CKB 30103 & CKB 30203 INDUSTRIAL SAFETY AND HEALTH

TUTORIAL 3

1. The chemical reaction involves 2 liquids, A & B, which flow from their respective
storage tanks into the stirred product C reactor. The flow rate of materials A & B is
regulated by control valves A & B, respectively. The liquid phase chemical reaction
that results is highly exothermic & generates considerable quantities of heat, which
must be controlled by cooling water on the jacket of product C reactor. The reaction
of materials A & B to produce product C proceeds rapidly& product C is drawn off
from the bottom of the reactor. Product C flows through valve C into the product C
storage vessel to await shipment. The reactor & each of the storage tanks have
pressure-operated relief valves in case of pressure buildup during the process
operation. Temperature, pressure and level indicator are provided in the product
C reactor for use in controlling process chemistry.
Carry out HAZOP study using appropriate OSHA guide words for the process
parameter FLOW using HAZOP worksheet.

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 CKB 30103 & CKB 30203 INDUSTRIAL SAFETY AND HEALTH
TUTORIAL 3

2. Calculate the probabilities of the top event if given the component failure rate as
shown in the table below.

Component Failure rate

Motor 0.05 / year
Battery 0.10 / year
Connectors 0.5 / year
Switch 0.10 / year
Human error 0.02 / year

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 CKB 30103 & CKB 30203 INDUSTRIAL SAFETY AND HEALTH
TUTORIAL 3

3. Referring to following figure, sulfuric acid is pumped from an atmospheric storage

tank, T-1 to a pressurized process vessel, V-1.Two pumps can perform this
service; P-1 is driven by a diesel engine; P-2 has an electric motor. During normal
operations the system uses P-2.In the event of an emergency, P-1 can be switched
into service. If P-2 fails, the operator has 4 minutes to switch to P-1 before a
potential hazard occurs. There is a low-flow alarm, LA-1, to the process vessel, V-
1. Construct Event Tree Analysis with initiating event of failure of P-2.

LA
P1
V1
T1

P2

4. The Fault Tree Analysis for the top event MOTOR DOES NOT RUN WHEN
SWITCH IS PRESSES for the following diagram as shown below:

5. Carry out the risk assessment for Q4 of tutorial 2 for the following
a. Occupational accident cases of this company
b. Occupational poisoning and diseases.
6. Suggest the action that the management should be taken to reduce the risk to
ALARP. [Hint: Control measure]

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