Safe Operation of Pilot Plant and Laboratory Equipment and Systems

20 hours

This course focuses on safety issues critical to the safe selection and operation of pilot plant and laboratory equipment. The course is intended to address often overlooked equipment hazards and offer practical guidance and recommendations for safe operations. It is intended for new to experienced personnel.

1. Gas Cylinder Safety
   a. General principles
   b. OSHA Requirements
   c. NFPA 55 Compressed Gases and Cryogenic Fluids Code
   d. Control areas and maximum allowable quantities
   e. General requirements
   f. Ventilation
   g. Storage
   h. Required separation distances
2. Cryogenic Systems
   a. General Principles
   b. NFPA 55 requirements
   c. Overpressure
   d. Safe Handling procedures
3. Relief Systems
   a. Situations requiring over pressure protection
   b. Sizing relief devices
   c. Set pressures
   d. Types of relief devices
   e. Back Pressure considerations
   f. Performance in research applications
   g. Miscellaneous topics
   h. Vent systems
4. Interlocks and Safety Systems
   a. General considerations
   b. Separation of safety and control systems
   c. Types of interlocks
   d. Safety system requirements
   e. Layers of protection
   f. Safety system reliability
   g. Reliability levels
   h. Field devices
   i. Miscellaneous issues
5. The Safe Installation and Use of Glass Equipment in Pilot Plants, Laboratories, and Research
   a. Basic considerations
   b. Mounting
   c. Guidelines for safe use
   d. Glass and hazardous liquids
6. Hoods and Ventilated Enclosures
   a. Hood components
   b. What belongs in a hood?
   c. Hood testing
   d. Hood performance
   e. Canopies
   f. Snorkels
   g. Using hoods and ventilated enclosures safely
7. Piping Testing and Inspection
   a. Hydrostatic testing
   b. Leak testing
   c. Guidelines for safe testing
8. Flow Limiting Devices
   a. Types of flow limiting devices
   b. Advantages and disadvantages of each
   c. Applying flow limiting devices effectively
9. Gas Monitoring systems
   a. Basic types
   b. Sensor placement issues
   c. System design issues
   d. Guidelines for effective systems
10. Sight Glass Safety
    a. Types of sight glasses
    b. Mounting concerns
    c. Guidelines for safe use of sight glasses
11. Rotating Equipment: Compressors, Pumps, and Mixers
    a. Compressors
    b. Pumps
    c. Mixers
12. Heated Equipment Safety
    a. Ovens and Furnaces
    b. Heat Tracing
    c. Over Temperature Protection
    d. Heaters in Electrically Classified Areas