DEKRA Process Safety

Preventing Reaction Runaway - Integrating Safety Assessment into the Process Life Cycle and Scaling-Up Chemical Processes Safely

process safety training


Dates 08/10/19 to 09/10/19
Location Southampton
Included Lunch, Refreshments & Course Notes
Venue Phi House, Southampton Science Park, Southampton


The loss of control of exothermic or gas generating chemical reactions, on plant scale, can have devastating primary and secondary consequences. Strategic assessment practices should be embedded to ensure that chemical reaction hazards are identified early in process development by chemists with a good understanding of risk identification such that the development process seeks to systematically and reliably eliminate or reduce the risk potential. This course is designed to equip staff with the necessary tools to be able to identify chemical reaction hazards, interpret test data correctly and develop a robust basis of safety. A special focus is provided on the design of emergency relief systems as a primary safeguard in asset protection and life preservation. It is a multidisciplinary course straddling chemistry and chemical engineering to seek to close the gap between the disciplines which often results in processes being scaled up that could have been inherently safer.


  • Equip chemists with tools to identify and quantify process safety risks – and hence make decisions which promote inherently safer processes.
  • Provide chemists and engineers with a systematic assessment process and knowledge to identify appropriate testing strategies.
  • Enable chemists and engineers to understand calorimetric and thermal stability data interpretation and application.
  • Gain awareness of safety measures available for safe scale-up, including relief system design concepts


Day 1:

Delegates will learn to identify significant sources of hazard in processes, understanding the latest techniques for assessing risk and measuring and quantifying chemical process hazards in a systematic manner. An understanding of established best practice in reducing the hazards of exothermic reaction systems with a focus on the development of inherently safer processes. The day covers identifying and handling potentially explosive compounds, thermal stability screening, reaction calorimetry and adiabatic calorimetry. The day concludes with an overview of prevention and protection techniques available. Extensive use of workshops is made to embed learning in practical sessions.

Day 2:

The provision of emergency relief systems for runaway chemical reactions and decompositions requires a detailed design approach that takes into account the dynamics of the uncontrolled reaction and the potential for multi-phase flow in the vent system. The DIERS (Design Institute for Emergency Relief Systems) methodology provides a practical framework for such studies, which is different to vent sizing for purely physical contingencies. This short course will examine the characterisation of runaway behaviour and the vent design approach. Data requirements, sizing equations and practical aspects will be discussed. Case studies and workshops are included to embed theories in practice.


Personnel involved with Research and Development, process research and development, process safety, EH&S, chemical engineering, operations and maintenance at all levels – Management, Technical, Operations and Maintenance.

PLEASE NOTE: Units can also be studied separately as single day courses, for more details on this please contact us via email or telephone.

A key aspect to our courses is for our delegates to gain the knowledge and solutions applicable to their own situations, so numbers are capped to ensure we have sufficient time for your feedback and early booking is therefore recommended.

Training will be held at our Southampton facility, with accommodation available at the Chilworth Manor Hotel, a 5 minute walk from Phi House.

Phone: +44 (0)23 8076 0722 - Fax: +44 (0)23 8076 7866

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