In the modern chemical and pharmaceutical landscape, reactive chemical hazards represent one of the most significant risks to process safety and business continuity. Undetected thermal instabilities or improperly sized relief systems can lead to catastrophic runaway reactions, resulting in loss of life, environmental damage, and total asset loss. This intensive two-day workshop, led by industry experts from Kaypear in collaboration with the PSCI, provides a comprehensive roadmap for identifying, quantifying, and mitigating reactive risks.

Registration Process
If you are interested in attending this workshop, please register your interest below. Registration does not guarantee a place and your attendance will be confirmed in due course. Please note that attendance is limited to one person per organization.

Who should attend
As this is a core technical topic, professionals with the following qualifications and job roles are requested to register:

• Process safety engineers/Chemical engineers in technology transfer, technical services, R&D, and process engineers with operations / technical back ground of more than 5 years is recommended.
• Engineers in senior management involved in technical reviews

Day 1

• 08:30-09:00: Registration, Networking, and Tea-Coffee
• 09:00-09:15: PSCI India Connect Overview
• 09:15-09:25: Context Setting / PSCI Audit Findings
• 09:25-09:30: Speaker Introduction
• 09:30-11:00: What reactive hazards are and why they matter with case studies: Examples of reactive hazard scenarios & Common types of reactive chemicals based on functional groups, chemical incompatibility, and thermal stability
• 11:00-11: 15:Tea Break/Net working
• 11:15-13:00: Testing and hazard evaluation using calorimetry (DSC, TGA, ARC, TMRad, ARSST, RC1, RC2, etc.)
  • Testing protocol and methods available
  • Limitation, advantage, and disadvantage of each type of calorimeter
  • Data interpretation of the thermal stability reports
• 13:00-14:00: Lunch/Networking
• 14:00-15:30: Development, calculation, and impact of heat of reaction, reaction rate, and TMRad with a workshop example
• 15:30-15:45: High Tea/Networking
• 15:45-17:00: Stossel’s Criticality Index, CCPS Probability vs Severity table - Sharing case studies - Optimization to safer criticality classes
• 17:00-17:30: Day 1 Summary & Q&A

Day 2

• 08:30-09:00: Registrations/Networking/Tea-Coffee
• 09:00-09:15: Recap & Quiz
• 09:15-11:15: Introduction to DIERS methodology and direct scale up
  • Test protocol for vent sizing using a workshop problem
  • Emergency Relief System (ERS) training for vent sizing using direct scale up
  • Scale up of high phi factor vs direct scale up
• 11:15-11:30: Tea Break/Networking
• 11:30-13:00: Credibility of external fire induced runaway reaction - Sizing for external fire scenario
• 13:00-14:00: Lunch/Networking
• 14:00-15:45: How to control reactive hazards, including:
  • Mode of operation depending on the reaction rate (Batch, Semi-Batch, Continuous)
  • Understanding the effect of temperature of no return (TNR)
  • Likelihood scale based on TMRad
  • Quench calculations and reaction termination chemicals
  • Vent sizing using direct scale up
  • Introduction of Modern DRIERS tools
• 15:45-16:00: High Tea/Networking
• 16:00-16:30: SRV/RD testing + frequency
  Type testing - Flow verification - Field observations + common issues
• 16:30-17:00: Workshop Summary & Q&A

Speakers

Mr. Rahul Raman
Rahul Raman is Principal Engineer and Subject Matter Expert at Kaypear with over 19 years of global expertise in process safety management (PSM) across the United States, Mexico, China, South Korea, and India. A Chartered Chemical Engineer with a Master's degree from Carnegie Mellon University and a B.Tech in Chemical Engineering from Anna University, he specializes in emergency relief system design, technical process safety, and process safety management implementation. Rahul has successfully led major projects in oil and gas, petrochemical, and chemical industries, including relief system gap assessments, HAZOP studies, quantitative risk assessments, and implementing process safety standards.

Mr. Pramod Mekhya
Mr. Pramodbhai Mekhya is a seasoned Chemical Engineer and Process Safety Specialist with over 19 years of industrial experience spanning process development, process safety, scale-up, and advanced calorimetry techniques in the pharmaceutical and chemical industries.
He has extensive hands-on expertise in thermal hazard assessment, reaction calorimetry, adiabatic calorimetry, and process scale-up, supporting both R&D laboratories and manufacturing plants to design safer and more efficient chemical processes. Through his workshops, he brings a rare combination of industrial manufacturing experience and advanced safety instrumentation expertise, enabling participants to gain practical insights into reaction hazard evaluation, calorimetry data interpretation, and safe process scale-up strategies.