CH 1 Introduction  Responses to toxicants 2-3: Respiratory problems with
 Safety Programs: Safety, Attitude, Fundamentals,
Experience, Time, You.
 Engineering Ethic’s: Table 1-1
 Accident and Loss Statistics: OSHA (injuries and illness) =
 OSHA (workdays) = ; FAR =
, Fatality Rate = .
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)
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)
 Cppm=
 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)
 Creating a Regulation: 1(Authorized organization or agency
decides if a reg is needed, then 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 SDWA 1974 Safe Drinking
Water Act TSCA 1976, 1986 Toxic Substances Control Act
RCRA 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 Cppm=Psat/KQvP * (φrfVc+KA) * 106, assume splash filling so
to federal, state, and local authorities) φ=1 p 93, remember to put Cppm/k and k can range from 0.1
 Evaluation of Exposure Section 3-3: (Volatile Toxicants p to 0.5, hood should have a velocity = 100 ft/min for hood) 3-
84, Dust p 88, Noise p. 89, Vapors p. 91 15 (TLV- TWA, STEL, C from table data) 3-31 (Cppm and TLV//,
 IH: (Anticipation and Identification Section 3-2, Evaluation 3- eq 3-24 Cppm= Psat/KQvP (φrfVc+ KA) * 106, rf(fill
3, Control 3-4) rate)=(1vol/30min)(1min/60sec), Vc (Volume of
 IH Control: p 101 Respirators (only for temporary time, container)=πd2/4 * h, φ=1 for splash filling, K=Ko(Mo/M)1/3,
emergency equipment, last resort in event environmental lnPsat=A-B/T+C)
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 of death) 2-5 (Qv//,
Cppm= , 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