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CME3034 : Design for Process Safety

  • Offered for Year: 2020/21
  • Module Leader(s): Mr John Dalton
  • Lecturer: Dr Evangelos Papaioannou, Dr Dana Ofiteru
  • Owning School: Engineering
  • Teaching Location: Newcastle City Campus
Semester 1 Credit Value: 10
ECTS Credits: 5.0


This module takes the students' theoretical knowledge of the concepts of safety (taught in Stage 2) and provides a more advanced insight into aspects related to the Chemical Engineering Industry. This will include appreciation and understanding of statutory Design Standards and best industrial practice in relation to the design, operation and control of plant.
The aims are to:
- build on the elements of safety taught in Stage 2 and Stage 1, and to introduce more advanced concepts,
- learn and put into practice design standards relating to pressure vessels,
- to understand and be able to perform calculations using appropriate standards relating to venting and relief valve sizing,
- utilise the knowledge of design standards to appreciate and understand thermal safety, quantitative design methodology for the prevention of thermal runaway including the application of reaction and adiabatic calorimetry,

- plant layout, maintenance, safe systems, management of change and safe designs.
- gain a knowledge and appreciation of instrumentation and protective systems, control systems and high integrity systems, and
- learn and appreciate the hazards associated with bio safety.

Outline Of Syllabus

The main subject headings, which outline the syllabus of this module, are:
- Design Standards: specific design standards related to the design of pressure vessels.
- Thermal safety and thermal runaway (Exothermic Reaction Hazards)
- Venting and relief valve sizing using standards, including the DIERS method.
- Plant Layout – Maintenance and safe systems at work.
- Management of change.
- Safe design for maintenance and operation.
- Instrumented Protective Systems.
- Target Safety Integrity Level (SIL) Assessment.
- Achieved SIL Assessment.
- Plant Layout.
- Occupied building assessment.
- Safe design.
- Bio safety.

Teaching Methods

Teaching Activities
Category Activity Number Length Student Hours Comment
Guided Independent StudyAssessment preparation and completion12:002:00Exam
Guided Independent StudyAssessment preparation and completion112:0012:00Exam revision
Guided Independent StudyAssessment preparation and completion115:0015:00Preparation of thermal assignment
Scheduled Learning And Teaching ActivitiesLecture241:0024:00N/A
Scheduled Learning And Teaching ActivitiesSmall group teaching121:0012:00tutorials
Scheduled Learning And Teaching ActivitiesSmall group teaching61:006:00seminars
Guided Independent StudyIndependent study129:0029:00Review lecture material. Solving questions for tutorial sessions
Teaching Rationale And Relationship

More advanced aspects of safety are introduced in lectures and linked to and developed from the theoretical safety subjects (i.e. hazard analysis topics) the student will have covered in Stage 1 and Stage 2.

Lectures are supported by tutorials for subject follow up and clarification of lecture material. Seminar sessions are included to give the students practical experience of the module and to explore aspects of topics not necessarily covered in lectures, i.e. application of theory to practical industrial examples.

Assessment Methods

The format of resits will be determined by the Board of Examiners

Description Length Semester When Set Percentage Comment
Written Examination1201A75All advanced safety topics covered in the lectures, including Bio safety
Other Assessment
Description Semester When Set Percentage Comment
Report1M25Assignment on a Process Safety related subject. Report will be approximately 5 pages, including calculations, charts and tables.
Assessment Rationale And Relationship

This module takes a more advanced look at aspects of safety within the Chemical Engineering industry. These topics involve a thorough knowledge of the topics and the ability to confidently carry out a number of related calculations. Therefore the most significant part of the assessment will be a 2 hour examination, which will account for 75% of the mark.

The assignment reinforces the subject material with an extended set of tasks that require in depth research, and self-study to achieve a successful outcome. This will be worth 25% of the total mark.

Reading Lists