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engineering
chemical process safety fundamentals with applications

Chemical Process Safety Fundamentals With Applications 4th Edition Daniel A. Crowl, Joseph F. Louvar - Solutions

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 \(50^{\circ} \mathrm{F}\) and the steel shell of the tank is suddenly heated to \(100^{\circ}
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 \(0.1 \mathrm{psig}\).
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 relief only, MAWP of 14 barg, conventional capacity-certified spring-operated relief.
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 safety procedures.
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 water. Use as a study node the cooling coil (process parameters: flow and temperature) and the stirrer
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 11-6. The reaction is exothermic, so a cooling system is used to remove the excess energy of
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 a safe mode of operation. Specify the proper fail-safe position for the following situations:a. A
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 Figure 11-6. The reaction is exothermic, so a cooling system is used to remove the excess energy of
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, and state your recommendations to prevent this type of problem.
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 the design of a polyether reactor described in Example 11-2 and Problem 11-5. As stated earlier,
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 valvec. Check valved. Automatic control valvee. Centrifugal pumpf. Piston pump g. Shell and tube heat
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 of steam to the heat exchanger to achieve the desired set point temperature.a. Identify the HAZOP
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 TRC Heat Exchanger Condensate Figure 11-7 Temperature control using a heat exchanger.
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 key. Specify the simplest mechanical interlock capable of achieving the following functions:a. A
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. Why?
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 temperature range of 0 to \(200^{\circ} \mathrm{C}\). This caused a runaway reaction that
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 did not close when it should have, and the plant exploded. Why? How would you prevent this problem?
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 filter assembly. The coffee product is collected in the coffee pot.a. Draw a sketch of the coffee
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 system and develop a much simpler system to achieve the same function. LC Sump Figure 11-8 A sump
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 PIC Reactor Feed Solenoid Valve Figure 12-5 A chemical reactor with an alarm and an inlet feed
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. Alarm at P> PA Pressure Switch PIA Reactor PIC Reactor Feed Solenoid Valve Figure 12-5 A chemical
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 Gate Faults per year, , for the given basic events: C LIC Loop Fails OR Gate 5 6 7
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 reliability, and the MTBF. B LIA Loop Fails OR Gate A 1 AND Gate 3 2 4 Tank Overflows T AND Gate Faults
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: Failures/demand: A 1 Initiating event: loss of cooling 1 occurrence/yr. High-temp alarm alerts operator
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: Failures/demand: Initiating event: loss of cooling 1 occurrence/yr. High-temp Operator Operator
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 vessel will overflow and the toxic material will be released into the operating environment. Use 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 coincidences, and the MTBC.
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 pump fails once per 10 years and requires 4 hours to repair. Determine the overall failure
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 \(r\) is the distance from the blast in feet. The plant employs 50 people who work in an area from 10 to
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 propylene oxide to a hydrocarbon alcohol), use the hierarchy concept to make recommendations for
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 mistakes, and the consequences of those errors may be serious. A critical task analysis is one
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. Not under stress c. Not fatigued d. Not overloaded with work e. Adequate time for the task f. Active
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 layers. Problem 13-5Use the CSB website to (a) describe the T2 Laboratories incident that occurred on
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 and Fire (2003) incident (CSB report) and (a) describe the incident, (b) list the major
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. Develop a new design of the double block and bleed system that is inherently safer than the one shown in
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 background and reasons for these inadequacies.
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 background and reasons for these inadequacies.Problem 14-1ll 20 RBPS elements are equally important
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 were not addressed properly.
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 and why.
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 Charlie." Describe the video and give your conclusions.
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 (c)between the mean plus the two standard deviations and infinity (Equation 2-1). State any
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 and the suggestions are reviewed and implemented on a timely basis.b. A change is made in a
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 must attend. At the meeting, the plant manager introduces a person from corporate safety and then
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 involuntary.a. A worker does not wear the required personal protective equipment for the chemicals
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 insurance claimsd. Number of visits to the plant first aid facilitye. Number of process alarms that
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 period is required for the hours-based fatal injury rate and the recordable incidence rate to be equal to
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 1-13. Also calculate the fatality rate. Table 1-13 Non-Occupational Fatalities in the United States
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 Matrix for Semi-Quantitative Classification of Incidents Risk Matrix 1. Select the severity from the
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 the threshold quantities for the following chemicals. If your plant site exceeds this threshold
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 reduce evaporation from a pool of leaked hydrocarbon.c. A dike around a storage vessel.d. A flow
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 element.An element may be used more than once.a. The plant has an open house for the local community.b. A
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 nonflammable solvent.b. A valve that requires 10 turns to close is replaced by a quarter-turn
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 graphs for the frequency and number affected. Example 2-1 Seventy-five people are tested for skin
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 hemorrhage?c. What fraction of people exposed will have their eardrums ruptured?d. What conclusions
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 air must be supplied to ensure that the concentration of the volatile is maintained below its TLV of
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 ppm for 3 hoursd. 150 ppm for 2 hourse. Repeat this problem with the concentrations given in parts (a)
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 oxideAppendix E, Table AE-1 Hazardous Chemicals Data for a Variety of Chemical Substances Compound
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 meters. The plant employs 500 people who work in an area from 3 to 150 m from the potential blast
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 Compound Acetaldehyde Acetic acid Acetic anhydride Acetone Acrolein Acrylic acid Acrylonitrile Alkane
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 (by volume), how many grams of benzene will be deposited in the lungs during an 8-hour shift if all

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