CSP STUDY NOTES
Management Styles/Theories
• Matrix:
– rows and columns w/
projects and managers
• Leikert:
– “participation” at all levels
– BHR Theory: worker
productivity and supervisor
control are inversely
proportional
– Exploitive-authoritative;
Benevolent-authoritative;
Consultative
• Herzberg:
– “Motivation” Hygiene
Theory:
• hygiene factors: salary,
status, challenging work,
benefits
• motivation factor:
achievement, promotion,
recognition; responsibility
• McGregor:
– Theory “X”: lazy
employees
– Theory “Y”: motivated
employees
 Management Styles/Theories
• Argyris: • Span of Control:
– # of employees reporting to one
– Employees treated like manager should be limited
children and/or adults
• TQM:
will act like such
– philosophy and technique that
– Conflict theory: uses statistical theory to improve
production quality and
– Leveling: boss doesn’t performance
make all the decisions – Every employee is responsible for
– Incongruence theory: product quality
– *Shewhart Cycle: Plan, Do,
mature workers desire Study Act
independence
• Multiple Causation:
• Drucker: MBO – accidents occur when causes and
sub-causes combine
 HEINRICH

• Father of modern • 88 (unsafe acts)/10 (unsafe

safety conditions) /2 % (Acts of
• 1st textbook on safety God)

• Domino Theory of • 4 steps of accident

Accident Causation(5 prevention
events): social, fault, • 4:1 ($ spent indirect vs direct)
unsafe act, accident, injury
• 3 “E’s” of safety: • Pyramid [NM (300), Minor
Engineering, Education, Event (29), Major Events (1)]
Enforcement
MJE
MNE
Near Miss
 DEMMING’S 14 STEPS
• Drive out fear
• Eliminate quotas and
numerical goals
• Breakdown barriers b/w
departments
• Eliminate inspection. Build
right the first time
• Institute a vigorous program
education and self-
improvement
• Institute Leadership: help
people do a better job
• Eliminate slogans and product
targets
• Adopt a new philosophy
w/ new age
• Base long term relationship
on loyalty – single
suppliers
• Continual improvement
• Put everybody to work to
accomplish transformation
• Institute job training
• Create constancy of
purpose toward
improvement
 Maslow’s Heirarchy of Needs

• Pyramid w/ SA at top

Self Actualization
Self - Esteem
Belonging-Love
Safety
Physiological
 Blake Mouton Grid

• Conceptualized management styles by

number sequence
9 *BEST
Country Club Team Leader

People Imporverished Authoritarian

9
1
Task
 BEHAVIOR BASED SAFETY

• Geller:
– “The ABCs of Behavior”
• Antecedent
• Behavior
• Consequence
 SAFETY MANAGEMENT
THEORY
• Most current thinking
• Management ultimately
responsible for safety
• Unsafe behaviors,
conditions and accidents
symptomatic of
management failure
• Circumstances can be
predicted to produce injuries
• Safety should be managed
like any other business
function
• Key to effectiveness is
defining management
accountability
• Safe design is key to
preventing root cause of
many accidents
• Function of safety is to
locate and define
operation errors that
contribute to accidents
MANAGEMENT PRINCIPLES

• Peter Principle:
– people promoted to level of incompetence
• Parkinson’s Principle:
– work expands to fill allotted time
• Pareto Principle of Mal-distribution:
– “80/20” Rule
• 20% of employees responsible for 80% of work
 TYPES OF COMMANDS
• Unity of Command: • Vertically Integrated:
– each employee report – company owns all
to only one individual aspects of the production
• Span of Control: process (eg/ Ford)
– number of employees • Horizontally Integrated:
reporting to one – company owns little to
individual none of production
process (eg/ Dell)
ORGANIZATIONAL
SYSTEMS
MATRIX
(eg/ Special Projects)

Project Manager

Electrical Propulsion Weapons Life Support

 ORGANIZATIONAL
SYSTEMS

FUNCTIONAL

PRESIDENT

Finance ENGR HRD Production

ORGANIZATIONAL
SYSTEMS

DIVISIONAL
(eg separate opeating systems,
companies and procedures)

PRESIDENT

Tractor Grader Doze Mower

 ORGANIZATIONAL
SYSTEMS

GEOGRAPHIC

GEN MANAGER

North South East West

ORGANIZATIONAL
SYSTEMS

CUSTOMER
(eg/ Customer driven,
not production driven)

SALES MANAGER

GovtT EDUC INDUSTRY Consumer

 ESH PROGRAM

• Line management is • Cost of preventing accidents

must show a return on profit
actually responsible line or avoid expenses
• ESH should be a staff – Annual cost of accidents is $100
billion
function which advises – Cost of Loss:
• Where PM is profit margin
management
• Safety culture involves COL = (PM)($volume of business)
behavioral, For recovery
environmental and COL = (PM)(#unit sold)(unit price)
personal factors
 ACCIDENT CAUSES

• BASIC: • DIRECT:
– Poor management – Unplanned release of
practices energy resulting in
fatality, injury, or
property damage
• INDIRECT:
– Unsafe acts or unsafe
conditions
– Can lead to direct
causes
 Safety Analysis Techniques - 1

• Fault Tree Analysis (FTA) • Zonal

• Failure Mode & Effect • JHA/JSA
Analysis (FMEA) • HAZOP
• Functional Hazard • Critical Incident
Analysis (FHA) Technique (CIT)
• MORT • Systems Hazard
• Technique for Human Analysis (SHA)
Error Rate Prediction • Event Tree Analysis
(THERP) (ETA)
 Safety Analysis Techniques - 2
• Fault Tree Analysis (FTA): • JHA/JSA:
– undesired event – Analysis by task
– deductive (backward) analysis or
Top down logic • HAZOP:
– and/or logic gates (‘and’ multiply, – study, table/logic diagram
‘or’ add) – PSM/PHA; failure modes
– graphical depiction – Initial effort to identify
– Uses Boolean postulates, looking potentially hazardous
for “minimal cut sets” components w/I a system
• Failure Mode & Effect Analysis during design phase
(FMEA):
• Functional Hazard
– manner in which failure occurs
and their effect on the system Analysis (FHA):
– good for reliability studies* – deductive
– Inductive or “Bottom Up” logic – “Top down”
– Criticality rankings; individually
 Safety Analysis Techniques - 3
• Technique for human Error
Rate Prediction (THERP)
– Calculates probability of human
errors
• Management Oversight and
Risk Tree (MORT):
– A logic tree to identify total risk
inherent in the system and arising
from operational/management
inadequacies
– Similar to FTA starts w/
undesirable event
• Zonal:
– Geographical; inspection of
hardware
• Systems Hazard Analysis
(SHA):
– Identifies physical and functional
incompatibilities b/w adjacent,
interconnected and interacting
elements
• Critical Incident Techniques
(CIT):
– Individuals are interviewed about
accidents, near misses and hazardous
conditions
• Event Tree Analysis (ETA)
– Forward analysis beginning with
initiating event to find consequences
– Evaluates success or failure of a
system
 Fault Tree Analysis (FTA)
Undesired Event
FIRE

AND
"multiply"

Intermediate Event Intermediate Event Intermediate Event

OXYGEN HEAT FUEL

OR
"add"

Basic Events Basic Events

OPEN FLAME STATIC SPARK
 Cause & Effect Diagram
(Fishbone )

Procedures People

EFFECT

ENV EQUIP
 SYSTEM SAFETY
• CLASSIFYING FAILURE • SYSTEM SAFETY:
IMPACTS: – Fail Safe Passive:
• 0 energy state
– Catastrophic • equipment stops
– Critical operating
• eg/ circuit breakers and
– Marginal fuses
– Negligible – Fail Safe Active:
• eg/ emergency lights
– Fail Safe Operational:
• safest for people
• eg/ feed water valve
 REDUNDANT SYSTEMS
A
• Single Parallel: FX
B
– Multiply failures
A
• Double Parallel: FX
B
C
• Standby:
– sensor FX

• Series: B Sensor

– Multiply successes A B C FX
– eg/ CGM: sample O2, Flam and Toxics
– Pf = 1 – (Ps)x
 RELIABILITY
• Basic Equation:
1 - # of failures / total # of items exposed

• Reliability in Series:
R1 x R2 x R3

• Reliability in Parallel:
1 - (1 - Ra)(1-Rb)(1-Rc) . . .
 DEFECTS & PROBABILITIES

• Basic Equation:

Pf + Ps = 1

• Redundant Series:
– Pf = 1 – (Ps)x
• Redundant Parallel:
– Ps = 1 – (Pf)x
 Probability of Defect
• Machine A produces 25% of parts, B produces 35% and C
produces 40%. Their rate of defects are .05, .04 and .02,
respectively. What is probability that machine A will produce a
defect?
• 1. Construct probability table:
A B C
25 35 40
.05 .04 .02
25*.05 35*.04 40*.02
1.25 1.4 0.8

• 2. Add up defects
– 1.25 + 1.4 + 0.8 = 3.45
• 3. Divide Machine A over total defect rate
– 1.25/3.45 = 0.36
 Probability of Success
• Question: An airplane has two engines, each
with a probability of success of 0.90. What is the
probability that the airplane will arrive safely if
one or both engines working will ensure a safe
arrival?

– Both engines working means “and” therefore multiply

• Pf = 1- Ps = 1- 0.9 = 0.1 Ps + Pf = 1
• Ps = 1- [(0.1)(0.1)] = 0.99
 Probability of Failure
• Question: a component has six parts connected
in series, each with a probability of failure of 0.05.
Determine probability of component failure.

– Pf = 0.05 therefore Ps = .95

– There are six parts therefore:
– Pf = 1- (.95)6 = .26
 Probability of Success
• Question: A widget is made of three components
called wiglets. Wiglet “A” has a Ps of .30, wiglet
“B” has a Ps of .45 and wiglet “C” has Ps of .60.
Calculate Ps if wiglets B and C are functionally
parallel and wiglet “A” is in series.
.45

B
– Calculate Ps of (B+C) .30
• Ps(B+C) = 1 – Pf
A
• Ps(B+C) = 1- [(.55)(.40)] = .78
– Calculate Ps of A(B+C) C
• Ps = (.30)(.78) = .23 .60
 POISSON DISTRIBUTION
• Question: A group of 20 chips are in a piece of
equipment. What is the probability of two and
only two chips failing if the chips are known to
be 0.03 defective.
P(r) = (λt)r e- λt/r!
•Where P is probability
• P2 = (0.03)(20)2 e-(.03)(20)/2!
•λ = average or rate
– P2 = (.6)2 ln(-.6) / 2! •t = time
– P2 = (.36)(.55) / 2 •r = number of occurrences
– P2 = .099 or 1.0 •e = natural log base (ln)
•! = factorial (r!)
 Probability Calculation
•Question: What is the probability that 2 men and 2 women will be
selected out of a group of 10 with 6 men and 4 women?

– 1.) Set up diagram
– 2.) Get individual Rates
a. Combo of 2 men
b. Combo of 2 women
c. Combo of 2 men and 2
women
– 3.) Calculate probability
Solution:
1. [6/2]*[4/2]**/[10/4]
2a. 6 nCR 2 = 15
2b. 4 nCR 2 = 6
2c. 10 nCR 4 = 210
3. [15][6]/[210] = 0.43
*Female, **Male
 Statistical Sampling Techniques
• Random
– each item from a popn has equal probability of being selected

• Cluster
– items from popn are grouped by similar characterisitics and the sample
group is selected randomly

• Stratified
– items popn grouped by similar characterisitcs and sample taken from
random selection in groups
– age groups such as: > 60, 20-60, <60

• Systematic
– items from popn are selected based upon factors such as time or
location/position (eg/ every 5th one)
– good for QC
 STATISTICS - 1

• Coefficient of Correlation (r):

– relationship b/w two variables to determine “strength
and direction”
– +/- 0.9-1.0 hi COC; +/- .4-.9 Lo COC; <.4 no COC
• Coefficient of Determination (cd):
– Explained variation divided by total variation
– Or COC (r) is the square root of (cd)
• Coefficient of Variation (cv):
– Compares % variations of two or more groups by
measures of central tendency
– eg/ salaries of managers to workers
 STATISTICS - 2

• Z score (Z):
– Determines the location of a single score in the normal distribution
– % area under the curve
– Eg/ your score compared to rest and % widgets that will fail
• T-test (t):
– compare population mean to sample mean
– data sets < 30
– eg/ compares two groups

• Chi Square (X2):

– “goodness of fit” b/w observed and expected
– usually a frequency table
Coefficient of Correlation Calculations

• High COC: +/- 0.9 - 1.0

• Low COC: =/- 0.4-0.9
• No COC: < =/- 0.4
 STATISTICS
(Coefficient of Variation)

• Question: Calculate manager and employee

variation given the following:
– Managers paid $4800/mos
– Employees paid $780/mos CV = SD/X
Where SD is std deviation
– SDmanager = $820 and X is the mean

– SDemployee = $64
• SDm = 820/4800 = .171 or 17%
• SDe = 64/780 = .08 or 8%
– Conclusion: more variation in managers salary
 Bell Curve
• 1 SD: +/- 68%
X = 120
• 2 SD: +/- 95% SD = 15
• 3 SD: +/- 99.7%

34% 34% 13.5%

13.5%
2.5% 2.5%

-3 -2 -1 0 +1 +2 +3
75 90 105 120 135 150 165
 Z score Calculation
(from previous curve)

• Question: Your score on the exam was 126. What %

of those taking exam did better than you?

– 1.) Calculate Z-score

• Z = X-μ/σ 126-120/15 = 0.40
• where z = # SD, x = data point, μ = popn and σ = popn SD

– 2.) Consult table p.2 of HO

• Z-score of 0.4 = .1554

– 3.) 0.5 - .1554 = .3446 or 34%

 Z score Calculation
(# of SDs from average χ)
• Question: Your facility made 1,000 widgets w/ an avg
life expectancy of 500 hrs and a SD of 100 hrs. What %
will fail in first 225 hrs?

Z = x-μ/σ

– Need area under curve therefore Z:

• Z = x-μ/σ = 225-500/100 = -2.75 SDs from χ
– Refer to table p2:
• 2.75 z-value yields .4970 or 49.7%
– Calculate %:
• 50% - 49.7% = 0.3%
 T-Test
(Compares μ (popn) to χ (sample) w/ data sets < 30)

• Question: The BCSP just released latest exam results. The

average score was 125 and the SD 15. A group of 21 people
took the ASP prep workshop prior to above exam. Their score
was 133 and the SD was 11. Are the scores of the workshop
participants significantly better the the average score at the
p= .05 level?
t = χ – μ/s(N-1)
• Calculate t: t = 133-125/11(21-1) = 3.25
• Use table p.3 to line p-value and df (N-1= 20) for value of 1.725
• Conclusion: Yes, reject null when t-test value is  table value – 3.25 
1.725
 CHI Square - 1
(determines difference b/w observed and Expected frequencies)
• Question: As Safety Director, you are concerned about the
number of first aid and recordable cases involving new
employees vs number of cases involving more experienced
employees. A survey of employee incident/accident data is
revealed below. Can you be 99% sure that any differences
observed in above data are not due to chance?
NEW OLD EEs TOTAL
EEs

FIRST AID 100 15 115

RECORDABLE 60 25 85

TOTAL 160 40 200

 CHI Square - 2

• Basic Equation: X2 = Σ(oj – ej)2/ej

– Where oj = observed frequency
– ej = expected frequency
– df = (rows-1)(columns-1)
– Oj equals:
• 100, 60, 15 and 25
– ej equals:
• (160)(115)/200 = 92
• (160)(85)/200 = 68
• (115)(40)/200 = 23
• (85)(40)/200 = 17
• Set-up Matrix Solution Table
 CHI Square - 3

• Set-up Solutions Matrix:

Oj Ej Oj-Ej (oj-ej)2/ej

100 92 8 .69

60 68 -8 .94

15 23 -8 2.78

25 17 8 3.76

Total (Σ) 8.18

 CHI Square - 4

• Refer to X2 table on BCSP handout

– df = 1,
– p = 0.01 (100 - .99 = .01)
– Table value is 6.635
• Conclusion:
– Reject null H0 b/c X2 > table or 8.18 > 6.635
 Present Value of Money

• One trip to the bank: P = F(1 + i)-n

where F is future value

• Many payments/trips to the bank:

P = A [(1+i)-n/i(1+i)n]
where A is amount of monthly payment
and n is # of time periods
 Present Value of Money
• Question:
– What is better deal, 1M over term or $3K
monthly?
• Answer:
– for 1M investment up front:
P = F(1+i)-n
Where F = 1M, i = interest rate and n= periods (eg/25)

– for $3K monthly:

P = A[(1+i)n - 1/i(1+i)n]
where A = periodic payments (eg/ $3K) and i = monthly interest (/12)
Future Value of $ from Present Value

• Question: $10K returns $5K over 5 years,

what is APR? F = P(1 + i)n
• Answer:
– 15K = 10K(1+i)5
– 15K = 10K(x)5 x=1+i
1.08 = 1 + i
– 1.5k = x5 .0845 = i
– 1.5 = x or 8.45%
– x = 1.08
 PRESENT/FUTURE VALUE OF $
• Question: You need to purchase a new machine. Two options: (1) lease a
machine for 10 years @ $2K/yr; or, (2) purchase the machine for $10K with a
maintenance agreement of $500/yr. After 10 yrs you can sell the machine for a
salvage value of $5K. Interest will be 15% for 10 yrs. Which option is best?
P = A[(1+i)n-1/i(1+i)n]
– Option 1 - Lease (PV regular payments):
• P = (2K)[(1+.15)10-1/(1.5)(1+.15)10] = 3.05/.607 (2K) = $10,038

P = F(1+i)-n
– Option 2 - Buy (PV lump sum):
• (a) Calculate Maintenance Costs = $10,038 x (500/2000)* = 2509
• (b) Initial cost plus maintenance = 10K + 2509 = $12,509
• © calculate salvage: P = F(1+i)-n = (5K)(1.15)-10 = $1236
• © Cost minus salvage = 12509 - 1236 = $11,273
• *maintenance agreement is 1/4 of original monthly lease amount

– Option 1 is better as $10,038 < $11,273

PRESENT/FUTURE VALUE OF $

• Question: The initial cost of a safety project will be $15K.

The project will cost $2K/yr to maintain, but will save
$4K/yr over 6 yrs @ 7%. Should the company invest in
the startup?
P = A[(1+i)n-1/i(1+i)n]

– (a) Calculate PV of maintenance cost: $9533

– (b) Add maintenance cost to project cost: 15K + 9533 = $24,533
– © Calculate PV of savings: use eqn (a) substituting 4K = $19,066
– © Cost is > than Savings
 PHYSIOLOGY OF HEARING
• Conductive Loss:
– interfere w/ transmission involving outer and middle ear
– mechanical
• Sensorineural Loss:
– damage to “organ of corti” (inner ear)
– degeneration of neural elements of auditory nerve
– irreversible
• Mixed:
– combination of above
• Central (CNS) Impairment:
– lack of ability to interpret what is heard
 LIFTING EQUATION
• Basic Equations:
RWL = LC x HM x VM x DM x AM x FM x CM
– where RWL is recommended weight limit
– LC is load constant
– HM is horizontal multiplier
– VM is vertical multiplier
– DM is distance multiplier
– AM is angular multiplier/displacement (twist)
– FM is frequency multiplier
– CM is coupling multiplier
 LIFTING INDEX
• Basic Equation: • Static Loads may
– where LI is index aggravate disorders
– and L is load such as:
– and RWL is – Tendonitis
recommended weight – Bursitis
limit – CTS
– Most lifted is either 51
lbs or 23 kg
LI = L/RWL
 Safety Factor Calculations
• Basic Equation: SF = allowable/actual
 Chemistry Terms

• Molarity:
– moles of solute dissolved in 1L of solution
• Molality:
– moles of solute/kg of solvent
• Equivalent:
– qty of acid/base that yields 1 mole H+
• Normality:
– # of equivalents dissolved in a liter
 BENZENE

• Sampling Media - charcoal tube

• Bioanalysis - urine test after work shift to
detect presence of phenols
 TOXICOLOGY - 1
• Bysinossis: cotton dust • Pnuemoconiosis:
• Leptospirosis: bacteria hardening, scarring and
in animals inability to transfer
• Erysipeloid: fish oxygen form tissues to
processing blood in lung
• Trichinosis: pork • Emphysemsa: smoking
processing
• Tetanus: bacillus
• Pulmonary Edema: bacteria
acid/gas exposure
 TOXICOLOGY - 2
• Hantavirus: rat • Tularemia: carried by
droppings rats; Rabbit fever
• Anthrax: bacterial • Raynaud’s Disease:
infection vibration-induced;
• Histoplasmosis: “white fingers”
pigeon/bird droppings
• Newcastle Disease:
• Brucellosis: bacterial
infection in farmers, viral infection in birds
vets and lab workers
 MISC. Industrial Hygiene
• Absorption: capture of a • Hpergolic: violent rxn
gas or vapor by passing an which occurs when two
airstream containing gas materials come in contact
or vapor through a liquids with each other
• Adsorption (adheres): • Pyrrolysis: process where
retention of gaseous materials decompose in
substance chemically presence of heat
unchanged on surface of • Deflagration: rapid burning
sorbent such as activated fire which produces flames
charcoal retaining organic that travel slower than speed
vapors (eg/ APR) of sound
• Pyrophoric: materials that • Detonation:rapid burning
ignite spontaneously when fire which produces flames
exposed to air (eg/ that travel faster than speed
fireworks) of sound
 GRAM-MOLES
• Question: What is the • Question: How many
volume of 100 grams of molecules are present in
N2 at 25°C and one ATM? 100 grams of N2 at 25°C
Element G/mole
Hydrogen 2 and one ATM?
Carbon 12
Nitrogen 28
Oxygen 32
– Molecules relate to
– NTP conditions Avogadro’s number,
– Convert from grams to therefore:
liters for calculation
• 100 g x 1 mole/28g x
• 100 g x 1 mole/gram x 6.02 x 1023 molecules/1
24.42 L/moles = 87.32 L
mole = 2.15 x 1024
 DILUTION VENTILATION
• Question: MIBK solvent based paint is used in a spray booth at steady
evaporation rate of 1 qt/hr. How many CFM of dilution ventilation is required
to maintain a concentration at or below the TLV? (TLV = 50 ppm; s.g. = .7;
MW = 100 and assume K = 6)

– Basic Equation: Q = 403 x 106 x SG x ER x K / MW x C

• where Q is flow
• SG is speicific gravity
• ER is evaporation rate in pts/min
• K is safety factor
• MW = molecular weight
• C = TLV concentration
– Convert qt/hr to pts/min for ER:
• 1 qt/hr x 2 pts/qt x 1 hr/60 min = .03 pts/min

– Dilution calulcation:
• Q = 403 x 106 x .7 x .03 pts/min x 6 / (100)(50 ppm) = 11,300 CFM
 TWA - Chemical Exposure

• Question: What is the TWA of the following exposure: 2 hrs @

5 ppm, 1 hr @ 2.0 ppm, 3 hrs @ 1 ppm and 2 hrs @ 1.5 ppm?

TWA = C1T1 + C2T2 + CnTn / ΣT

– Basic Equation:
• where C = concentration
• T = time

– TWA = (2)(5) + (1)(2) + (3)(1) + (2)(1.5) / 480

minutes = 1.1 ppm
 MIXTURES -
Exceeding the TLV
• Question: Given the following exposure: Toluene 5.5 hrs @
50 ppm (TLV 50 ppm), MC 1.9 hrs @ 75 ppm (TLV 50 ppm)
and Xylene .3 hrs @ 250 ppm (TLV 100 ppm). Has the TLV of
the mixture been exceeded?
– Set up ratio: Actual/Allowed
– Can add because all FX same target organ

TLV = C1T1/TLV1(8hrs) + C2T2/TLV2(8hrs)

– TLV = (5.5)(50) + (1.9)(75) + (.3)(250) /(8)(50) +

(50)(8) + (100)(8) = 1.175
– 1.175 is > than 1 therefore overexposed
 CALCULATING [UNK]

• Question: 1-L of benzene breaks and evaporates in a

20x20x10m closed room at NTP. If the MW is 78 and the sg
is .6, what is the concentration?

ppm = mg/m3 x 24.45/ MW

• Calculate mg:
– 1L of benzene = 600 g (60% of L of H20 is 1)
– 600g x 1000mg/g = 600K mg
• Calculate area: 4000 m3
• Calculate ppm: (600Kmg/4000m3)(24.45)/78 = 47 ppm
REDUCING CONCENTRATIONS
• Question: A furniture drying area contains 100 ppm of a
solvent. If the volume of the room is 100Kft3, the ventilation
rate 2,000 cfm, how long to reduce the [solvent] to 25 ppm?
– Where C1 is initial [ ]
– C2 is final [ ] ln(C2/C1) = -Q’/V(t2-t1)
– Q’ is ventilation rate in cfm
– V is volume of room in ft3
– t1 is start time
– t2 is end time
• Looking for t2:
• t2 = ln(C2/C1)(V/Q’)
• t2= ln (.25)(100Kft3)/(-2000ft3/min) = 69.31 min
 SAMPLING SAEs
• Question: A sample reveals xylene exposure for an 8-hr
period was 105 ppm. The PEL for xylene is 100 ppm. The
SAE is 0.10. What can you conclude from these results?

– Where Y = standardized [ ]
Y = X/PEL
– X = given concentration
UCL = Y + SAE
– CL = confidence limits
LCL = Y - SAE

• Y = X/PEL = 105/100 = 1.05

• UCL = Y + SAE = 1.05 + 0.1 = 1.15
• LCL = Y - SAE = 1.05 - 0.1 = .95
• Therefore a possible overexposure exists because UCL> 1 and
LCL < 1.
 TLV of MIXTURES
• Question: What is the TLV of the following mixture? 50% heptane (TLV 400
ppm or 1640 mg/m3), 30% methyl chloroform (TLV 350 ppm or 1,910 mg/m3)
and 20% perchloroethylene (TLV 25 ppm or 170 mg/m3).

TLVm = 1/(f1/TLV1) + (f2/TLV2) + (fn/TLVn)

– Calculate mg:
• TLV = 1/(.5/1640) + (.3/1910) + 9.2/170) = 1/34 = 610 mg/m3
– Calculate MW:
• (610)((.5) = 305 mg/m3
• (610)(.3) = 183 mg/m3
• (610)(.2) = 122 mg/m3
– Calculate ppm:
• 305 mg/m3 x 400 ppm/1640 mg/m3 = 74.39 ppm
• 183 x 350/1910 = 33 ppm
• 122x 24/170 = 18 ppm
– Calculate total PPM:
• 74 + 33 + 18 = 125 ppm
 4 Elements of Risk Management

• Insurance Risk Management

• ESH AVOIDANCE

• Contracts INS
CONTRACTS
• Avoidance
ESH
 RISK MANAGEMENT
• Pure Risk:
– expectation of an event that
will only produce loss should it
occur (eg/ FIRE)
• Speculative Risk:
– result of an event which will
produce a gain or loss should it
occur (eg/ business venture)
• Societal Risk:
– # of incidences/consequences
that occur per year
• Individual Risk:
– Probability of a single
consequence occurring to an
individual in a given year
• Types of Companies
– Captive:
• self-insured; pools, can’t
get public insurance
– Stock:
• for profit
– Mutual Company:
• Company owned by policy
holders
• eg/ State Farm, USAA
– Lloyds of London:
• syndicate (not insurance
company)
 INSURANCE
• Items covered under basic • WC organization’s pay
policy: “insured cost” of accidents
only
– “WHARVES”
• An accident resulting in
• Wind hospital TX is “insured”
• Hail cost of accident
• Aircraft
• Riot
• Uninsured costs are
• Vandalism “deductible” part of policy
• Explosion
• Smoke
CALCULATING PREMIUMS

– Basic Equation:

Gross Premium = Pure Premium / 1-Load Percent

Worker Compensation Definitions

• Premiums:
PR = (manual rating)(EMR)(earnings/100)

• Retrospective:
– immediate past year’s loss experience
• EMR: EMR = actual expenses/expected expenses
• WC Loss Ratio:
– ratio of 0.6-0.7 is reasonable
LR = losses (or benefits paid)/premium received
 WC Miscellaneous
• Schedule Rating:
– Assigning companies credits
and debits based upon safety
performance compared to a
baseline
• Manual Rating:
– Rate based upon hazard
associated with occupation
• Premium Discounting:
– Large employers receive
discounts based upon their
size
• No fault system provides
“exclusive remedy”
• Retrospective rating based
upon immediate past year’s
loss experience
• Manual rate based upon avg
rate per $100 of payroll
• EMR based upon loss
experience over 3 yrs
– adjust company’s premium
based upon losses compared
to like industry
– Uses an average of 1 for
industry (eg/ >1 worse than
industry std and <1 better)
 WC Calculation

• Questions:
– Employee earns $1000, manual rating of 3.50
and EMR of 1.5. What is WC premium?

• Answer:
– $3.50 (rate per $100 of payroll) x 10 ($1000/100) x 1.5 (b/c
above avgEMR of 1.0) = $40.25
 OSHA Incident Rate Calculations
• Basic Equations:
– Incident Rate (IR)
IR = # cases x 200,000/exposure hours

– Days Away, Restricted, Transfer (DART)

• *exposure hours is the # of ee’s x 2000 hrs/yr

DART = #cases x 200,000/exposure hours*

• Record Maintenance:
– I&I Logs must be maintained for 3 years
– Medical records must be maintained for 30 yrs past date
of employment
 CONSUMER PRODUCTS SAFETY
COMMISSION (CPSC)
• Established as a result of
the CPS Act of 1972
• Operates a national info
network called the NEISS
• Products regulated:
– Apparel and non-apparel
fabrics
– Hazardous substances
– Materials required child-
resistant packaging (eg/
food, drugs, cosmetics and
fuels)
– Household/educational /
recreational products
• MFRs, Distributors and
Retailers must report to
CPSC when product:
– Fails to comply with
standards
– Contains a defect which
creates hazards
– Poses unreasonable risk of
serious injury or death
– Subject to 3 or more civil
actions in one year
 HYDROSTATICS
• Basic Equation: Pv = Q2/891d4
– where Q is volume in gpm
– where d is distance in inches

• Question: The VP in a 2” pipe w/ 1000

gpm flowing is?
– Answer:
• Pv = (1000)2/(891)(2)4 or 70.14 psi
 HYDROSTATICS
• Question: A 4’x 6’ container is 10’ deep and
contains 50% water and 50% oil with a sg of 0.8.
What is P ½ distance from surface if oil and water
remain separated?

P = .433 psi/f (h)(sg)

– Where P is pressure
– H is height
5 ft
– Sg is specific gravity Oil

• Ph20 = (.433psi/f)(5ft)(.8) = 1.732 psi Water

10 ft
 ELECTRICITY
Ohms Law
• Basic Equations:
– where P is power P = VI

– V is volts
– I is current V = IR

– R is resistance
 ELECTRICITY
(Resistance - 1)

• Question: Given the below diagram, what is the

total Resistance R? 5Ω 5Ω
110V 50Ω
5Ω 5Ω
– Rules of Thumb: R
• w/ parallel R, total R must be < the smallest R
• w/ combination series and parallel, do series first than parallel

Rseries = R1 + R2 + Rn
– 1/Rp = 1/50 + 1/10 + 1/10 = 1/.22
– 2.) Invert: 1/.22 = 4.54 ohms 1/Rp = 1/R1 + 1/R2 + 1/Rn
Note: always invert final answer
 ELECTRICITY
(Resistance - 2)

• Question: What is the current in B (on previous

page)?

– Where V is voltage V = IR
– I is amps
– R is resistance in ohms
– V= IR I = V/R = 110V/10ohms = 11 amps
• Rule of thumb:
• Voltage doesn’t change thru system in parallel/series
 Bonding and Grounding
• Bonding: • Grounding:
– connecting two – provides a conducting
conducting bodies by path b/w charged
means of a conductor objects and the earth
– flam liquids build up
electrostatic charge
when agitated or
during transfer
 ELECTRICITY MISC
• Interlocks used in electrical
equipment must meet “fail-
safe” criteria
• An electrical “open knife”
switch cannot be used in
hazardous locations because:
– Live parts are exposed
– It has sharp edges
• “Snap switches” enclose live
parts and are safer than open
knife switches
• Electrical circuit protective
devices (eg/ fuse or circuit
breaker) open the circuit
• Electrical bonding eliminates
the potential difference b/w
two conductors
• Electrolytic fluid in in lead-
acid batteries during
changing can produce
hydrogen gas
• An electrical system is “de-
energized” only after it has
been shut off and tested
• Conductive (protective)
clothing is used for
electrostatic hazards
Flammable/Combustible Liquids
• Flammable Liquids • Combustible Liquids
– Class IA: – Class II:
• FP < 73F and BP < • FP> 100F and < 140F
100F – Class IIIA:
– Class IB: • FP > 140F and < 200F
• FP < 73F and BP > – Class IIIB:
100F
• FP > 200F
– Class IC:
• FP > 73F and < 100F
Electrical Classifications (NEC 500)
• Class I:
– Div. 1:ignitable [flam. Gases and vapors] normally exist,
(eg/open systems)
– Div. 2: volatile liquids or gases confined

• Class II:
– Div. 1: comb. dust under normal conditions
– Div. 2: sufficient qty of dust not normally present

• Class III:
– Div. 1: ignitable fibers are handled and/or processed
– Div. 2: ignitable fibers are handled only
 FIRE MISCELLANEOUS - 1
• Extinguisher Requirements
– Visual inspection monthly
– Maintenance checks annually
– Hydrostatic testing every 5 and
12 years
– Travel distance to Class A is
75 feet
– Travel distance to Class B &C
is 50 ft
• 2 TYPES OF SMOKE
DETECTORS:
– Ionizing
• smaller smoke particles
• incipient stage of fire
– Photoelectric
• larger particles
• smoldering fires
 FIRE MISCELLANEOUS - 2

• TETRAHYDRAN OF COMBUSTION:
– Requires the following 4 elements:
• Fuel
• Oxygen
• Ignition
• Chain Reaction
 Fire Prevention
(Basic Principles)
• Combustion • Conduction
– rapid chemical rxn of 02 w/
a fuel – mechanism of thermal
– produces CO and CO2 plus E transfer b/w
heat materials
– elements include 02, heat, – materials have high
ignition conduction (metals) or
• Convection low (plastics)
– a result of movement of air
and combustion products
– determines direction which
a fire will spread
 Fire Prevention
Properties of Flam and Comb Liquids - 2
• Flash Point
– lowest temp at which a liquid can
generate enough vapor above its
surface to support combustion in
presence of ignition source
• Vapor Pressure
– Pressure exerted by a vapor on
its liquid at equilibrium
– strongly affected by Temperature
• Equilibrium
– Vaporization and condensation
of molecules until the rates of the
two become equal
– strongly affected by Temperature
• Fire Point
– lowest temp at which a flam
liquid in an open container
gives off enough vapors to
continue to burn once ignited.
• Explosive/flammable Range
– Concentration of flam vapor or
gas in air that can ignite in
presence of ignition source
– LFL: min conc of vapor in air
below which flame will not
propagate (eg/ 1.4 for gas)
– UFL: max conc of vapor in air
below which flame will not
propagate (eg/ 7.6 for gas)
 Fire Prevention
Properties of Flam and Comb Liquids - 2
• Autoignition Temp
– lowest temp that will produce
combustion w/o an ignition
source
• Specific Gravity
– density of liquid relative to
density of water
• Vapor Density
– measure of relative densities of
vapors and gases compared to
air
– most flam liquids VP> air
therefore ventilation needed at
floor level
– most flam gases VP<1 therefore
ventilation needed above floor
level
• Evaporation Rate
– rate at which liquid is converted to
vapor at given T and P
– ER reported in relation to
butylacetate
• Water Solubility
– many flam liquids (ROHs, ethers,
ketones) completely soluble in water
– mixture reduces flammability and
static charge
• Boiling Point (BP)
– temp at which the liquid transforms
into vapor at given P
– a strong function of P and always
decreases with a decrease in P
• Boiling Liquid-Expanding Vapor
Explosion (BLEVE)
– failure of a container at atm P holding
a liquid above it’s B
 FLAMMABLE GASES
• Definition: • Can be liquified by T
– Must satisfy either: and P
• a UFL of 13% or • Wider explosive range
less at ambient T than vapors
and P
• Usually lighter than
• Flammability range
wider than 12% at air
ambient T and P
 FIRE GASES
• CO
– results from incomplete
combustion of C12-containing
compounds
– large amounts produced in fires
– 210 times more reactive with
blood than O2
– Simple Asphyxiant
• CO2
– large amounts produced in fires
– not toxic gas but reduces
concentration of O2
• HCN
– deadly, produced from wool,
silk, acrylonitrile, ag chems,
rodenticides and polyurethane
• SO
– from sulfur-containing materials;
strong irritant
• Ammonia
– generated from wool, silk, fertilizers,
explosives, nylon
• HCL
– generated by PVC, dyes, perfumes,
ag chems
• HS2
– generated via incomplete
combustion of sulfur-containing
compounds such as wool and rubber
• NO2
– generated via N2-containing cmpds
such as fabrics, cellulose, catalysts
and polymerase inhibitors
 FIRE EXTINGUISHER
AGENTS
• CO2
– flammable liquids, ordinary
combustibles, electrical fires
– forms barrier b/w O2 and flammable
vapors
• Dry Chemical
– Regular/Ordinary Chems: for flam
liquid fires
– Multipurpose Dry Chems: flam
liquid fires and electrical fires
– Use dilution, cooling, radiation,
shields and flame-retardant actions
to extinguish
• Foam
– flam liquid fires
– use mechanical or chemical means
– forms cooling blanket that prevents
transfer of flam vapors from surface
of liquid
• Halogenated Agents
– HC with one or more atoms of H2
replaced with halogens
– replacement w/ halogen eliminated
flammability characteristics and
imparts flame-retardant capability
– known as Halons
– Halons stop combustion rxns by
interfering w/ progress and
development of combustion
intermediate free radicals
– Halon numbering system:
• eg/1301 (1st place indicates
number of C atoms, 2nd is Fl,
3rd is Cl, 4th is Br and 5th is I
• Dry Powder
– Used on combustible metals
 4 CLASSES OF FIRES AND
EXTINGUISHERS
• Class A • Numerical rating on
– ordinary combustible materials;
use water Class A and B:
– eg/ wood, cloth, paper, rubber and – the larger the #, the
plastics
more the capacity
• Class B
– flam or comb liquids, flam gases, • Should be visible from
greases
– can use water but recommend dry
3 feet away
chem and halon • OSHA required travel
• Class C
– energized electrical equipment
distances:
– use halons – Class A: 75 feet
• Class D – Class B: 50 feet
– comb metals (eg/ Mg, Ti, Zi, Na,
and K) – Class D: 75 feet
 SPRINKLER SYSTEMS
• Regular Dry Pipe • Deluge
– sprinkler heads attached to
– sprinkler heads are open at
piping containing air or N2
all times
– sprinkler head opens due to heat
– air in piping
• Wet Pipe
– heads attached to piping
containing water under P at all • Combined Dry Pipe and Pre-
times action
– head opens due to heat
• Pre-Action Automatic • Special and Limited Water
– control fire when possibility of Supply
damage to piping or heads
– special situations only
– water valve added to dry pipe
system
– operates like “wet system” w/o
water in piping at all times
 COLOR CODING FOR
SPRINKLER HEADS
• Max. Ceiling T (°F):
– 100 Uncolored
– 150 white
– 225 blue
– 300 red
– 375 green
– 425 orange
– 475 orange
 Sprinkler Calculations
• Question: what is the required pressure for a
fire protection sprinkler with a K value of 5.6,
protecting 120ft2 with a density of .22 gpm per
ft2?
• Q = (.22 gal/min/ft2)(120 ft2) = 26.4 gpm

Q = gpm/ft2 x ft2
where Q is flow

• P = (Q/K)2 = (26.4 gpm/5.6)2 = 22.2 psi

P = (Q/K) 2
where P is pressure
and K is factor
 FIRE DETECTION
INSTRUMENTS
• Fixed T Thermal Detectors • Smoke Detectors
– bimetallic element with two metals – respond to products of combustion
having different coefficient of based upon less or more light
expansions reaching them
– *thermal lag • Flame Detectors
• Rate-Compensation – respond to either UV or IF portion
– respond to fixed pre-determined T of light generated by flame
in air • Combustible Gas Indicators
• Rate-of-Rise – resistance of heated element
– respond to pre-determined rate of increases w/ contact w/ gas
rise of T in air • Fire Alarms
• Pneumatic – Type A: operator receives alarm
– increase of air P inside bulb due to and transmits to FD
increase in T – Type B: alarm automatically
– completely mechanical and good for transmitted to FD
explosive environments
 BUILDING FIRE SAFETY
• Flame Spreading Rate
– measure of burning
characteristics of a material
• Fire Loading
– max amount of heat
generated in given area as
result of a fire
• Fire Proofing
– insulating steel in structures
from heat generated during
fire
• Fire Safe
– area designated such that fire
will not spread to other areas
• Fire doors
– classified by hourly rating
– Classes A, B, C, D, and E
• Hot Work Permits
– authorization to perform work
w/ equipment or devices
capable of igniting
combustible materials
– Most important step is a
“policy statement”
HAZARD AND RISK CONTROL
(General Info) - 1
• Scaffolds should be designed
to 4X anticipated load
• Scaffolds > 20 ft require
safety belt and lifeline
• Rope on scaffold must be at
least 6X > than load
• Ladders position at 4:1 ratio
• Cranes should be at least 30
feet apart
• 3” b/w cranes and overhead
structures
• Hydrostatic P should not
exceed 1.5X maximum
working P
• Max value of a slope is
15°; never exceed 20°
• VP and T increase in
closed containers of
volatile liquids
• Fuel containers for LPG
FL trucks conform to
DOT/ASME
• FL Truck confirms to
ANSI
HAZARD AND RISK CONTROL
(General Info) - 2
• Treating Cold Contact • System grounding
protects “system”
Burns:
• Capacitors pose hazard
– water b/w 105° and “on” or “off”
115 F° • GFCI protects people
and equipment by
• Treating 3rd Degree opening an electrical
circuit & line to ground
Burns: contact
– keep hands elevated • “Explosion-Proof”
above heart electrical equipment
withstands “internal”
explosion
HAZARD AND RISK CONTROL
(General Info) - 3
• 3 Types of Electrical • High T welding air
contaminant is Nox
Fuses:
• Cutting and welding
– link generates O3 and UV
– plug • Trench is a:
– cartridge – narrow excavation
– deeper than wide
• 2 Main Categories of – never wider than 15 feet
Circuit Breakers: – Bracing ad shoring required
– magnetic at 5ft or > unless sloped to
angle of repose or stable
– thermal rock
 Block and Tackle Systems
(Mechanical Advantage or MA)
• 1 part system - 1 rope: 0 MA
• 2 part system - 2 ropes: 2:1 MA
• 3 part system - 3 ropes: 3:1 MA
• 4 part system - 4 ropes: 4:1 MA
• 5 part system - 5 ropes: 5:1 MA
• Question: Lifting 2500 lbs with 5 part rope system. How
many pounds of force are required for equilibrium lifting
conditin?
• Answer: 5 ropes are 1:5 ratio therefore 2500/5 = 500 lbs.
 Block and Tackle

• Question: A 5-part B&T is used to lift 500

lbs. If friction loss is %10 for each sheave,
what force is required?

F = P(1+i)n

– F = (100)(1.1)5 = 160 lbs.

 Compression
• Questions: What is the compression in
member BC?
– 980 lbs/1.5 ft = x/ 3 ft = 1960 lbs

1.5 ft

B C
3 ft
980 lbs
 COMPRESSION
(Rules for Trusses)
• Cats crawl across the roof
• Turtles crawl along the
ground
• C is compression and T is
tension
• If you cut at center and it
falls “inward” then
compression
• If you cut at center and it
falls “outward” then
tension
• Inverted trusses act the
same
• Compression members
can be replaced by I/H-
beams, channel/angle iron
or pipe/solid dowels
• Tension can be replaced
by cables, chains, or
turnbuckles (because
pulling action)
 COMPRESSION
(Rules for Trusses)

C Load C
B C C A D
E
C C C C
T T T T

A T E T D B T C

Compression (c) Tension (T)

 Definitions - Material Properties
• Bending Moment • Dangerous Section
– tendency of loaded beam to – cross section of beam
bend when acted upon by a
force operating through a where bending moment
distance is greatest
– tendency to rotate about a
point
• Flexure Stress
– must be able to resist – indicates stress caused
bending or failure by bending
• Section Modulus
– measure of capacity of a
section to resist any
bending moment to which it
is subjected
 HAZARD AND RISK CONTROL

• Basic Equations: F = μN
– Friction Force
• where F = frictional force
• μ = coefficient of friction
• N = total weight

– Distance for Presence Sensing Device

• where D = distance
• V = velocity D=VxT
• T = time
 FRICTION
• Question: How much pressure is lost to friction
for 200 ft of 6-in steel pipe when providing a
flow rate of 1850 gpm. Assume a C factor of
100.
Pd = 4.52Q1.85/C1.85d4.87

• Pd = (4.52)(1850)1.85/(100)1.85(6.065)4.87 = 5005023/32537637 =
.1538
• Factor drop for 200 ft:
– (.1538)(200ft) = 30.1 psi
 THE EFFECTS OF FRICTION
(STICK/SLIDE - 1)
• Question: The coefficient of friction is .5 b/w the 100-lb box
and the upper ramp and .3 b/w the 40-lb box and the lower
portion of the ramp, and the pulley is frictionless. Will the
boxes remain on the ramp?
• Equation: 100
20°
40
Ff = μN 30°
where Ff = pushing/pulling force (parallel force)
μ = coefficient of static friction
N = normal force (perpendicular to surface)
40

30° N
30°
40

R
 THE EFFECTS OF FRICTION
(STICK/SLIDE - 2)
• Three parts of ramp question: (1) friction (stick), (2) non-friction
(slide) and (3) Fnet.
• 40-lb weight:
– Friction calculation (stick):
• F = μN = (.3)(N) and N = cah (from SOHCAHTOA) therefore: cos30
A/40 = 34.6 lbs.
• F = (.3)(34.6) = 10.38 lbs.
– Non-Friction calculation (slide):
• Solve for R where R = SOH or sin30° = O/H or R/H = 20 lbs.
– Calculate Fnet:
• 20lbs - 10.38lbs = 9.6 lbs
• More slide than stick
 THE EFFECTS OF FRICTION
(STICK/SLIDE - 3)
• 100 lb weight:
– Friction calculation (stick):
• Ff = μN = (.5)(N) = cah = cos20° N/100 = 93.96 lbs.
• Ff = (.5)(93.96 lbs) = 46.98 lbs. Stick

– Non-Friction calculation (slide):

• FR= SOH = sin 20° R/100 = 34.20 lbs.
– Calculate Fnet:
• 46.98 - 34.20 = 12.78 lbs
• More stick than slide
 THE EFFECTS OF FRICTION
(STICK/SLIDE - 4)

• Set up Solutions Table:

Solutions Table
N Ff = N Ramp Result
40-lb box 34.6 10.38 20 lbs 9.6 lbs slide
100-lb box 93.96 46.98 34.20 12.78 lbs stick

• Solution:
– Will the boxes remain on the ramp?
– 9.6 lbs (slide) compared to 12.78 lbs (stick) = 12.78 - 9.6 = 3
– Yes, by 3 lbs.
HAZARD AND RISK CONTROL

• Breaking Strength:
– where B is rope breaking strength
– S = # of parts of sheaves in rope
– W = weight
– F = Safety Factor

B = [W + 0.1WS/S]F
 Calculating Dikes - 1
• Question:
– What is min. height dike required in a 50’x80’ area containing
3 tanks (one 100K gal w/ 35’ diameter and two 20K gal w/ 20’
diameters)?
• Answer:
– 1. ) Convert largest tank from gal to ft3
• 100Kgal x 1 ft3/7.48 gal = 13,369 ft3
– 2.) Calculate tank farm area
• A = hw = 50*80 = 4000 ft2
– 3.) Subtract out area for other tanks from #2
• 2(Π)(10ft2)= 628 ft2
• 4000 ft2 - 628 ft2 = 3372 ft2
– 4.) Solve for H (height) of dike
– V = ah or h = V/a = 13369/3372 ft2 = 3.96 or 4 ft
 Floor Loading and Tank Sizing
• Question: A 5000 lb capacity tank weighs 6500 lbs.
Floor loading is 200 PSF. How high can tank be?
• Answer:
– 1.) Convert tank size (in gal) to lbs. x sg
• eg/ 5000gal x 8.34 lb/gal x 0.8
– 2.) Add tank volume (in lbs) to tank weight
• eg/ 33.360 lbs + 6500lbs = 39860 lbs
– 3.) Convert lbs to ft2 for area eqtn a = Πr2
• 39860 x 1ft2/200 lb = 199 ft2
– 4.) Solve for radius: a = Πr2 so
– r2 = a/Π = 1.99/3.14 = r = 63 r = 7.9 of 8 ft
 PLANT LAYOUT
• Considerations during
design and operations:
– Direction of wind
– # of employees to run plant
– Cost of future revisions
• During design of
“outdoor” plant layout, all
equipment containing
flammable materials
should be located on the
“downwind” side such
that vapors do not re-
entrain
• “Flow” plant layout:
– Advantages:
• Minimization of length
of transfer lines
• Minimization of energy
requirement for transport
of materials
– Disadvantages:
• Requires more people
• “Grouped” Plant Layout:
– All similar equipment is
placed together
 Safety Facts
• 3 leading causes of • Code developed by ASME
UST releases are: requires pressure for
hydrostatic test at 150%
– Piping failure
MAWP
– Corrosion
• Per ANSI/ASME A17.2,
– Spilling/overflowing the recommended
frequency for inspections
for passenger elevators is
every 6 months
 PPE Consensus Standards
• ANSI Z87.1 –1989 • ANSI Z89.1-1986
– Eyes – Head
• ANSI Z41-1991: • ANSI Z53.1
– Shoes – Color coding for safety
 Classes of Hardhats

• Class A:
– falling objects, electricity and low voltage
conductors
• Class B:
– falling objects, electricity and high voltage
conductors
• Class C:
– falling objects
 49 CFR 172 - Labeling
Hazardous Materials
• RED • Flammables
• YELLOW • Oxidizers
• GREEN • NF gas
• BLACK & WHITE • Corrosive
• ORANGE • Explosive
• BLUE • Dangerous
Classifying Hazardous Materials
• F List: • P List:
– finishing compounds, – acutely toxic chemicals
solvents, TCDD, – “P” for potent
plating
• U List:
– “F for finishing”
– other toxic chemicals
• K List: -”U” for udder
– special industrial
processes
– “K for special K”
 Branches of the Government
EXECUTIVE BRANCH

EPA OSHRC
Review OSH cases

NTSB CPSC

NRC

HHS Transportation Homeland Security Labor

NIOSH CDC FAA TSA USCG MSHA OSHA

FRA

FMCSA

RSPA
Haz Mat

NHTSA
CDLs
 Federal Motor Carrier Safety
Administration (FMCSA)
• Issue CDL
• Random alcohol testing 25%
• Controlled substance testing 50%
• Alcohol test required within 2 hrs of
accident
• Substance test required within 32 hrs of
accident
 PLAYGROUND SAFETY
• Recommended use zones • Recommended diameter
for playground equipment of rungs and other hand
should extend a minimum gripping components is
of 6ft in all directions 1.25.
from perimeter of – The younger the
equipment children the > the grip
• Minimum distance b/w size due to motor skills
structures w/ designated
play surfaces of 30” or >
is 9 ft
 Communication

• 4 Elements of Effective • Berlo 7 steps:

Communication: – Communication Source
– Sender – Encoding
– Message – Message
– Receiver – Channel
– Feedback – Decoding
– Receiver
– Feedback
 4 ELEMENTS OF BHR-BASED
LEARNING/TRAINING OBJECTIVES
• A, B and C’s of • Learning Theories:
Learning/Training – Expectancy (eg/ value)
Objectives: – Needs
– A for Audience – Adult learning
– B for Behavior – Info processing
– C for Conditions – Reinforcement
– D for Degree – Social learning
– Goal setting
 Rules of Training

• People generally remember:

– 10% of what they read
– 20% of what they hear
– 30% of what they see
– 50% of what they see and hear
– 70% of what they say
– 90% of what they say and do
 TRAINING CONCEPTS
• Reliability:
– consistency in measuring
employee’s knowledge and
abilities
– eg/ returns same basic
results time and again
• Validity:
– Effectiveness
– Relevance of test to job
knowledge and skills
– eg/ final test for maintenance
department on confined space
entry
• Norm-referenced:
– Grading system where
student’s performance is
compared to that of others
• Criterion-referenced:
– Performance is dependent
upon predetermined
standard of conduct or
behavior
– eg/ competency on
employee HazCom exam
 LAWS OF LEARNING
• Law of Frequency:
– Repetition; practice makes
perfect,
• Law of Recency:
– Better learning w/ most
recent information
• Law of Readiness:
– When you have chance to
use it, you’re ready
• Law of Disuse:
– Use it or lose it
• Law of Effect:
– Will learn better if area
of interest
• Law of Primacy:
– Of prime importance,
high retention
• Law of Intensity:
– Increase involvement
level, increase
retention
COMPUTER TECHNOLOGY - 1

• 3 Functions of a computer:
– Input
– Output
– Process (CPU)

• 4 Major Types of Software Events (Hazards):

– Unwanted
– Prevents needed event
– Out-of-sequence
– Out-of-tolerance
COMPUTER TECHNOLOGY - 2

• Two Types of • DB classifications:

Networks:
– Peer-to-Peer – Single User
• inexpensive – Multi-User
• simple
• centralized control
– Client-Server
• centralization
• expensive
• security
 Computer Terminology - 1
• ASCI
– American std code for info
interchange
• Buffer
– Memory area used for
temporary storage during
input/output operations
• DBMS
– Collection of data organized for
efficient storage, editing, etc.
• DNS
– Domain name system,
registration for domains
• Ethernet
– interconnects computers
• GIF/JPG
– Graphical interchange format
• HUB
– used to connect multiple
computers to an ethernet LAN
• GUI
– Graphical user interface
• HTML
– Hpertext markup language,
web language
• HTTP
– Hypertext transfer protocol
 Computer Terminology - 2
• LAN
– Local area network
• Protocol
– System of rules/procedures
governing communication b/w
devices
• RAM
– Random access memory,
temporary memory while power
is on
• ROM
– Read only memory; permanent
memory
• RAID
– Redundant array of independent
drives for data protection
• SQL
– Structured Query Language
• URL
– Uniform resource locator;
protocol for web address
• USB
– Universal serial bus;
connector replacing serial
port for printers, scanners,
cameras, etc.
• VPN
– Virtual private network
• WAN
– Wide area network
ENVIRONMENTAL ENGINEERING
• Large quantity generators • Environmental Risk Assessment
must sign Uniform Techniques:
Hazardous Waste Manifest – Probability Analysis
that includes waste
minimization certification – Systems Analysis
• Manifests must be – Cost-Benefit Analysis
maintained for 3 years • Risk Assessment Process:
• Open drum: – Hazard Identification
drum/container that has a
removable lid – Hazard Accounting
• Small quantity generator – Risk Characterization
can store waste on-site w/o – Risk Evaluation
permit for 180 days
ENVIRONMENTAL ENGINEERING
TX of Hazardous Waste
• Precipitation: • Biological TX:
– Uses coagulants and – Aerobic (free O2) and
flocculants to TX waste water Anearobic
– Heavy metals precipitate at – Low Temp oxidation
different pH levels
• Ion Exchange: • Aeration:
– Chemical process
– Used to TX contaminated
water
• Distillation: – Uses adsorption and air
– Reduces volume of waste stripping
stream by separation into haz
and non-haz streams – Adsorption is removal of
– Physical TX
components of gas mixture
onto a solid bed
• Sedimentation: • Turbid meter:
– Removal of solids by
gravitational force – Device used to measure
– Physical treatment clarity
 ENVIRONMENTAL ENGINEERING
Control of Air Pollution

• Incineration: • Scrubbers:
• Controlled combustion • Remove contaminants
• Afterburners convert by absorption into
CO to CO2 liquid
• “Excess Air” enhances • Neutralize gas mixtures
combustion • Operate on
• Removes organics but countercurrent flow
not heavy metals basis
 LEGAL CONCEPTS
• Tort:
– A wrongful act or failure to
exercise due care, other than
breach of contract, resulting in
legal injury (eg/ libel, slander,
assault and negligence)
• Liability:
– An obligation to rectify or
recompense an injury or damage
by the responsible party
• Negligence:
– Failure to exercise a reasonable
amount of care or to carry out a
legal duty so that injury or
damage occurs to another
• Contributory Negligence:
– defense used by employers
prior to WC laws
• Concept of Privity:
– direction connection to one
another
• Patent Defect
– discovered in all items of a
given manufactured batch
• Latent Defect
– occur in a limited number of
manufactured items of a
given batch
 LEGAL CONCEPTS
• Liabilities:
– Implied Warranty: expectation,
what product should be able to
do
• Warranty of Fitness: will
meet buyer’s intended use
• Warranty of Merchantability:
relates to buyer’s expectations
or what the product should do
– Express Warranty: written or
oral promise
– Strict Liability: negligence or
fault not necessary for liability
– Limited Liability: to
compensate injured parties
• Breach of Warranty:
– Failure of product to fulfill
contractual obligation
regarding product’s
specifications and
suitability
• Doctrine of “Fellow
Servant Rule:”
– Employer not responsible
for injuries suffered by an
employee due to negligence
of another employee
• Statutory law is codified
by a governing body
 LEGAL PRINCIPLES
• 4 Parts of a Contract • res ipsa loquitur:
– Agreement speaks for itself
– Consideration • caveat emptor: buyer
– Legal Purpose beware
– Competent parties • caveat venditor: seller
beware
• Note: considered a • ultra vires: beyond
contract when placed in
given authority
mail or fax received
 REGULATORY
(OSHA - 1)
• OSHA
– OSH Act of 1971
– Standards to protect S&H of
employees
– Created NIOSH and OSHRC
– National Consensus Standards
• NFPA and ANSI
– General Standards
• OSHA
– Emergency Temporary
Standards
• Created by OSHA in response
to IDLH situations
• Record Keeping
– Must be maintained by
employers with 11 or >
employees
– Forms:
– OSHA 300: “Log of Work-
related Injuries & Illnesses”;
detailed description of I&I
containing employee info
– OSHA 300A: Total numbers
of I&I; must be posted annually
FEB-APR
– Injury must be recorded w/I 6
days
• All I&I records must be
maintained for 5 years
 REGULATORY (OSHA - 2)

• Variances • Citations
– Temporary: to give ER
additional time to come into
compliance; must show “on-
going” compliance program
– Permanent: must show
existing procedures will result
in environment as safe and
healthful as procedure
mandated by standard
• OSHA Inspections
– Regular: normal “planned”
inspection schedule
– Special: result of complaint,
referral, accident, etc.
– Issued by OSH Area
Director
– ER can appeal w/in 15 days
of issuance
– May issue “notice” rather
than citation
– 6 Types: IDLH, Willful,
Repeat, Serious, Non-
Serious, FTA
 REGULATORY
(Haz Com)
• “Workers Right-to- • Requirements:
– Written program, MSDSs,
Know” of 1983 labeling & training
– Affects 3 groups: – Above must be available
• Chemical MFRs, importers during each work shift and
available upon request
or distributors
– Labels must be in English
• Employers
• Employees
• Exemptions:
– Haz waste, food additives,
drugs and cosmetics, consumer
products or hazardous
substances (by CPSC),
Pesticides and Alcohol not
intended for industrial use.
 REGULATORY
(HAZWOPER)

• Operations involving: • Requirements:

– Site characterization
– Hazardous waste TX – Site Control
– TSDs – Training
– Hazardous materials – Medical Surveillance
(annual)
response
– ENG, PPE & Work
– Haz mat clean-up Practices
– Decon
– Emergency Response
– Illumination
– Sanitation
– Site S&H Plan
 REGULATORY
(RCRA - 1)
• Amendment to Solid Waste Disposal Act
(1976)
• Deals with safe disposal of both haz and
non-haz waste
• Subtitles
– D: management of non-haz solid
waste
– C: management of haz waste
– I: regulations for USTs
• Does not deal with abandon haz waste
sites (CERCLA)
• “Solid Waste:” solid, semi-solid, liquid
or contained gas
• “Open Dump”: under Title D, a solid
waste facility which does not meet
“minimum technical standards”
– Must be either upgraded or stopped
• “Hazardous Waste”:
– one or more of following
characterstics:
• corrosive, reactive, ignitable or
toxic
• Or, a listed waste
• Or, a mixture containing a
listed hazardous waste
• Generator responsible for haz waste
determination
• Generator must apply and obtain EPA
ID number
• Exclusions: household waste, industrial
wastewater, domestic sewage, energy
and mineral deposits, fossil fuel
combustion products, mining wastes,
nuclear waste and irrigation wastes
 REGULATORY
(RCRA - 2)
• Generator Types:
– Conditionally Exempt: < 100
kg/month
– Small Quantity: 100-1000 kg/month
– Large Quantity: >1000 kg/month
• Transporters must have an EPA ID
number
• TSD’s must have an EPA permit
• “Storage Facility”: facilities storing
haz waste in excess of 90 days
– Large Qty Generators must have permit
for >90 day storage
• Manifest or “cradle-to-grave” document
tracks waste from generation to disposal
• Large QTY generators must
certify on manifest that haz
waste minimization program is
in place
• “Exception Report” required
when manifest not received
from TSD w/I 45 days
• Generators must submit
“Biennial” report to EPA by
March 1 of each even-
numbered year
• All generators, transporters, and
TSDs must maintain records for
at least 3 years
 REGULATORY
(CERCLA)
• “Superfund Law”
• Involves clean-up of abandoned hazardous waste
sites
• Site must be placed by EPA on NPL using HRS (a
score of at least 28.5 required)
• Concept of “Joint and Several” liability: one
polluter can be held liable for cleanup when many
are involved
• Waste from clean-up managed under RCRA
 REGULATORY
(SARA – Title III - 1)
• Amendment to Superfund Law in
1986
• “Community Right-to-Know” as a
result of Bhopal incident
• Also known as EPCRA
• Deals with chemical emergencies in
communities
• Governor responsible for forming
an SERC
• SERC responsible for forming
LEPC and dividing state into EPDs
• Each facility must designate a
“facility emergency coordinator”
• Any facility that produces, uses or
stores any of the chems on EPA list of
extremely hazardous substances
(40CFR) exceeding the TPQ is
subject to SARA
• If subject, facility must notify SERC
w/I 60 days
• SERC and LEPC must be notified if
release off-site beyond RQ
• Affected facilities must submit
MSDSs or list of haz chems to SERC,
LEPC and local FD
• LEPC must submit copies of MSDSs
upon request
 REGULATORY
(SARA – Title III - 2)
• Reporting:
– Tier I: aggregate information by hazard type
– Tier II: specific chemical information
• Must be submitted by March 1 of each year
– Form R: reflects all releases from facility for previous
calendar year
• Must be submitted by July 1 of each year
• Based upon usage threshold
• FOI
– All plans, MSDSs, inventory forms and release forms must
be available to public during normal working hours
 REGULATORY
(FWPCA)
• Federal Water Pollution
Control Act
• Goal to bring all bodies of water
into fishable/swimmable condition
• Covers “point” and “non-point”
sources of pollution
• NPDES permits required for
discharge
– Must be renewed every 5 years
• Must meet discharge limits set by
EPA based upon “best available
and practicable” (BACT)
technologies for TX prior to
discharge
• Sludge produced by TX facility
treated as hazardous waste
• EPA and FDA set “action levels”
for toxic materials in water
• Discharges into POTW must be
pre-treated
• Act also controls vessel sewage
• NDPES permits required for any
“point source” discharge of
pollutants into bodies of water
• NPDES applicant data must be
maintained for 3 years
• 1987 amendment to CWA
introduced management of “non-
point” sources
 REGULATORY
(TSCA)
• Toxic Substances Control
Act of 1976
• Identifying haz chems and their
means of control
• Risk factors for any new or existing
chems put into substantial new use
must be evaluated by EPA before
commercialization and/or
distribution
• Gives EPA authority to place
controls on MFR, distribution and
use of a chemical, including total ban
• Exemptions:
– FDA controlled chems
– FIFRA controlled chems
– NRC controlled materials
• EPA, after public hearing, can force
MFRs to perform additional testing
• MFR and importers of new chems must
provide a “90 day Notice of Intent” to
EPA
• New chemical: any chem not EPA list
of existing chems
• Chems produced in small quantity for
research purposes are exempt from
notification
• EPA must inform other countries of
chem export
• EPA has authority to inspect any
facility that stores, mfrs, or processes
chems
• PCBs and Asbestos are covered under
TSCA
 REGULATORY
(CAA - 1)
• Clean Air Act passed in 1970
• Primary and secondary NAAQS
(national ambient air quality standards)
• Standards set maximum allowable
concentration of pollutants
• Amendment of 1977 created”
– Prevention of Signification
Deterioration (PSDS):
• intent to limit pollution in areas
in compliance with NAAQS
• requires permit for
owner/operator of “stationary
sources” prior to new
construction
• Mandates use of BACT (best
available control technology)
– Non-attainment:
• restricts construction which
may add to sources of air
pollution; also requires
permit
• Titles:
– I: stationary sources such as
mfg plants
– II: mobile sources such as
automobiles
– III: judicial review/citizen
lawsuits
 REGULATORY
(CAA - 2)
• Standards:
• Hazard air pollutant is one which
– Ambient: max safe has no NAAQS
pollutant concentrations • Operator/owner of emission source
– Emission: controls amount must:
of pollution produced by a – keep records
given source – Install/maintain monitoring
• NESHAPS (national equipment
emission standars for – Comply with reporting
haz air pollutants) requirements
• NSPS (new source • If SIP violated, EPA issues notice,
performance standards) to be corrected within 30 days
• Violations of NESHAPS/NSPS do
– State responsible for not require notice by EPA, but may
designing and illicit immediate action
implementing a SIP (state • Allows citizen suits against EPA
implementation plan) that and owner/operator
achieves NAAQS
 REGULATORY
• NEPA: National • FIFRA: Federal
Environmental Pollutant Act Insecticide, Fungicide,
of 1970 Rodenticide Act of 1972
– CEQ has responsibility for – Regs for labeling,
enforcement storage and disposal of
– EIS (environmental impact pesticides
statements) must be prepared
prior to undertaking any project – Requires pre-market
which may have averse affect on clearance for pesticides
environment
– EPA has established
– Activities which require EIS:
educational programs
• Those requiring federal permit
for users
• Those using any source of
federal resources for their
implementation
 REGULATORY
• SDA: Safe Water • MPRSA: Marine
Drinking Act of 1974 Protection, Research
– Major objectives: and Sanctuaries Act of
1972
• Set maximum
– Major objective:
pollutant levels on
• Eliminate ocean
drinking water dumping of hazardous
• Protect waste
underground water – Requires permit for any
waste disposed of at sea
– Pre-empts any state
regulations
 Misc. Safety History

• Marshall v. Barlow (1978): • American Textile MFG

– 1st Supreme court case lost Institute v. Donovan
by OSHA
– 4th amendment issue
(1981):
– Right to entry of OSHA – “Cotton Dust decision”
– Brought about right of – Cost benefit analysis
refusal of entry and
subsequent warrant process not most important
to enter consideration
• Whirlpool Decision (1980):
– Expanded OSHA protection
to EEs
– EEs could refuse to perform
“IDLH” work
 SAFETY ORGANIZATIONS /
ASSOCIATIONS
• ASSE • System Safety Society
– Formed in 1911 as – Journal of System Safety
United Assoc. of • AIHA
Casualty Inspectors
– AIHA Journal
– Professional Safety
Journal • NFPA
• NSC – NFPA Journal
– Formed in 1913 as
Assoc. of Iron and Steel
Electrical Engineers
 MISC. BCSP
• MEMBERSHIP • ACCREDIATION
ORGANIZATION FOR AGENCIES OF BCSP:
BCSP: – CESB (Council of
– ASSE Engineering and Scientific
Specialty Boards)
– SFPE (Society of Fire Protection
Engineers) – NCCA (National
– AIHA Commission for Certifying
Agencies)
– NSC
– SSS (System Safety Society)
– IIE (Institute of Industrial Engineers)
 BCSP Ethics

• Hold paramount S&H of • Avoid deceptive acts

people, Environment & • Adhere to highest
property professional standards
• Be honest and fair • Act in a way that is
• Issue public statements free of bias
based upon fact & • Seek opportunities for
knowledge constructive service
• Undertake assignments
when qualified