Job Safety Assessment Form

Department of Chemical Engineering

Michigan Technological University

Equipment Name: Shell and Tube Heat Exchanger JSA Author: DWC
Room Number/Building: B005 Chem Sci Faculty Supervisor: Sandell
Revision #: 1 Revision Date: 8-25-2009

Purpose of Experiment / Equipment: Briefly describe what this experiment is designed to

achieve and the types of data collected.
Determine heat exchanger characteristics for a steam-fired Basco type 500, 5", 4-pass Shell and
Tube exchanger.

Personal Protective Equipment (PPE) – Check all PPE worn during the entire experiment.
Do not list these in the procedure section.
Long Pants Safety Glasses Hard Hat Apron
Long Sleeves Splash Goggles Insulated Gloves Ear Protection
Non-porous Shoes Face Shield Chemical Gloves Other:

Hazard Summary – Check all general hazards that are likely to be encountered during this
experiment and list the major source of the hazard.
Hazard Major Source of Hazard
Toxicity
Fire/Flammability
Reactivity
Pressure Hazard
Electrical Shock
Mechanical Hazard
Hot Surfaces/ High Temp steam lines and condensate drain
> 150 F
Biohazard
Laser Radiation
Ionizing radiation
Other:
Other:

Expected Operating Conditions –

Temperature Pressure
Normal: 120 Normal: 30 psig
Minimum: 80 Minimum: amb.
Maximum: 180 Maximum: 60 psig

1 August, 2004 Rev. 1

Special Operating Conditions - Check all that apply and consult department Safety Manual.
Unattended Operation: Drying Oven:
Regulated Chemicals: Class 3b or 4 Lasers:
Pressures Exceeding 35 atm (515 psia) or Equipment Specifications:
Temperatures Exceeding 1000oC or Equipment Specifications:

Available Safety Equipment – Provide the location of each item shown below. Show the
location of this equipment on the attached floor plan. If not available, type “NA” in the field.
Item Location
Fire Extinguisher: B005 SE exit door
Eyewash: B005 SE exit door
Safety Shower: B005 SE exit door
Telephone: B005A -- lab office
First Aid Kit: Hallway between B003 and B005
Other:
Other:

Spill Response Supplies - Provide the location of each item shown below. Show the location of
this equipment on the attached floor plan. If not available, type “NA” in the field.
Item Location
Spill Kit: n/a
Floor-Dri: n/a
Spill Dikes: n/a
Sodium Bicarbonate: n/a
Drain Plugs: n/a
Spill Pillows: n/a
Mercury Spill Kit: n/a
Other: mop/bucket B005B
Other:

Required Attachments:
Diagram of process or equipment
Label all valves and identify all equipment for reference in procedure.
Laboratory Floor Plan
Identify the location of your experiment and all safety and spill response equipment.
Equipment Specifications
Include materials of construction, maximum temperature and pressure, standard operating
values, and any other specifications important to the safe operation.
Material Safety Data Sheets (MSDS)
Include for all reactants, products and any intermediate or other chemicals which may occur.

Additional Attachments: As necessary.

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 Chemical Information Page
Fill in as much data below as available. If data are not available, leave the field blank.
List all chemicals, including reactants, products, intermediates, solvents, and any others used.

Chemical Properties and Hazards

Physical Incompatible Chemicals Flash Flammability
Chemical Name State NFPA Ratings* List chemicals present within the laboratory, and Point Limits
S, L, G H F S Sp. any others that may come in contact. Temp. LFL UFL
Water L 0 0 0 0
Steam G 0 0 0 0
Condensate L 0 0 0 0

*
NFPA Ratings: H – Health, F – Flammability, S – Stability, Sp. – Special

Chemical Toxicology, Regulation and Disposal: List the same chemicals that appear above, in the same order.
Toxicology Hazardous Regulated?
Chemical Name Waste See Safety Personal Protective Equipment
TWA PEL Other Number #
Manual Specific to this Chemical
Water none
Steam long sleeves, insulated gloves
Condensate long sleeves, insulated gloves

#
See Chemical Engineering Hazardous Waste Manual.

3
Chemical Reactions: Provide details below on any chemical reaction(s) that occur in your process. Please show the species involved, the
stoichiometry and the heat of reaction, if available. Also list side reactions and any other reactions that may impact safety. You cannot type
subscripts in the form field provided – use the names for the species and the stoichiometric coefficients.
none

4
 Job Safety Assessment Form
Safe Operating Procedures Page

PPE or Equipment
Sequence of Steps Potential Hazards Procedure to Control Hazard Required
Emergency Shutdown
1. Close the main steam valve (V-2). 1. Valve is hot 1. Do not touch hot surfaces. 1. insulated gloves

2. Turn off power to the data logger/controller. 2. none 2. none 2. none

3. Close main water valve (V-3). 3. none 3. none 3. none

4. Evacuate the laboratory. 4. none 4. none 4. none

Start-up Procedure
1. Turn on power switch on side of Yokogawa CX1000 data 1. none 1. none 1. none
logger/controller and open valve V-4, instrument air supply.

2. Check that the CW header main shut off valve is open, 2. Valve is overhead. Need to 2. Use correct ladder. Don't stand on top two steps of 2. none
then fully open V-3. use a step ladder. ladder. Maintain 3 points of contact with ladder.

3. Open small front panel cover on CX1000 to expose 3. CW flow starts when 3. Be sure rubber hose is in drain trench before 3. none
control panel. Set controller FIC-02 to manual mode and controller output is increased. starting CW flow. Clean up water with mop or
increase the output to get desired valve position, or set Water could run out on floor if squeegee
controller to auto mode and enter a set point of the desired discharge hose is not in drain
CW flow rate. Range is approx 0.5 to 12 gpm. trench.

4.Check that the steam header main shut off valve is open 4. Valves are overhead. Need 4. Use correct ladder. Don't stand on top two steps of 4. insulated gloves
then fully open V-1 and V-2. to use a step ladder. ladder. Maintain 3 points of contact with ladder. Do
not touch hot surfaces.

5. Set the mode of TIC-04 to manual and increase the output 5. Steam flow starts when 5. Be sure rubber hose is in drain trench before 5. insulated gloves
to get the desired steam valve position, or set the controller controller output is increased. starting steam flow. Do not touch hot surfaces.
to auto mode and enter the setpoint to get the desired outlet Steam condensate is hot.
water temperature.

6. Allow system to stabilize. 6. none 6. none 6. none

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Run Time Procedure
1. Record heat exchanger inlet temp (TT03); outlet temp 1. none 1. none 1. none
(TT04); steam flow rate (FT01); CW flow rate (FT02); heat
exchanger shell-side pressure (PG07); any additional data
required to satisfy ojectives.

2. Wait 3 minutes and repeat measurements. 2. none 2. none 2. none

3. Wait another 3 minutes and take a third set of 3. none 3. none 3. none
measurements.

4. Adjust flow and temperature setpoints on CX1000 as 4. none 4. none 4. none

needed to meet objectives, wait for system to stabilize and
repeat steps 1-3.

Shutdown Procedure
1. Put TIC-04 in Manual mode and reduce the output to zero. 1. none 1. none 1. none

2. Put FIC-02 in Manual mode and reduce the output to zero. 2. none 2. none 2. none

3. Close steam valves V-1 and V-2. 3. Hot surfaces, thermal burns. 3. Do not touch hot surfaces. 3. Insulated gloves.

4. Close CW valve V-3. 4. none 4. none 4. none

5. Leave main CW and steam shut-off valves open at end of 5. none 5. none 5. none
experiment.

6. Turn off power to CX1000. 6. none 6. none 6. none

Cleanup / Waste Disposal

1. Use a mop and/or squeegee to clean up any spilled water. 1. none 1. none 1. none