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.
- 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
- Understand principle and schedules of Plant Maintenance.
- Know various procedures of Chemical Plant Maintenance.
- Understand the importance of Industrial Safety and Safety Precautions to be adopted,
- Understand the operation and use of Personnel Protective equipments.
- 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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