CH 1 Introduction  Creating a Regulation: 1(Authorized organization or agency decides if a reg is needed, then
 Safety Programs: Safety, Attitude, Fundamentals, Experience, Time, You.
 Engineering Ethic’s: Table 1-1
# of injuries X 200000
 Accident and Loss Statistics: OSHA (injuries and illness) = 𝑇𝑜𝑡𝑎𝑙 ℎ𝑜𝑢𝑟𝑠 𝑤𝑜𝑟𝑘𝑒𝑑 𝑏𝑦 𝑒𝑚𝑝𝑙𝑜𝑦𝑒𝑒𝑠
# of fatalities
# of workdays X 200000
 OSHA (workdays) = 𝑇𝑜𝑡𝑎𝑙 ℎ𝑜𝑢𝑟𝑠 𝑤𝑜𝑟𝑘𝑒𝑑 𝑏𝑦 𝑒𝑚𝑝𝑙𝑜𝑦𝑒𝑒𝑠; FAR = 𝑦𝑒𝑎𝑟
𝑇𝑜𝑡𝑎𝑙 ℎ𝑜𝑢𝑟𝑠 𝑤𝑜𝑟𝑘𝑒𝑑 𝑏𝑦 𝑒𝑚𝑝𝑙𝑜𝑦𝑒𝑒𝑠
, SDWA 1974 Safe Drinking Water Act TSCA 1976, 1986 Toxic Substances Control Act RCRA
# of fatalities
𝑦𝑒𝑎𝑟
Fatality Rate = 𝑇𝑜𝑡𝑎𝑙 # 𝑜𝑓 𝑝𝑝𝑙 𝑖𝑛 𝑝𝑜𝑝.
. Table in book for statistics T 1-3, 1-4.
 Acceptable Risk: We cannot eliminate risk entirely. No engineer should ever design a process that
he or she knows will result in certain human loss or injury
 Public Perception: The general public has great difficulty with the concept of acceptable risk.
Involuntary nature of acceptable risk.
 Number of Accident: Initiation: the event that starts the accident; Propagation: the event or
events that maintain or expand the accident; Termination: the event or events that stop the
accident or diminish it in size.
 Inherent Safety: Minimize (intensification), Substitute (substitution), Moderate (attenuation and
limitation of effects), Simplify (simplification and error tolerance).
 Significant Disasters: Flixborough ( June 1974, UK, 70000 tons per year of caprolactam, reactor
in series, reactor 5 went down and was bypassed and exploded at bypass, 30 tons of cyclohexane
vaporized, explosion leveled entire complex, 28 dead 36 injured); Bhopal (12/3/84, 2000 civilian
deaths, Madhya Pradesh in central India, methyl isocyanate (MIC) very dangerous and volatile,
exothermic with water, exact cause unknown, 25 tons MIC released; Seveso (TCDD dioxin
undesirable side product, toxic to humans, 7/10/76, 2 kg TCDD released 10 sq miles contaminated,
area uninhabited; Pasadena (10/23/89, 23 fatalities 314 injured $715 mil, 85000 lbs flammable
mixture released, gas cloud that ignited 2 mins after release, damage hid cause, in polyethylene
product takeoff system, SOP not followed DEMCO valve left open; Texas City (3/25/2005, ISOM
unit, CSB investigation, 15 dead, 180 injured, startup over loaded no flare vapor fires and
explosions; Jacksonville (12/19/07, 4 dead 32 injured, MCMT in 2500 gallon batch, 175th batch of
MCMT at 390 F unwanted side reaction, equivalent 1400 lbs TNT, debris over 1 mile away); Port
Wentworth (2/7/08 14 dead 36 injured sugar dust explosion, conveyors caused explosion of dust,
CSB investigation)
CH 2 Toxicology
 How Toxicants enter organism: Ingestion (through the mouth into the stomach) no eating
drinking smoking; Inhalation (through the mouth or nose into the lungs) ventilation respirator hood
PPE; Injection (through cuts into the skin) PPE; Dermal absorption (through skin membrane) PPE
 How toxicants are Eliminated: Excretion (through the kidneys liver lungs or other organs);
Detoxification (by changing the chemical into something less harmful by biotransformation);
Storage (in the fatty tissue)
 Responses to toxicants 2-3: Respiratory problems with spirometer; Nervous system disorders
mental status; Skin texture, pigmentation, vascularity, blood counts.
 Dose v Responses: Section 2-5 and 2-6 Probit variable equation Y=k1+k2lnV; Trans from %
to Probit T 2-4; Probit Correlations T 2-5
 Threshold Limit Values T 2-7 TWA (Time weighed average, 8 hr workday, 40 hr workweek, no
lifetime effects); STEL (short term exposure limit, 15 min TWA in 1 workday with no suffering);
C (ceiling, never be exceeded)
22.4 𝑋 𝑇 𝑋 1 𝑚𝑔 𝑇 𝑚𝑔
 Cppm=𝑀 𝑋 273 𝑋 𝑃 ( 𝑚3 ) = 0.08205(𝑃𝑀)( 𝑚3 )
 LD50 (lethal dose 50) MC
 Relative Toxicity Section 2-7
CH 3 Industrial Hygiene
 Anticipation (expectation of the presence of workplace hazards and worker exposures);
Identification (determination of the presence of workplace exposures); Evaluation (determination
of the magnitude of the exposure); Control (application of appropriate technology to reduce
workplace exposures to acceptable levels NIOSH National Institute for Occupational Safety and
Health Administration EPA Environmental Protection Agency
 Government Regulations: OSHA 1970 Occupational Safety and Health Administration DHS
Department of Homeland Security
 Creating a Law: 1(Member of Congress proposes a Bill, if approves=Law); 2(If both Houses of
Congress approve Bill goes to President, if signed=Act); 3(Text of Law is published in USC,
official record of all federal laws)
researches develop and proposes a reg. Sent to FR so public can evaluate and send comments that
are used to revise reg); 2(after reg is rewritten sent to FR as final rule and codified in CFR, code of
federal regulations)
 Important Acts: OSHA 1970 Occupational Safety and Health Act CWA 1972 Clean Water Act
1976 Resource Conservation and Recovery Act CERCLA 1980 Comprehensive Environmental
Response Compensation and Liability Act HSWA 1984 Hazardous and Solid Waste Amendment
SARA 1986 (SARA 313 Right to Know) Superfund Amendments and Reauthorization Act
 Process Safety Management(a. PSM OSHA b. RMP EPA): 1. Employee Participation or Process
Safety Information, 2. Process Safety Information of Hazard Evaluation, 3. Process hazard analysis
or Standard Operating Procedures, 4. Operating procedures, 5. Training, 6. Contractors, 7. Pre-
Startup review, 8. Mechanical integrity or Maintenance, 9. Hot Work Permits, 10. Management of
Change, 11. Incident Investigation or Accident investigation, 12. Emergency planning and
Response or Emergency Response, 13. Compliance Audits or Safety Audits, 14. Trade Secrets (add
Risk Assessments for EPA)
 Risk Management Plan RMP (Hazard Assessments, Prevention Program, Emergency Response
Programs, Documentation that is maintained on the site and submitted to federal, state, and local
authorities)
 Evaluation of Exposure Section 3-3: (Volatile Toxicants p 84, Dust p 88, Noise p. 89, Vapors
p. 91
 IH: (Anticipation and Identification Section 3-2, Evaluation 3-3, Control 3-4)
 IH Control: p 101 Respirators (only for temporary time, emergency equipment, last resort in
event environmental control fails) p103 Ventilation (can quickly remove dangerous concentrations
of flammable and toxic material, highly localized, reducing the quantity of air moved and
equipment size, readily available and easily installed, can be added to existing facility) Local
ventilation (Enclosed hood contains contaminant, exterior hood draws contaminants into an
exhaust for some distance away, receiving hood exterior hood that uses the discharged motion of
the contaminant for collection, push pull hood uses a stream of air form a supply to push
contaminants toward an exhaust system.) Dilute ventilation (limitation not toxic, evolved in
uniform rate, workers must be a distance away, no scrubbing system must be required.
 Videos: Piper Alpha (UK, 7/6/88, 167 dead, $3.4 bil, 61 workers escaped and survived, continued
to produce even after alert signal at first facility), Bhopal (India, 12/2-3/84, MIC 500000 exposed,
chloroacne, shantytown, 8000 died within 2 wks, over 550000 injured), Imperial Sugar (Georgia,
US, 2/7/08, Port Wentworth, (13 dead 40 injured, sugar dust explosion, new safety regs on dust
instituted)
Homework Problem Equations Per Problem
 1-5 (FAR) 1-7 (Initiation, Propagation, Termination) 1-9 (OSHA incident rate injuries and
workdays) 1-23 (MCpΔT=Q) 1-28 (A=πr2, P=F/A) 1-29 (Multi-Step Process) 1-31 (Sloshing 20%-
80% Full)
 2-2 (Y=slope*log(dose)+intercept eq 2-5) 2-3 (Probits, table 2-5, Y=K1+K2ln(Po), changes by type
22.4 𝑋 𝑇 𝑋 1 𝑚𝑔 𝑇 𝑚𝑔
of death) 2-5 (Qv//, Cppm=𝑀 𝑋 273 𝑋 𝑃 ( 𝑚3 ) = 0.08205(𝑃𝑀)( 𝑚3 ), to ft^3/min) 2-7 (amount of acetone
evaporated, V=LWH, Total V of room(Volume of Acetone or Cppm Acetone, Ideal Gas Law
PV=nRT to n=PT/RT) 2-12 (IDHL, PEL, TWA) 2-17 (Conc.//, T 2-4 and 2-5, y=K1+K2CK2T,
V=CK2T) 2-24 (Conc.//, Y=K1+K2mV and T PROBITS) 2-32 (Grams Benzene in lungs/8hr & #
drops if drop = 0.05 mL, Vol Fract of Benzene (10*10 -6L Benzene/I L gas, Total inhaled/shift=(0.5
L/Breath)*(12 Breath/min)*(60 min/hr)*(8hr/shift), Vol of Ben inhaled= (2880 L(10*10 -6L
Benzene/I L gas), MW Benzene, Ideal Gas Law n=PV/RT, mass of benzene= n(MW), Vol of
Benzene=(mass of Benzene* spec grav), V benzene/.05 mL=drops total)
 3-1, 3-2, 3-3 (Threshold Limit Value from App) 3-7 (end point parameters for consequence analysis,
worse case scenarios) 3-12 (hazards associated with material) 3-17 (Conc. Of Toluene//, App E, ln
(Psat)= A- B/C+T, Dalton’s Law: X=Psat/P, convert to PPM) 3-21 (Time to evaporate all
Toluene//, Qm= MKAPsat/RgTL, find K:K=Ko(Mo/M)1/3, A=πd2/4, lnPsat=A-B/T+C, Qm, look
at problem 3-16 for time equation, Use eq 3-14 for conc in PPM, kCppm=KAPsat/kQvP * 106, put
PPM/k either 0.1 or 0.5 dependent on mixing for entire TLV on spectrum) 3-25 (splash filling//,
using eq 3-24 Cppm=Psat/KQvP * (φrfVc+KA) * 106, assume splash filling so φ=1 p 93,
remember to put Cppm/k and k can range from 0.1 to 0.5, hood should have a velocity = 100 ft/min
for hood) 3-15 (TLV- TWA, STEL, C from table data) 3-31 (Cppm and TLV//, eq 3-24 Cppm=
Psat/KQvP (φrfVc+ KA) * 106, rf(fill rate)=(1vol/30min)(1min/60sec), Vc (Volume of
container)=πd2/4 * h, φ=1 for splash filling, K=Ko(Mo/M)1/3, lnPsat=A-B/T+C)
 Chapter 4 Source Models  Chapter 10 Relief Sizing
o Liquid Flow  Conventional Spring operated Reliefs in Liquid Service (Ex 10-1, Sec. 10-1)
 o Gas (Sec 10-2)
Flow of Liquid through a hole (Ex 4-1)
 Use of non-corrected and correct equation for calculating the area of the PRV (p.449)
 Hole in Tank (Ex 4-2)  Know how to calculate Reynolds number
 Flow of Liquids through pipes (Ex 4-3)  Calculations for conventional and balanced bellows PRV for liquids (Ex 10-1, Sec 10-1)
o Gases Flow  The use of Figures 10-1 thru 10-4
  Review Example 10-1
Vapor through holes (Ex 4-4)
 Calculations for conventional and balanced bellows PRV for vapors (Sec 10-2, Ex 10-2)
 Adiabatic Flows (Ex 4-5)
 Know how to use Figures 10-5 and 10-6
 Isothermal Flows (Ex 4-5)
 Review Example 10-2
 Flashing of Liquids (Ex 4-6,7,8)
 Know how to calculate the area of Rupture Disks in vapor and Gas service (Sec 10-4, Ex
 Liquid Pool evaporation or boiling (p.167)
10-4, 5)
o Conservative Analysis (S 4-10)
o Problems (Handwritten Explanations)  Calculate the area of a SRV to address two-phase releases (Sec 10-5, Ex 10-5)
 Leak Rate of Fluids from containers (p. 1, 19, 23, 40)  Know how to use figure 10-8
 Pressure in piping (p.11)  Review examples 10-3 & 10-4
 Leak rate of gases from containers (p.4)  Know how to use Nomographs and Figure 10-9
 Size of orifice required to reduce gas flow rate during releases (p.25)  Calculate the area of deflagration Venting for Dust and Vapor Explosions (Sec 10-7)
 Flow of gas in pipes (p.14)  Work example 10-5
 Size of dike to prevent liquid releases (p.33)  Review example 10-6
 Chapter 9  Calculate the area for vents for low and high pressure structures
o Low (Ex 10-7)
 Relief Concepts: 1 To protect personnel from the dangers of over pressuring equipment. 2. To o High (p. 473, Ex 10-8)
minimize chemical losses during pressure upsets 3. To prevent damage to equipment 4. To  Calculate the area for SRV for venting vessels exposed to external Fires (Sec. 10-8, Ex
prevent damage to adjoining property 5. To reduce insurance premiums 6. To comply with 10-8)
government regulations.
 Set pressure: The pressure at which the relief device begins to activate. Maximum Allowable
Working Pressure: The maximum gauge pressure permissible at the top of a vessel for a
designated temperature. This is sometimes called the design pressure. Operating Pressure:
The gauge pressure during normal service, usually 10% below the MAWP Accumulation:
The pressure increase over the MAWP of a vessel during the relief process. Overpressure:
The pressure increase in the vessel over the set pressure during the relieving process.
Overpressure is equivalent to the accumulation when the set pressure is at the MAWP.
Backpressure: The Pressure at the outlet of the relief device during the relief process resulting
from pressure in the discharge system. Blowdown: The pressure difference between the relief
and set pressure and the relief reseating pressure. It is expressed as a percentage of the set
pressure. Maximum allowable accumulated pressure: The sum of the MAWP and the
allowable accumulation. Relief System: The network of components around a relief device.
 Locating Reliefs: Look at 9-3
 Types of Characteristics
o Spring: the valve opens based on the pressure drop across the valve seat; that is,
the set pressure is proportional to the pressure drop
o Disk: rupture disk are specially designed to rupture at a specified relief set
pressure
o Buckling Pin: similar to a rupture disc, when the pressure buckles the pin, the
valve opens fully. Advantage: buckles at exact pressure, disadvantage: when
buckles valve stays open
 Chatter: is the rapid opening and closing of a relief valve that can cause valve seat damage or
the mechanical failure of the internals. Caused by oversized relief valve. Solutions 1. Use
larger inlet pipe sizes and fewer elbows and constrictions 2. Increase the size of exit lines and
eliminating elbows and constrictions 3. Use different size valves to cover the range of release
scenarios
 Relief Systems
o Relief Design Considerations p.437
o Knockdown Drums, Flares, Scrubbers, Condensers 438-442