Process Technology Safety, Health, and Environment

Physical Hazard

A term applied to a chemical that statistically falls into one of the following categories: combustible liquid, compressed gas, explosive or flammable, organic peroxide, oxidizer, pyrophoric, unstable, or water reactive.

4 Types of Respirators

Air purifying Respirators come in two designs, half face and full face. Air supplying Respirators come 6 in two designs; self contained breathing apparati (SCBA) and hose line respirators.

4 Hazards of Chemicals.

Carcinogens, mutagens, teratogens, reproductive toxins

Cutaneous hazards are?

Chemicals that affect the dermal layer of the body.

Flashpoints

Combustible Liquid-between 100 degrees F and 200 degrees F/ Flammable Liquid- flashpoint below 100 degrees F Pyrophoric- ignites spontaneously with air at temperatures below 130 degrees F.

Physical hazards associated with chemicals are categorized as.

Combustible liquids and compressed gas. Explosive, a flammable gas, and a flammable liquid. Organic peroxides, oxidizer, pyrophoric, unstable and water reactive.

Cutaneous hazards are _____.

chemicals that affect the dermal layer of the body.

Physical hazards associated with chemicals are categorized as ______.

combustible liquids and compressed gas, explosive, a flammable gas, and a flammable liquid, organic peroxides, oxidizer, pyrophoric, unstable and water reactive.

Ergonomic hazards are activities that require chemical technicians to work in awkward positions for extended periods of time.

repetitive motions, monotony, and console operators work pressure and equipment and system operation inability to match the standards of performance.

In the United States, the industrial safety movement closely parallels the____________.

rise of the labor movement

Penalties for a civil and a criminal abuse of the Clean Air Act range from ________.

$25,000 a day to $250,000 and 2 to 15 years in jail.

Penalties for a civil and a criminal abuse of the Clean air Act range from?

$25,000 a day to $250,000 and 2 to 15 years in jail.

1 gallon of water can make how much steam?

1,600 gallons of steam.

Material Safety Data Sheets 3 Categories

1. Product Identification and Emergency Information- Chemical name, chemical family, formula, trade name, manufacture address, and emergency telephone number available 24 hours a day. 2.Hazardous Ingredients-Chemical component percentages and OSHA hazard. 3. Storage and Handling- Storage temperature, storage, transport pressure.

The Federal Clean Water Act was passed in ___.

1898

The Federal Clean Water Act was passed in what year?

1898

In _______, OSHA's Hazard Communication Standard was implemented.

1983

Year HAZCOM was established

1983, A program designed to increase plant worker awareness of chemical hazards and give instructions on appropriate safety measures for handling, storing, and working with these chemicals.

The Toxic Substance Control Act (TSCA) inventory includes more than ___ chemicals and was established to trace and record all products manufactured, imported, sold, processed or used for commercial purposes.

75,000

The trigger point that requires hearing protection ____.

85 decibels.

The trigger point that requires hearing protection is?

85 decibels.

NFPA Diamond

A four diamond hazard labeling system. Each small diamond is color coded and has its own severity rating form 1 to 4. The four color coded topic blocks are: blue for health hazards, red for fire hazards, yellow for reactivity hazards, and white for specific hazards.

Standby

A technician who is certified and trained to support and warn technicians who have entered a confined space.

Unplugging Permit

Barricades area, clears lines for unplugging, informs personnel, issues opening blinding permit, and issues unplugging permit.

List 4 different types of dusts that pose a hazard to process technicians.

Anesthetic, Allergic, Asphyxiants, Inert dust, systemic poisons

List four different types of dusts that pose a hazard to process technicians.

Anesthetic, Allergic, Asphyxiate, Systemic Poisons.

Hot Work Permit

Any maintenance procedure that produces a spark or excessive heat or requires welding or burning.

Chronic Hazards (delayed)

Asbestos fibers, coal dust, and toxic metals such as lead or manganese.

6 typical work place hazards

Burning, Exploding, cutting, Electrocution, Impaling, Tripping, Falling

Engineering Controls

Hard technology improvements designed to make the work environment safer.

CERCLA

Comprehensive Environmental Response Compensation and Liability Act. This act is frequently referred to as the "Superfund Law." many large companies have been required to provide money for cleanup activities for materials dumped by them or their parent companies years ago. This effort supports the "cradle to grave" concept. This act holds generators and disposers of hazardous waste liable for past practices, and established the "Superfund" of $1.6 billion to pay for cleanup operations of abandoned hazardous waste sites.

DOT

Department of Transportation shipments of hazardous materials are regulated by the U.S. Department of transportation. These regulations contain specific information on how hazardous materials are identified, placarded, documented, labeled, marked, and packaged.

Confined Space Entry, Permit to Enter

Designed to protect employees from oxygen deficient atmospheres, hazardous conditions, power driven equipment, and toxic and flammable materials.

Plant managers are typically responsible for.

Designing a company's safety policy, Encouraging safety awareness, and Facilitating safe and healthful work conditions.

Keys to accident prevention

Determine the cause. Prevent its recurrence.

What are the significant differences between industrial safety in the past versus the present?

During the past management wasn't concerned about the deplorable conditions they put their workers in. Employees had to work long hours with low pay, there were no benefits for employees. If a worker was injured or happened to die the family wasn't compensated.

Physical hazards are classified as?

Electrical, Noise, Radiation, Temperature.

Process Technicians Responsibilities

Equipment and Technology-Valves, pumps, piping, compressors, tanks, steam turbines, motors, heat exchangers. Maintenance-Use of hand tools, perform minor maintenance.

Routine Maintenance Permit

General maintenance and mechanical work that does not involve hot work or opening up a vessel.

Process technicians are responsible for.

Good house keeping, Safe work practices and environment, Hazard recognition.

Hazard Communication

HAZCOM established in 1983

The National fire protection association has a standardized system that is designed to?

Identify chemical hazards.

List the typical routs of entry a chemical uses to enter a body.

Ingestion, Injection, Absorption, Inhalation

List the typical routes of entry a chemical uses to enter a body.

Ingestion, Injection, Absorption, Inhalation.

Vapor Pressure

Is the pressure exerted in a confined space by the vapor above its own liquid.

Energy Isolation Procedure (lockout/tagout)

Isolates potentially hazardous forms of energy. Shut down a piece of equipment at the local start and stop switch.

Energy Isolation Procedure, Lockout/Tagout

Isolates potentially hazardous forms of energy: electricity, pressurized gases and liquids, gravity, and spring tension (The standard is also designed to shut down a piece of equipment at the local star/stop switch, turn the main breaker off, attack lockout adapter and process padlock, try to start the equipment, and tagout and record in lockout logbook.)

Administrative Controls

Programs and activities used to control industrial hazards.

PH Scale

Neutral 7 pure water, Alkalinity (Bases) 8 sea water 1/10, 9 baking soda 1/100, 10 great salt lake 1/1000, 11 ammonia 1/10,000; 12 soap 1/100,000; 13 Bleach 1/1,000,000; 14 drain cleaner 1/10,000,000: (Acids) 6 urine 10; 5 coffee 100; 4 tomato juice 1000; 3 orange juice 10,000; 2 lemon juice 100,000; 1 hydrochloric acid 1,000,000; 0 battery acid 10,000,000.

NRC

Nuclear Regulatory Commission regulates the nuclear devices used in the chemical processing industry. This includes x-ray and measuring devices used to inspect vessels and equipment.

What is covered by OSHA?

PPE, permit systems, confined space entry, hot work, isolation of hazardous energy, HAZCOM

PEL is the ________ established by OSHA.

Permissible Exposure Limit

PPE

Personal Protective Equipment is the special equipment used to protect a technician from hazards found in a plant. There are four levels of PPE (A,B,C,D) Level A provides the most protection and level D requires the least.

"Cradle to grave" is a term associated with which government act?

RCRA

Opening or blinding permit

Removing blinds, installing blinds or opening vessels, lines, and equipment.

Opening/Blinding permit

Removing blinds, installing blinds, or opening vessels, lines, and equipment.

4 Risks of Light Ends

Risk of explosion, Low viscosity ratio allows light ends to escape enclosed systems, Frostbite, Thermal expansion.

General Plant safety Rules

Stay clear of suspended loads. Use the right tool for the right job. Take steps to remove hazardous conditions. Drink from designated water fountains and potable water outlets.

What liquid is expected to have an adverse effect o the development of human fetus?

Teratogen

Which is a liquid that is expected to have an adverse effect on the development of the human fetus?

Teratogen

_________ provided the first statistical data on how many people were being killed or injured in the United States.

The Pittsburgh Survey 1907.

Process Safety

The application of engineering, science, and human factors to the design and operation of chemical processes and systems.

Process safety is described as?

The application of engineering, science, and human factors to the design and operation of chemical processes and systems.

UEL

The highest concentration at which a vapor or gas will produce a rich enough vapor concentration in air to ignite in the presence of an ignition source.

Lower Explosive Limit (LEL)

The lowest concentration at which a vapor or gas will produce a rich enough vapor concentration in air to ignite in the presence of an ignition source.

Process Technology

The study and application of the scientific principles associated with the operation and maintenance of the chemical processing industry.

The Pittsburgh Survey 1907

This survey provided the first statistical data on how many people were being killed or injured in the United States.

TSCA

Toxic Substance Control Act a Federal Law enacted in 1976. TSCA was intended to protect human health and the environment. TSCA was also designed to regulate commerce by (1) requiring testing and (2) imposing necessary restrictions on certain chemical substances. TSCA imposes requirements on all manufacturers, exporters, importers, processors, distributors, and disposers of chemical substances in the United States.

Before entering a refinery or chemical plant.

Uses the right tool for the right job. Firearms and cameras are not allowed in the plant. Illegal drugs and alcohol are not permitted in the plant. Obey all traffic rules. Do not park in designated fire lanes.

Asphyxiation

When oxygen is removed or displaced by a chemical.

Unplugging Permit

barricades area, clears lines for unplugging, informs personnel, issues opening blinding permit, and issues unplugging permit.

Confined Space Entry, permit to enter

designed to protect employees from oxygen deficient atmospheres, hazardous conditions, power drive equipment and toxic and flammable materials.

Plant managers are typically responsible for _________.

designing a company's safety policy, encouraging safety awareness, facilitating safe and healthful work conditions.

Physical hazards are classified as ____.

electrical, noise, radiation, and temperature.

Systemic poisons are ____?

formed when toxic agents enter the bloodstream through the lungs and target specific body organs.

Process technicians are responsible for _________.

good housekeeping, safe work practices and environment, hazard recognition.

Chronic hazards have the following characteristics.

have a delayed effect, are cumulative and frequently occur over an extended period of time, includes asbestos fibers, coal dust, irritants, and toxic metals.

The National Fire protection Association has a standardized system that is designed to.

identify chemical hazards.

accident investigation is designed to _____.

identify the point of failure and prevent recurrence.

Accurate safety records were _________.

never recorded during the early years of the Industrial Revolution

Four general plant safety rules you might find at a modern facility.

obey the speed limits, don't park in designated fire lanes, drink from designated drinking fountains, in an emergency don not enter the affected area unless you have been given permission and have been given a specific task.

PEL is the _______ established by OSHA.

permissible exposure limit

OSHA deals with the following __________.

personal protective equipment, permit system and confined space entry, and hot work and isolation of hazardous energy.

Four specific hazard classifications that are found in the workplace.

physical hazards, chemical hazards, ergonomic hazards, and radiation hazards.

Process safety is described as ______.

the application of engineering, science, and human factors to the design and operation of chemical processes and systems.