Process Risks
Name one process risk at East Hanover ?
1)Fire (Heptane, N.gas, hot oil, electrical spark, welding and forklift
2)Burn by steam
3) Burn by hot oil
4) Release of chemicals to the environment
5) Chemical burn –
6) Over pressurization (explosion)
7) Under pressurization
8) Dust explosion
9) Exposure to harmful vapors
10) Loss of containment
PPE stands for
Personal Protective Equipment
Phone extension do you call to alert the security guard about an emergency situation
ex.1260
There are 13 Process Safety Management Elements.
True or False?
False. There are 14 elements.
M.O.C.
stands
Management of Change
Name one way to mitigate or eliminate process risks?
1.Training
2.SOP’s
3.PSM (PHA, PSSR, MI, Hot Work, MOC, Incident Investigation)
4.Safety Devices
5.Safety Interlocks
6.Inherently safer design
Name a specific Engineering Control
Engineering Controls
Local exhaust ventilations, machine guards, automatic shut off valves, etc.
You do if you hear any of the emergency alarms
•Stop what you are doing!!!!
•Shut down equipment, if safe to do so
•Walk to muster point (assemble area)
A hot work permit must be issued for hot work operations conducted on or near processes involving hazardous or flammable chemicals.
True or False?
True
Changing out a 100 hp centrifugal pump with a 100 hp mag drive pump does not require an MOC
FALSE.
MOC process shall be used prior to any permanent or temporary change whenever the change in equipment or chemical used is not a replacement-in-kind (“RIK”, i.e, an equivalent substitution) or constitutes routine maintenance.
Name one safety device?
1.Check valves
2.Relief Valves
3.Rupture Disks
4.Conservation Vents
5.Vacuum Relief
6.Over Flow Protection
7.Analyzers
8.Sensors for temperature, pressure, level
9.Alarm system
10.Safety interlocks
Name a Administrative control
Administrative Controls SOPs, Training, Safety Rules, etc.
The plant has two means of signaling an emergency in the plant.
- The primary a manual pull station at any exit.
-pressing the page button or dialing 88 from any telephone or call Guard extension at 1260
Investigation is required for each incident that resulted in, or could reasonably have resulted in a process safety incident.
True or False?
True
True or False?
Every change, especially simple ones, does not require a safety review?
FALSE.
Every change requires some form of safety review adequate to the level of hazard and risk of the change.
A safety Interlock system consists of one or more devices used to shutdown or not allow the operation of equipment, when a process parameter exceeds the pre-defined safe operating range.True or False?
True
To replace the material or process with less hazardous materials or equipment is what type of safeguard?
a. elimination
b. Engineering control
c. substitution
d. PPE
C. Substitution
Drills need to be completed
Annually
Name an incident investigation methodology
– Taproot
– Causal Map
– 5 Why’s
– Fishbone
Kind of safety review is required for the most significant change
Process Hazard Analysis (PHA) is required for a significant change
PHA must address:
–The hazards of the process.
–The identification of any previous incident which had a likely potential for catastrophic consequences in the workplace.
–Engineering and administrative controls applicable to the hazards
–Consequences of failure of engineering and administrative controls.
–Facility siting – Study of the placement of process near occupied structures or other hazardous processes.
–Human factors- study the impact of human failure on process.
–A qualitative evaluation of the possible safety and health effects of failure of controls on employees in the workplace.
Name a Set-point Trigger?
Set-point Triggers:
•Pressure
•Temperature
•Level
•Flow
•Analyzer/Sensor
•Fail-open or Fail-close Valves
What are 3 of the 5 safeguards in the hierarchy of risk reduction?
1.Elimination
2.Substitution
3.Engineering Controls
4.Administrative Controls
5.PPE
A Prime Incident?
•A loss of primary containment (LOPC) greater than ACC/API Tier 1, Tier 2, or Global PSI (CEFIC) thresholds
–ACC/CEFIC 1-hour time limit does not apply when determining PRIME, if acute then PRIME
•A Level 1, 2, or 3 fire in a process area
•A recordable injury due to exposure to process materials or energy
•Activation of pressure safety relief device or blowout of equipment due to high pressure
•Activation of a safety critical or emergency measure (technical or administrative)
•Emergency shutdown of a process or unit
•An offsite impact – evacuation, shelter-in-place, road closures, personnel seeking medical attention
•Other significant process impacts with potentially serious consequences
___________ are required to provide a Job Safety Analysis (JSA) for the task being performed on-site prior to being work.
Contractors
Once a change is implemented/constructed, what kind of safety review must be performed before operating the change
Pre-Startup Safety Review (PSSR)
The PSSR must confirm:
–Construction and equipment is in accordance with design specifications;
–Safety, operating, maintenance, and emergency procedures are in place and are adequate.
–For new facilities, a process hazard analysis has been performed and recommendations have been resolved or implemented before startup; and modified facilities meet the requirements contained in management of change.
–Training of employees has been completed.