biosystems engineering design -...

ERT 461 - Week 9 SEM 1 2016/2017 1

Firdaus Muttalib

School of Bioprocess

Engineering

8/11/2016

Biosystems Engineering Design

(ERT 461/3)

Safety and Health in Engineering

Firdaus Muttalib


Engineering

8/11/2016

Introduction

Safety is define as a freedom from harm or danger.

Health is define as the condition of being free from illness or disease.

Danger expresses the relative exposure to hazard (source of danger; a possibility of loss). A hazard may presence, but there may be little danger because of the precautiontaken.

ERT 461 - Week 9 SEM 1 2016/2017 2

Firdaus Muttalib


Engineering

8/11/2016

Works or processes must meet acceptable safety and environmental performance standards because:

• It is required by law

• The costs (human, social, economic) of non-compliance can be catastrophic.

• Negligent attitudes are reflected in insurance premiums, stock prices.

• Moral and ethical obligations

Safety & Environment

Firdaus Muttalib


Engineering

8/11/2016

• Factory and Machinery Act (FMA) 1967

• 11 regulations of FMA 1967:

1. STEAM BOILER AND UPV 1970

2. ELECTRIC PASSENGER AND GOODS LIFT 1970

3. FENCING OF MACHINERY AND SAFETY 1970

4. SAFETY, HEALTH AND WELFARE 1970

5. CERTIFICATES OF COMPETENCY—EXAMINATIONS 1970

6. NOTIFICATION, CERTIFICATE OF FITNESS AND INSPECTION 1970

7. LEAD 1984

8. ASBESTOS PROCESS 1986

9. BUILDING OPERATIONS AND WORKS OF ENGINEERING CONSTRUCTION (SAFETY) 1986

10. NOISE EXPOSURE 1989

11. MINERAL DUST 1989

Safety Legislation

Firdaus Muttalib


Engineering

8/11/2016

• The Occupational Safety and Health Act (OSHA) 1994• Employers must provide a place of employment free from recognized hazards to safety and

health, such as exposure to toxic chemicals, excessive noise levels, mechanical dangers, heat or cold stress, or unsanitary conditions.

• Seven regulations of OSHA 1994:

1. EMPLOYERS SAFETY AND HEALTH GENERAL POLICY STATEMENT (EXCEPTION) REGULATION 1995

2. CONTROL OF INDUSTRY MAJOR HAZARDS (CIMAH) REGULATIONS 1996

3. SAFETY AND HEALTH COMMITTEE REGULATIONS 1996

4. CLASSIFICATION, PACKAGING AND LABELING OF HAZARDOUS CHEMICALS (CPL) REGULATIONS 1997

5. SAFETY AND HEALTH OFFICER REGULATIONS 1997

6. USE AND STANDARDS OF EXPOSURE OF CHEMICALS HAZARDOUS TO HEALTH (USECHH) REGULATIONS 2000

7. NOTIFICATION OF ACCIDENT, DANGEROUS OCCURRENCE, OCCUPATIONAL POISONING AND OCCUPATIONAL DISEASE (NADOPOD) REGULATION 2004

Safety Legislation

Firdaus Muttalib


Engineering

8/11/2016

The Occupational Safety and Health Act (OSHA) 1994• For all industries

• If >5 Employees-Safety & Health Policy

• ≥40 Employees (S30) -Safety & Health Policy + Safety & Health Committee

• For high risk industries (i.e. construction, ship building, gas etc.)

• >100 Employees (Order 1997) -Safety & Health Policy + Safety & Health Committee + a Certified Safety & Health Officer

• For low risk industries (other than the above mentioned industries)

• >500 Employees (Order 1997) -Safety & Health Policy + Safety & Health Committee + a Certified Safety & Health Officer

Safety Legislation

Firdaus Muttalib


Engineering

8/11/2016

Types of HAZARDS

1. Physical Hazards

2. Chemical Hazards

3. Biological Hazards

4. Electrical Hazards

5. Radiation Hazards

6. Psychological Hazards

ERT 461 - Week 9 SEM 1 2016/2017 7

Firdaus Muttalib


Engineering

8/11/2016

Types of HAZARDS

1. Physical Hazards

2. Chemical Hazards





ERT 461 - Week 9 SEM 1 2016/2017 8

Firdaus Muttalib


Engineering

8/11/2016

Physical Hazards

Physical Hazards

Example: height, force, noise, vibration, lighting, etc

Can cause tissue damage, hearing loss, lifting, manual handling, ergonomic, traffic hazards, collapse, falling objects

ERT 461 - Week 9 SEM 1 2016/2017 9

Firdaus Muttalib


Engineering

8/11/2016

Physical Hazards

Manual Handling

• The lifting and carrying of loads is a big problem in everyindustry.

• Manual handling injuries contributed about 25% of all work-related injuries

ERT 461 - Week 9 SEM 1 2016/2017 10

Firdaus Muttalib


Engineering

8/11/2016

Physical Hazards

How to reduce the effects• Bagged materials must be less than 25 kg.• Apart of the weight factor, other factors also affect this

manual handling related accident such as:1. Individual

-Age

-Gender

-Training

-Experience

-Previous injury

2. The overall operation

ERT 461 - Week 9 SEM 1 2016/2017 11

Firdaus Muttalib


Engineering

8/11/2016

Physical Hazards

Works Related Upper Limb Disorder (WRULD)

• WRULD is caused by repetitive movements diseases

associated such as:

• Neck, shoulder and elbow disorder

• Wrists and hand lesions

• Thoracic outlet syndrome

ERT 461 - Week 9 SEM 1 2016/2017 12

Firdaus Muttalib


Engineering

8/11/2016

Physical Hazards

Factors associated with the development of WRULD

• Resisting Excessive Force• Frequency and duration of movement• Posture – ergonomic• Works ogranization

Length of work period without rest break, lack of training and

inadequate supervision.• Psychosomatic factors (illness due to the interaction of

the mind and the body)• Poor awareness by managers and empoyess

• Lack of management to detect problems.

• Poor ergonomic job design

• Lack of training to control WRULD

ERT 461 - Week 9 SEM 1 2016/2017 13

Firdaus Muttalib


Engineering

8/11/2016

Physical Hazard

Noise

• It can cause hearing loss

• Factors influencing hearing loss• Intensity of the noise

• Frequency

• Length of exposure

• Individual tolerance. This factor is also affected by other factors such as age and effect of drugs.

ERT 461 - Week 9 SEM 1 2016/2017 14

Firdaus Muttalib


Engineering

8/11/2016

Physical Hazard

Noise

ERT 461 - Week 9 SEM 1 2016/2017 15

Sound Level in dB (A) Sources

Harmfull140 Jet Engine

130 Riveting Hammer

Critical

120 Propeller Aircraft

110 Rock Drill

100 Typical outdoor construction, plate fabrication noise

90 Heavy Vehicle

Safe

80 Pile drivers, power lawn mower, very busy traffic

70 Private car

60 Air compressor and concrete mixers

50 Conversation (at 1 m)

40 Average business office

30 Quite Whisper

Levels

Firdaus Muttalib


Engineering

8/11/2016

How to control noise hazard ?

• Review the design and change if possible

• Change with other processes or equipment

• PPE (Personal Protective Equipment) : Earmuff

ERT 461 - Week 9 SEM 1 2016/2017 16

Firdaus Muttalib


Engineering

8/11/2016

Physical Hazard

Vibration

• Result in tissue damage

• Two kind of vibration • Whole body vibration:vehicles

• Segmental vibration:pneumatic handheld tools

• How to control this hazard ?• Use of vibrational isolator

• Select equipment that produces less vibration.

ERT 461 - Week 9 SEM 1 2016/2017 17

Firdaus Muttalib


Engineering

8/11/2016

Types of HAZARDS

1. Physical Hazards

2. Chemical Hazards





ERT 461 - Week 9 SEM 1 2016/2017 18

Firdaus Muttalib


Engineering

8/11/2016

Chemical Hazards

Example: Gas, Liquid, Vapor, Fumes, Mist, Dust, Asbestos, Lead

Can cause inhalation, skin contact with chemical, ingestion of chemical.

ERT 461 - Week 9 SEM 1 2016/2017 19

Firdaus Muttalib


Engineering

8/11/2016

Chemical Hazards

Routes of Entry of Toxic Agents

• Respiratory

• Skin and eye contact

• Mouth (Ingestion)

• Injection

ERT 461 - Week 9 SEM 1 2016/2017 20

Firdaus Muttalib


Engineering

8/11/2016

Chemical Hazards

Type of effects

• Acute• A lot of exposure

• The reaction happen in short period of time

• Chronic• Repeated small exposure

• Long period of time

ERT 461 - Week 9 SEM 1 2016/2017 21

Firdaus Muttalib


Engineering

8/11/2016

Chemical Hazards

ERT 461 - Week 9 SEM 1 2016/2017 22

Common Types of Toxic Effect

• Irritations- Lung

• By inhaling some chemicals, e.g. ozone,sulfur dioxide and nitrogen dioxide

- Skin: chemical, physical, mechanical and biological

• Central Nervous System (CNS) Depression

- Headache, Drowsiness, Unconsciousness - Organ affected: brain

- Many solvents (toluene, xylene, ether, acetone)produce this effect if the vapor concentration ishigh

Firdaus Muttalib


Engineering

8/11/2016

Chemical Hazards

ERT 461 - Week 9 SEM 1 2016/2017 23

• Cancer

- The effect is about 20-30 years

Sources

• Benzene Leukemia• Chromium and Arsenic Trioxide Lung Cancer • Asbestos Larynx, Lung and Abdomen cancer • Vynil Chloride Liver Cancer • Coal Tar Pitch Skin Cancer• Benzidine Bladder Cancer

Common Types of Toxic Effect

Firdaus Muttalib


Engineering

8/11/2016

Chemical Hazards

ERT 461 - Week 9 SEM 1 2016/2017 24

Factors Affecting Toxic Effect• Factors related to the agent

- Chemical Composition- Physical properties

- Solubility in body fluids

• Factors related to the Exposure Situation- Dose: how much and how long?

- Co-factors: Presence of other materials

• Factors related to the individuals- Individual differences: genetic status and allergic status -

Age

- Presence of predisposing disease:

• Angina (Heart Disease) cannot tolerate carbon monoxide• Emphysema (lung ailment)

Firdaus Muttalib


Engineering

8/11/2016

Chemical Hazards

ERT 461 - Week 9 SEM 1 2016/2017 25

Asbestos

• It can cause lung cancer

• The disease develops 20-40 years after exposure

• Problems with asbestos in construction

- Many construction contracts are being awarded without the

contractors being informed of the presence of asbestos materials

Construction Materials Causing

Occupational Diseases

Firdaus Muttalib


Engineering

8/11/2016

Chemical Hazards

ERT 461 - Week 9 SEM 1 2016/2017 26

Hazards related materials

- Workplace Hazardous MaterialInformation System (WHMIS) (Canada’s National Workplace Hazard Communication

Std)

The key elements of the system are cautionary labelling of

containers of WHMIS "controlled products", the provision of

Material Safety Data Sheets (MSDSs) and worker

education and training programs

http://www.safetyemporium.com/?08807

http://www.safetyemporium.com/?08807

Firdaus Muttalib


Engineering

8/11/2016

Chemical Hazards

Hazards related materials usually has

• Workplace Hazardous Material Information System (WHMIS) symbols

• Material Safety Data Sheets (MSDSs)

ERT 461 - Week 9 SEM 1 2016/2017 27

Firdaus Muttalib


Engineering

8/11/2016

Chemical Hazards

ERT 461 - Week 9 SEM 1 2016/2017 28

Class B: FlammableClass A: Compressed Gas& Combustible

WHMIS Symbol

Class C: Oxidizing Material Class D: Poisonous andInfectious Material

Firdaus Muttalib


Engineering

8/11/2016

Chemical Hazards

ERT 461 - Week 9 SEM 1 2016/2017 29

Firdaus Muttalib


Engineering

8/11/2016

Chemical Hazards

Material Safety Data Sheets - MSDS

ERT 461 - Week 9 SEM 1 2016/2017 30

A form with data regarding the detailed properties of aparticular hazardous material

An important component of product stewardship andworkplace safety, it is intended to provide workers andemergency personnel with procedures for handling orworking with that substance in a safe manner

Firdaus Muttalib


Engineering

8/11/2016

Chemical Hazards

What is MSDS ?

ERT 461 - Week 9 SEM 1 2016/2017 31

• A Material Safety Data Sheet (MSDS) providesdetailed information about a specific hazardousmaterial. An MSDS contains the followinginformation:

- Identity (name of substance)

- Physical Hazards (target organ)

- Health Hazards

- Routes of Body Entry

- Permissible Exposure Limits (PEL)

- Carcinogenic Factors (cancer causing)

- Safe-Handling Procedures

Firdaus Muttalib


Engineering

8/11/2016

Chemical Hazards

What is MSDS ?

ERT 461 - Week 9 SEM 1 2016/2017 32

• A Material Safety Data Sheet (MSDS) providesdetailed information about a specific hazardousmaterial. An MSDS contains the followinginformation:

- Data of Sheet Preparation

- Control Measures (personal protective equipment)

- Emergency First Aid Procedures

- Contact Information (for the preparer of the sheet)

- Special Instructions

Firdaus Muttalib


Engineering

8/11/2016

Chemical Hazards

ERT 461 - Week 9 SEM 1 2016/2017 33

http://upload.wikimedia.org/wikipedia/commons/7/7e/Material_safety_data_sheet.JPG

http://upload.wikimedia.org/wikipedia/commons/7/7e/Material_safety_data_sheet.JPG

Firdaus Muttalib


Engineering

8/11/2016

Chemical Hazards

Why do you use a MSDS ?

ERT 461 - Week 9 SEM 1 2016/2017 34

• You should use an MSDS whenever you need additionalinformation about a hazardousmaterial that is not includedon the product label.

• For example, you have spillednitric acid on the floor, and youneed to know how to clean itup safely. You need only refer to the "Safe-Handling Procedures" section of the nitric acid MSDS.

Firdaus Muttalib


Engineering

8/11/2016

Chemical Hazards

ERT 461 - Week 9 SEM 1 2016/2017 35

Why do you use a MSDS ?

• Some chemicals, such as sodium hydroxide, are very

dangerous. If you have an accident, you may not have

time to look up the information you need in an MSDS.

• You should read the MSDSs for the hazardous materials

present in your work area before you work with them.

Firdaus Muttalib


Engineering

8/11/2016

Types of HAZARDS

1. Physical Hazards

2. Chemical Hazards





ERT 461 - Week 9 SEM 1 2016/2017 36

Firdaus Muttalib


Engineering

8/11/2016

Biological Hazards

• Microorganism -Fungi, Bacteria, Viruses

route –in contact with bacteria thro’ improper treated cooling towers

• Arthropods – mosquitoes, spiders

route – bitten by infected mosquitoes

• Animals – crocodiles, snakes

• Plant allergens and toxins – pollen

• Protein allergens – food, urine, feces, hair

route – rodent dropping/urine

ERT 461 - Week 9 SEM 1 2016/2017 37

Firdaus Muttalib


Engineering

8/11/2016

Types of HAZARDS

1. Physical Hazards

2. Chemical Hazards





ERT 461 - Week 9 SEM 1 2016/2017 38

Firdaus Muttalib


Engineering

8/11/2016

Electrical Hazards

Example: current, voltage, sparks

Can cause direct electrocution, contact with overhead or underground cables

ERT 461 - Week 9 SEM 1 2016/2017 39

Firdaus Muttalib


Engineering

8/11/2016

Types of HAZARDS

1. Physical Hazards

2. Chemical Hazards





ERT 461 - Week 9 SEM 1 2016/2017 40

Firdaus Muttalib


Engineering

8/11/2016

Radiation Hazards

Example: UV light, lasers etc

Can cause skin contact, eye contact

ERT 461 - Week 9 SEM 1 2016/2017 41

Firdaus Muttalib


Engineering

8/11/2016

Radiation Hazards

ERT 461 - Week 9 SEM 1 2016/2017 42

• UV can damage eyes and skin

- Skin cancer

- Skin burn

- Eye discomfort

• Where is the exposure of this hazard?

- Outdoor job

- Welding

- Work using high intensity lamp

• How to reduce the hazard?

- Sun block

- UV Protection Sunglasses - Blue color costume

Firdaus Muttalib


Engineering

8/11/2016

Types of HAZARDS

1. Physical Hazards

2. Chemical Hazards





ERT 461 - Week 9 SEM 1 2016/2017 43

Firdaus Muttalib


Engineering

8/11/2016

Psychological Hazards

Example: workplace, space, organizational culture, stress

ERT 461 - Week 9 SEM 1 2016/2017 44

Occupational Stress

• Three types of occupational stress

- Physical

- Mental

- Emotional

Firdaus Muttalib


Engineering

8/11/2016


Causes of occupational stress

ERT 461 - Week 9 SEM 1 2016/2017 45

• Uncertainty and lack of control (low jobdiscretion)

• Lack of support from others, including co-workers

• Conflicts

• High demands of working environment, e.g. long hours, high responsibility, commitment

• Very low demands: boredom, lack of meaning in work

• Work station: noise, poor lighting, lack of space, extremetemperatures, poor ergonomics

• Chemical hazards, fumes, passive smoking

Firdaus Muttalib


Engineering

8/11/2016


Causes of occupational stress

ERT 461 - Week 9 SEM 1 2016/2017 46

• Organizational culture

• Repetitive Tasks

• Low pay leading to overtime and piecework

• Change

Firdaus Muttalib


Engineering

8/11/2016


ERT 461 - Week 9 SEM 1 2016/2017 47

How do humans react? 3 stages

• Alarm Stage

-Immediate reaction

- Fight or Flight?

- Human body coordinates the readiness of

action, influencing mood, causing heart

palpitation, shallow fast breathing, muscle

tension, dryness of throat, dizziness and light-

headedness, numbness of the limbs, nausea,

anxiety and sweating

Firdaus Muttalib


Engineering

8/11/2016


ERT 461 - Week 9 SEM 1 2016/2017 48

Alarm stage cannot be maintained indefinitelyAt one point, resistance stage occurs in which humansdevelop survival strategies and a way of fighting the stress

Typically, short-term relief is preferable

• Exhaustion Stage-Stress response is healthy and a motivator- When expectations are not realistic, humans becomesuffer

How do humans react?

• Resistance Stage

Firdaus Muttalib


Engineering

8/11/2016

RISK MANAGEMENT

ERT 461 - Week 9 SEM 1 2016/2017 49

Firdaus Muttalib


Engineering

8/11/2016

Risk Management

ERT 461 - Week 9 SEM 1 2016/2017 50

Checking and Reviewing the risk control

Controlling the risk• Eliminating the hazard, if possible

• Minimizing, if possible

• Controlling the hazard

Risk management involves the:

identification,

assessment, and prioritization of risks followed

by coordinated and economical application of resources to

minimize, monitor, and control the probability

and/or impact of unfortunate events or to

maximize the realization of opportunities.

Firdaus Muttalib


Engineering

8/11/2016 ERT 461 - Week 9 SEM 1 2016/2017 51

Firdaus Muttalib


Engineering

8/11/2016 ERT 461 - Week 9 SEM 1 2016/2017 52

Firdaus Muttalib


Engineering

8/11/2016 ERT 461 - Week 9 SEM 1 2016/2017 53

Firdaus Muttalib


Engineering

8/11/2016 ERT 461 - Week 9 SEM 1 2016/2017 54

Firdaus Muttalib


Engineering

8/11/2016 ERT 461 - Week 9 SEM 1 2016/2017 55

Firdaus Muttalib


Engineering

8/11/2016

Failure Mode Effect Analysis

• An early stage approach to identifying problems with a technology

• Scope encompasses safety, environment, operational feasibility

• Slightly different versions can be used for process design and product design

• Goal is to identify the critical technical risks using a semi-quantitative procedure

Firdaus Muttalib


Engineering

8/11/2016

FMEA Procedure

1. Brainstorm for failure modes

2. For each FM, rate severity of impact (SEV, 1 - 10)

3. For each FM, brainstorm for possible causes (there may be multiple)

4. For each cause, rate likelihood of occurring (OCC, 1-10)

5. Rate the probability that the systems currently in placewill detect & prevent the problem before it has an impact (DET, 10 - 1). Do not assume that something that will be added to the design later will take care of the problem.

6. Overall Risk Probability Number RPN = SEV x OCC x DET

Firdaus Muttalib


Engineering

8/11/2016 ERT 461 - Week 9 SEM 1 2016/2017 58

FMEA Notes

• Most practitioners use a 1,4,7,10 scale to increase granularity

• DET scale is inverse to SEV and OCC

• FMEA is always associated with a particular design revision and should be updated whenever a new revision is released

Rating Likelihood of Occurrence Severity Detection

1 Failure is very unlikely Effect is insignificant Current safeguard will almost

certainly prevent the failure mode

4 Occasional failure likely Minor disruption, Customer

dissatisfied

High chance that safeguard will

detect

7 Moderate likelihood of failure Major components must be

replaced

Low chance that safeguard will detect

10 Failure is very likely Fails without warning may

endanger customer

No known method of detection

Suggested Rating Scale

FMEA Notes

• Most practitioners use a 1,4,7,10 scale to increase granularity

• DET scale is inverse to SEV and OCC

• FMEA is always associated with a particular design revision and should be updated whenever a new revision is released

Rating Likelihood of Occurrence Severity Detection

1 Failure is very unlikely Effect is insignificant Current safeguard will almost

certainly prevent the failure mode

4 Occasional failure likely Minor disruption, Customer

dissatisfied

High chance that safeguard will

detect

7 Moderate likelihood of failure Major components must be

replaced

Low chance that safeguard will detect

10 Failure is very likely Fails without warning may

endanger customer

No known method of detection

Suggested Rating Scale

Firdaus Muttalib


Engineering

8/11/2016 ERT 461 - Week 9 SEM 1 2016/2017 60

Firdaus Muttalib


Engineering

8/11/2016

FMEA Tool

Project Name

Project Number Sheet 1REV DATE BY REV DATE BY APVD

Owner's Name

Plant Location

Case Description

Process Step or Key

InputFailure Mode Consequence

Impact

SE

V

Cause

Fre

quencey O

CC

Dete

ction D

ET

Priority

RP

N

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

Current Control Action

APVDAddress

Company Name

Form XXXXX-YY-ZZ

FAILURE MODE EFFECT ANALYSIS

FMEA is easily implemented in a spreadsheet:

Firdaus Muttalib


Engineering

8/11/2016

Example: Dryer FMEA

• In the manufacture of chocolate, cocoa butter is extracted from the cocoa solids using butane as solvent

• The solids are dried in a rotary dryer. The off gas from the dryer is sent to cyclones to recover solids fines, cooled to recover solvent and then recycled to the dryer

• Part of the cocoa solids is sold as product and part is used in downstream processing to make different grades of chocolate

ERT 461 - Week 9 SEM 1 2016/2017 62

Firdaus Muttalib


Engineering

8/11/2016

Example: Dryer FMEA

Solids out

Make-up gas

Solids in

Cooler

HeaterDryer

Fan

Solids fines

Solvent out

Loss of heat source to heater

Loss of coolant to cooler

Blockage of solids flow

Blockage of solids flow

Solids carryover

and fouling of cooler

Loss of power

Fan failure

Level

control

failure

Loss of feed

Erosion

Firdaus Muttalib


Engineering

8/11/2016

FMEA Example

• Failure mode

• Interruption of solids flow from second stage cyclone

• Consequence

• 2nd stage cyclone does not operate effectively, solids carry over into cooler, cooler becomes fouled and eventually pressure drop becomes high and gas flow is reduced limiting dryer capacity

• Cause

• 2nd stage cyclone dip leg plugged with solids

• Frequency of occurrence: occasional, OCC = 4

• Severity

• Minor disruption. Takes long time to have serious effect as long as first stage cyclone is still working. Nuisance to clean out though. SEV = 4

• Detection

• Hard to detect solids flow, fouling or build up of powder in cooler. Might show up as sediment in the recovered solvent, but it is probably always pretty dusty and may not even be sampled (difficult to sample butane as it will flash). DET = 10

• Risk Probability Number

• RPN = OCC x SEV x DET = 4 x 4 x 10 = 160

Firdaus Muttalib


Engineering

8/11/2016 ERT 461 - Week 9 SEM 1 2016/2017 65

Firdaus Muttalib


Engineering

8/11/2016 ERT 461 - Week 9 SEM 1 2016/2017 66

Firdaus Muttalib


Engineering

8/11/2016 ERT 461 - Week 9 SEM 1 2016/2017 67

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