Safety 2020-21

CHEN 20152
One hour
THE UNIVERSITY OF MANCHESTER
Process Safety
7th June 2021
09:15 – 10:15
Answer BOTH questions in this exam paper
Calculators may be used in accordance with the University regulations.
ALL numerical working must be shown
Tables of mathematical formulae are available and may be used without

restriction.
© The University of Manchester, 2021
Page 1 of 5
CHEN 20152
Answer ALL Questions
Q1. Answer ALL parts of this question. [Total 25 marks]

An exothermic batch reaction is cooled with cold utility. The cold utility fails once
a year. In 90% of these events, the temperature in the reactor starts to rise,
leading to a dangerous increase in pressure, but in 10% of these events the
reaction is almost complete and the temperature rise is not significant. The
reactor is connected to a dump tank containing a neutralizing chemical.
The layers of protection are:

• The Basic Plant Control System should raise an alarm whenever the cold
utility fails. Probability of failure on demand = 0.1
o An operator must respond to the alarm by draining some of the
reactor contents to the dump tank. Probability of failure to respond
correctly to the alarm = 0.2
• A trip which opens a valve connected to the dump tank if the temperature
rises significantly. Probability of failure on demand = 0.1
• A bursting disk, connected to a flare stack, which ruptures if the pressure
approaches the rating of the reactor. Probability of failure to reduce
pressure enough to prevent failure of the reactor = 0.05
There is always one operator near the reactor. If the temperature starts to rise
dangerously and the protection systems fail, the reactor will burst, killing the
operator.
a. Draw an event tree for the outcomes of failure of the cold utility,
including all the probability values
[9 Marks]
b. Calculate:
i. The probability in any year of a near miss where cooling utility fails
when the reaction is almost complete, but the operator is unaware
because the alarm has failed
[1 Mark]
ii. The number of times the dump tank will be used in the plant lifetime
of 50 years.
[2 Marks]
iii. The average annual individual risk of fatality for the operator near the
reactor. Comment on the tolerability of this risk.
[4 Marks]
Question 1 continues on next page
Page 2 of 5
CHEN 20152
Question 1 continued…
c. Management considers your event tree analysis and asks you to review
the safety of the whole process.
Explain the approach you would take. Include three process hazard
analysis methods, giving reasons for your choices and suggesting who
might be involved in the analysis teams. Consider the process as a
whole, not just the cooling system, and take the results of your event tree
calculations into account.
[9 Marks]
End of Question 1
Paper Continues/
Page 3 of 5
CHEN 20152
Q2. Answer ALL parts of this question. [Total 25 marks]

The P&ID on the next page shows a glass lined reactor vessel. An organic
powder is first added from the hopper and then a flammable organic solvent so
that an exothermic batch reaction can be carried out.
The contents must be cooled during the process to prevent undesirable side
reactions from taking place.
Mixing at constant speed is required so each batch is complete within a

reasonable period of time.
The reaction is known to be complete when the heating caused by the

exothermic reaction is complete, at which point the bottom outlet valve is
opened and the product pumped to storage.
Each batch requires a certain amount of the previous batch to act as an initiator
for the new reaction, so the vessel must not be completely emptied.
The pressure in the vessel must be recorded during the reaction and the vessel
protected against overpressure.
a. Using standard P&ID symbols add the equipment/control items required

to fulfil the specification described above to the diagram provided on the
next page (Figure 1). In addition, explain the modifications and how they
are designed to work.
Include in your modifications the failure positions of the on/off valves and
explain why you have chosen them. Do not include valves only needed
for maintenance.
Include a photograph of the diagram with your answer sheets or if

you do not have access to a printer, a ppt file of the Figure is
provided which you can annotate using the draw function for
submission with the finished exam.
[12 Marks]
b. Discuss the properties of organic powders which cause them to be

hazardous. Describe the measures which could be carried out to mitigate
the hazards of working with organic powders in this system.
[8 Marks]
c. The chemical formula of the organic powder is C6H4N2O4. Carry out an

oxygen balance and from your result, state if you think the powder is
explosive. Explain the volume increase/violence of the explosion in
terms of moles of gas.
[5 Marks]
Question 2 continues on next page
Page 4 of 5
CHEN 20152
Figure 1. Annotate Diagram for question 2 part a. (Either draw on this

diagram and scan/copy the image for submission OR annotate the attached
PowerPoint file using the draw function and submit that if you do not have
access to a scanner)
End of Question 2
END OF EXAMINATION PAPER
Page 5 of 5

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CHEN 20152

THE UNIVERSITY OF MANCHESTER

7th June 2021

Answer BOTH questions in this exam paper

Calculators may be used in accordance with the University regulations.

ALL numerical working must be shown

Tables of mathematical formulae are available and may be used without

© The University of Manchester, 2021

Answer ALL Questions

Q1. Answer ALL parts of this question. [Total 25 marks]

The layers of protection are:

Question 1 continues on next page

Q2. Answer ALL parts of this question. [Total 25 marks]

Mixing at constant speed is required so each batch is complete within a

The reaction is known to be complete when the heating caused by the

a. Using standard P&ID symbols add the equipment/control items required

Include a photograph of the diagram with your answer sheets or if

b. Discuss the properties of organic powders which cause them to be

c. The chemical formula of the organic powder is C6H4N2O4. Carry out an

Question 2 continues on next page

Figure 1. Annotate Diagram for question 2 part a. (Either draw on this

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