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engineering
chemical process safety fundamentals with applications

Questions and Answers of Chemical Process Safety Fundamentals With Applications

A cylindrical tank, \(4 \mathrm{ft}\) in diameter and \(10 \mathrm{ft}\) long, is completely filled with water and blocked in. Estimate the thermal expansion rate of the water if the water is at
A 10 -ft-wide by \(10-\mathrm{ft}\)-long by \(10-\mathrm{ft}\)-high shed is used to store tanks of methane. What deflagration vent area is required? Assume a maximum internal overpressure of \(0.1
A horizontal vessel, \(3 \mathrm{~m}\) long and \(1 \mathrm{~m}\) in diameter, contains water. What relief size is required to protect the vessel from fire exposure? Assume the following: vapor
In a pilot plant, toluene is transferred from a drum to an open bucket. Develop a checklist for this procedure. Include inerting/purging, ventilation, grounding, and bonding, along with any other
Perform a HAZOP study for the reactor in Example 11-2. The reaction is exothermic, so cooling coils removes the heat of reaction. The temperature is controlled by controlling the flow of cooling
If the monomer in Example 11-2 is ethylene oxide, identify the hazards by developing a list of material hazards and a list of process hazards.Example 11-2 Consider the reactor system shown in Figure
The "fail safe" concept is used to specify the position (fail closed or fail open) of all process valves in the event of a utility failure. The specified fail open or fail closed puts the process in
Conduct a safety review for the design of the system described in Example 11-2. This reactor is used to polymerize ethylene oxide to form polyols.Example 11-2 Consider the reactor system shown in
An operator needs to charge 5 kilograms of a catalyst into a batch reactor (Reactor A) 3 hours after the start of the batch. List 10 or more ways the operator can fail to perform this task correctly,
A good management practice is to set objectives before safety reviews are conducted. The objectives should include the timing for completing the objectives. Develop objectives for a safety review for
For each equipment item listed below, clearly state the design intent of each piece of equipment and identify at least five failure modes.a. Manually operated gate valveb. Manually operated ball
A heat exchanger is used to heat flammable, volatile solvents, as shown in Figure 11-7. The temperature of the outlet stream is measured by a thermocouple, and a control valve manipulates the amount
For the heat exchanger system shown in Figure 11-7, identify at least five failure modes and explain how these failures would affect the downstream process. Volatile Solvent V1 Steam Control Valve
Interlocks are used to ensure that operations in a chemical plant are performed in the proper sequence. Interlocks can be mechanical or electronic. In many cases. they can be as simple as a lock and
Liquid levels in storage tanks are frequently determined by measuring the pressure at the bottom of the tank. In one such tank, the material stored in the tank was changed and an overflow resulted.
An operator was told to control the temperature of a reactor at \(60^{\circ} \mathrm{C}\). He set the set point of the temperature controller at 60 . The scale actually indicated 0 to \(100 \%\) of a
A light in the control room of a chemical plant was supposed to indicate whether a valve was closed or not. In reality, it indicated only the status of the signal being sent to the valve. The valve
A coffee maker has a reservoir where a quantity of clean water is poured. A small heater percolates the water up to the top of the coffee maker, where it drips down through the coffee grounds and
A sump pump process is shown in Figure 11-8. This system required a lot of maintenance because the level sensor, control system, or pump frequently failed. Perform an inherent safety review on this
For the reactor shown in Figure 12-5, sketch a fault tree and determine the overall failure rate, the failure probability, the reliability, and the MTBF. Alarm at P> PA Pressure Switch PIA Reactor
For the reactor shown in Figure 12-5, sketch a fault tree with redundant alarm and shutdown loops, and determine the overall failure rate, the failure probability, the reliability, and the MTBF.
For the figure and failure rates shown below, determine for the top event the probability of failure, the reliability, and the MTBF. B LIA Loop Fails OR Gate A 1 AND Gate 3 2 4 Tank Overflows T AND
Determine the minimum cut sets for the fault tree provided in Problem 12-3.Problem 12-3.For the figure and failure rates shown below, determine for the top event the probability of failure, the
Modify the event tree of Figure 12-9 to determine the runaways per year if the loss of cooling initiating event is reduced to 0.02 occurrence per year. Figure 12-9 Safety function: Identifier:
Modify the event tree of Figure 12-11 to determine the runaways per year if the loss of cooling initiating event is reduced to 0.80 occurrence per year. Figure 12-11 Safety function: Identifier:
A toxic liquid 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
A reactor experiences trouble once every 16 months. The protection device fails once every 25 years. Inspection takes place once every month. Calculate the unavailability, the frequency of dangerous
A starter is connected to a motor that is connected to a pump. The starter fails once in 50 years and requires 2 hours to repair. The motor fails once in 20 years and requires 36 hours to repair. The
If a regulator has a consequence frequency of \(10^{-1}\) failure \(/ \mathrm{yr}\), what will be the frequency if this regulator is given preventive maintenance once per month?
Draw an \(F-N\) curve using the following data: Incident outcome case Frequency, F; (per year) Estimated number of fatalities, N 1 x 10-6 20 1 x 10-4 1 x 10 1 10 5 1 10-4 1 2 34 5 -5 57 3 NW 2
The peak overpressure expected as a result of the explosion of a tank in a plant is approximated by the following equation:\[\log P=6.0-1.8 \log r \]where \(P\) is the overpressure in psi and \(r\)
For a large semi-batch polyether reactor (add ethylene and/or propylene oxide to a hydrocarbon alcohol), use the hierarchy concept to make recommendations for improving the safety of this process.
For the polyether reactor described in Problem 13-1, list a few of the most important safeguards that should be in place.Problem 13-1For a large semi-batch polyether reactor (add ethylene and/or
Human factors must be addressed during all phases of an operation. Expand the descriptions given in the "Human Factors" subsection in Section 13-1.Section 13-1 Human Factors Operators sometimes make
As shown in Table 13-1, operators make mistakes that are related to the operators' environment. List the six items in this list in order of importance.Table 13-1 Operator environment a. Trained b.
Use the CSB website to (a) describe the T2 Laboratories incident that occurred on December 19, 2007, and (b) list the CSB recommendations following this incident.
Use the T2 Laboratories incident of Problem 13-5 to list the details of this incident investigation:(a) the underlying and root causes of the incident and(b) the first and other recommendation
Many incidents are due to the failure to apply codes, standards, and other Recognized and Generally Accepted Good Engineering Practices (RAGAGEP). Read the West Pharmaceutical Services Dust Explosion
Summarize the content of NFPA Standard 654.
The double block and bleed system shown in Figure 13-2 is a design feature often added to all monomer feed lines. However, it has one problem: It creates another tank with a hazardous monomer.
The LOTO permit is one that is used often in an industrial environment. Search the Internet for a more thorough procedure.
All 20 RBPS elements are equally important and cannot be prioritized. Based on your personal and/or company experiences, what are two elements you have found to be inadequately addressed? State the
As a follow-up to Problem 14-1 and based on your personal and/or company experiences, list several additional RBPS elements that you have personally found to be inadequately addressed and state the
Review the CSB video on the October 21, 2016, MGPI Processing facility incident and describe (a) the incident and (b) the RBPS elements that were inadequately addressed. Explain why those elements
Review the CSB video on the December 2007 T2 Laboratories incident: "Runaway: Explosion at T2 Laboratories." (a) Describe the incident. (b) Summarize the CSB recommendations.
Review the CSB video on the February 2008 Imperial Sugar Refinery explosions incident: "Combustible Dust: An Insidious Hazard." (a) Describe the incident. (b) Summarize the CSB recommendations.
Review the CSB video on the ExxonMobil Refinery 2013 incident: "Dangerously Close: Explosion in West Texas." (a) Describe the incident. (b) Identify which RBPS elements were inadequately addressed
Review the CSB video: "CSB Video Excerpts from Dr. Trevor Kletz." Describe Dr. Kletz's major teachings.
Review the CSB Video: "Fire in Baton Rouge." Describe (a) the incident and (b) the CSB findings.
It is recommended to show training videos to engineers and students to encourage them to recognize that safety is especially important. Review the Internet information concerning the video "Remember
On the Internet, you will find a case history about a "Gas Station Fire." Describe the incident and make recommendations to prevent this type of incident.
Using the data provided in Example 2-1, determine the accumulated frequency(a) between minus infinity and infinity (using Equation 2-1),(b) between the mean and infinity (using Equation 2-1), and
Engineering ethics: Write an essay on why you think safety (and process safety) is an important part of any engineering ethics statement.
Classify the following from 0 to 5 based on the hierarchy of safety programs provided in Table 1-3. Explain why.a. The company and plant executive teams are very receptive to any safety suggestions
Safety culture: Classify the following activities as either strengthening or weakening process safety culture. Explain why.a. The plant manager schedules an important safety meeting that everyone
Individual and societal risk: For the following cases, identify the primary risk population, classify the case as involving individual risk and/or societal risk, and identify the risk as voluntary or
Safety metrics: Classify the following as either leading or lagging safety metrics. Explain why.a. Number of reports of unsafe activities in a plantb. Number of near-miss incidentsc. Money spent on
Accident and loss statistics: Return to Example 1-1. For parts (b) and (c), the length of time for both the hours-based fatal injury rate and the recordable incidence rate was 1 year. What time
Accident and loss statistics: If the U.S. population in 2014 was 325 million people, calculate the deaths per 100,000 people from lightning strikes using the total fatalities from lightning in Table
Use the risk matrix in Table 1-14 to determine the risk level for the Bhopal incident. Estimate the severity category, the safety severity level, the likelihood, and the risk level. Table 1-14 Risk
Codes, standards, and regulations: Go to the www.osha.gov web site and look up the OSHA regulation CFR 1910.119: Process Safety Management of Highly Hazardous Chemicals. Use Appendix A to determine
Safeguards: Classify the following safeguards as either preventive or mitigative.a. A safety instrumented system to shut down a process if an unsafe operating condition occurs.b. A foam system to
CCPS elements: Classify the following activities as being most directly related to one of the 20 elements of RBPS. Although many elements may be involved, list only the single most applicable
Inherently safer design: Which inherently safer design strategy applies to each of the following?a. A flammable solvent is used to control the temperature in a reactor. The solvent is replaced by a
Using the data provided in Example 2-1, determine (a) the mean and variance, (b) the frequency as a function of the response, and (c) the number affected as a function of the response. Also, (d) show
Using Equation 2-6, determine the probability for probits of 4.39, 5.25, and 6.23. P-50 [1 + 5*()] Y-5 Y - = 1+ Y-5/ erf 2 (2-6)
A blast produces a peak overpressure of 47,000 N/m2.a. What fraction of structures will be damaged by exposure to this overpressure?b. What fraction of people exposed will die as a result of lung
A volatile substance evaporates from an open container into a room of volume 28.3 m3. The evaporation rate is 100 mg/min. If the air in the room is assumed to be well mixed, how many m3/min of fresh
If 500 workers in a plant are exposed to the following concentrations of ammonia for the given number of hours, how many deaths will be expected?a. 1000 ppm for 1 hourb. 2000 ppm for 2 hoursc. 300
Using TLV data from Appendix E, convert TLV in ppm to mg/m3 for the following compounds.Assume a temperature of 25°C and a pressure of 1 atm.a. benzeneb. chlorinec. cyclohexanold. ethylene
Estimate four exposure concentrations in ppm that will result in fatalities for 80% of the exposed individuals if they are exposed to chlorine for 2, 4, 6, and 8 minutes.
Determine the deaths resulting from the following exposures to chlorine:a. 200 ppm for 150 minb. 100 ppm for 50 minc. 50 ppm for 20 min
The peak overpressure expected as a result of the explosion of a tank in a plant facility is approximated by the equation:where P is the overpressure in N/m2 and r is the distance from the blast in
Use Appendix E to determine the hazardous properties of ammonia—that is, TLV-TWA, TLV-STEL, TLV-C, and PEL.Appendix E, Table AE-1 Hazardous Chemicals Data for a Variety of Chemical Substances
At what overpressure (Pa and psi) would 50% of structures be damaged?
For methane in air at 1 atm and 298 K, how many ppm is 100 mg/m3?
Humans breathe about 500 mL of air per breath and take about 12 breaths per minute during normal activities. If a person is exposed to an atmosphere containing benzene at a concentration of 10 ppm

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