Chemical Process Safety

Welcome to Chemical engineering World!!! I am Rohit, BTech chemical engineer. Working as Process safety professional, Professional trainer & Consultant. Professional Skill: Chemical process simulation & equipment design. Risk evaluation & mitigation by qualitative Risk Assessment techniques like HAZOP, FEMA analysis, what if, Why-Why analysis & Fish bone diagram Quantitative Risk analysis by Source & Dynamic modelling

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Tuesday, March 30, 2021

H.S.E. QUESTIONNAIRE & ANSWERS

 81) What is an Emergency Evacuation Plan? 

It is the procedure to provide concise guidelines for evacuation in case of some emergencies and to identify the emergencies in advance. This also helps us to plan and to define roles and responsibilities of all building custodian, fire wardens and occupants. 
82) What is a hydro-test? 
It is the test carried out for leak test for pipes, equipments etc, by filling water in these equipments and pipes with some pressure and its joints and connections are checked for ant leak or breakage. 
83) What is a hypo-test? 
It is the insulation leakage test done for high electrical cables, with high voltage merger.  
84) What are the safety requirements for doing a hot work? 
 Remove all combustible materials from the area (with in 10m), if possible.
 Use fire blanket to protect immovable combustible materials and also for welding slugs.  Cover the area with fire blanket for containment of sparks generated while doing hot work.
 Provide proper fire extinguisher in sufficient numbers.
 Appoint a fire-watch with red jacket, if necessary.
 Barricade the area and post proper signage.
 Use of proper PPE and damage free 
 Conduct gas test if presence of combustible gases expected prior to work.    
85) What are the benefits of near-miss reporting? 
To make analysis of the incident, in order to avoid re-occurrence. To rectify the cause of those near misses before it turns into accidents. To identify the deficiencies of site safety performances and find remedial actions. To improve safety performances by reducing LTA’s incidents and near misses. 
86) What is a risk assessment? 
Risk assessment is a method of estimating the rate of risk of an activity, by classifying actual and potential consequence and finding out mitigation actions to limit that risk. 
87) In what situation “ear protection is needed”? 
In the areas, where sound pollution is more than 85 dBA  
88) What is the emergency evacuation procedure to follow in the event of a gas release? 
Don’t get panic on hearing alarm Observe the direction of wind flow, proceed out in the cross wind direction to the plant boundary fence and then proceed up wind. Obey further instructions from emergency response team. Resume work after getting clearance only. 
89) What is an “Assembly Muster Point “? 
The area determined and marked, for assemble of people working the area in case of any emergency. 
90) What is meant by “Head counting”? What is the purpose? 
On hearing emergency alarm, all people have to assemble in “Assembly Muster Point”. There area supervisor will call his workers with attendance sheet and confirm that nobody is trapped in the site. This procedure is called head counting. Its purpose is to ensure all workers are present in the assembly area, they are safely evacuated and identify the person if anybody is trapped and take necessary actions to rescue these trapped workers. 
91) What is heat stroke? What are the different stage through which a person undergoes before he gets heat stroke? 
During hot days, due to dehydration, body temperature increases beyond safe limit, because of break down of body’s heat regulating mechanism. Due to this the person collapses and if not taken care off he can even die. This is called heat stroke. Generally pulse raises 20 beats per minute for each 1 degree C rise in temperature, heat cramps: Exercising in hot weather can lead to muscle cramps, because of brief imbalances in body salt. Heat exhaustion: further losing of fluid and salt can lead to dizziness and weakness body temperature may rise up to 102 degree F. Heat stroke: In some cases, extreme heat can upset body’s thermostat, causing body temperature to rise to 105 degree F. or higher. Symptoms are lethargy, confusion and unconsciousness, heat stroke can kill.  
92) How is the soil classified? What is the slope to be given for each type of soil while excavating? 
The following is a short explanation of soil classifications. You should check the standard for detailed information regarding classifying soils 
.Type A soils 
 Cohesive soils that have an unconfined compressive strength of 1.5 tsf or greater.  E.g., clay, salty clay, sandy clay & clay loam Type A soils cannot have or be subjected to the following:  Fissures  Subjection to vibration from traffic, pile driving or similar conditions  Been previously disturbed  Or if it has been subjected to other factors that would change it’s classification 
Type B soils 
 Cohesive soils that have an unconfined compressive strength greater than 0.5 tsf but less than 1.5tsf  E.g., angular gravel, silt, silt loam, sandy loam and previously disrobed soils except those which would be classified as Type C soil  Also includes soils that meet some of the requirements of Type A soils but is fissured or subject to vibration; or dry rock that is not stable.  
Type C soils 
 Cohesive soils with an unconfined compressive strength of 0.5tsf or less  E.g. granular soils including gravel, sand and loamy sand  Also submerged soil or soil from which water is freely seeping or submerged rock that is not stable Stable rock  A natural solid mineral material that can be excavated with vertical sides and will remain intact while exposed. Maximum allowable slopes  Stable rock: vertical (90degrees)  Type A: ¾ :1 (53degrees)  Type B 1:1   (45degreed)  Type C : 1 ½ : 1 (34degrees)  ½ : 1 (63 degrees ) slope is allowed for only short term excavations that are 12feet deep or le 
93) What are the precautions to be taken while handling and storing compressed cylinders? 
1) Where cylinders are to be kept for an appreciable length of time should be provided to ensure that they cause no hazard to workers or public in the area.
2) Cylinders should be stored in a well ventilated area-preferable in open air but protected from the weather.
3) The store should be away from fire risks and source of heat and ignition. Nothing else should be stored in the area.
 4) The cylinders should be stored upright on a firm level, well drained surface free from hollows and cavities. All long grass, weeds etc. should be removed.
5) Cylinders should be secured so as they are prevented from falling over, when in storage or use.
6) Cylinders should be segregated within the store according to type and weather full or empty. 7) Oxygen and oxidizing gases should be separated flammable gases by 6m or by a fire resistant partition.
8) No electrical apparatus should be installed within a cylinder store unless it is constructed to a suitable standard for the hazard.
9) No cylinder should be used in a storage area.
10)  Appropriate warning signs “HIGHLY FLAMMABLE”. NO SMOKING”, “FULL/EMPTY” etc. should be displayed.
11)  Suitable fire fighting apparatus should be situated adjacent to the store. Typically dry powder fire extinguishers. These should be inspected and maintained at intervals not exceeding 1 year. 
12)  Where cylinders area required to be stored in a compound this should be located not less than 3 meters from any building, site or public access road. The compound fence should be a minimum of 2 meters high, and it should have two means of escape, with the gates opening outwards.
13) Where it is necessary to take precautions vandalism or theft, suitable protection cages should be used. 
14)  Each cylinder should be adequate marked to include the manufacturer’s mark and serial number, together with an indication of the specification to which the cylinder is constructed and its years of manufacture. A date of test and pressure test, together with weight of cylinder and the name of the product, should be displayed.
15)When gas cylinders are to be transported they should be protected from physical damage and the   consequences of any leaks that may occur minimized
16)Move cylinders by hand in proper cylinder trolleys where the cylinder is secured in the trolley.
17)Take great care when lifting cylinders as they can be very heavy and awkward to handle. 18)Before moving any cylinders remove all attached equipment including regulators and safety cap must be provided. 
19)The cylinders should be properly supported and secures within the vehicle so they cannot move during the journey. They should be totally within the vehicle and protected from impact.
20)The cylinders should be checked to ensure that the valves are closed and there are no leaks.
21)The vehicle should be equipped with a suitable fire extinguisher. Typically dry powder,             minimum capacity 2kg.
22)There should be no smoking within the vehicle while crying cylinders.
23)The driver of the vehicle should be conversant with the load and have written information on the  hazards and the action to be taken should any problems occur. The driver should also have  training in the operation of the fire extinguisher and any other safety equipment carried.  
94)  What are the type of fire extinguishers commonly used and briefly, explain each one? 
Multipurpose dry chemical, carbon dioxide, halon, wet chemical or foam, pressurized water are the commonly used fire extinguishers. 
Multipurpose dry chemical / class “A”, “B”, or “C” fires.2.5-20lb. dry chemical (ammonium phosphate) pressurized to 10.5-18 bar by CO2 gas (8-25 seconds discharge time). Has pressure gauge to allow visual capacity check.5-20ft maximum effective range. Extinguisher by smothering burning materials 
Smothering – Cut off oxygen / close the ventilation using fire extinguisher Starving        Remove the fuel / remove the material going to burn Cooling         Reduce the heat / use water 
Carbon Dioxide – Class “B” or “C” fires 2.5-100lb. of CO2 gas at 150-200 psi (8-30seconds discharge time). Has NO pressure gauge-capacity verified by weight 3-8 ft. maximum effective range. Extinguisher by smothering burning materials, Effectiveness decreases as temperature of burning material increases. Halon – Class “A”,”B”, or “C” fires (smaller sizes ineffective against class “A”). 9-17 lb. Halon 1211 (pressurized liquid) releases as vapor (8-18 seconds discharge time). Has pressure gauge to allow visual capacity check 9-16 ft. maximum effective range. Works best in confined area – ideal for electronics fire due to lack of residue. Extinguishers by smothering burning materials, Fumes toxic if inhaled, Halon is ozone depleting chemical – production halted in Jan ’94.
 Wet Chemical or Foam – Class “A”, “B” fires 1.5gal of stored pressure PRX wet chemical extinguishing agent (40 sec. discharge time) 10-12 ft. maximum effective range. On Class “K” fires, don’t use until after fixed extinguishing system has activated, Extinguishes by cooling and forming foam blanket to prevent reigniting.  What is S 95) What is the formula for incident rate?  Number of Record able injuries X 200,000                                                                          Number of employees Hour Worked 200,000 is the equivalent of 100 full time employees working for 40 hours per week or 50 weeks per year (OSHA guidelines) 
96) What is First Aid and CPR?  
Medical aid provide to a victim of an accident scene. This first aid is administered by trained nurse. CPR (Cardio Pulmonary Resuscitation) a first aid given to a person having heart blocked or chocked due to sudden shock. FIRE 97) What is Fire?  
Chain reaction of FUEL, HEAT, OXYGEN. A) Fuel any material which can burn like Paper, Rubber, Wood, Oil, Lubricants, Gases, Metals like Phosphorous, Magnesium. B) Heat or temperature at which the any fuel can ignite this depends on its flash point. C) Oxygen which is helping in combustion and is present in the air. 
98) How Fire can be extinguished? 
Remove anyone of the above three elements of Fire. Fire will extinguished,
 A) Remove the burning material, the remaining materials will be safe.
B) Cut off the Oxygen by blanketing with foam or Fire blanket or any other materials which can not burn the oxygen will be cut off and fire extinguished.
C) Remove or lessen the heat with water or use Carbon Dioxide fire cylinder. Never use Water for Electric Fire as water is good conductor of electricity and you will get electric shock if water is used for electric fire.
99) What common type of the fire extinguisher is used for fire? 
ABC or Dry Chemical Powder Fire Extinguisher used for Solid, Liquid Gases and Electric Fire. 

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