tutorial 1 accident statistic answer (1)

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



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




Hazard: height

26/5/2010 Worker died after receiving multiple bee stings while working outside an apartment building.NADOPOD :Fatality





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




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]





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.



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


[ 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


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.



8. The Fault Tree Analysis for the top event MOTOR DOES NOT RUN WHEN

SWITCH IS PRESSES for the following diagram as shown below:



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


2. Fatal Accident Rate:

Number of fatalities x 108


3. Days Away and Restricted Transfer (DART)

Number of days away and Restricted Transfer x 200,000


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


tutorial 1 accident statistic answer (1)

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