Solution Manual For Chemical Process Safety: Fundamentals With Applications, 3rd Edition

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[1]FAR=H@0°exposedhoursDeathsperpersonperyear|N(4(22she)(4deathsShsyearTosnS-5=3.3x10deths/person-yenyEoBEET[Threeprocessvittg—FAR's:05,0310)Assuming2xposutetoallthreeunitsNetFAR=¥TARS=0.5403+,0=[8By30%SXtive,0ares.1wilyFAR0.5Ho%Wwnnuwa0"0:3uo%$ileSelEyi1.0NetFAR=(0.2)(08)+(0.4)(0.3)+(04)(1.6)=-[3FromToble+dFARrravellingbycox=57desths/10?exposedhpurs2o¢|deothpec&=175x10°hours5we(75%10°hours)(BE)=87.5illionmilesCi-)3Ir-olinileNEARReonREE

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DownloadedfromStudyXY.com®+StudyXYSdYe.o>\|iF’prE\3SStudyAnythingThisContentHasbeenPostedOnStudyXY.comassupplementarylearningmaterial.StudyXYdoesnotendroseanyuniversity,collegeorpublisher.Allmaterialspostedareundertheliabilityofthecontributors.wv8)www.studyxy.com

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Nocenalworkinghoursareapproximately3000hausperyenr,ForBogyears)we.have,(500yeoes)(2x)=[x10°hoursWe,wonossume.|.deathevery0*eyposedhours,BufFARSaxebasedon108exposedhoofs,Thismeans;wo?ioe=100deathspes10%hoursJ,FAR=(COTheworkersshouldbealarmed!ForanavecoqecremcolplantFarsydeaths(10%hrsDeathpacyear=(3000hea)(4deaths\_-5?ROy5(Age)=x0<oteeiYeoxsperdecth=0°=13,500Crar®Sshouldbe|in12,500yearsofexpasure,Totalworkinghourspax:yedy2000hLp=(i500worker)(3505155)73x10]hesAse,jeay=ANE5deathsDeathper(Brio(C4Tes=545deaths’Adeathcanbeexpectedevery60:6years,Cl9

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FARoFrockclimbing=HoodFARofHovellingbycox=574000)Sa.©70.2hesAravelbycoxa)Inrriation-cuttingnfo10-inchpropone,linePropagation-leakageofpropane~Qormoaionofvaporcloud=ignitionofvaporcloud-destructionoffiepumpequipmestTermination-blockingin&+hepropanebo)TRFiation-improperclosing&valve,otcleaning&strainecwith;escapebutanePropogation—iggdionofvaporcloud&copturingoFpipeline-SallingofFractionationTowerondbreakingofpipeline.Tecwination~\sola¥ionoffuelsource,:cl=-1|

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Arline,industryhasfewestdeathsperpassengermile,bildoeTohighrateofspeedoftheowcraft,manymilesoreoccumulafed.FromTable"4,FARfor;Cox-57Bieyele—6Aw-340ThosonapechourbasisTravellingboyplave1salmost5+imesmovedangerousFRE“rrovellingby:car,aTocomputetheFARweneedhe,totalhoursexposed.Thiswouldfequire,onavexoqespeed.Suppose,heaveragespeed1S300MPH,;Totalhoorsexposed=(ox10°miles200mi/hr=30000rsLaie®preFRR=Er=8000whichislargerthanthe,AHOreportedinTable|-H.Gil=3

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ASotalityrotewouldrequire,thetotalrobber&fpassengersinthe107miles,Suppose.eodh{ripawroaged300miles,Totalpossenaers=10mkshe300wi[person33,333possenges;iyLFatalityrate=335=hax10")which15highci-6

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[19auniversityhadabout1200full-timeemployees.Inaparticularyear,thisuniversityhadatotalof38reportablelosttimeinjurieswitharesulting274lostworkdays.ComputetheOSHAincidenceratebasedoninjuriesandlostworkdays.Solution,.gH[3AswAngeryrake=Me9flaurenWX#00,000hrs28gTotalhoursWevwed553{88Totol Wburswore?«=(1200employes(2000hoursQamPloyesA*LYR10WouvsOspAjongvate=(DBjunesbl200,000ours)»2.4x10Wows=3.7(»©sH4LestA3-(274LestWerwdes(z=©00Wau)2.4xwot=22.8i:|ci—6

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210|BasedomIwerwplaceJatetitiee(#peeEEROnaSheraAde-~vavesPenpilinhy«ocfurypevemoF[SN©yogdm,whatUE)EXToperiyeHSolukiem3YoucomntobeydedncalausJoofworeFiama~eensporbekiom2st,7vaLSSVistawre,1—qupmandsede,,3ARSFev0°hmorpesiienwns30m=TreewnFpesis,Fives—~—aexplosions,Mowvvew,.ont[VNArveAmeveefferr©ecewmsaPeSimeFoeovexplavimcandSaacabeedngbaeventfemCnyvdesamdfoteritiay[ORSaComeagbyGurreleffedCrmprehendRema|ansth.Cl-17

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[N-\\|MeesedooAmeCaviteofEwaVersestlosses,Fu4"=,whekweldqosSnesaad-sefer,progr?SolutTen:Base4abYneoaShaATok=,[RYVsVvorwetepisreeds+oSegow4AreacoangpooendeVigoodYowpersdne RCmiaiamAdrbenllyaksheebevecoqmize2POYnpekTyel)paoAaccdenA>waWhamedetyAve vesull~§peepeeomsteamyaneateee,Des-—-&Treimn“1reqsaPSYakSEToffer, NeceussPOATevesPNweINeyPCR27Ps7oprope~~©eveldentoyoClas.FyianalALI[ad>[AR]+StudyXxy

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Areveviawimgremgmavs3prodlamsVilpamd=H,senvaheredsefeyyhep?Solution:CeleryAmrcemcepts98AmialanindieSubs¥ihbempnodereliom,andBlampwficede€omonemyepacksoopredSef-boFedeiomendSimepVfremkiomovecovcapbtEvelcenbeprocticadeEwvonewLaWeeycleof.Phen¥The[2eept°idRevpiomnTkSimpleshomllbeappliedkeAmsdcochiedevigmeamqes,kveiam~4,CrmamiansCokie,ekeC\-9+StudyXY

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BYWineyCPNSie,cnyoundevivefo3RFrquve1-9.SolutiomQa5tweTHEY\osvenavaSree5eraavaAwembasawddellamagadudeAddinovnPs(FmdiatedRE23Iobe«ffacs:wii>the\enkTva-“1ngemitsfretqsPernodvetslbee-v<hinSigheeknemonkwvasepeasde087Thame,SeameedLdmereEwwedcheedueYrami,appt)APONfeatmonn,owCveankiandusty,elTrsiaminyTemedmesg,—owwevebyFeaAaedsheSewerLeVteve 3hmekweecmbuvetheemegabivedvemtspresseRIELEYeouniversbytovrsss|oddovetreizim.3wikiaotic,TEagqueireWinlevelsoppetVawemiversibieyan@wéusdviaybuYewenLuapertentcracepeofAEERASERINsofedy.Ci-10+StudyXxy

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[1amistheworstthingthatcouldhappentoyouasachemicalengineerinindustry?Solution:Mostpeoplewouldprobablyagreethattheworstthingthatcouldhappentoyouasachemicalengineeristoberesponsibleforthedeathofafellowemployeeorfriend.AHdtypicalresponsefromsomestudentsmightbethattheworstigthingthatcouldhappentothemistomakeamistakeinahecalculation!Thisismostlikelyduetothecalculational138natureoftheChEcurriculum.53thE0){1s]anexplosionhasogcyrredinyourplantandenemployeehasbeenkilled.Aninvestigationshowedthattheaccidentwasthefaultofthedeademployeewhomanuallychargedthewrongingredienttoareactorvessel.Whatistheappropriateresponsefromthefollowinggroups?a.theotheremployeeswhoworkintheprocessareaaffectedb.theotheremployeeselsewhereintheplantsite¢.middlemanagementd.-uppermanagemente.thepresidentofthecompanyf.theunionSolution’Oursocietyismuchtoohung-uponfindingfault.Theproblemthiscreatesisthatoncethe"guiltyparty"hasbeenidentified,manypeoplebelievetheproblemhasbeensolved.Themostappropriateresponsefromallgroupsistoaskthequestion"Whatcanwedotopreventthisaccidentfromoccurringagaininthefuture?"andthenworktogetherto{achievethisobjective.Thus,thefollowingactivitiesmightbeinitiatedbytheindicatedgroups:Employeesinprocessareaaffected:redesignworksituationto,reducehumanerrordesigninterlockstopreventproblem.lookelsewhereforsimilarproblemsCl-1}

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\Employeeselsewhereatplantsite:lookatprocesstoidentifysimilarproblemsManagement:employeetrainingprogramsafetyauditsinvokehazardidentificationmethodsimprovemanagementsystemsUnion:poereviewemployeeandmanagementperformancetoinsuregadthatcorrectionsareimplementedandareactuallyF333working3288insuringthatemployeesunderstandthenatureoftheficeproblemarehavethecorrectattitudetowork38towardsitssolutionddd1-16[¥ouhavejustbegunworkatachemicalplant.Afterseveralweeksonthejobyoudeterminethata)theplantmanagerrunstheplantwithanironfist.Heisafewyearsawayfromretirementafterworkinghiswayupfromtheverybottom.b)anumberofunsafepracticesareperformedattheplant,includingsomethatcouldleadtocatastrophicresults.Youbringuptheseproblemstoyourimmediatesupervisorbuthedecidestodonothinginfearthattheplantmanagerwillbeupset.Afterall,hesays,“Weveoperatedthisplantforfortyyearswithoutanaccident.”Whatwouldyoudointhissituation?Solution;Somepossibleresponsesare:QuitjobandlookforemploymentelsewhereGooverimmediatesupervisordirectlytoplantmanagerSendanonymouslettertoOSHAdetailingproblemsSecretlyworkwithotherplantpeopletosolveproblemsAmasstechnicalinformationtoconvincesupervisorthatyouarecorrectandproblemsmustbecorrectedThelastresponseisprobablythe"best"waytohandletheproblem,atleastintheshortterm.Youmightconsiderdevelopingafew"quickfixes"forexistingsafetyproblemsthatcanbedoneeasilyandwithminimalcosttobuildupconfidencewithyoursupervisor.ACi~12.aie‘2hSE,

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iia.Youwalkintoastoreandafterashortwhileyoudecidetoleave,preferringnottodoianybusinessthere.Whatdidyouobservetomakeyouleave?Whatconclusionsmightyoureachabouttheattitudesofthepeoplewhomanageandoperatethisstore?b.Youwalkintoachemicalplantandafterashortwhileyoudecidetoleave,fearingthateetheplantmightexplodeatanymoment.Whatdidyouobservetomakeyouleave?IzWhatconclusionsmightyoureachabouttheattitudesofthepeoplewhomanageand28operatethischemicalplant?53|daa,Commentonthesimilaritiesofpartsaandb.i;0)SowuTion}a.Youmightobservethatthestoreisamessortheemployeesarenotprovidingthecorrectservice.Inanycase,youdecidethatthepeoplewhomanageoroperatethestoresimplydonotcare.Iftheycaredabouttheirstorethenitwouldbeoperatedefficientlyandcleanlywithsalespeoplewiththecorrectattitude.~b.Youmightobservethatthechemicalplantisamess,propersafetyproceduresarelacking,ortheemployeesdonothavethecorrectattitudewithrespecttosafety.In)anycase,youdecidethatthepeoplewhomanageoroperatethechemicalplantsimplydonotcare.Iftheycaredabouttheplantthenitwouldbeoperatedefficientlyandsafelywithemployeeswhohavethecorrectattitude.Bothcasesareamazinglysimilar.Theessentialingredient,however,isthatthepeoplewhomanageandoperatetheplantmustcare.Furthermore,inorderfortheemployeestocare,themanagementmustcare.Inorderformanagementtocare,thepresidentmustalsocare.e\-13

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—ee—————————————————————————Withoutthehighlevelalarm,theoperatorwasrequiredtopayattentiontothetanklevelasthetankwasfilled.However,oncethehighlevelalarmwasinstalledtheoperatordecidedthatheorshecouldrelyonthealarmtoalerthimorherwhenthetankwasfilled.Thereliabilityofthehighlevelalarmwaslessthanthereliabilityoftheoperatormanuallyfillingthetank.Thus,thenumberofoverfillsincreased.—————————————————————————————————————————————————————Ifyoupronounce“J1001”and“JA1001”theybothsoundthesame.Thus,whentheoperatorwastoldtoprepareJA1001,heheardJ1001sincetheysoundthesame.Equipmentmustbeclearlyidentified,evenwithrespecttopronunciation.———————ee————————————————————kTheboltsshouldbeloosened,butnotremoved.Thenthecoverplateisprieduptoloosenit.Ifliquidcomesouttheboltscanbere-tightenedtostoptheflow.Asimplechangeinthisprocedurehasaclearimpactonsafety.cl~Y

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eesmeaSOEUYNTWOe113IRESmAesos2re,Ton0eneamed|Theliquidlevelinatank10metersinheightisdeterminedbymeasuringthepressureatthebottomofthetank.Thelevelgaugewascalibratedtoworkwithaliquidhavinga%specificgravityof0.9.Iftheusualliquidisreplacedwithanewliquidwithaspecificgravityof0.8,willthetankbeoverfilledorunderfilled?Iftheactualliquidlevelis8meters,whatisthereadingonthelevelgauge?Isitpossiblethatthetankwilloverflowwithoutthelevelgaugeindicatingthesituation?SowaTion$:INTheforceatthebottomofthetankisgivenbyF=n(&)F9g.c,Ci-15+StudyXxy

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