Chemical Process Safety Final Exam Questions With Accurate Answers| Graded A+

Process Safety - correct answers A discipline that is focused on prevention of, preparation for, mitigation of, response to, and restoration from catastrophic releases of chemicals or energy from a process associated with a facility. The protection of people and property from episodic and catastrophic incidents that may result from unplanned or unexpected deviations in process conditions. PSM-Process Safety Management - correct answers A management system that is focused on prevention of, preparation for, mitigation of, response to, and restoration from catastrophic releases of chemicals or energy from a process associated with a facility. Is a general term used to describe a comprehensive sets of policies, procedures and practices to ensure barriers are in place to mitigate the chance of a catastrophic release of chemicals or energy. OSHA PSM - correct answers a specific subset of PSM referring only to the US PSM standard 1919.119. Applicable when the hazard is above the toxic quantity of Appendix A or quantities greater than 10,000 pounds are stored Example of PS global regulations - correct answers • US • OSHA 29 CFR1910.119 PSM • 40 CFR Section 68 - RMP • Europe (EMEA) • European Union "Seveso" Directives • Control of Major Hazards (COMAH) in UK • China (AP) • China Regulation GB - Major Hazard Identification of Hazardous Chemicals • China Regulation AQ - General Norms for Safety Standardization of Hazardous Chemical Enterprises Process Safety Impacts - correct answers • EVALUATE EXCURSIONS FROM THE "NORMAL" OPERATION. • HOW FAR WE ARE FROM THE "CLIFF" AND HOW FAR THE FALL MAY BE. • WHAT CAN BE DONE TO PREVENT OR MITIGAT THE POTENTIAL RISK? Background of PSM - correct answers The fourteen elements of the Process Safety Management (PSM) rule (29 CFR 1910.119) were published in the Federal Register on Monday, February 24,1992. The objective of the rule is to prevent or minimize the consequences of catastrophic releases of toxic, reactive, flammable, or explosive chemicals. The rule will accomplish its goal by requiring a comprehensive management program: a holistic approach that integrates technologies, procedures, and management practices. Process Hazards Analysis may not be performed unless complete Process Safety Information is available for the process Risk Based Process Safety - correct answers Twenty total elements under four major foundation groups: • Commit to Process Safety 1. Process safety culture 2. Compliance with standards 3. Process safety competency 4. Workforce involvement 5. Stakeholder outreach • Understand Hazards and Risk 6. Process knowledge management 7. Hazard identification and risk analysis • Manage Risk 8. Operating procedures 9. Safe work practices 10. Asset integrity and reliability 11. Contractor management 12. Training and performance assurance 13. Management of change 14. Operational readiness 15. Conduct of operations 16. Emergency management • Learn from Experience 17. Incident investigation 18. Measurement and metrics 19. Auditing 20. Management review and continuous improvement Lagging Indicators - correct answers measure a company's incidents in the form of past accident statistics. Examples include: Injury frequency and severity OSHA recordable injuries Lost workdays Worker's compensation costs Why use lagging indicators - correct answers traditional safety metrics used to indicate progress toward compliance with safety rules. These are the bottom-line numbers that evaluate the overall effectiveness of safety at your facility. They tell you how many people got hurt and how badly. Drawbacks of lagging indicators - correct answers The major drawback to only using lagging indicators of safety performance is that they tell you how many people got hurt and how badly, but not how well your company is doing at preventing incidents and accidents. The reactionary nature of lagging indicators makes them a poor gauge of prevention. For example, when managers see a low injury rate, they may become complacent and put safety on the bottom of their to-do list, when in fact, there are numerous risk factors present in the workplace that will contribute to future injuries. leading indicator - correct answers is a measure preceding or indicating a future event used to drive and measure activities carried out to prevent and control injury. Examples include: Safety training Ergonomic opportunities identified and corrected Reduction of MSD risk factors Employee perception surveys Safety audits Lagging indicators measure failure; leading indicators measure performance - correct answers what is the difference between leading and lagging indicators leading indicators should - correct answers Allow you to see small improvements in performance Measure the positive: what people are doing versus failing to do Enable frequent feedback to all stakeholders Be credible to performers Be predictive Increase constructive problem solving around safety Make it clear what needs to be done to get better Track Impact versus Intention Risk - correct answers A coupling of the CONSEQUENCE of a scenario, and the FREQUENCY of the scenario. greater risk. - correct answers High consequence and high frequency lesser risk. - correct answers Lower frequency and smaller consequences 3 key actions to reduce risk - correct answers 1. Identifying and classifying a risk level 2. Identifying ways to decrease the risk 3. Quantify the effects of the risk reduction efforts. Risk is a perception. - correct answers High and low and greater and less are relative terms. Risk Evaluation/Risk Reduction - correct answers In most cases, Company will have risk /risk tolerance defined. Risk reduction steps will be : evaluate current risk Add additional mitigation/protection if required Continue until desired risk level is attained Risk evaluation may be qualitative/semi- quantitative/quantitative Layers of Protection Analysis (LOPA) - correct answers Layers of protection can be used semi-quantitatively to determine if you have enough layers. Estimate consequence and severity based on size of release, magnitude of damage, or consequence cost ($) and use table to determine consequence category. 2. Develop scenarios. Apply LOPA to one scenario at a time. Each scenario describes a single cause - consequence pair. 3. Identify initiating event frequencey. Can estimate these using a table. 4. Identify related independent protection layers (IPLs). These can be passive (dike) or active. Can be human, equipment or control system. 5. Estimate scenario frequency. Can use tables for this. 6. Estimate additional protection layers required using table. Inherently Safer Designs - correct answers avoidance of hazards rather than control of hazards. permanently and inseparably reduce or eliminate process hazards that must be contained and controlled to avoid accidents. Inherently Safer Design Strategies - correct answers MINIMIZE SUBSTITUTE MODERATE SIMPLIFY GHS - Globally Harmonized System - correct answers In 2013 the federal Occupational Safety and Health Administration (OSHA), changed their Hazard Communication Standards to bring them into alignment with the Globally Harmonized System (GHS) for classification and labeling of chemicals. NFPA Diamond - correct answers higher number worse hazard, lower number less hazard Problem with NFPA vs GHS - correct answers The numbers are opposite--lower number worse for GHS, higher numbers worse NFPA GHS changes to the Hazard Communication Standards are as follows: - correct answers Hazard classification: The standard requires chemical manufacturers and importers to determine the hazards associated with the chemicals they produce or import. The specific health and physical hazards of these chemicals must be provided to the consumer. • Labels: Chemical labels must include the name of the chemical as well as a signal word, pictograms, hazard statements, and precautionary statements that describe the hazards associated with chemical. • Material Safety Data Sheets: Now called Safety Data Sheets or SDS's, the new format requires 16 specific sections, ensuring consistency in the presentation of important safety information about a chemical. Entry method: Ingestion - correct answers Mouth, stomach There must be rules on eating, drinking, smoking Entry method: Inhalation - correct answers Mouth, nose Must be ventilation, hoods, protection equipment Entry Method: Injection - correct answers Cuts in skin Protective clothing Entry Method: Dermal Absorption - correct answers Skin Protective clothing Entry Routes for Toxicants - correct answers ingestion, inhalation, injection, dermal absorption Effective dose - EDn - correct answers dose which produces measurable but reversible effect in n% of the population. Toxic dose - TDn - correct answers dose which produces harmful effect in n% of the population. Lethal dose - LDn - correct answers - Kills n% of the population