Industrial/Safety

ChE 4284/5292: Industrial Safety Final Exam Name: …………………………………………………………. Due Date: 07.02.2024 at 11:59 pm EST Note: There are seven questions. Students enrolled for CHE 4284: Please answer the first six problems. Students enrolled for CHE 5292, please answer all the questions for full credit. Show your work. Write and carry units. This is a take home, open-book, and open-notes exam. If you have used any computational software, please print out the codes and upload them with the exam. Cheating of any kind will not be tolerated. Instructor will use similarity to detect cheating. Problem 1. a. ABC Airlines Company reported 5 deaths per 10,000,000 passenger miles. If the average speed of the airplane is 200 miles per hour, please calculate the FAR and fatality rate. Assume average miles per trip is 300 miles. Please compare your results with the Table 1-4. Should you be worried or happy to fly with ABC airlines? In Table 1-4, please assume fatality rate of car is similar to air. (8) b. A leak of 2,000 kg of octane results in an explosion with a financial loss of $900,000. The last incident of this type occurred 9 years ago. Use the risk matrix to determine the Severity Category, the Safety Severity Level and the Risk Level. (7) Likelihood Risk Matrix 1. Select the severity from the highest box in either of columns 1, 2 or 3. Read the Category and Safety Severity Level from the same row. 2. Select the likelihood from columns 4 thru 7. 3. Read the Risk Level from the intersection of the severity row and the likelihood column. Severity TMEF: Target mitigated event frequency TQ: Threshold Quantity 1 2 3 Human Health Impact Fire, Explosion Direct Cost in $ Chemical Impact Severity Category Safety Severity Level Public fatality possible, employee fatalities likely Greater than $10 MM ≥ 20x TQ CATASTROPHIC 4 TMEF = Employee fatality possible. Major injury likely $1 MM to < $10 MM From 9x to < 20x TQ VERY SERIOUS 3 TMEF = Lost time injury (LTI) likelya $100K to < $1 MM From 3x to < 9x TQ SERIOUS 2 TMEF = Recordable Injuryb $25K to < $100K From 1x to 1000 years Risk Level A Risk Level A Risk Level B Risk Level C Risk Level A Risk Level B Risk Level C Risk Level D Risk Level B Risk Level C Risk Level D Negligible Risk Risk Level C Risk Level D Negligible Risk Negligible Risk Risk Level A: Unacceptable risk, additional safeguards must be implemented immediately. Risk Level B: Undesirable risk, additional safeguards must be implemented within 3 months. Risk Level C: Acceptable risk, but only if existing safeguards reduces the risk to As Low as Reasonably Practicable (ALARP) levels. Risk Level D: Acceptable risk, no additional safeguards required. aLost time injury (LTI): The injured worker is unable to perform regular job duties, takes time off for recovery, or is assigned modified work duties while recovering. bRecordable injury: Death, days away from work (DAW), restricted work or transfer to another job, medical treatment beyond first aid, or loss of consciousness. Table 1-15: Risk matrix for semi-quantitative classification of incidents. 1 Table 1-16 Threshold quantities (TQ) for a variety of chemicals. Source: AICHE/CCPS 2,000 kg = 4,400 lbm Acrylamide Ammonium nitrate fertilizer Amyl acetate Amyl nitrate Bromobenzene Calcium oxide Carbon dioxide Carbon, activated Chloroform Copper chloride Kerosene Maleic anhydride n-Decane Nitroethane Nitrogen, compressed Nitrous oxide Nonanes Oxygen, compressed Paraldehyde Phosphoric acid Potassium fluoride Potassium nitrate Sulfur Tetrachloroethylene Undecane 1,000 kg = 2,200 lbm Acetic anhydride Acetone Acetonitrile Aldol Ammonium perchlorate Aniline Arsenic Barium Benzene Benzidine Butyraldehyde Carbon tetrachloride Coper chlorate Copper cyanide Cycloheptane Cycloheptene Cyclohexene Dioxane Epichlorohydrin Ethyl acetate Ethyl benzene Ethylenediamine Formic acid Heptane Hexane Methacrylic acid Methyl acetate n-Heptene Nitrobenzene Nitromethane Octanes Phenol, molten or solid Propylamine Pyridine Silver nitrate Sodium permanganate Tetrahydrofuran Toluene Triethylamine Vinyl acetate Zinc peroxide 500 kg = 1,100 lbm Acetaldehyde Acrylonitrile Calcium cyanide Carbon disulfide Cyclobutane Diethyl ether or Ethyl ether Ethane Ethylamine Ethylene Furan Hydrazine, anhydrous Hydrogen, compressed Lithium Methylamine, anhydrous Potassium Potassium cyanide Propylene oxide Silane Sodium Sodium cyanide Sodium peroxide Trichlorosilane 200 kg = 440 lbm Ammonia, anhydrous Carbon monoxide 100 kg = 220 lbm Hydrogen bromide, anhydrous Hydrogen chloride, anhydrous Hydrogen fluoride, anhydrous Methyl bromide Methyl mercaptan Sulfur dioxide 25 kg = 55 lbm Chlorine Cyanogen Germane Hydrogen sulfide Nitric acid, red fuming Sulfuric acid, fuming 5 kg = 11 lbm Acrolein Arsine Diborane Dinitrogen tetroxide Methyl isocyanate Nitric oxide, compressed Nitrogen trioxide Phosgene Phosphine Stibine 2 Problem 2. a. Please define TLV-TWA, OSHA PEL, and LC50. b. Please find the LC50 of the data provided below: Dose of drug (mg/l) Number of insects Number affected (deaths) 0 50 8 3 46 20 5 48 28 8 49 45 11 50 50 (5) (10) Please show your work and upload the excel file with the exam. 3 Problem 3. a. Gasoline GHS label usually comes with these symbols below. What do they mean? (5) b. NFPA diamond for gasoline is shown below. What do the color and numbers mean? (5) c. Let’s calculate how safe it is in the gas station when you are filling the gas in the car. Suppose a sedan has a gasoline tank of 14-gal volume and it usually takes 3 min to fill the gas. Estimate the concentration of gasoline vapor (in ppm) at the gas station? Please assume molecular weight of gasoline is 94 lbm/lb-mole, vapor pressure of gasoline is 4.6 psi at 77 F, and ventilation at the gas station is 3000 ft3/min. Assume, specific gravity of gasoline is 0.713. Assume, k = 0.1. Ideal gas constant, Rg = 0.7302 ft3-atm/lb-mole-R. Conversion of Rankine, R = 460 + F, 1 gal = 0.1337 ft3, 1ft3 of water = 62.43 lbm of water (10) 4 Problem 4. a. Hydrogen sulfide (H2S) is a toxic byproduct of municipal wastewater treatment plants. H2S has a TLV-TWA of 10 ppm. Please convert the TLV-TWA to lbm/s. Molecular weight of H2S is 34 lbm/lb-mole. If the local ventilation rate is 2000 ft3/min. Assume 80 F is the temperature and 1 atm pressure. Ideal gas constant, Rg = 0.7302 ft3-atm/lb-mole-R. Conversion of Rankine, R = 460 + F. Assume, k = 0.1 (5) b. Let’s assume that local wastewater treatment plant stores H2S in a tank at 100 psig and 80 F. If the local ventilation rate is 2000 ft3/min. Please calculate the diameter of a hole in the tank that could lead to a local H2S concentration equals TLV-TWA. Choked flow is applicable and assume 𝛾= 1.32 and C0 = 1. Ideal gas constant, Rg = 1545 ft-lbf/lb-mole-R, x psig = (x+14.7) psia = (x+14.7) lbf/in2 (10) 5 Problem 5. a. Please define ERPG-1, ERPG-3, EEGL-24 hour, AEGL-level 3, and LOC (level of concern) (5) b. A storage tank of a toxic chemical (ERPG-1 = 0.25 mg/m3) is located 1.5 km from a residential area of Melbourne. It is always sunny in Melbourne and assume wind is blowing at 3.9 m/s. Please calculate the amount of toxic chemical instantaneously released at the ground level to produce a concentration at the boundary of the residential area equal to ERPG-1. (10) Pasquill–Gifford Stability Class y (m) Plume z (m) Rural conditions A 0.22x(1 + 0.0001x)–1/2 0.20x B 0.16x(1 + 0.0001x)–1/2 0.12x C 0.11x(1 + 0.0001x)–1/2 0.08x(1 + 0.0002x)–1/2 D 0.08x(1 + 0.0001x)–1/2 0.06x(1 + 0.0015x)–1/2 E 0.06x(1 + 0.0001x)–1/2 0.03x(1 + 0.0003x)–1 F 0.04x(1 + 0.0001x)–1/2 0.016x(1 + 0.0003x)–1 A–B 0.32x(1 + 0.0004x)–1/2 0.24x(1 + 0.001x)+1/2 C 0.22x(1 + 0.0004x)–1/2 0.20x D 0.16x(1 + 0.0004x)–1/2 0.14x(1 + 0.0003x)–1/2 E–F 0.11x(1 + 0.0004x)–1/2 0.08x(1 + 0.0015x)–1/2 Pasquill-Gifford Stability Class y (m) or x (m) z (m) A 0.18×0.92 0.60×0.75 B 0.14×0.92 0.53×0.73 C 0.10×0.92 0.34×0.71 D 0.06×0.92 0.15×0.70 E 0.04×0.92 0.10×0.65 F 0.02×0.89 0.05×0.61 Urban conditions Puff 6 Problem 6. 7 Assume ethane combustion in air: 𝐶2 𝐻6 + 2 𝑂2 = 2𝐶𝑂2 + 3𝐻2 𝑂 a. Find LFL, UFL, and LOC (limiting oxygen concentration) (5) b. If LOL and UOL of ethane are 3.0% fuel in oxygen and 66% fuel in oxygen, respectively, please find the stoichiometric line and draw a flammability diagram of ethane (grid lines are provided in the next page). Identify LOL, UFL, LFL, UFL, LOC line, air-line, stoichiometric line, and flammability zone. (10) c. If an ethane tank needs to be out of service, please calculate out of service fuel concentration (OSFC). Please redraw the flammability diagram of ethane and identify the out-of-service lines in the flammability diagram. (5) d. After the maintenance of the ethane tank, we need to bring the tank into service. Please calculate the percentage of N2 needs to be added prior to fill ethane to the tank. Please show the tank into service line in the flammability diagram. (5) 7 8 (CHE 5292 students only) Problem 7. (a) In our cars, we fill gasoline in the tank. Now, when we start the engine, it uses battery to start a “starter”, which then starts a “motor” that is connected to a “gas pump”. The starter fails once in 50 yr and requires 2 hr to repair. The motor fails once in 20 yr and requires 36 hr to repair. The pump fails once per 10 yr and requires 4 hr to repair. Starter Motor Pump Determine the overall failure frequency, the probability that the system will fail in the coming 2 yr, the reliability, and the unavailability for this system. (10) (b) Liquid Acrolein (see page 2 of the exam) is pumped into a storage vessel. The vessel is equipped with a high-level sensor to stop the flow and sound an alarm if the level is too high. If the level sensor and alarm fail, the vessel will overflow, and the deadly toxic material will be released into the operating environment. The overall instrument system is also known as basic process control system (BPCS) and failure is known as “BPCS instrument loop failure”. Use the LOPA method to determine if this system requires additional safeguards and suggest additional safeguards that will satisfy the need (if needed). The pumping rate is 1 lb per minute and it will take 20 minutes for the operator to notice the spill and stop the flow manually. Make suggestions for improvement if additional safeguards are required. (10) 9

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