CONFIDENTIAL UNIVERSITI KUALA LUMPUR Malaysian Institute Of Chemical & Bioengineering Technology FINAL EXAMINATION JANUARY 2014 SESSION SUBJECT CODE : CKB 30102 SUBJECT TITLE : INDUSTRIAL SAFETY AND HEALTH LEVEL : BACHELOR TIME / DURATION : 3HOURS INSTRUCTIONS TO CANDIDATES . Please read CAREFULLY the instructions given in the question paper. . This question paper has information printed on both sides of the paper. . This question paper consists of two sections; Section A and Section B. |. Answer ALL questions in Section A and Section 8. . Answer all questions in English ONLY. THERE ARE 5 PAGES OF QUESTIONS, EXCLUDING THIS PAGE.JANUARY 2014 CONFIDENTIAL, SECTION A (Total: 60 marks) INSTRUCTION: Answer ALL questions. Please use separate answer booklet for this section. Question 1 (2) List four oriteria to determine safety probability in risk assessment. (4 marks) Gas combustion will generate two types of explosion; detonation and deflagration. Explain the term detonation (2 marks) Explain term of pyrophoric material (2 marks) Discuss four methods of controlling chemical hazard, (6 marks) ‘Ahmad works as a tanker driver with Petronas Dagangan Sdn Bhd. His job routine is to deliver chemical product to the customers. As a tanker driver, he should make sure that his vehicle should be fully equipped. State four materials that his tanker must have before proceed his journey. (4 marks) Question 2 (2) Explain three factors that influence toxicity (6 marks) (©) Compare the differences between Biosafety Level 2 and Biosafety level 4 by taking into account of risk group 2 and 4. ‘CKB 30102 INDUSTRIAL SAFETY AND HEALTH.JANUARY 2014 CONFIDENTIAL, (©) Alex has been working with Top Medical Devices Sdn. Bhd. for § years. He is exposed fo Methyl Ethyl Ketone (MEK) vepors in a day as shown in Table 1 Table 1: MEK exposure per day. | Duration of exposure [ Measured concentration (rn (opm) | 2 170 rr 330 | 4 ‘90 L Evaluate the 8-hr Time Weighted Average (TINA) exposure for Alex Decide whether the permissible exposure level has been exceeded. (TLV of MEK is 200ppm). (4 marks) li. Explain the methed how toxicant can be eliminated from human body. (a marks) Question 3 (2) i. Provide four types of machine guerd used to mitigate for mechanical hazards. (4 marks) li. List the reason of negative pressure Is better than positive pressure found in a building consist of noxious gas. (2 marks) (©) i. Explain the etement of “Perform dill 2t regular intervat" and “Perform postmortem meeting” as stated in emergency planning (marks) ji, State three elements of Process Safety Management. (marks) (CKB 30102 INDUSTRIAL SAFETY AND HEALTH 2JANUARY 2014 CONFIDENTIAL (©) Teble 2 shown below is accident statistic for selected industries. Assume total hours worked is 500 000 hours. Table 2: Accident statistic, | OSHA Incidence Rate industry __ 1890 1995 Chemical 050 O25 Food 3.28 2.20 | Construction 3.25 1.25 ‘Motor Vehicla 40 5 ‘Agriculture 728 240 Calculate the fatality rate of motor vehicle in 2010 if the number of employee of motor vehicle is 1200 workers. (4 marks) Determine the OSHA Incidence Rate in 1991 for the Food industries, if the accident rate is 75% higher than the rate in 1995. (4 marks) (CK 30102 INDUSTRIAL SAFETY AND HEALTH.JANUARY 2014 ‘SECTION 6 (Total: 40 marks) INSTRUCTION: Answer ALL questions. Please use separate answer booklet for this section. Question 4 @) ©) ©) CONFIDENTIAL, Based on the Material safety data sheet given in Appendix 1; construct a label for a drum of 300 liters of this chemical according to CLASS regulation 2013. (Hint: Label dimension is required] Write two branches of environmental health, (10 marks) (2 marks) Construct the Fault Tree Analysis from Figure 1; for the top event “MOTOR DOES NOT RUN" when switch is press. ae Battery Motor ++» Motor does not & run when switch is pressed Figure 4 (CKB 30102 INDUSTRIAL SAFETY AND HEALTH (8 marks)JANUARY 2014 CONFIDENTIAL Question 5 (2) During the routine inspection of DOSH officer toa chemical plant of 250 staff, NatChem ‘Sdn Bhd; the officer had issued noncompliance report due to no safety and health committee (SHO) at the workplace, Establish a safe and heath committee for NatChem according to the regulation. (Hint: Indicate number of members for SHC and its composition]. Write the reasons for each of your answer. (8 marks) (0) Write two Biosafety Leve! 3 (BSL 3) practices to control biohazard of risk group 3. (2 marks) (©) A100 kg tank of liquid propane (Cota) Is going to be installed to heat a house during winter. i. Determine the equivelent amount of TNT if it explode: assume the explosion efficiency is 1.5%. [The energy explosion for propane is 2110.3 ku/mol and the eneray of explosion Of TNT is 4686 kltky. MW: Carbon — 12; Hydrogen — 1. (3 marks) li Estimate the loss in term people death percentage, if the tank is going be located at 53.6m avray from the house. [Ambient pressure: 101.3kPa/ 14 7psia /101,325 Nima per atm]. (7 marks) END OF QUESTION (CKB 30102 INDUSTRIAL SAFETY AND HEALTH. 5APPENDIX + SIGMA-ALDRICH sioma-bich com SAFETY DATA SHEET acccecing to Reguiaion (EC) No. 1907/2006 Versicn 5:0 Revision Dete 09.08.2012 Print Date 04.08.2014 “ENERIC EU MSDS - NO COUNTRY SPECIFIC DATA - NO OBL DATA IDENTIFICATION OF THE SUBSTANCEIMIXTURE AND OF THE COMPANY/UNDERTAKING. Product identifiers Frodiot name Sodium hydroxide solution Product Number 415413 Brand Sigma-Aldrich Relevant identified uses of tho substance or mixture and uses advised against Kdentfied uses Lavoratory chemicals, Manufacture of substances Details of the supplier of the safety data sheet Company Sigma-Aldrich (M) Sdn. Bhd. A-07-14, Empire Office, Empire Subang Jalan SS16/1, $816 47500 SUBANG JAYA-SELANGOR DARUL EHSAN, MALAYSIA Telephone +60 (603) 668 53321 Fax +60 (603) 865 54116 Emergency telephone number Emergency Phone # HAZARDS IDENTIFICATION Classification of the substance or mixture Classification according to Regulation (EC) No 1272/2008 [EU-GHS/CLP] Skin corrosion (Category 1A) Classification according to EU Directives G7/S48/EEC or 1909145/EC Gauses severe burns. Label elements Labelling according Regulation (EC) No 1272/2008 [CLP] Pictogram Signal word Danger Hazard statements) Hot Causes severe skin bums and eye damage Precautionary sttement(s) P80 Wear proestve gloves/protectve clothing eye protecon! face srotecton. P05 + Past « P39e FINEYEG: Rinse cautiously with water for several minutes. Remove contact enses, present and easy to do. Continue énsing. rato Iramodiatly calla POISON CENTER or doctor physician Supplemental Hazard sone ‘Statements According to European Directive 67IS4S/EEC as amended Hazard symbol(s) = et Sloman 415413, Paget of 6Rephrase(s) Ras, Causes severe burns. S-phrase(s) S26 In case of contact with eyes, rinse immodiatoly with plenty of water and seek medical advice, $3739 Wear suitable cloves and eyeiface protection, S45 In case of acci¢ent ori you feel unwell, seek medical advice immeciately (show the label whore possible), 23° Other hazards - none ‘COMPOSITIONINFORNATION ON INGREDIENTS 32 Mixtures Formula Hao Molecular Weight 40,00 gimot [Compenent [Cassification [Concentration ‘Sodium hydroxide CAS-No. TsiO-7S2 ‘Skin Com, 1A, AS1E 50-00% EC-No. 215-485.5 C, Ras Index-No. 0)1-002-00-6 For the full text of the H-Statements and R-Phrases mentioned In this Section, see Section 16 &__ FIRST AD MEASURES 4.1 Description of first aid measures, General advice Consult a physician. Show this safety data sheet to the doctor in attendance. finhated Ifbbreathed in, move person inio frach cir. If not bresthing, give artificial respiration. Consulta physician, In case of skin contact Take off contaminated clothing and shoes immediataly. Wash off with soap and planty of wator. Consulta physician, In case of eye contact Rinse thoroughly with plenty of water fer at least 15 minutos and consult @ physician. If swallowed Do NOT induce vomiting. Never give anything by mouth to an uneanssious person. Rinse mouth with water. Consult a physician, 42 Most important symptoms and effects, both acute and delayed burning sensation, Cough, wheezing, laryngtis, Shortness of broath, epaem, inflammation and edema of the larynx, spesm, inflamnvation and edema of the bronchi, pneumonitis, pulmonary edema, Material is extremely destructive to tissue of the mucous mambranes and upper respiratory trac, eyes, and skin. 43 Indication of any immediate medical attontion and special treatment needed no data avaliable FIREFIGHTING NEASURES 5.1 Extinguishing media Suitable extinguishing media Use water spray, alcohol-rasistant foam, dry chemical or carbon dioxide. 5.2 Special hazards arising from the substance or mixture no data avaliable 53 Advice for firefighters, Sigme-Alerh 41543, \Viear seif contained breathing apparatus for firefighting f necessary. Pane? of &Further information no date evailable TACGIDENTAL RELEASE MEASURES: Personal precautions, protective equipment and emergency procedures: Use personal protective equipmont. Avoid brosthing vapors, mist or gas. Ensure adequete ventilation. Evacuate personnel to safe areas. Environmental precautions Prevent further leekage or spillage If sale to do so. Do nat let product enter drains. D’scharge into the environment must be avoided. Methods and materials for containment and cleaning up Soak up with inert absorbent material and dispose of as hazardous waste. Keep in sullable, cosed Containers for disposal Reference to other sections For disposal see section 15, HANDLING AND STORAGE Precautions for safe handling ‘Avoid inhalation of vapour or mist, CConcitions for safe storage, including any incompatibilities Siore in cool place. Koop container tightly closed in a dry and well-ventiated place. Conteiners which are Opened must be carefully resealed and kept upright to prevent leakage Specificend uses no data avaiable EXPOSURE CONTROLS/PERSONAL PROTECTION Control! parameters, ‘Components with workplace control parameters Exposure controls Appropriate engineering controls Handle in accordance with good incustial hygiene and safety practice. Wash hands before breaks and al the end of workday. Personal protective equipment Eyelface protection Tightly fittng safety goggles. Faceshield(8-inch minimum). Use equipment for aye protection tested end approved under anpropriate govemmert stardards such as NIOSH (US) or EN 165(EU). Skin protection Handle with gloves, Gloves must be inspected prior to use. Use proper glove removal technique (without touching glove's outer surface) to avoid skin contact with this product. Dispose of contaminated gloves afte use in accordance with applicable laws and good laboratory practoes, Wash and dry hands. ‘The selected protective gloves have to satsty me specificatons of EU Directive B9686/EEC and tho standard EN 374 derived from it. Body Protection Complete sult protecting against chemicals, Tha type of protective equipment must be selected according tothe concentration and emount othe cangercus substance at the specific workplace Respiratory protection ‘Where rick assessment shows air-punfing respiatore ere appropriate use aful-face respirator ‘wih mult-purpose combination (US) crtype ABEK (EN 14367) resprator carridges as a backup toenginesring control. I the respirator isthe sole means of protaction, use a full-face supplied ar Sigme-Aidich = 418419 Poze 3 ef 8respirator. Use respirators and components tested and approved under appropriate government standards such as NIOSH (US) or GEN (EU), PHYSICAL AND CHEMICAL PROPERTIES 9:4 Information on basic physical and chemical properties 8). Appocrance Form: iui Colour colouress b) Odour no data avalabla ©} OdourThreshold no data avalabio a) ph 180 €). Moling peintreszing ~12-10°C point £). nite bing point and 408 -140 °C toling range 9}. Flesh point notappicebio ‘h) Evaporation rate ‘no data available ji) Flammabiity (solid, gas) no data available 1) Uppartiower no date available flammabilty or explosive limis k) Vapour pressure <24 hPa at20°C 1) Vapour density 1,38 -(Air= 1.9) m) Relative density 1,515 gimL at25°C 1n) Water solubiity completely miscible, soluble 0). Partition onefficient: n- na data available ‘octanoliwater } Autoignition no data avaliebie temperature 4) Decomposition no data available temperature 1) Viscosity no data available 8s) Explosive properties no data available 4) Osidizing propertios no data available 9.2 Other safety information ‘no data avaiable 70. STABILITY AND REACTIVITY 104 Reactivity no data avaliable 102 Chemical stability no data avaliable 10.3 Possibility of hazardous reactions no data avaliable 10.4 Conditions te avoid no data avalable 40.5 Incompatible materials Weler, acids, Organic materials, Chlorinated solvents, Aluminum, Pnosahorus, Tintin oxides. Zine Sgme-Acich = 418419 Panes of 6Hazardous decomposition products Other decomposition products - no data avaiable TOXICOLOGICAL INFORMATION Information on toxicological effects Acute toxicity ro data available ‘Skin corrosiontitritation no data avatable Sorious oye damage/oye irritation no data avaliable Respiratory or skin sensitization ro data availale Germ cell mutagenicity ro data avaiable Carcinogenicity IARC: No component ofthis product present at levels greater tian or equal to 0.1% is Identfiad as probable, possible or confirmed human carcinogen by IARC. Roproductive toxicity No data available Specific target organ toxicity - single exposure no data available Specific target organ toxicity - repeated exposure 1o data available Aspiration hazard To data available Potential health effects Inhalation Mey be hermfulif inhaled, Material is extremely destructive (othe tissue of the mucous membranes and upper respiratory tract. Ingestion, May be hermfulf swallowed. Causes bums. skin ‘May be harmful if absorbed through skin. Causes skin burns, Eyos Causes eye turns. Signs and Symptoms of Exposure burning sensation, Cough, wheezing, laryngtis, Shortness of breath, spasm, inflammation and edema of the larynx, spesm, infammation and edema of the bronchi, pneumonitis, pulmonary edema, Material is ‘extromaly‘desiructive to lissue of the mucous membranas and upper cespiratory tract, eyes, and skin. ‘Additional Information RTECS: Not available m nA 2 123 R4 125 ECOLOGICAL INFORMATION Toxicity no deta available Persistence and degradability no data available Bioaccumnulative potential no dats available Mobility in soit no data avaiable Results of PBT and vPVB assessment no data available Somaaidien = 41542128 Other adverse offocts Harmful to aquatic ite % 134 DISPOSAL CONSIDERATIONS Waste troatment mothods Product Offer surplus and non-recyctable solutions to a licensed disposal company. Contaminated packaging Dispose of as unused product a 144 142 143 18s 14.5 146 TRANSPORT INFORMATION UN number ADRIRID: 1824 IMDe: 1824 ATA: 1824 UN proper shipping name ADRIRID’ SODIUM HYDROXIDE SOLUTION IDG: ‘SODIUM HYDROXIDE SOLUTION @ IATA: Sodium hyéroxide solution Transport hazard clasa(es) ADRIRID: 6 IMOG: 8 IATA: Packaging group. ADRURID: I INDG: It IATA:I Environmental hazards ADRIRID: no IMOG Marino pollutant: no IATA: no Special precautions for user no data available % 154 152 REGULATORY INFORMATION This safety datashest complies with the requirements of Regulation (EC) No. 1907/2006 Safety, health and environmental regulationsilegislation specific for the substance or mixture no data avalable Chemical Safety Assossmont no data avaiable 6. OTHER RFORURTION e TemofH-coom ara R-ptraaaiay masts Seton 3 tae Camas vv hone day mage cuss = Giremeion : ae Ss ae Picnic reematon FE eer gah os 150 an gad ee INIA om NLS a SRY saisoreatnin itdandinbe omelin done ne puerta help ard eh bw ee ee ee ee ee rete Beene Re pa naa tak ee ae gre ee ee ea ns re ea re re ee Sets lee prio sori pee teed epeinior ree seein De Signe-Atich = 418419 Pege 6 of 81[Page APPENDIX 2 1 OSHA* = Number of injuries & illness x 200.000- __ oiat hours worked by all employees during period covered = (Number of fatalities > 10%) otal hours worked by all employees during period covered Fatality rate = (Number of fatal per year) ows! number of peaple (per year) in applicable population TWA=—|C(ddt a i 8 (TLV - TWA )mix = — 2 1 (TLV -TWA), a Ze = scaled distance (mn/ke™*)2|Page 9. The scaled overpressure p: is given by Ps=Po/ Po where _ pz - the scaled overpressure (unitless.) Po - peak side-on overpressure. Pa - the ambient temperature. The ambient pressure is 1 atm=101.3kPa 10. The equivalent mass TNT is estimated using the following equation: mass behaves like exploding TNT on an equivalent energy basis. The equivalent mass of TN’ is estimated using the following equation: amAH, Ox where mrvris the equivalent mass of TNT (mass) nis the empirical explosion efficie: of hydrocarbon (mas), (unites). plosion of the fammuble gas (energy/mass), and losion of TNT. Atypical value for the et of explosion of TNT is 1120, 4686 kI/kg = 2016 Bras. The heat of combustion for the flammable gas can be used in place of the energy of expiosion @ for the combustible ga The explosion efficiency is one of the major problems in the equivalency method. The ex-(g,, 554/44) Zz ‘a9ue]SIP pe|yeos L OL L Lo 100 oo Lo'O Lo D Ss 3 s ty = 2 & Sg B OL 2 s e = - 001 oo0ot “SOVAYNS LV1d V NO NOISO1dX4 LNL ¥ YO4 JUNSSIYdYIAO. 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COUTISIP OES ~ Loe co sy lasso [ested cor sre yo SBweotel 6o0 bo sin woe ter eer) sereu DAO seo +00 eyes aspun Apessie Teucrewsro, reo foo Con Clot -Kausnbow mol 303) HP Le 1) ose Busou ree foo, abewea eam Gea TSUORELINOIGTS GIS SOMER SSOU)) SINETOIAIENS US poses soimonns USUNHOD 10) SeTEUASS SHEUET 6-9 SIGELSlPage TABLE 2-4 Transformation from Percentages to Probits. sa (Chaoter2 + Todeoty % "735 "1 Fines Pra ol. (Cv Cambie Unters Press. 1971) p28. Reprneby peomsion, Figure 2-10 The prosit transformation converts he sigmoidal responce vs. log dose curve into asitsight line when plottes on a linear poait eosle, Seurce: DJ, Finpey, Probit Analyaia, Sd 9 (Geronege: Gamrice University Press, 1277), p. 24. Reprinted by permisson,BIPage 11. The Probit (probability unit) variable Y is computed from Y = ky + kz In P TABLE 2-5 PROBIT CORRELATION FOR VARIETY OF EXPOSURES. Table 2-5 Probit Correlations for a Variety of Exposures (The causative eriable Is representative of the magnitude of the exposure.) Probit parameters Causative —— Type of Injury or damage variable ky ha Burn deaths from Mash fire oie Lg. 256 Burn deaths from poo! burning wg Mo 256 Explosion! Deaiths fram jung hemorrhage * -74 691 Bordram ruptures > -155 193 Deaths from impact i 46.1 45: Injuries from impos : 438 Injuries feom Bing fragments ! 426 Structural damage a 202 Glass breakage > 279 roles Ammonis deaths Ess Carbon monoxice deaths 37, Chlorine deaths -829 92 Elylene oxide deaths 619 10 Hydrogen chloride deaths 1685 20) Nitrogen dioxide deaths =1379 14 Phongens eats 1937 360 Propylene omide deaths 12 pst Sulfur dionive deaths 567 10) Toluene 679 oat 3 = impulse (= = concentrate T= tne interval ( ‘Selected from Frack F Lees, Lass Prevention the ACCPS. Gielnes for Conse Richard. Purgh. “Oval tative Evaluation of nnaladion Foxe Hazards"in receding of heh Loss Prevention Somposion (American lestiute cf Chemical Engineers July 31,1999) races Indices (Lenders: Butterworths. 1985). pl no Aneless of Chemica! Releases (New York: American lnstiure ot Chemical tingle 12, Sound intensity, represent the decibel units of sound intensity, Li,L= 10 logiol | /1o] 13, Time-weighted average noise (TWAN): TWAN = C1/T1 4 €2/T2 tecsuuCn/TA where Cxis the total time of exposure at a specified noise level and ‘Tx is the total time of exposure permitted at the specified noise level. 14. Noise dose in percent is D=100[C/T] where Cis the total length of the workday in hours Tis the reference duration in hours for a measured A-weighted sound level, L, in decibels. 15.Ts derived from an expansion of the OSHA exposure limits (Table 2) and is computed as T=8 /2(L-90)/5