ELA984 Inherently Safer Design

The Operations, Maintenance, and Modifications stage will likely last:

A decade or more

__________ design features reduce risk, including the frequency or severity, by relying on the active functioning of a device or control system.

Active

Which of the following is NOT one of the four different safety strategies in design?

Aggressive

Elements of which strategies will be required for a comprehensive process safety management program when all hazards of a process and plant are considered?

Passive, Procedural, Inherent, Active (Choose all)

Documenting the exact state of the decommissioned equipment is a form of the inherently safer strategy of:

Simplification

What ISD guideword is associated with this checklist question: "Are all manuals guides and instructional material clear and easy to understand, especially those that are used in an emergency situation?"

Simplify

What are the key human factor areas associated with ISD principles?

The operator-process/equipment interface Human error assessment Administrative controls

T or F: ISD features are particularly susceptible to lapses in corporate memory given that they are such a fundamental part of the design that their purpose may not be obvious, unlike an add-on device (such as a high-pressure alarm).

True

T or F: Plant modifications during the Operations, Maintenance, and Modifications stage of the process life cycle provide an opportunity to incorporate inherently safer strategies that were overlooked or deferred during the initial design.

True

T or F: Process Safety Management systems accept the fact that there are inherent risks in a process.

True

T or F: Risk is a function of frequency and severity and it can be quite complicated due to all the various types of risks that must be considered.

True

CCPS defines ________ as "An inherent chemical or physical characteristic that has the potential for causing damage to people, property, or the environment"

hazard

Of the questions listed below, which are the most appropriate to ask for ISD considerations during the Development stage of the process life cycle?

CHOOSE TWO OPTIONS BELOW AND WAS WRONG: Is a flammable solvent necessary? Can a different mode of operation be used and result in smaller accumulations of hazardous materials?

Application of ISD principles reminds us that _________ are often the least effective control measures and that organizations should implement inherently safer controls where ever possible.

DO NOT CHOOSE THE ANSWER: None of the above

During the detailed design stage there is an opportunity to evaluate the siting of the equipment processing hazardous material to establish if adequate separation distances have been established. This is an application of which ISD strategy?

DO NOT CHOOSE THIS ANSWER: Eliminate/minimize

From an ISD perspective, the process design needs to be taken into consideration in order to:

DO NOT CHOOSE THIS ANSWER: Reduce or eliminate risks associated with batch processes

During the Operations, Maintenance, and Modifications stage, conduct of operations should include an ISD approach so as to eliminate or minimize the hazards and reduce the number of _______ safeguards required.

DO NOT CHOOSE THIS ANSWER: inherently safe

The __________ step is the last step at which changes can be made at moderate cost because most of the equipment is purchased after this step is approved.

Detailed Design

T or F: A mitigative safeguard is an example of inherently safer design.

False

T or F: Inherent safety means that all hazards have been designed out of the process up front.

False

T or F: Inherently safer design is applicable to the chemical and process industries only.

False

T or F: Since there is a substantial impact on the cost of modification after the Design and Construction stage has been completed, there can be no further ISD implementation.

False

T or F: The design and implementation of inherently safer chemical processes doesn't need to be considered for when the plant is no longer a productive unit or plant and is decommissioned.

False

Developing a complete knowledge of all the potential hazards and their severity for a material or process is key to implementing an effective inherently safer design. Which Process Safety Management system element does this apply to?

Hazard Identification and Risk Analysis

A hazard identification and risk analysis (HIRA) study is targeted towards determining:

How bad could it be? How often might it happen? What can go wrong?

A hazard:

Is intrinsic to a material or its condition of use Can be changed by changing the conditions of use Can be changed by changing the material

What are the key actions necessary that a decommissioned plant or individual piece of equipment remains in a safe and stable condition during the decommissioning process?

Isolate equipment mechanically Isolate equipment electrically Remove hazardous inventories Document exact state of decommissioned equipment

A process engineering group is reviewing an existing process...

Make the design of the overhead condenser system less complex Run the process at lower temperature and pressure Evaluate using a less toxic raw material

Since implementation of ISD concepts is often more costly than easier procedural barriers... Which Process Safety Management system element does this apply to?

Management Review and Continuous Improvement

Both the Flixborough case and the Synthron case show the consequences of ignoring ISD in which Process Safety Management system element?

Management of Change (MOC)

What ISD guideword is associated with this checklist question: "Are just in time deliveries used when dealing with hazardous materials?"

Minimize

In the handling of a flammable liquid, a facility determines that it is possible to dilute it to a 20% conc. and still operate effectively. This is an example of which inherently safer design strategy?

Moderate

With the _____ approach, techniques such as dilution, refrigeration, or less severe process conditions are used.

Moderate

Inherently safer design strategies:

Moderate, Simplify, Eliminate/Minimize, Substitute (Choose all)

With respect to inherent safety, what issues should be addressed during the Operations, Maintenance, and Modifications phase of the process life cycle?

Preserving the inherent safety features and practices provided during the Development phase of the process life cycle Seeking opportunities for continues improvement in inherent safety

_______ methods reduce risk by relying on personnel actions governed by operating procedures, safety rules and standards, emergency response procedures, and training.

Procedural

The inherently safer design guidewords focus on:

Process routes, procedures, equipment, materials (choose all)

When the ______ stage of the process life cycle is reached, the chemistry, unit operations, and type of equipment have been set.

design and construction

Evaluating equipment required for an inherently safer process usually occurs first in which step of the process life cycle?

development

The design basis of the process, especially those inherently safer features that are built into the design and installation of the process, must be clearly:

documented

Inherently safer design optimally happens _____ in the life cycle of the process

early

The image shown is an example of a ___________, which can be used to identify which chemicals interactions pose potential reaction hazards.

reactivity matrix

During PHAs each safety device or procedure should be evaluated to see if it can be eliminated or modified by applying inherently safer principles of:

simplification

The failure to design equipment to reduce the potential for error (such as complex and confusing equipment, positioning of dials, color coding, or different directions for on/off) is an issue associated with:

the operator-process/equipment interface

The Management of Change process should ensure that changes do not _________ change existing inherently safer barriers.

unintentionally