Semester-wise Syllabus for a Diploma in Chemical Plant Safety 

Semester 1: Fundamentals of Chemical Safety

1. Introduction to Chemical Process Safety

   • History of chemical disasters (Bhopal, Texas City)

   • Layers of Protection Analysis (LOPA)

   • Roles of safety professionals in chemical plants

2. Basic Chemistry for Safety

   • Flammability, reactivity, toxicity concepts

   • Material Safety Data Sheets (MSDS/GHS)

3. Chemical Plant Hazards Identification

   • HAZID techniques

   • Inherently Safer Design principles

4. Occupational Health in Chemical Plants

   • Chemical exposure limits (TLV, PEL)

   • Respiratory protection programs

5. Fire Safety Fundamentals

   • Fire triangle, flammability diagrams

   • Classification of hazardous areas (Zone system)

6. Practical Lab

   • PPE donning/doffing

   • Chemical spill simulation

Semester 2: Process Safety Management

1. OSHA Process Safety Management (PSM)

   • 14 elements of PSM

   • Management of Change (MOC) procedures

2. Hazard and Operability Studies (HAZOP)

   • Guideword methodology

   • Node selection and documentation

3. Pressure Systems Safety

   • ASME Boiler and Pressure Vessel Code

   • Relief valve sizing and maintenance

4. Toxic Gas Monitoring

   • Fixed and portable gas detectors

   • Calibration procedures

5. Emergency Response Planning

   • ERPG levels

   • Shelter-in-place vs. evacuation

6. Practical Lab

   • HAZOP workshop

   • Gas detector calibration

Semester 3: Advanced Chemical Safety

1. Reactive Chemical Hazards

   • DSC/ARC testing interpretation

   • CHETAH program basics

2. Static Electricity Hazards

   • Bonding and grounding requirements

   • Minimum Ignition Energy (MIE) concepts

3. Human Factors in Chemical Safety

   • Alarm management

   • Control room ergonomics

4. Quantitative Risk Assessment

   • Fault Tree Analysis

   • Consequence modeling (DEGADIS, ALOHA)

5. Process Safety Metrics

   • Leading vs. lagging indicators

   • Tiered performance measurement

6. Practical Lab

   • Dust explosion testing

   • Relief system sizing exercises

Semester 4: Specializations & Professional Practice

1. Batch Process Safety

   • Reaction calorimetry

   • Thermal runaway prevention

2. Safety Instrumented Systems (SIS)

   • IEC 61511 standard

   • Safety Integrity Level (SIL) determination

3. Chemical Security

   • CFATS regulations

   • Security Vulnerability Analysis (SVA)

4. Regulatory Compliance

   • EPA RMP requirements

   • PSM audit techniques

5. Capstone Project

   • Complete PSM implementation plan for a mock facility

6. Internship

   • 8-12 weeks in a chemical plant safety department