Pilot Plant Equipment 2 Safe Installation and Operation

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Course Overview

Engineers and scientists—who are involved in pilot plant and laboratory units—will learn the essentials and critically examine ways to deal with the hardware and research specific issues not covered elsewhere.

During the course, you will gain a comprehensive overview of the safety issues and concerns involving:

  • Gas cylinders and cryogenic liquids.
  • Relief systems.
  • Glass use.
  • Hoses and plastic tubing.
  • Gas monitoring.
  • Sight glasses.
  • Rotating and heated equipment safety.

Who Should Attend?

This course will be valuable to those involved in academic, private, and government research and training laboratories. It will be especially important to those who are:

  • New to the pilot plant and laboratory and need to learn about the safety implications of the equipment they will be using.
  • Responsible for designing and operating safe pilot plants and laboratories.
  • Managing the safety aspects of pilot plants and laboratories.

Additional Information

Note: Although these courses are independent, stand-alone courses, we recommend that Pilot Plant Equipment 1: Fundamentals for Proper Selection be completed prior to attending Pilot Plant Equipment 2: Safe Installation and Operation. The equipment and design focus provided in the first course provides the discussion basis for safe operation in the second. Attend both courses and receive a 10% discount off the enrollment fee of each.

Course Outline


Compressed Gas Cylinders

  • Legal and code requirements
  • Quantity limitations
  • Storage guidelines
  • Special cases
  • General precautions and recommendations

Cryogenic Gases and Liquids

  • Design concerns
  • Transportation issues
  • Over pressure protection
  • Other hazards

Relief Devices

  • Sizing relief devices properly
  • Sizing equations
  • Class problems
  • Types of relief devices
    • spring loaded relief valves
    • rupture disks
    • hydrostatic head devices
    • conservation vents
    • balanced bellows relief valves
    • rupture pins
    • electronic systems
  • Advantages and disadvantages of each type
  • Choosing the best one for your service
  • Miscellaneous relief valve issues
  • Vent systems for research

Safety Shutdown Systems

  • General considerations
  • Matching the safety system design to your needs
  • Microprocessor issues
  • Using Layer of Protection Analysis to evaluate your safety system effectiveness
  • Field device reliability and testing

The Safe Installation and Use of Glass Equipment

  • Safety concerns about using glass
  • Shielding: the right and wrong ways
  • Guidelines for safe use of glass equipment
  • Glass and hazardous materials

Hoods and Ventilated Enclosures

  • Anatomy of a properly functioning hood
  • Issues with hood exhaust systems
  • Laboratory exhaust and hoods
  • Common problems with hood use and how to avoid them and correct them
  • What belongs in a hood and what doesn’t?
  • Hood certification and testing
  • Hood alarms
  • Local exhaust and exhausted enclosures issues: How to use them properly

Hoses and Plastic Tubing

  • Issues with laboratory tubing
  • Plastic tubing issues
  • Flexible metal hose issues
  • Guidelines for safe use

Leak Testing vs Hydrostatic Testing

  • What are the differences
  • When to use each
  • How to safely test

Flow Limiting Devices

  • Selecting the right type for your application
  • Problems with the different types and how to avoid them 

Gas Monitoring Systems

  • Types of applications
  • Types of monitoring systems
  • Selecting the right system for your application
  • Guidelines for effective use

Sight Glasses

  • Types of sight glasses
  • Safety considerations for each type
  • Guidelines for safe use of sight glasses

Rotating Equipment: Compressors, Pumps, and Mixers

  • Guidelines for safe compressor installations
  • Guidelines for safe pump installations
  • Guidelines for safe mixer installations

Heated Equipment

  • Ovens and furnace safety
  • NFPA 86 requirements
  • Heat tracing safety
  • Over temperature protection
  • Sensor placement concerns
  • Complying with electrically classified areas

Wrap Up and Class Questions


Richard Palluzi

Richard P. Palluzi, PE, CSP, of Richard P. Palluzi LLC is a consultant to the pilot plant and laboratory research community on safety, design, and research project management. He retired as a Distinguished Engineering Associate after almost 40 years at ExxonMobil Research and Engineering, where he was involved in the design, construction, and support of pilot plants and laboratories for ExxonMobil’s research site in Clinton, New Jersey, as well as affiliates worldwide. Rich is the author of two books, and numerous articles and presentations as well as a past chair of the American Institute of Chemical Engineers Pilot Plant Committee, ExxonMobil’s Pilot Plant and Laboratory Safety Standards Committee, and ExxonMobil’s Safe Operations Team for their Clinton facility. Rich is on the National Fire Protection Association (NFPA) NFPA-45 Fire Protection for Laboratories Using Chemicals and NFPA-55 Industrial and Medical Gasses committees. He has BE and ME degrees in chemical engineering from Stevens Institute of Technology. 

Elaine Andrysick

Elaine M. Andrysick, joined Engineering Professional Development, University of Wisconsin-Madison, as a continuing engineering education specialist in 1988.  She is responsible for the development and delivery of high-value continuing engineering education short courses for practicing professionals in the areas of chemical and process engineering and laser material processing.  Also, she manages the University’s Laser Welding Certificate program.

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Take this course when it’s offered next!

Program Director

Elaine Andrysick

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