Process Safety Exam 1

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Process Knowledge Management

(AICHE Risk Based Process Safety Element): assembly and management of all info needed to perform process safety activities. verification of accuracy of info, confirmation that this info is up to date. Also make info readily available

Workforce involvement

(AICHE Risk Based Process Safety Element): broad involvement of operating and maintenance personnel in process safety activities, to make sure that lessons learned by the people closest to the process are considered and addressed

weather conditions, presence of people, probability of ignition

3 examples of conditional modifiers

T/P (either too high or too low), presence of raw materials, process in particular state of operation

3 examples of enabling conditions

riding a car, mountain climbing, skiing

3 examples of voluntary risk

ALCOA (aluminum company of america)

Paul O'Neill turned around this company by implementing safety program, which promoted good habits throughout the company

storage

Routes and elimination of toxicants: fat tissue, bones, hair, brain

excretion

Routes and elimination of toxicants: kidneys, liver, lungs, skin

detoxification

Routes and elimination of toxicants: liver

fires, chemical, 15

Safety showers: -use for ______ and ______ spills -time: ________ _min

False (no, must work from bottom up)

T/F: Can you achieve a higher level on the hierarchy of safety programs without accomplishing a lower?

False (only flammables!)

T/F: You can store other chemicals besides flammables inside of a flammable storage cabinet

False

T/F: You can store things on top of a flammable storage cabinet

Time Weighted Average

TWA

(NFPA) Standard on Explosion Prevention systems, (ASTM) Standard Test Method for Concentration Limits of Flammability of Chemicals, (API) Selection and Installation of Pressure Relieving Devices in Refineries

What are 3 examples of standards?

(National Fire Protection Agency) Life Safety Code, (American society of mechanical engineers) Boiler and vessel code

What are two examples of a code?

Noise Reduction Ratio

What does NRR stand for?

Permissible Exposure Limit

What does PEL stand for?

Short Term Exposure Limit

What does STEL mean in TLV-STEL?

Threshold Limit Value

What does TLV stand for?

Ceiling Limit

What does the C mean in TLV-C?

Specific Hazard (ie oxidizer, acid, alkali, no water)

What does the bottommost diamond represent on the NFPA diamond?

Health

What does the leftmost diamond mean in the NFPA diamond?

Reactivity/stability

What does the rightmost diamond stand for on the NFPA diamond?

Fire

What does the topmost diamond on the NFPA diamond stand for?

protection layer

What is another name for preventive safeguards?

120

What is the level of noise (in dB) that corresponds to "painful"?

80-100 ft/min

What is the target velocity of a hood (in ft/min)?

highest

When utilizing the risk matrix (people, environment, reputation impact, economic, property), the overall severity is the ________ severity level of the categories

velometer

a device that measures flow

Two and Three gas monitors

a method of measuring volatile concentrations where a hand-held monitor reports gas concentrations

filter unit

a method of measuring volatile concentrations where a unit goes with worker and contains activated charcoal

colorimetric tubes

a method of measuring volatile concentrations, where a reagent reacts with volatiles and changes color

code

a set of rules developed by a team of knowledgeable people. These people are most likely associated with an industrial professional organization.

toxic hazard

likelihood of damage based on exposure. reduced by appropriate techniques

operational readiness

(AICHE Risk Based Process Safety Element): Evaluation of the process before start-up or restart to ensure the process can be safely STARTED.

Contractor Management

(AICHE Risk Based Process Safety Element): Practice to ensure that contract workers can perform their jobs safely, and that contracted services do not add to or increase operational risks

measurement and metrics

(AICHE Risk Based Process Safety Element): STATISTICS; leading and lagging indicator analysis

Asset Integrity and Reliability

(AICHE Risk Based Process Safety Element): activities to ensure that important equipment remains suitable for its intended purpose throughout its service. includes testing, inspection, and preventive maintenance

Operating Procedures

(AICHE Risk Based Process Safety Element): instructions for how to carry out operation safely, explaining the consequences of not following procedure, describing key safeguards, addressing special situations and emergencies

Conduct of Operations

(AICHE Risk Based Process Safety Element): means by which management and operational tasks required for process safety are carried out in a deliberate, faithful and structured manner.

Auditing

(AICHE Risk Based Process Safety Element): periodic CRITICAL REVIEW of process safety management system performance by auditors not assigned to the site to identify gaps in performance and identify improvement opportunities

Emergency Management

(AICHE Risk Based Process Safety Element): plans for possible emergencies that define actions in an EMERGENCY, resources to execute those actions, practice drills, continuous improvement, training or informing

Training and Performance Assurance

(AICHE Risk Based Process Safety Element): practical instruction in job and task requirements and methods for operations and maintenance workers, supervisors, engineers, leaders and process safety professionals.

Safe Work Practices

(AICHE Risk Based Process Safety Element): procedures to safely maintain and repair equipment such as permits-to-work, line breaking, and hot work permits

Incident Investigation

(AICHE Risk Based Process Safety Element): process of reporting, tracking and investigating incidents and near-misses to identify root causes, taking corrective actions, evaluating incident trends and communicating lessons learned.

Management of Change (MOC)

(AICHE Risk Based Process Safety Element): process of reviewing and authorizing proposed changes to facility design, operations, organizations, or activities prior to implementing them; ensuring that process safety info is updated accordingly

Management Review and Continuous Improvement

(AICHE Risk Based Process Safety Element): the practice of managers at all levels of setting process safety expectations and goals with their staff and reviewing performance and progress towards those goals

substitute

(Inherently safer design): a flammable solvent is replaced by a non-flammable solvent

minimize

(Inherently safer design): a plant stores a large quantity of hazardous intermediate chemical to keep the plant operating during upsets. the intermediate storage is eliminated and the process reliability is improved to prevent upsets/downtime

simplify

(Inherently safer design): a valve that requires ten turns to close is replaced by a quarter turn valve

substitute

(Inherently safer design): an alternate reaction pathway is used that involves less hazardous raw materials

moderate

(Inherently safer design): the equipment in a process can with 10 barg, but it is reduced from 10 barg to 8 barg

moderate/simplify

(Inherently safer design): the trays on a distillation column are replaced by structured packing which operates over a wider range of operating conditions

lagging

(lagging/leading): money spent on insurance claims

leading

(lagging/leading): number of near miss incidents

leading

(lagging/leading): number of process alarms that were managed without incident

leading

(lagging/leading): number of reports of unsafe activities in a plant

leading

(lagging/leading): time duration to complete maintenance

lagging

(lagging/leading): visits to first aid

mitigative

(preventive/mitigative): a containment pond is built to collect any liquid runoff from a plant

mitigative

(preventive/mitigative): a containment system is installed to collect the effluent from a relief device

preventive

(preventive/mitigative): a flow limiter is installed on a feed line to a chemical reactor to insure that the reaction rate does not exceed a maximum value

mitigative

(preventive/mitigative): a foam system to reduce evaporation from a pool of leaked hydrocarbon

preventive

(preventive/mitigative): a gas chromatograph is installed to confirm chemical concentrations in a process

mitigative

(preventive/mitigative): a relief device is installed on a chemical reactor to protect the reactor vessel from the damaging effects of high pressure

mitigative

(preventive/mitigative): a safety instrumented system to shut down a process if an unsafe operating condition occurs

mitigative

(preventive/mitigative): all plant operations personnel are given yearly emergency response training

preventive

(preventive/mitigative): an alarm system to notify the operator of out of limits process conditions

mitigative

(preventive/mitigative): an emergency alarm system

mitigative

(preventive/mitigative): covers are placed over pipe flanges to prevent liquid spraying

preventive

(preventive/mitigative): the basic process control system

mitigative

(preventive/mitigative):a dike is built around a storage vessel

YES (they are implemented via OSHA, a gov organization)

Do PEL's have legal authority?

NO

Do TLV's have legal authority?

grounded, 1

Flammable storage cabinets: -Must be ________ to prevent static -Only designed to hold chemicals for ______ hour(s)

False

For chemical spills, the victim needn't remove their clothes to enter shower

Minimize, Substitute, Moderate, Simplify

Four Inherently Safer Design Strategies

1-most dangerous, 4 least dangerous

GHS is essentially the same as the NFPA labelling system except for this change:

(lowest) procedural, active, passive, inherent (most robust)

Hierarchy of Process Risk Management Strategies (4)

inherent

Hierarchy of Process Risk Management Strategies: having a culture of safety

passive (1)

Hierarchy of Process Risk Management Strategies: minimizes the hazard through process and equipment design features that reduce either the frequency or consequence without the active functioning of any device

Procedural (3)

Hierarchy of Process Risk Management Strategies: these are based on an established or official way of doing something. commonly referred to as administrative controls (training, policies, operating procedures)

Active (2)

Hierarchy of Process Risk Management Strategies: these systems are commonly referred to as engineering controls, REQUIRES AN ACTIVE RESPONSE from a device

we need to work harder to prevent exposures

If a chemical has a lower TLV it means that: it is more toxic than a relative chemical with higher TLV OR we need to work harder to prevent exposures

GHS

In 2013 OSHA changed their hazard communication standards to bring them into alignment with this system for classification and labeling of chemicals.

Moderate

Inherently Safer: Use under less hazardous conditions

Minimize

Inherently Safer: reduce hazardous material/energy quantity

Simplify

Inherently Safer: reduce unnecessary complexity to reduce the likelihood of an accident

Substitute

Inherently Safer: replace with a less hazardous material

Yes

Is it possible for some toxicants to have zero thresholds?

NO

Is there a detectable effect at the threshold dose?

4, 30

Minimum flows for: -Eyewash : _______ gpm (gallons per minute) - Shower: _______ gpm

0 is no hazard, 4 is max hazard

On the NFPA diamond, which number corresponds to no hazard and which one corresponds to max hazard?

dermal absorption

entry route for toxicants: skin. Controlled by: protective clothing

probit, causitive

Probit equations: Y is the ________ variables, V is the __________ variable

injection

entry route for toxicants: cuts in skin. Controlled by: protective clothing

inhalation

entry route for toxicants: mouth, nose. Controlled by ventiliation, hoods, PPE

ingestion

entry route for toxicants: mouth, stomach. Controlled by rules on eating, drinking, smoking

industrial hygiene

prevention or reduction of entry of chemical agents, physical agents into organism

toxicity

property related to effect on organism

toxicology

study of entry of toxicants into organism, elimination from organism, effects on organism

odor threshold

the concentration at which most people detect an odor

Inherently Safe Design

the idea of eliminating hazards rather than providing complex safeguard hierarchies around the hazards. AVOIDANCE OF HAZARDS

TLV

the maximum exposure limit to humans for 8 hours a day, 40 hours a week that does not cause any noticeable effect.

PEL

the same thing as a TLV-TWA but implemented by OSHA and has legal authority

lagging, leading

two types of safety metrics

safety metrics

used to measure the effectiveness of a safety program

MIC (methyl isocyanate)

what was the dangerous chemical stored in the Bhopal plant that was extremely toxic to humans?

Hazard Identification and Risk Analysis

(AICHE Risk Based Process Safety Element): identification of process safety hazards and their potential consequences. definition of the risk posed these hazard scenarios. recommendations to reduce or eliminate hazards, reduce potential consequences, reduce frequency of occurrence.

Preventive

(Preventive/Mitigative) Pressure relief system with containment

lagging

(lagging/leading): injuries

leading

(lagging/leading): number of operating procedures updated each year

leading

(lagging/leading): number of workers with overdue training

lagging

(lagging/leading): property damage

leading

(lagging/leading): response time for process safety suggestions

leading

(lagging/leading): work order backlog

True (hazards may be continuously present or may change based on operations)

T/F: It is not possible to list all the potential hazards of a working environment.

False (although they overlap at points)

T/F: Process safety is the same as personal safety

True

T/F: Regulations have legal authority.

False

T/F: Standards have legal authority

lagging

accident statistics are _____ indicators

process safety

a framework for managing the integrity of operating systems and process handling hazardous substances by applying good design principles, engineering and operating practices

societal risk

a group of people exposed to one or more hazards. hazard and group must be carefully defined

risk

a measure of human injury, environmental damage, or economic loss in terms of both the incident likelihood and the magnitude of the loss or injury

incident

an event or series of events, resulting in one or more undesirable consequences, such as harm to people, damage to the environment or asset/business losses.

hazard

an inherent chemical or physical characteristic that has the potential for causing damage to people, property or the environment

accident

an unplanned event or sequence of events that results in an undesirable consequence

Compliance with Standards

(AICHE Risk Based Process Safety Element): Applicable regulations, standards, codes and other requirements issued by national (etc) governments. Interpretation and implementation of said requirements.

Process Safety Competency

(AICHE Risk Based Process Safety Element): Skills and resources that THE COMPANY NEEDS to have in the right places to manage its process hazards. Verification that company collectively has these skills and resources. Application of this info in succession planning and management of organizational change.

Process Safety Culture

(AICHE Risk Based Process Safety Element): a positive environment where employees at all levels are committed to process safety. process safety leaders nurture this process

Stakeholder Outreach

(AICHE Risk Based Process Safety Element): a process for maintaining contact with stakeholder groups, such as community, suppliers of materials, customers, gov agencies, contractors, etc.

lagging

(lagging/leading): fatalities

2

Hierarchy of Safety Programs: Complying to rules and regulations

lagging

loss of primary containment (LOPC) incidents

lagging

(lagging/leading): first aid incidents

1

Hierarchy of Safety Programs: Reacting to accidents as they occur

Preventive

Preventive vs Mitigative: Alarm systems

False

T/F: Codes have legal authority

living in the vicinity of a chemical plant, being hit by a train

2 examples of involuntary risk

hold safety in utmost importance, formally advise employers or clients if negative consequence is perceived

AICHE Engineering Ethics statement (2 points that were mentioned in class)

low, convince, financial losses

Conclusions from statistics: -Chemical industry has a _______ number of fatalities/injuries -The chemical industry has to perform better to _________ the public of their safety. -Incident _____ ______ from chemical plant accidents are huge

no safety program, reacting as incidents occur, complying to rules, management systems, performance monitoring, adapting

Hierarchy of Safety Programs (6 levels, lowest to highest safety)

3

Hierarchy of Safety Programs: Management systems based such as Job Safety Assessment (JSA), lock-out/tag-out etc

0

Hierarchy of Safety Programs: No safety program. Maybe even disdain for safety

4

Hierarchy of Safety Programs: Performance monitoring using statistics to drive continuous improvement

5

Hierarchy of Safety Programs: adapting- safety is a core value of the organization and a primary driver for successful enterprise

risk based process safety

It is difficult to identify hazards for a plant that is being designed and doesn't exist yet. Therefore, we will rely on _________ procedures to help us with this

Preventive

Preventive vs Mitigative: Emergency cooling systems

Preventive

Preventive vs Mitigative: Emergency shutoff valves

Preventive

Preventive vs Mitigative: Grounding and bonding to prevent static accumulation

Preventive

Preventive vs Mitigative: Interlocks

Preventive

Preventive vs Mitigative: Maintenence

Preventive

Preventive vs Mitigative: Operator response to an alarm or process conditions

mitigative

Preventive vs Mitigative: active fire protection, including sprinklers, sprays

Preventive

Preventive vs Mitigative: basic process control system (BPCS)

mitigative

Preventive vs Mitigative: blast resistance control rooms

mitigative

Preventive vs Mitigative: blast walls

mitigative

Preventive vs Mitigative: diking around storage areas/process

mitigative

Preventive vs Mitigative: emergency fire water system

mitigative

Preventive vs Mitigative: emergency power

mitigative

Preventive vs Mitigative: emergency response, including on-site and off-site

mitigative

Preventive vs Mitigative: explosion blow-out panels on process vessels

mitigative

Preventive vs Mitigative: flammable vapor detectors

Preventive

Preventive vs Mitigative: normal testing and inspection

mitigative

Preventive vs Mitigative: passive fire protection including insulation

mitigative

Preventive vs Mitigative: plant and equipment layout and spacing

mitigative

Preventive vs Mitigative: water curtains to disperse vapors

consequence, frequency (such as fires, explosions, and accidental releases of hazardous materials)

Process safety addresses the control and prevention of "high _______, low __________ events"

Myth

Truth/Myth: "Process safety only applies to the petrochemical industry"

Myth (process safety saves money. increased cost of process safety is offset by savings due to fewer accidents)

Truth/Myth: Process safety costs lots of money and has a negative effect on the company's profits

Myth (companies are responsible for the safety of their product throughout its entire lifespan.)

Truth/Myth: Process safety does not include product safety.

lagging

_________ indicators are easier to define and tabulate

safeguards

barriers that are enacted to prevent incident and reduce consequences of said incident

conditional modifiers

conditions that occur after initiation and impact a step in the sequence either before or after the incident has occurred

lagging metrics

data collected after an incident has occurred

leading metrics

data collected before an incident has occurred

regulation

developed by a government. may be based on a code or standard

enabling conditions

do not independently cause the incident, but must be present or active for it to proceed.

leading indicators

indicators that occur before an accident has occurred

standard

more elaborate, explaining in a lot more detail how to meet a code.

individual risk

one person exposed to one or more hazards. usually location dependent

preventive safeguard

prevents an initiating event from proceeding to a defined, undesirable incident. STOPS incident from proceeding

risk is a function of what two variables?

probability (how likely it is to happen), consequence (how bad it is when it does happen)

mitigative safeguards

reduces the consequences after an incident has occurred. May already have consequences as a result of the incident

voluntary risk

risk that is consciously tolerated by someone seeking to obtain the benefits of the activity that poses the risk

involuntary risk

risk that is imposed on someone who does not directly benefit from the activity that poses the risk

safety

strategy for accident prevention- not very well defined

safety culture

the common set of values behaviors, and norms at all levels in a facility or in the wider organization that affect process safety

swiss cheese model

which model describes how incidents can occur despite having multiple safeguards?

Department of Homeland Security- Chemical Facility Anti-Terrorism Standards

which regulation establishes risk-based performance standards for the security of chemical facilities

OSHA- Process safety management of highly hazardous materials

which regulation pertains to on-site inventories that contain chemicals in quantities that exceed threshold values?

EPA- Risk Management Programs (RMP)

which regulation pertains to releases of toxic or flammable materials that have off-site impacts.


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