Department of Chemical Engineering

Indian Institute of Technology (ISM), Dhanbad

Mid-Semester Examination (Winter, 2023-24)
CHC-302: Process Safety and Hazard Management
Time: 2 Hrs Attempt all questions Marks: 30

1. Workers of a factory stay in their workshop for 9 hours from 8:00 am to 5:00 pm with a
lunch break from 12:00 noon to 1:00 pm. The concentrations of hazardous materials
recorded periodically in the work area are shown in the following table:
08:00 08:45 10:00 11:30 1:30 2:00 3:45 5:00
100 115 130 145 156 158 160 155
The company advises its employees to take their lunch in the open shade, located 100
meters away from the work area, where the concentration is zero. However, many
workers take their lunch in an adjacent room. Due to an open door joining the workplace
and the adjoining room, the concentration of the hazardous material is the same as in the
workspace. Calculate the exposure to the workers who take their lunch in the open space
and those who take their lunch in the adjoining room. TLV-TWA of the hazardous
material is 150 ppm. Assume concentration varies linearly between two consecutive
recordings. [10]
Ans:
𝐶̅ Δ𝑇
The TWA exposure is given by ∑ 𝑖 𝑖 where the average concentration between two
8
𝐶 +𝐶
recordings at the times 𝑇𝑖 and 𝑇𝑖+1 is 𝐶̅𝑖 (= 𝑖 2 𝑖+1 ) and time interval Δ𝑇𝑖 (= 𝑇𝑖+1 − 𝑇𝑖 )
(in hours).
Therefore, the exposure to the workers who take their lunch in the adjoining room is:
Δ𝑇𝑖 𝐶𝑖
Time (Hours) (given) 𝐶̅𝑖 𝐶̅𝑖 Δ𝑇𝑖
08:00 100
0.75 107.5 80.625
08:45 115
1.25 122.5 153.125
10:00 130
1.5 137.5 206.25
11:30 145
2.0 150.5 301
1:30 156
0.5 157 78.5
2:00 158
1.75 159 278.25
3:45 160
1.25 157.5 196.875
5:00 155
1
∑ ̅̅̅
𝐶𝑖 Δ𝑇𝑖 = 1294.625 ∑ ̅̅̅
𝐶𝑖 Δ𝑇𝑖 = 161.83
8
Workers taking lunch at a distance of 100 m from the workplace have less exposure for
one hour. Taking the average concentration during that period to be 150.5 ppm, 𝐶 Δ𝑇 =
150.5 ∗ 1, therefore the total exposure is 1294.625 − 150.5 = 1144.125 and TWA =
1144.625
= 143.01 ppm.
8

Thus, workers who take lunch outside the workplace are safe, whereas those who take it
in the adjoining room are over-exposed.
2. (a) At the time of the blast in a factory, there were 214 persons present, of which three
persons got ruptured eardrums. Estimate the probability of deaths from lung hemorrhage
and percent structural damage. [5]
Ans:
3
3 out of 214 persons got ruptured eardrum, i.e., 100 ∗ 214 = 1.4% of persons had
ruptured eardrum.
𝑌 −𝑌
For a probability of 1.4%, linear interpolation (𝑌 = 𝑌1 + (𝑃 − 𝑃1 ) ∗ 𝑃2 −𝑃1 ) of the probit
2 1
value data for 1% and 2% given in the probit table can be applied. Which gives
2.95−2.67
𝑌(1.4%) = 2.67 + (1.4 − 1) ∗ 2−1 = 2.782.
From the probit correlation table, we have for eardrum rupture, 𝑘1 and 𝑘2 values are
−15.6 and 1.93, respectively. Therefore, from probit correlation 𝑌 = 𝑘1 + 𝑘2 ln(𝑝𝑜 ) we
𝑌−𝑘1
get 𝑝𝑜 = 𝑒 𝑘2 = 𝑒 (2.782+15.6)⁄1.92 = 𝑒 9.574 = 14,386 (N/m2) peak overpressure.

For death from lung hemorrhage, 𝑘1 = −77.1 and 𝑘2 = 6.91, giving probit values for a
peak overpressure of 14,386 (N/m2) 𝑌 = −77.1 + 6.91 ln(14386) = −10.94, which is
less than zero. Therefore, the probability of death is Nill.

For percent structural damage, 𝑘1 = −23.8 and 𝑘2 = 2.92 giving a probit value for the
peak overpressure of 14,386 (N/m2), 𝑌 = −23.8 + 2.92 ln(14386) = 4.156.
Therefore, by using the interpolation formula to estimate the probability for 𝑌 = 4.156
(lying between 19% and 20% values), we have
𝑌−𝑌 4.156−4.12
𝑃 = 𝑃1 + 𝑌 −𝑌1 (𝑃2 − 𝑃1 ) = 19 + 4.16−4.12 (20 − 19) = 𝟏𝟗. 𝟗 ≈ 𝟐𝟎% structural damage.
2 1

(b) This explosion triggered a rupture in an ammonia tank, leading to 23,000 ppm of
ammonia in the air, to which all persons were exposed for 2 minutes (before evacuation).
How many people would have died due to the ammonia leak? [5]
From the probit correlation table, we have for ammonia death, 𝑘1 and 𝑘2 values are
−35.9 and 1.85, respectively, and the causative variable is ∑ 𝐶 2 𝑇.
In the given circumstance, the causative variable is ∑ 𝐶 2 𝑇 = 230002 ∗ 2 = 10.58 × 108
Therefore, from probit correlation 𝑌 = 𝑘1 + 𝑘2 ln(∑ 𝐶 2 𝑇) = −35.9 + 1.85 ln(10.58 ×
108 ) = 2.542.
The probit value of 2.542 is less than the probability of 1%. Assuming, for 0%
probability, the probit value Y tends to zero (lim 𝑌 = 0). Therefore, by interpolation
𝑃→0
between 0% and 1% we have
𝑌−𝑌 2.542−0
𝑃 = 𝑃1 + 𝑌 −𝑌1 (𝑃2 − 𝑃1 ) = 0 + 2.67−0 (1 − 0) = 𝟎. 𝟗𝟓𝟐%.
2 1
0.952
Therefore, out of 214 persons, 214 ∗ = 2.04 ≈ 2 persons may succumb to ammonia
100
exposure.
3. What is the maximum allowable open surface area of a tank containing Acetone in a
room of dimension 3 × 4 × 10 having a ventilation rate of 50 m3/min so that the vapor
concentration in the room is less than the permissible limit? The tank temperature is
30°C, and the ambient pressure is 1 atm (760 mmHg). Assume the non-ideal mixing
factor 𝑘 = 0.25. The properties of Acetone are as follows:
Molecular TLV (ppm) Specific Antoine equation coefficient
weight TWA STEL gravity A B C
58 250 500 0.7899 7.2316 1277.03 237.23
[10]
Ans:
From the correlation between the ventilation rate and the rate of evaporation, we have
𝑄𝑚 𝑅𝑔 𝑇
𝐶𝑝𝑝𝑚 = × 106 (A)
𝑘 𝑄𝑣 𝑃 𝑀
The rate of evaporation is given by
𝑀 𝐾 𝐴 𝑃 𝑠𝑎𝑡
𝑄𝑚 = 𝑅𝑔 𝑇𝐿
Substituting in equation (A), we get
𝐾 𝐴 𝑃 𝑠𝑎𝑡 𝑇
𝐶𝑝𝑝𝑚 = (𝑇 ) × 106
𝑘 𝑄𝑣 𝑃 𝐿

𝐶𝑝𝑝𝑚 𝑘 𝑄𝑣 𝑃 𝑇
Or, 𝐴 = ( 𝑇𝐿) × 10−6 (B)
𝐾 𝑃 𝑠𝑎𝑡
𝑀 1⁄3
For which the mass transfer coefficient can be estimated using 𝐾 = 𝐾0 [ 𝑀0 ] with water
as a reference substance, having 𝐾0 = 0.83 (𝑐𝑚/𝑠) = 0.0083 (𝑚/𝑠) giving
18 1⁄3
𝐾 = 0.0083 [58] = 0.005619 (𝑚/𝑠).
𝐵
Antoine equation log10 (𝑃 𝑠𝑎𝑡 ) = 𝐴 − 𝑇+𝐶 is applied to find 𝑃 𝑠𝑎𝑡 such that
1277.03
𝑃 𝑠𝑎𝑡 = 10[7.2316−30+237.23] = 283.68 (𝑚𝑚𝐻𝑔)
Since ambient pressure is not given, it can be taken as standard atmospheric pressure, 760
mmHg.
The non-ideal mixing factor is 0.25, and the ventilation rate is 50 m3/min = 50/60 m3/s.
𝑇𝐿
Taking ≈ 1, equation (B) gives
𝑇
𝐶𝑝𝑝𝑚 ∗0.25∗(50/60)∗760
𝐴= × 10−6 = 𝐶𝑝𝑝𝑚 × 9.933 × 10−5 𝑚2
0.005619∗283.68
In the case when the room is used continuously, such as in a normal workplace, the
permissible TLV is 250 ppm, giving
𝐴 = 250 × 9.933 × 10−5 = 0.02483 𝑚2 = 248.3 𝑐𝑚2 (a hole of 2√𝐴/𝜋 = 17.78 𝑐𝑚 diameter).
However, if the room is used for a short time, like a store room, where human exposure is
less than 15 min, the allowable opening area can be
𝐴 = 500 × 9.933 × 10−5 = 0.04967 𝑚2 = 496.7 𝑐𝑚2 (a hole of 2√𝐴/𝜋 = 25.15 𝑐𝑚 diameter).

The open area of the tank should be less than 248 cm2 for continuous use or 497 cm2
for occasional use.
Useful Correlations/Data
Pressure conversion: 1 𝑎𝑡𝑚. = 760 𝑚𝑚𝐻𝑔 = 1.01325 𝑏𝑎𝑟 = 101325 𝑃𝑎 = 14.6959 𝑝𝑠𝑖
𝐽 𝑚3 .𝑃𝑎 𝑚3 .𝑎𝑡𝑚 𝑚3 .𝑚𝑚𝐻𝑔
Gas constant 𝑅𝑔 = 8.314 (𝑚𝑜𝑙.𝐾) or ( 𝑚𝑜𝑙.𝐾 ) = 0.082057 ( 𝑘𝑚𝑜𝑙.𝐾 ) = 62.36 ( )
𝑘𝑚𝑜𝑙.𝐾
𝐵
Antoine equation: log10 (𝑃 𝑠𝑎𝑡 ) = 𝐴 − 𝑇+𝐶 where 𝑃 𝑠𝑎𝑡 is in mmHg and T in °C.

𝑀 1⁄3
The mass transfer coefficient 𝐾 = 𝐾0 [ 𝑀0 ] (Note: K of water is 0.83 cm/s.)
𝑘𝑔 𝑚 2
𝑘𝑔 𝑀 𝐾 𝐴 𝑃 𝑠𝑎𝑡 (𝑘𝑚𝑜𝑙) ( 𝑠 ) (𝑚 ) (𝑚𝑚𝐻𝑔)
Evaporation rate ( 𝑠 ): 𝑄𝑚 (𝑘𝑔/𝑠) = [ 3
𝑚 .𝑚𝑚𝐻𝑔
]
𝑅𝑔 𝑇𝐿 ( )(𝐾)
𝑘𝑚𝑜𝑙.𝐾

𝑘𝑔 𝑎𝑡𝑚..𝑚3
𝑄𝑚 𝑅𝑔 𝑇 ( )( )(𝐾)
𝑠 𝑘𝑚𝑜𝑙.𝐾
Ventilation: 𝐶𝑝𝑝𝑚 = 𝑘 𝑄 × 106 [ 𝑚 3 𝑘𝑔
]
𝑣 𝑃𝑀 (−)( )(𝑎𝑡𝑚.)( )
𝑠 𝑘𝑚𝑜𝑙