..

-j Universiti
Malaysia
PAHANG

J1

Engineering Technology Creativity

FACULTY OF CHEMICAL & NATURAL RESOURCES ENGINEERING

FINAL EXAMINATION
COURSE

: OSH IN CHEMICAL INDUSTRIES

COURSE CODE

: BKC3533

LECTURER

: JUWARI PURWO SUTIKNO

MIOR AHMAD KIIUSHAIRI BIN MOHD ZAHARI

DATE

: 07 JANUARY 2013

DURATION

: 3 HOURS

SESSION/SEMESTER : SESSION 2012/2013 SEMESTER I

PROGRAMME CODE : BKC
INSTRUCTIONS TO CANDIDATE:
1.
2.
3.
4.

This question paper consists of FOUR (4) questions. Answer ALL questions.
All answers to a new question should start on new page.
All the calculations and assumptions must be clearly stated.
Candidates are not allowed to bring any material other than those allowed by
the invigilator into the examination room.

EXAMINATION REQUIREMENTS:
1.

Original hand writing summary on one (1) sheet paper A4 with lecturer's
endorsement (cop).

DO NOT TURN THIS PAGE UNTIL YOU ARE TOLD TO DO SO

This examination paper consists of SEVEN (7) printed pages including front page.

CONFIDENTIAL

BKC/121311BKC3533

QUESTION 1
On February 24, 1992, OSHA published the final rule "Process Safety Management of
Highly Hazardous Chemical". This standard is performance oriented; that is, it sets general
requirements for the management of hazardous chemical.
a) What the accident that encourage the Process safety Management (PSM) was
developed?
(3 Marks)
b) Give the conclusion what is the definition of PSM?
(3 Marks)
c) There are 14 elements of PSM, state EIGHT (8) elements of PSM.
(8 Marks)
d) One of the elements of PSM is contractor. Give the reason, why the contractor is
included in the PSM element?
(4 Marks)
e) Explain TWO (2) methods of Process Hazard Analysis (PHA).
(7 Marks)

QUESTION 2
a) Toxicity can be classified into two types; acute toxicity and chronic toxicity.
i)

Give the most suitable definition for toxicity

ii)

Compare the differences between acute and chronic toxicity

(3 Marks)
2

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BKC/1213I1BKC3533

b) Toxicant can enter biological system by many ways. Explain the entry routes and the
method to control of toxicant into biological system.

(4 Marks)

A group of students are tested for skin irritation due to the usage of skin products. The

c)

following are the data findings of toxicity analysis involving the effect of different
skin products upon a specific number of students.

Table 1: Percentage of individuals affected by product of A and B at different

dose
Dose of skin

Dose of skin

Total of

% of students

% of students

product A

product B

students

affected from

affected from

(mg/1)

(mg/1)

product A

product B

10.2

20.3

100

84

84

7.7

17.6

100

72

72

5.1

10.5

100

64

64

3.8

3.0

100

35

35

2.6

1.3

100

21

21

100

1)

Draw a response versus log dose graph for both product A and B on a same
graph paper.
(10 Marks)

ii)

Determine which product is more toxic based on 50 percent response. State your
reason.
(4 Marks)

iii)

What conclusion can you made, based on the result of (a) about the toxicity of
both products.
3

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BKC/121311BKC3533

QUESTION 3
A field engineer makes a morning inspection. The morning inspection finds a leak in the
liquid chlorine tank (at atmospheric pressure). An investigation finds that the leak was 0.2
in in diameter and 10 ft above the tank bottom and the field engineer immediately repair
the leak. Records show that the liquid chlorine level in the tank was 21 ft before the leak
occurred and 18 ft after the leak was repaired. The tank diameter is 15 ft. The density of
liquid chlorine at these conditions is 65 lbm/ft3.
a) Calculate the total amount of liquid Chlorine spilled (ibm)
(4 Marks)
b) Determine the maximum spill rate
(11 Marks)
c) Estimate the total time the leak was active
(10 Marks)

QUESTION 4
a) Give the definition for the following terms:
i)

Combustion

ii)

Ignition

iii)

Auto-ignition temperature
(3 Marks)

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BKC/12131/BKC3533

b) Draw a flammability diagram for methane at an initial temperature and pressure of 25

and 1 atmosphere, respectively.
Given: CITh HX OY + z02 -* mCO2

+ x H2

Stoichiometric line intersection: ioo(_)

1+z
(12 Marks)
c) A storage vessel containing a mixture of 60% methane, 20% oxygen and 20% nitrogen
is considered.
i)

If there is a significant energy of ignition source exist, would there be a fire

occur? Please provide an explanation for your answer. You need to use the
flammability diagram from 2 (b) to justify your answer.
(2 Marks)

ii)

As a chemical engineer, you are responsible to fill this vessel safely with pure
air. Please provide some suggestions/ steps to complete the task. You need to
use the flammability diagram from 2 (b) to justify your answer.
(8 Marks)

END OF QUESTION PAPER

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BKC/121311BKC3533

APPENDIX: Related data

Table 1: Limiting Oxygen Concentrations (LOCs) (volume percent oxygen

concentration above which combustion can occur)
Table 6-2 Limiting Oxygen Concentrations (LOCs) (volume percent
oxygen concentration above which combustion can occur)1

Gas or vapor

N2/Air

Ethylene
Propylene
1-Butene
isobutyiene
Butadiene
3-Mcthyl . l-hutene

12
ii
11.5
12
12
12 .
12
12
11.5
10
11.5
11.5
12
10.5
11.5

Benzene
Toluene
Styrene
Ethylbenzcne
Viltolene
Diethvlbenzenc
cyclopropane

11,4
95
9.0
9.0
90
8.5
11.5

Methane
Ethane
Propane
n.Butane
Isobutane
n-Pentane
Isopentnne
n-Hexane
i-Heptane

CO2/Air

Gas or vapor

14,5

Kerosene
JP-1 fuel
JP-3 fuel
JP-4 fuel
Natural gas
n-Duty! chloride

13.5
14.5

14.5
15
14.5
14.5
14.5
14.5
U.S
14
14
1.5
13
14
14
14

Gasoline
(73/100)

(1001130)
(1151145)

12
12
12

15
15
145

'Data from NFPA 68, Vcming of Deflarains(Quincy,

Methylene chloride
Ethylene dichloride
Methylchioroform
Trichloroethylcnc
Acetone'
i-butanoi
Carbon disulfide
Carbon monoxide
Ethanol
2-Ethyl butanol
Ethyl ether
Hydrogen
HydrognsuHide
isohutyl formate
Methanol
Methyl acetate

CO2/Air

N2/Air

13 (150C)
10 (150C)
10.5 (150C)
14(150C)
12
14.5
11.5
14.5
14.5
12
14
12 (100C)
19 (30C)
17(100-C)
13
11.5 (100C)
14
9 (101)C)
11.5
NA,
5
5.5
10.5

14

16.5 (150C)
7.5
5.5

9.5 (150C)

105
5
7.5
12.5

10
Ii

13
13
5.2
11,5
15
12
13.5

MA: NtionaA Fire Protection Association, 1994).

N.

BKC/121311BKC3533

CONFIDENTIAL
Table 2: Flammability Limits in Pure Oxygen

Table 6-3 Flammability Limits in Pure Oxygen

Limits of flammability
in pure oxygen
Compound

Formula

Hydrogen
Deuterium
Carbon monoxide-'
Ammonia
Methane
Ethane
Ethylene

H2
D2
CO
NH
CM4

Propylene

C31-1

Cyclopro pane
Diethyl ether

C3H6
c4HL00

Divinyl ether

C4H60

CA
z.H4

Lower

Upper

4.0
5.0
15.5
15.0
5.1
3.0

94
95
94
79
61
66

3.0
2.1

80

2.5

53
60

2.0
1.8

82
85

'Data from B. Lewis and C. von Elbe. Combustion, Flames, and Explosions of Gases
(New York: Harcourt Brace Jovanovich, 1987).
2The limits are insensitive to p above a few mm Hg.