Safety Training Our expertise in the field of Hazard Analysis enable Safety Consulting Engineers, Inc. to provide different workshops to scientists, process engineers and production personnel that focus on the identification of areas where explosions can occur, on the ways to evaluate their potential and seriousness, and finally on the prevention and protection methods to implement. Safety Consulting Engineers, Inc. (SCE) can offer extended training programs in the following areas: 2009 Training Course Brochure OSHA Dust Explosion Inspection Preparatory Training Course Flyer Understanding & Controlling Electrostatic Hazards Dust Explosion Prevention & Protection Techniques Gas/Vapor Explosion Hazards Thermal Instability of Solids Training for Operators Hazards & Operability Studies (HAZOP) Chemical Reaction Hazards OSHA Dust Explosion Inspection Preparatory Training OSHA "Hazardous Chemical Communication Standard" with Emphasis on Combustible Powders and Dusts Please click on each one for course details and contact us for further information. Understanding and Controlling Static Electricity Course Design and Objectives This course will explain how and where electrostatic charge is generated, how to diagnose static problems and how to find solutions. Practical static control techniques are presented by considering case histories of explosion incidents investigated by Chilworth consultants and by hands-on demonstrations utilizing laboratory equipment. Upon its completion, attendees will have gained an understanding of how electrostatic charge is generated in industrial environments. They will be able to recognize those electrostatic hazards which can trigger industrial fires and explosions, and will have an awareness of how to control electrostatic charge in order to reduce or eliminate such risks. Introduction to Electrostatics Background information and definitions. Electrostatic Discharges Four types of "Discharges" - Evaluation of each in terms of their incendivity in gas, vapor, aerosol and dust cloud flammable atmospheres. Electrostatic Hazards Evaluation A systematic approach to the diagnosis of electrostatic problems and hazards People and Plant Powder Handling Liquid-Vapor Handling Use of Plastics IChE Video on Electrostatic Hazards Discussion Dust Explosion Prevention and Protection Techniques Course Design and Objectives This course presents the techniques available for preventing dust explosions and protecting people and plant from their effects. It demonstrates a systematic approach to dust explosion hazards assessment directed towards obtaining a basis of safety for a process. Course attendees will have gained an understanding of the serious consequences of dust explosions, the conditions under which they can occur, and the latest techniques recommended for their prevention. They will also learn the role of dust testing and how to interpret test data. Introduction Basis Theory and Definitions Flammability Assessment Ignition Sensitivity Explosion Severity Burning Properties Conditions Affecting Flammability Temperature Oxidant Dust Explosion Hazard Control Avoiding Ignition Sources Avoiding Flammable Concentrations Avoiding Oxidants Explosion Protection Techniques Relief Venting Suppression Containment Isolation Video/Discussions Gas/Vapor Explosion Hazards Course Design and Objectives This course has been designed to assist the engineers and process safety personnel who are involved with processes and operations where flammable gases and vapors are present. Practical prevention techniques are presented along with case studies and the theoretical knowledge necessary to gain a complete understanding of the subject. Upon completion of this course, participants will be well versed in the flammability attributes of gas, vapor and mist atmospheres. Gaining new insight into their existing and future processes, they will be qualified to define a basis of safety for their operations. Introduction to Flammable Atmospheres Basic theory and definitions Flammability of Vapors, Gases and Mists Flash Points, Flammable Ranges, Explosion Severity, Auto Ignition Temperatures Conditions Affecting Flammability Temperature, Pressure, Oxidant, Mixtures Establishing a Basis of Safety Avoiding Ignition Sources    - Static Electricity, Friction, Impact, Electrical Equipment Avoiding Flammable Concentrations    - Ventilation, Temperature Control Avoiding Oxidant    - Inert Gas Blanketing Discussion Thermal Instability Hazards Course Design and Objectives Many everyday operations in the processing industry involve the heating of a wet or moist compound in order to have the compound finish the process as a dry particle. Most natural and synthetic powders are combustible, and the risk of combustion increases when flammable solvents are present. Potential ignition sources include electrostatic and frictional sparks, faulty electrical equipment and frictional heating, as well as exothermic decomposition (self-heating). Attendees of this course will gain the tools needed to implement a basis of safety during their process operations, gaining a broad understanding of thermal instability. Understanding Thermal Stability Background Information Theory of Thermal Instability Statistical Analysis Laboratory Tests and Their Uses Types of Tests Test Interpretation Basis of Safety During Drying Operations Ensuring safety during the use of vacuum drying, tray ovens, fluid bed dryers, pneumatic conveying (flash) dryers, spray dryers, etc. Workshop Video Presentation Discussion Training for Operators Designed for operators and technicians, this course presents basic definitions and theories in the subjects of process safety fundamentals and the possible hazards associated with working with dust and electrostatics. Among the topics covered are: Introduction to Fire and Explosion Hazards Identifying and Eliminating Potential Ignition Sources Condition Affecting Explosions and Fires Steps that should be taken to reduce risk of fires and explosions Upon completion, attendees will be able to recognize the potential risks they might run into during their day to day duties, along with the appropriate actions that need to be taken. Hazard and Operability Studies (HAZOP) HAZOP (Hazard and Operability Study) is a structured method for identifying hazards and problems associated with the operation of a process plant. The results of a HAZOP study can not only allow engineers to improve the safety of an operation, but also serve to highlight operability problems at an early stage in project development. Equally, the technique is used for the analysis of process modifications and existing processes which have been operating for many years. The procedures can apply equally to batch or continuous operations and are valid for both simple and complex plants. In recent years, process engineers have increasingly chosen to use Programmable Logic Controllers (PLCs), Distributed Control Systems (DCSs) and computers for process control. While these systems provide flexibility and close control of the process, they introduce an additional mode of failure to the plant. Modern HAZOP techniques including Computer HAZOP (CHAZOP) are used to consider such systems. Special Features Interactive workshops using the HAZOP technique Demonstration of computer assisted HAZOP software Objectives At the end of this course, the attendees will have an understanding of the application of HAZOP and other identification techniques in process safety studies. Practical experience of participating in HAZOP exercises of both batch and continuous operations will have been gained. The impact of human factors and automated control systems will also be understood. For personnel not participating directly in HAZOP identification studies, the course has been oriented towards an understanding of when hazard identification tools should be applied and the auditing of such studies undertaken by third parties. Introduction Background - why carry out a HAZOP? HAZOP in the Context of Safety Management Overview of process safety Management The place of hazard identification in a typical project schedule Techniques for a hazard identification (What if, Checklists, FMEA, HAZOP) Hazard Analysis and Risk Assessment HAZOP Methodology Choosing the HAZOP team/Role of team leader Preparing for the study (documents, fixing the scope, etc.) HAZOP guide words Recording the meeting Actions and follow-up Carrying out the study -- an example HAZOP Workshop I HAZOP study of a simple process operation Feedback from the workshop HAZOP Team Leadership Role of the leader Approaches in managing a team Batch Operations The elements of time and sequence order Constructing an event "model" Human factors HAZOP Workshop II Preparation and HAZOP study of a batch process operation Feedback from workshop HAZOP and Programmable Electronic Systems (CHAZOP) PES control system architecture Analysis approach Integration with the process HAZOP Establishing HAZOP Procedures Defining the scope and depth of the study The costs involved in a HAZOP review When to conduct a HAZOP Controlling the follow-up actions Documentation Auditing the HAZOP Understanding, Evaluating and Controlling the Hazards of Exothermic Reactions Introduction Course Overview Fundamental concepts The event profile of a runaway Data requirements for safety assessment Desired and undesired chemistry The Chemical Hazard Potential Desk-top Thermal Hazards Screening Figures of Merit of Thermally Unstable Materials Auto-catalysis and the chemistry of energetic materials Characterization of the Thermal Runaway Reaction The importance of thermokinetics data Rates of heat and pressure generation The heat balance The Phi factor Safe process scale-up Parameters used to characterize thermal runaway in batch reactors Case studies and incident investigations Principles of Reactive Hazards Testing Characteristic Thermal Safety Data Principle of similarity Immediate requirements on testing Normal process characterizations Adiabatic techniques for runaway simulation Comparison of Calorimeters: Do the right job. Safety Measure Selection Criteria for the assessment of thermal risk Defining critical limits Prevention and protection techniques Deciding upon a basis of safety Applications taken from the literature Use of TMR theory to plan an intervention strategy Thermal risk of a process modification Synthesis of diazonium salt Designing a safer nitration reaction Estimating the safe storage temperature using laboratory-scale tests Systematic risk analysis of a Grignard reaction Introduction to Emergency Relief Systems Venting as a basis of safety The problem of two-phase flow from venting runaways OSHA Dust Explosion Inspection Preparatory Training Course Design and Objectives This course has been specifically developed to prepare plant personnel for an OSHA dust explosion hazard inspection at their facility. The course addresses four primary areas of focus including combustible dust accumulations within the facility, specific plant operations that may be targeted by OSHA, classification of electrical equipment, and the Hazardous Chemical Communication Standard requirements. Course Contents Introduction Background Information Concerning the Recent Emphasis for Targeted Dust Explosion Hazard Inspections Incident History of Dust Fires and Explosions in the Process Industry OSHA Local Emphasis and Pending National Emphasis Programs The Chemical Safety Board Report Codes and Standards OSHA Regulations and the General Duty Clause Consensus Standards – NFPA, State, and Local Building Codes Elements of a Targeted Inspection Explosion Hazards Housekeeping Process Equipment Energy Control 29CFR 1910.147 - Lock Out /Tag Out 29CFR 1910.307 - Electrical Classification 29CFR 1910.1200 - The Hazardous Communication Standard What are your Responsibilities as an Employer/Employee? The Hazardous Communication Plan Information and Training Requirements for Employers Citations for Specific Hazards Written Under the General Duty Clause What Can You do To Prepare Housekeeping Do’s and Don’ts Electrical Classification Schemes Specific Citations that May be Issued for Your Processes The Hazardous Chemical Standard Q&A and Group Discussion Course Duration This course can be provided in a 4 hour (condensed) or 8 hour (more detailed) mode Who Should Attend Technical and Management Personnel from the Chemical and processing industries including bulk and finished pharmaceutical, bulk and fine chemicals, detergents & soaps, petrochemicals, food and drink, plastics and rubbers, metals, textile, paper and lumber, agrochemicals and dyes and paints Benefits This training will prepare the attendee for a targeted OSHA dust explosion hazard inspection at their facility. Course participants will develop a thorough understanding of the areas that OSHA will focus on in carrying out this type of inspection. Completion of the course will enable the attendees to prepare for the inspection and address any issues that may arise or to mitigate hazards that may currently exist prior to the arrival of the inspector. OSHA "Hazardous Chemical Communication Standard" with Emphasis on Combustible Powders and Dusts Course Design and Objectives: This course has been developed to train employees working in areas where hazardous chemicals are being produced or used. It is specifically designed to address the OSHA Hazardous Communication Standard (HCS) training requirements in 29CFR 1910.1200(g). Upon completion of the course attendees will be cognizant of the physical hazards presented by hazardous chemicals (combustible powders/dusts) in their work areas and the measures that can be used to prevent or mitigate these hazards. Course Contents Introduction Background Information Regarding the OSHA HCS and How it Applies to Employees Important Definitions in the HCS The OSHA Written Hazardous Communication Program Program Requirements Employee Information and Training Requirements Information Required to be Provided by the Employer Training Component Details of the Specific Hazardous Materials Communication Program in Place at Your Facility Physical Hazards of the Chemicals (Powders/Dusts) (customized for the Specific Operation) Methods and Observations Used to Detect the Presence or Release of Hazardous Chemicals (Combustible Powders/Dusts) Preventive or Mitigating Measures Q&A and Group Discussion Course length Duration of this course is one hour Who Should Attend All employees who may be exposed to hazardous chemicals under normal operating conditions or in foreseeable emergencies Benefits This training will serve as a vehicle for employers to meet the requirements of the HCS with respect to training of employees. In addition, employees will be provided with the needed information and training as required by the standard. This training can be customized to meet the customers’ specific training needs.
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