able to

  1. Understand principle and schedules of Plant Maintenance.
  2. Know various procedures of Chemical Plant Maintenance.
  3. Understand the importance of Industrial Safety and Safety Precautions to be adopted,
  4. Understand the operation and use of Personnel Protective equipments.
  5. Understand causes of Pollution and its Control

SPECIFIC OBJECTIVES

Section-I

Unit-1

       1.1       Explain the need for maintenance of Chemical equipments and plants.

       1.2       List the objectives of plant maintenance

       1.3       Describe the features of break downs.

       1.4       Explain the duties, functions and responsibilities of plant maintenance department.

       1.5       Explain the following briefly:

                                I.      Corrective maintenance.

                             II.      Preventive maintenance.

                           III.      Productive maintenance.

       1.6       Explain scheduled maintenance.

       1.7       Explain plant maintenance schedule.

       1.8       Describe the effect of maintenance on output quality.

       1.9       Describe the organization of maintenance department.

     1.10      Explain spare part control and  Equipment replacement analysis.  

     1.11     Describe the methods used in co-ordination of maintenance department with others.

     1.12     Explain the various steps of in  preparing the equipment of maintenance

     1.13     Explain the maintenance procedure of vessel entry and lubrication.

     1.14     Explain the types of lubricant, purpose of lubrication and properties of lubricants.

     1.15     Explain the methods used in dismantling , cleaning and reassembling of     

 a) centrifugal pump    b)  reactors       c) heat exchanger         d) furnaces     

e) Pressure Vessels  f)  Pipe lines , fittings,  Valves, Boilers and Compressors.

Unit-2

    2.1     Explain  safety in process industries

    2.2     Explain  need and importance of safety.

    2.3     Describe the role of safety organization , management, and supervisor.

    2.4     Explain safety programme.

    2.5     Describe safety education and enforcement.

    2.6     Explain   motivation for safety practices

    2.7     Explain safety performance

    2.8     Explain unsafe act and unsafe conditions

    2.9     Explain safety inspection, types of inspection and safety survey.

    2.10   List the types of industrial hazards

    2.11   Explain job analysis

    2.12   Explain the need  and importance of emergency planning.

    2.13   Explain  on site and off site emergency plan

    2.14   Explain the work permit system and their types.

    2.15   Explain hot work, vessel entry, excavation, electrical work, acid area

              work  permit.

    2.16   Explain personal protection equipments for head, face, eye, ear,  hand arm,

              hand  arm, foot, leg protection.

    2.17   Explain industrial accidents and accident sequences .

    2.18   Explain cost of accidents.

    2.19   Identify and analyze causes of injury to men and machinery.

    2.20   Classify the fire and explain fire triangle.

    2.21    Explain detection and prevention of fire, fire alarms and fire extinguishes.

    2.22   Explain fire suppression systems used in industries like water, foam,  

              chemicals and gasses .

    2.23   Explain the first aid practices .

    2.24   Explain failure analysis and case study of Bhopal accident.

   

UNIT – III

POLLUTION CONTROL

3.1   List the sources of air pollutants.

3.2   Explain primary and secondary  air pollutants.

3.3   Explain ozone depletion and its effects.

3.4   Explain acid rains and its effects.

3.5   Explain global warming and its effects and control measures.

3.6  Define BOD and COD.

3.7  Identify water pollutants.

3.8  Explain following methods of effluent and waste water treatment.

           i) Equalization       ii) Neutralization       iii) Sedimentation and flotation         

3.9   Explain following chemical treatment  of waste water

           i) coagulation     ii) biological treatment    

          iii) activated sludge process    iv) trickling filter    v) stabilization pond

3.10   Explain the causes of pollution and their control in flowing chemical industries:        

         i) sugar                   ii) fertilizer            iii) refinery 

      iv) pulp and paper   v) tanneries           vi) cement industry

BOARD OF TECHNICAL EDUCATION

DIPLOMA IN CHEMICAL ENGINEERING

CLASS      : VI SEMESTER

SUBJECT : plant maintenance, INDUSTRIAL SAFETY and                                                   pollution Control

SUBJECT CODE       :          

QUESTION PAPER MARKS WEIGHTAGE TABLE

Note :               1. Question I is compulsory  - Objective Type Question & short note –5+5 marks

                2. Answer any Six Full Questions from the remaining sections (Choosing TWO Questions from each section )

 

SL. NO

 

SECTIONS

 

TOPICS

 

MARKS ALLOTTED

 

MARKS TO BE ANSWERED

 

1

 

Section-I

 

Plant MAINTENANCE:

 

 

5+5

 

10

 

2

 

Section-II

 

industrial SAFETY

 

45

 

30

 

3

 

Section-III

 

POLLUTION CONTROL

 

 

45

 

30

 

4

 

 

 

Total

 

145

 

100

 

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