MKKH1243 – Process Safety & Loss Prevention

MKKH1243 – Process Safety & Loss Prevention


Learning Outcomes

At the end of the course, students should be able to:

  1. Discuss key factors influencing process safety, and illustrate the human, environmental and business consequences of poor process safety
  2. Model the effect of process failures and analyze their consequences on workers, surrounding community, and environment
  3. Evaluate adequateness of layer of protection and select suitable safety features required to satisfy the given process plant objectives and conditions
  4. Synthesise multiple sources of information to create new insights for solving given problems and generating alternative approaches to problem-solving.
  5. Communicate effectively with peers and interest groups concerned with the hazards and associated risks

Course Content

1. Hazards in Process Industries

1.1 Learning from Accidents (1.1-Learning-from-history (1.1-Learning-from-history)

  • Memories:  Overview of some major accidents in process industries 
  • Lesson Learned from selected cases


2. Hazards in Process Industry

2.1 Typical Hazards (1.2-Hazards)

2.2 Release Source Model (1.3_Source_Model)

2.3 Mass Dispersion (1.4-Mass-Dispersion)

2.4 Heat Dispersion ( 1.5-Heat Dispersion)

  • Fire and Explosion Model
  • Equivalent TNT Model
  • Radiation Heat Transfer

2.5 Aloha Software (PLSP-1.6-ALOHA)

2.6 Impact Model (1.7-Impact-Model)


3.0 Loss Prevention in Process Industry

3.1 Plant Operability (Download)

3.2 Layer of Protections in Process Plant Operations  (PLSP2.1-Layer of protection)

a. DIN P&ID (Download P&I D Symbols – DIN)
b. ISA P&ID (Download P&I D Symbols – ISA)
c. Sample P&ID (Download Sample P&I D)

3.3 Functional Safety and Safety Integrity Level (SIL)  (PSLP2.4-SIL)

3.4 Release Mitigation and Emergency Response (PSLP2.3-Accident-Mitigation)


4.0 Process Hazard Analysis

4.1 Hazard & Operability Studies (HAZOP)  (PSLP2.3-HAZOP)

4.2 Layer of Protection Analysis (LOPA) (PSLP2.5-LOPA)

4.3 Other Process Hazard Analysis  (PSLP2.2-OVERVIEW-PHA)


5.0 Process Safety Management

5.1 Common Legislation: FMA, CIMAH, SEVESO Directives,COMAH UK, PSM

(Download 29 CFR 1910.119)  (Download Lecture Notes)

5.2  Ageing Plant Issue 

Class Activities

1. Lectures are held at lecture room 1-11 on Tuesday 2.00 to 5.00 pm.
2. There will be a series of class workshop activities
3. There will be few take-home group projects
4. There will be 1 Mid-term and a final exam