SAChE Inherently Safer Design

True or False: A mitigative safeguard is an Example of inherently safer design

False

In general, which two strategies are the most robust and reliable?

Inherent and Passive

In which order should the designer apply strategies?

Inherent>Passive>Active>Procedural

In the Flixboroough case, the plant site had very large inventories of flammable material which is contrary to the ISD principle of:

Minimization

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

Not (none of the above)

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

Not minimize or moderate

What ISD guideword is associated with this checklist question: "Can pressure be used instead of a pump to move hazardous fluids from one unit operation to another?"

Substitute

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

True or false: Inherently safer design concepts can be utilized at later stages of the process life cycle.

True

True or false: Process control must be provided during all modes of operation, not just in the normal, steady state operating mode?

True

To choose the "inherently safer" chemistry, the research team needs to take into account

all of the options

A process Safety Management (PSM) or Risk Management Program (RMP)- covered facility will perform Process Hazard Analyses (PHA) or similar studies at least once every:

5 years

Inherently safer design optimally happens ___ in the life cycle of the process.

Early

Which PSM element is most important in preserving and protecting against elimination of inherently safer features during the operation, maintenance, and modification stage of the process life cycle?

MOC

A process engineering group is reviewing an existing process that will be modified to improve the yield. They have been asked to perform a MOC review and provide potential process safety recs before the process moves forward ot a full safety review. These are some of the recommendations the engineering group is proposing: Which of the engineering group's recs below can be considered ISD actions?

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

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

Minimize

What is the longest stage in the life cycle of a process

NOT -design and construction

The inherently safer design guidewords focus on:

all the options

True or false: 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

The management of Change process should ensure that changes do not ____ change existing inherently safer barriers

unintentionally

In their search for the best chemistry, researchers attempt to identify and minimize which of the following hazards?

-Toxicity -Reactivity -Flammability

Inherently safer design is:

A way of thinking about the design of chemical processes and plants that focuses on the elimination or reduction of hazards

In addition to inherently safer design, what are other stratifies for safety?

Active Procedural Passive

The last stage of the process life cycle:

Decommissioning

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

Design and Construction

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

Detailed design

True or False: ISD cannot be implemented until the Development stage of the process life cycle is completed because the chemistry and the basic hazards of the material are not known yet

False

True or False: Implementing an ISD approach always results in a process having no risk.

False

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

False

True or False: Once the development stage of the process life cycle is underway, it's too late to revisit the basic chemistry of the process

False

True or False: Passive control measures, since they don't have to rely on the active intervention of devices or human operators, are considered the most robust approach to hazard control.

False

True or False: 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

True or false: Hazards are not inherent to a material or its conditions of use.

False

True or false: Inherently safer design is applicable to the chemical and process industries only

False

True or false: the design and implementation of inherently safer chemical processes does not need to be considered for hen the plant is no longer 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

Which of the following Process Safety Management system elements are particularly well-suited for the application of ISD principles?

Hazard Identification and Risk Analysis (HIRA) & Management of Change (MOC)

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

MOC

The ISD concept of ___ includes review of process changes before they are implemented, documentation of changes and revision of training as a consequence of changes.

MOC

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

Management Review & Continuous Improvement

The ___ Process Safety Management system element has ISD significance because it is an opportunity to consider incorporating ISD concepts

Management of Change (MOC)

below are the stages of the process life cycle

NOT - research - Design and construction - Development -Operations, maintenance and modification -Decommissioning

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

NOT all of them

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

NOT decommissioning

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:

NOT labeled

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

Not minimize, nor substitute

When decommissioning equipment, the inherently safer strategy of ___ is used to remove the inventory of hazardous materials

Not substitution

A packaging system for an explosive power is built with a design pressure of 200 psig (max explosion pressure from a dust explosion of the material is 140 psig). This is an example of which of the following types of control?

Passive

A reaction with a max adiabatic rxn pressure of 200 psig is conducted in a reactor with a design pressure of 150 psig. One of the reactants is gradually added at a rate to control the rxn temp, and the rxn stops if the reactant feed is stopped. The process operator is trained to monitor the reactor temp and pressure and stop the reactant feed if either gets too high. Which type of control is this?

Procedural

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

Reduce the potential for large releases of hazardous materials

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

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

Changes to the process design to incorporate inherently safer strategies during the _____ stage of the life cycle can be easy to accomplish and relatively inexpensive, yet this effort can significantly affect the outcome.

Research

Many opportunities still exist to apply the ___ strategy during detailed design.

Simplification

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

Simplify

To choose the "inherently safer design", the team needs to take into account:

Transportation of raw materials & final products

True or False: Alternative types of process equipment have different inherently safer characteristics

True

True or False: Applying the ISD approach to distillation system designs can be evaluated during the development stage of a process

True

True or False: Human factors have a strong relationship with the principles of inherent safety.

True

True or False: 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.

True

True or False: Process Safety Management systems accept that fact that there are inherent risks in a process.

True

True or False: 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

It is inherently safer to develop processes with:

Wide safer operating limits A robust process

The design and construction stage focus primarily on:

installation Details Detailed equipment specifications Piping and instrumentation design

With the ___ approach, the design could replace a hazardous material with a less hazardous alternative or use less hazardous reaction chemistry

not minimize

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

not moderation

What ISD guideword is associated with this checklist question: " Can hazards be reduced via lower temperatures or pressures?"

not substitute

The image shown is an example ____, which can be used to identify which chemicals interactions pose potential reaction hazards

reactivity matrix

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

simplification