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Individual Assignment 1 PDF

The document discusses a refinery in Malaysia and analyzes whether various OSHA regulations apply given its operations and workforce size. It asks how to categorize the refinery's risk and recommends safety improvements. It also provides data to calculate injury and accident rates, and asks about fatality expectations from occupational, driving, and recreational activities.

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Dimas Andrya
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288 views

Individual Assignment 1 PDF

The document discusses a refinery in Malaysia and analyzes whether various OSHA regulations apply given its operations and workforce size. It asks how to categorize the refinery's risk and recommends safety improvements. It also provides data to calculate injury and accident rates, and asks about fatality expectations from occupational, driving, and recreational activities.

Uploaded by

Dimas Andrya
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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INDIVIDUAL ASSIGNMENT

Question 1 (CO1)
Accidents in Chemical process industries constitute major threat to property and population
because of the magnitude. With the rapid development in science and technology, several new
innovations have come up and Chemical process industries (CPI) deal with thousands of new
chemicals and several processes.
Disaster is an accident / event that can lead to tremendous destruction to the environment,
equipment, plant and people. The consequences of the chemical disaster are the chemical toxic
gas release and dispersion. Some of the worst disasters of toxic releases have occurred in toxic
chemicals like MIC, Ammonia, and Chlorine cyclohexane.
According to above scenario, list 3 factors that contributing of CPI incidents and describe briefly.
Then you are also requires to describe briefly 2 factors that can overcome the mentioned CPI
incidents.

Question 2 (CO2)
a. Give definitions of these words: Risk, Accident, Hazard, Risk Assessment and Incident.

b. Pauh City refinery in Perlis, Malaysia was built in 2001. The process units in the plant being
operated include a 60,000 barrels/day vacuum distillation, a 25,000 barrels/day catalytic
reformer, a 35,000 barrels/day desulfutization unit and a 20,000 barrels/day delayed coker. The
company has 165 workers.
i. Analyze the company’s operation whether the company need or not apply the
following sections of OSHA 1994. Provide your reasons.

I. OSHA 1994 Section 15


II. OSHA 1994 Section 16
III.OSHA 1994 Section 21
IV.OSHA 1994 Section 29
V. OSHA 1994 Section 30

ii. If you are a DOSH officer and was asked by the Director General of DOSH to
recommend whether this installation (at Pauh City Refiney in Perlis) would be
categorized as major hazard or not, please describe how you would doing your job?
(refers to CIMAH)

c. Plant A has started the operation at 1998 with total workers of 800. After operating for 5 years,
the plant had 63 reportable lost time injuries with a resulting 312 lost workdays. Compute the
OSHA incidence rate based on injuries and lost workdays. If on average each worker spends 4
hrs/day driving and 3 hrs/month canoeing, how many members will die due to occupational
accident, road accident and canoeing within 5 years?
d. If you drive a car with an average speed of 100 miles per hour, how many miles must be
driven before a fatality is expected.

Question 3 (CO2)
a. The main implementation strategy of OSHA 1994 is through “self-regulation” concept.
Explain this concept and its requirement to be effective.
b. As a Safety and Health Officer (SHO) of a chemical processing facility; discuss the key
elements to be considered for effective OSH Management System.
c. Name the four categories of chemical process strategies ?
d. Choose any two categories from your answer in question (c) and explain by giving an
example from industry.
e. Do you agree with the statement “Inherently Safer Design (ISD) will eliminate all hazards”
and why?
d. Give one advantage and one disadvantage of a rupture disc as compared to a spring loaded
pressure relief device.
e. It is frequently installed in series with spring loaded pressure relief device e.g. relief valve.
Why? Give two reasons.

Question 4 (CO6)
You are required to carry out CHRA for a work unit in XYZ Sdn. Bhd. which utilises chloroform in its
work activities. The work unit consists of 20 male workers and 10 female workers. The workers work 4
days a week, 12 hours a day. On average, they stay in the work unit 10 hours per day. Answer the
following questions based on the given information and the following simplified MSDS of Chloroform:

MSDS of Chloroform

Physical data
Melting point: -63 ˚C Boiling point: 60.5 ˚C
Specific gravity: 1.49 Vapor density: 4.1 (Air = 1) Odor threshold = 100 ppm

Stability
Stable. Under normal conditions of storage and use, hazardous reactions will not occur.
Substances to be avoided include oxidizing materials, metals and alkalis.

Toxicity data Risk Phrases


(a) Explain the meaning of these toxicity data of chloroform using the language which can be understood
LD
by (rat)school
a 50high = 695mg/kg
student.(oral) R22, R38
LD
LC5050(rat)
(rat)==695mg/kg
6 mg/litre(oral)
LC50 (rat)
PEL = 6 TWA)
(8-hour mg/litre= 10 ppm
(b) Determine the hazard rating (HR) for the work unit.
(c) The magnitude rating (MR) of the work unit is determined as 3. Determine the exposure rating (ER) of
the work unit.
(d) Determine whether the risk of the work unit is significant.
(e) Give 2 recommendations for this work unit.
(f) As you walk into the work unit, you could smell the odor of chloroform. What would be your action in
responding to this situation? Justify your answer. (Hint: refer to the MSDS of chloroform)
(7 marks)

You might need to refer to these tables:

Table 1: Hazard Rating Based on Risk Phrases


Table 2: Frequency Rating

Table 3: Duration Rating

Table 4: Exposure Rating


Question 5 (CO3)
As the HSE engineer in your company, you have been assigned to perform a Hazard and
Operability Studies (HAZOP) on a heat exchanger unit which is used to heat flammable, volatile
solvents. The temperature of the outlet stream is measured by a thermocouple, and a controller
valve manipulates the amount of steam to the heat exchanger to achieve the desired set point
temperature.
(a) Briefly describe how you are going to undertake this task.
(b) Show the HAZOP study in a table to be presented to the management team. Choose
TWO (2) parameters and for each parameter, choose TWO (2) guide words. Suggest
possible modifications to improve the safety of this process.
(c) Sketch the piping and instrumentation diagram (PI&D) of the heat exchanger unit after
the HAZOP study.

Question 6 (CO3)
(i) In your own words, explain the importance of Hazop and Operability Studies (HAZOP)
for a chemical process plant. When should you do the HAZOP analysis?
(ii) Flammable, volatile solvent ‘A’ is heated in a heat exchanger using steam as the heating
medium. The temperature of the outlet stream is measured by a thermocouple, and a controller
valve manipulates the amount of steam to the heat exchanger to achieve the desired set point
temperature. Control valve V1 is used to control the flow of solvent ‘A’ to the heat exchanger.
(a) Sketch the schematic diagram of this process.
(b) Perform a HAZOP study by choosing TWO parameters and TWO guide words
for each parameter. The focus should be on getting “hot solvent from heat exchanger”.
Recommend possible modifications to improve the safety of this process.

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