tutorial 1 accident statistic answer (1)
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8/10/2019 TUTORIAL 1 Accident Statistic Answer (1)
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INDUSTRIAL SAFETY AND HEALTH
CKB 30103
TUTORIAL 1
1. The following data is accident statistic of a company.
a. Identify the type of incident name (or consequences); according to OSHA
and NADOPOD regulation 2005) for the following data.b. Identify type of hazard(s) in each incident.
c. Calculate the OSHA Incident Rate, Fatal Accident Rate, Lost Time Case
and Days Away and Restricted Transfer (DART)from this accident
statistics.
OSHA Incident Rate
Number occupational injuries & Illness x 200,000Total hours work by all employees during period covered
Assume the company has 100 worker or use info below. i.e thecompany has 150 employee.
No of injuries & illness = 7OSHA IR = 7 x 200, 000 = 7.
100 x 50 x 40
Fatal Ac ciden t Rate
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Fatal Ac ciden t Rate
Just for the student info:
Lo st Time Injury Rate :
Number LTI x 200,000
Total hours work by all employees during period covered
[480+48000+48000+240+48000+320] x 200000 /200000 = 145040
d. Calculate the Fatality rate if total number of employee is 150.
[also known as Number of fatalities expected per person per year]
Number of fatalities per year = 2/150 =0.0133
Total no. of people (per year) in applicable population
Date of
Incident Preliminary Description of Incident
11/1/2010 Worker was conducting repairs on a milling machine, which was not locked out. The machine started,
crushing the worker leg and caused the bone broke. He was away from work 2 months.NADOPOD :Serious bodily injury- fracture or dislocation of the bone
OSHA: Occupational injury
Lost Work Days:60 days
Number of Lost Time due to injury:
{Lost time injury (in hours according to NADOPOD; 1 day = 8 hours;
1 death=6000 lost work days)}
Hence: Loss Time Injury = 8hrs x 60days = 480hrs
Hazard: Mechanical hazard[crushing]12/2/2010 Four workers injured while jack hammering a septic tank when propane fumes in the tank exploded.Two employees were from ARCG department, and two worked for DHI Department.
NADOPOD :Serious bodily injury
OSHA: Occupational injury
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Hazard: height
26/5/2010 Worker died after receiving multiple bee stings while working outside an apartment building.NADOPOD :Fatality
Number of Lost Time due to injury:
{Lost time injury (in hours according to NADOPOD; 1 day = 8 hours;
1 death=6000 lost work days)}
Hence: Loss Time Injury = 8hrs x 6000days = 48000hrs
OSHA: Fatality case
Hazard: Biohazard (poisonous animal)
27/6/2010 Worker was working at a grain bin. The grain bin collapsed and caused loses about 200kg grain.
NADOPOD :
OSHA:
Hazard: heavy load
Incident name: Economical loss
24/7/2010 Worker was performing decking work at a height of 10 feet above ground level and fell through
the decking caused twisted his ankle.
NADOPOD :Serious bodily injuryOSHA: Occupational injury
Hazard: working at height
30/7/2010 Worker was performing housekeeping job in the detergent store and found fainted by his coworker;
was rushed to clinic and work as usual on the following day.
NADOPOD :
OSHA: Occupational illness
Hazard: chemical hazard (toxic fumes)
4/8/2010 Worker was installing heating and cooling equipment and fell from a ladder An orthopedic confirmed
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OSHA: Occupational injury
Hazard: working at height
3/12/2010 10 workers were hospitalized for 4 days after consuming meal provided by the companycaterer due to stomach upset.
NADOPOD :
OSHA: Occupational illness
Lost work days= 40 days, [10 worker x 4 days]
Number of Lost Time due to injury:
{Lost time injury (in hours according to NADOPOD; 1 day = 8 hours;
1 death=6000 lost work days)}
Hence: Loss Time Injury = 8hrs x 40days = 320hrs
Hazard: biohazard (microoraganism infection)
2. State the definition of the following terms:-a. Hazardb. Riskc. Accident
3. Laila, who work as receptionist cum telephone operator has been informed thatshe is exposed to ergonomic hazard. Due to her ignorant, she consulted you, assafety and health officer, about ergonomic hazards. Explain in full detail ofergonomic hazards and its consequences.
4. The following is the details of safety performance from various industries in year2011.
a. If total number of workers in manufacturing is 200. Determine FR.
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b. The total number of hours work for Professional & technical services is300,000. Calculate the number of occupational illnesses, if half of OSHA
IR is due to illnesses.Use formula OSHA Incidence Rate to find the no of injuries.
Assume the number of employee as 100OSHA Incidence Rate is 5.33
Number occupational injuries & Illness[ X ]x 200,000
Total hours work by all employees during period covered
[ X ]= No of injuries + illness = 5.33 x 300,000 /200,000 = 7.995= 8.0Therefore No of occ illnesses is 4.0
c. Calculate the Lost Time Injury Rate of transport & warehouse, if 75% ofDART is Loss Time Injury Case.
Lost Time Injury Rate =
Number Lost time injury[ Y ] x 200,000
Total hours work by all employees during period covered
75% of DART is Lost time Injury: 75/100 x 2.5 = 1.875
LTIR = is calculated in Hours. DART is Lost work daysHence 1.875 x 8 hours =15 hrs
There LTIR = 15 x 200,000 / 100 x 50 x40 = 15.
d. Rank the safety performance of various industries according to the OSHAIncident Rate.
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8. The Fault Tree Analysis for the top event MOTOR DOES NOT RUN WHEN
SWITCH IS PRESSES for the following diagram as shown below:
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Calculate the probabilities of the top event if given the component failure rate as shownin 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
9. The chemical reaction involves 2 liquids, A & B, which flow from their respectivestorage tanks into the stirred product C reactor. The flow rate of materials A & Bis regulated by control valves A & B,respectively.The liquid phase chemicalreaction that results is highly exothermic & generates considerable quantities of
heat, which must be controlled by cooling water on the jacket of product Creactor.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 throughvalve C into the product C storage vessel to await shipment. The reactor & eachof the storage tanks have pressure-operated relief valves in case of pressurebuild-up during the process operation.Temperature, pressure and level indicatorare 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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ANSWER:
STEP 1: Break the PFD into 3 smaller study nodes ;
study nodes A from storage tank material A through valve A to Reactor.
study nodes B from storage tank material A through valve B to Reactor.
study nodes C from Reactor through valve C to storage tank C.
Step 2 : Identify the process parameter; i.e : FLOW
Step 3: Identify the OSHA guide words can be used; NO, MORE, LESS , As well as, Part of, Reverse
Step 4: Identify the dangerous occurrence and control measure [present protection]
Dangerous occurrence=
1. The liquid phase chemical reaction that results is highly exothermic & generates considerable quantities of heat,
Present Protection=
1. 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.
2. The reactor & each of the storage tanks have pressure-operated relief valves in case of pressure build-up
during the process operation
Step 5 : Use Hazop Work sheet to complete this worksheet.
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Company Name: ABC TechnolgySdnBhd
Project Title: XYZ Project Diagram & Node No:Study Node A
Meeting Date: DDMMYYYY Team Name & leader:MNA bin JKL
Parameter study:FLOW
Guide
words
Deviation Causes Consequences Present Protection Recommendation
No No flow of material A to
reactor
Run out of material in
the tank
Valve A closed
completely
Substandard product C.
No dangerous
occurrence.
Not available
More More flow of material A to
reactor
Valve A fully opened
Valve A failure
As above Not available
Less Less flow of material A to
reactor
Valve A is opened less
than the actual
setting.
Leakage at the
pipeline
As above Not available
Reverse Reverse flow of material A
from reactor
Not possible.
Part of Part of material A flow from
st. tank A to reactor (
contamination occurred)
Quality of material A
supplied is low.
As above Not available Suggest to Procurement
Dept to request from
supplier to provide
Incoming Inspection Sheet
during delivery of goods.
Tighten/stringent quality
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check by QA personnel.
As well
as
As above
This may repeat for study node B.
Company Name: ABC TechnolgySdnBhd
Project Title: XYZ Project Diagram & Node No:Study Node C
Meeting Date: DDMMYYYY Team Name & leader:MNA bin JKL
Parameter study:FLOW
Guide
words
Deviation Causes Consequences Present Protection Recommendation
No No flow of product C to
storage tank C
Valve C closed
completely
Dangerous occurrence
in reactor due to highly
exothermic reaction by
chemical reaction to
produce product C.
Not available Install level sensor at the
reactor & Install flow
sensor at the pipeline from
reactor to storage tank C.
Both sensor need to
connected to alarm.
Run out of material in
the tank
More More flow of product C to
storage tank C
Valve C fully opened
Valve A failure
Substandard product C
due to incomplete
chemical reaction
No dangerous
occurrence.
Not available As above
Less Less flow of material A to
reactor
Valve A is opened less
than the actual
As above Not available As above
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setting.
Leakage at the
pipeline
Reverse Reverse flow of product Cfrom reactor
Not possible.
Part of Part of C flow from reactor
to storage tank C
(substandard)
Less flow of material A
or B resulted in
substandard product C
No dangerous
occurrence. But will
have economical loss
Not available Install flow sensor at both
pipeline A & B to detect no
flow deviation.
Provide security method at
the valve, in order to
control and avoid illegal
changes.
As well
as
As above
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Appendix
1. OSHA incidence Rate:
Number occupational injuries & Illness x 200,000
Total hours work by all employees during period covered
2. Fatal Accident Rate:
Number of fatalities x 108
Total hours work by all employees during period covered
3. Days Away and Restricted Transfer (DART)
Number of days away and Restricted Transfer x 200,000
Total hours work by all employees during period covered
4. Fatality Rate:[also known as Number of fatalities expected per person per year]
Number of fatalities per year
Total no. of people (per year) in applicable population
5. Lost Time Injury Rate:
Number of loss time injury x 200,000
Total hours work by all employees during period covered
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