Process Safety Test 1|104 Questions with Verified Answers,100% CORRECT

Process Safety Test 1|104 Questions with Verified Answers Flixborough is an example of failure of which process safety management system - CORRECT ANSWER Management of Change -a change was made to process equipment without understanding the possible hazards -design codes were not followed -plant layout & design of occupied buildings Hazard Identification and Risk Analysis falls under which pillar? - CORRECT ANSWER Understand Hazards and Risks What is the UN packing group for Acetic Anhydride? - CORRECT ANSWER Packing Group 2 What happened in Flixborough? - CORRECT ANSWER -Crack in rx leaking cyclohexane -Reactor bypassed with a 20" pipe with flexible joints -3 months later the bypass failed resulting in loss of primary containment of cyclohexane and subsequent massive fire What happened in Bhopal India? - CORRECT ANSWER -Massive methyl isocyanate (MIC) toxic vapor cloud release after a storage tank overpressure and subsequent relief valve lift -simultaneous MIC releases from scrubber and process Causes of Flixborough - CORRECT ANSWER -Management of Change--a change was made to process equipment without understanding the possible hazards -Design codes were not followed -plant layout and design of occupied buildings (facility citing) Causes of Bhopal - CORRECT ANSWER -Process safety equipment bypassed--including flare and refrigeration system -Chemical reaction hazard--water reacted with isocyanate to increase pressure causing LOPC. The source is unknown -This reactive chemical incident was not well understood Bhopal was a _____________ event - CORRECT ANSWER watershed; it changed the way process safety is regulated across the glove and changed how we design, build, operate, and maintain our facilities. Consequences of flixborough - CORRECT ANSWER -50 T cyclohexane vapor cloud explosiong -28 fatalities -36 injured -$100M damage Consequences of Bhopal - CORRECT ANSWER -56M lb of toxic MIC ->2,500 Fatalities -20,000 medical treatment -70,000 evacuated What happened at Phillips 66 in Pasadena TX? - CORRECT ANSWER -settling legs collect polyethylene from the reactor loop -legs cleaned by closing a single isolation valve to prevent ethylene release -during this 85,000 lb of ethylene released and ignited Causes of Phillips 66 incident in Pasadena TX - CORRECT ANSWER Poor maintenance isolation practice -did not follow company standard of double block and bleed or blind Procedures not followed -Lock (LOTO) removed that allowed the valve to be opened -Air supply attached to pneumatic valve violating LOTO, connected backwards consequences of phillips 66 incident in pasadena TX - CORRECT ANSWER -Ethylene Vapor Cloud Explosion -23 fatalities -130 injured -$1B in damage What happened at Olin in lake charles? - CORRECT ANSWER -disengagement drum V201 designed to separate anhydrous HCl from high pressure (200psig) phosgene -HCl pressure let down to atmospheric pressure to absorb in water to make muriatic acid -liquid phosgene carried over to HCl absorbers, with rapid flashing over pressured and rupture muriatic acid accumulator Causes of Olin incident in lake charles - CORRECT ANSWER -liquid carryover scenario hazard not recognized in the process hazard analysis -no engineered controls existed to prevent -administrative controls to prevent high pressure in acid system inadequate to prevent Consequences of Olin in Lake Charles incident - CORRECT ANSWER -Phosgene/HCl overpressure -1 fatality -1 serious injury What happened at BP in Texas City? - CORRECT ANSWER -During startup of a raffinate splitter tower of an isomerization unit, the tower over-filled causing a hydrocarbon release and subsequent explosion Causes of BP incident in Texas City - CORRECT ANSWER -Culture -faculty level transmitter in column -lack of supervisory oversight during startup -poor communication, poor shift relief practices -operator fatigue having worked 12 hour continuous shifts for 29 days -inadequate training -inadequate operating procedures -inadequate design on relief blowdown drum -previous near miss ignored -facility siting of trailers -inadequate pre-startup reviews Consequences of BP at Texas City - CORRECT ANSWER -Explosion -15 fatalities -170 injured -$5B in damage What happened at the ARCO tank explosion in Channelview TX? - CORRECT ANSWER -A 900,000 gal storage tank design to separate oxygenated hydrocarbons from waster water exploded upon start-up of a compressor -the incident occurred near the end of a long turn around Causes of ARCO tank explosion in Channelview TX - CORRECT ANSWER -Oxygen buildup in the tank due to a low nitrogen purge and failure of the oxygen monitor -Culture-- a unique aspect of this incident is that ARCO recognized several management system failures including: -lack of awareness of the hazard -a "can-do/ get er done" attitude -worker fatigue - a weak process safety management system -low process safety competency among employees Consequences of the ARCO tank explosion in Channelview TX - CORRECT ANSWER -Explosion -17 fatalities -$100M in damage -ARCO became one of the first to develop an operational excellence management system Steps to build a maximum intended invetory - CORRECT ANSWER 1. gather to process equipment 2. gather facts about the equipment -variable volume containers -fixed volume containers 3. Determine all chemicals used in the process, and match the maximum concetrations found in #2 above 4. Complete your material balance 1992 rule in response to incidents such as _____________________ - CORRECT ANSWER Bhopal, P66, Pasadena, and ARCO Channelview A facility is covered under OSHA if - CORRECT ANSWER it handles one of the 130 toxic chemicals above the threshold quantity given in the rule's appendix A or 10,000 lb or more of flammable liquid or gas What is a P&ID? - CORRECT ANSWER -shows relative location of process equipment, sensors, and actuators -conceptual outline -shows connections between sensors and actuators What is a P&ID not? - CORRECT ANSWER -not an architectural diagram -not to scale -not a diagram of reaction kinetics -not a control diagram What is LOPC - CORRECT ANSWER Loss of Primary Containment -occurs when chemicals get out of the pipes -an unplanned or uncontrolled loss of primary containment of energy or a chemical in any 60 minute window Primary Contianment - CORRECT ANSWER A tank, vessel, pipe, truck, rail car, or other equipment designed to keep material in, typically for the purpose of storage, separation, processing, or transfer of material Unplanned/uncontrolled definition - CORRECT ANSWER deal with intention of release. it is possible to plan for a safe release of material above its threshold quantity to a pre-defined safe location without consequences of injury, damage, or community impact and not classify as a process safety incident Exclusions for LOPC - CORRECT ANSWER Safe releases from an engineered pressure relief (e.g. PRD, SIS, or manually initiated emergency de-pressure) discharge OR an upset emission from a permitted or regulated source, of a quantify greater than or equal to the threshold quantities in any one hour period. Safe releases do not have injury, damage, or community impact potential, nor one of the following consequences: rainout, discharge to an unsafe location, an on-site shelter-in-place or on-site evacuation, excluding precautionary on-site shelter in place or on-site evacuation, or public protective measures (e.g. road closure) including precautionary public protective measures A safe release does not exceed _________________ of ________________ for flammables - CORRECT ANSWER 50%; lower flammability limit A safe release does not exceed ________________ for toxics at grade - CORRECT ANSWER ERPG-2 Tier 1 LOPC - CORRECT ANSWER -"days away" from work injury -hospital admission and/or fatality of a 3rd party -officially declared shelter in place or community evacuation -fire or explosion resulting in >100,000 USD direct cost -a release at or above the Tier 1 thershold quantity from a PRD activation or upset emission from a permitted source with certain consequences -a release of material above the tier 1 threshold quantity in any one hour period Tier 2 LOPC - CORRECT ANSWER -recordable injury -fire or explosion resulting in >2500 USD direct cost, <100,000 -a release at or above Tier 2 thershold quantity form a PRD activation or upset emission from a permitted source with certain consequences -a release of material above the Tier 2 thershold quantity, which is about 10% of the tier 1 in any one hour period An material with a TQ of 1000kg spills unintentionally from an open valve. 1500kg is released in 10 minutes. Tier 1 or Tier 2? - CORRECT ANSWER Tier 1 An material with a TQ of 1000kg spills unintentionally from an open valve. 950kg is released in 10 minutes. - CORRECT ANSWER Tier 2 An material with a TQ of 1000kg spills unintentionally from an open valve. 1500kg is released in 180 minutes. - CORRECT ANSWER 1500kg/180min=8.3 kg/min *60 min = 500 kg Tier 2 An material with a TQ of 1000kg spills unintentionally from an open valve. 1500kg is released indoors in 180 minutes. - CORRECT ANSWER Indoor PSQ = 0.1(1000)=100kg Tier 1 An material with a TQ of 1000kg spills unintentionally from an open valve. 1500kg is released indoors in 1800 minutes. - CORRECT ANSWER 1500/1800*60=50kg not a PSE An material with a TQ of 1000kg spills unintentionally from an open valve. 15kg is released in 10 minutes. - CORRECT ANSWER Not a Tier 1 or Tier 2 An material with a TQ of 1000kg spills unintentionally from an open valve. 15kg is released in 10 minutes. This incident resulted in a lost time incident. - CORRECT ANSWER Tier 1 An material with a TQ of 1000kg spills unintentionally from an open valve. 15kg is released in 10 minutes. This incident caused a recordable injury. - CORRECT ANSWER Tier 2 An material with a TQ of 1000kg spills unintentionally from an open valve. 15kg is released in 10 minutes. The incident is safe due to an engineered vent. - CORRECT ANSWER Not a tier 1 or 2 An material with a TQ of 1000kg spills unintentionally from an open valve. 15kg is released in 10 minutes. The incident is safe due to an engineered vent. A community shelter in place is called. - CORRECT ANSWER Tier 1 An material with a TQ of 1000kg spills unintentionally from an open valve. 15kg is released in 10 minutes. A jet fire occurs causing $125,000 in direct damage. - CORRECT ANSWER Tier 1 What could go wrong from heating Dinitrotoluene (DNT) with confinement? - CORRECT ANSWER It could realses NOx, and can cause over pressures and explosions What could go wrong with Toluene diisocyanate? - CORRECT ANSWER Their residues are reactive and polymerize very quickly. Since they are typically pumped with gear pumps solidification can cause overpressure and explosion What could go wrong with Phosgene and hydrogen chloride? - CORRECT ANSWER They react with water to produce muriatic acid which is very corrosive. What could go wrong with 50% NaOH? - CORRECT ANSWER It freezes and expands at 58 F What could go wrong with flashing ethylene? - CORRECT ANSWER IT experiences a joule-thompson expansion and very cold temperatures that can cause carbon steel embrittlement, pipe failure and ethylene release with possibility of explosion Example Design Codes and Standards: Atmospheric Tanks API 620 - CORRECT ANSWER design and construction of large, welded, low pressure storage tanks Example Design Codes and Standards: Chlorine--Chlorine Institute Pamphlet 6 - CORRECT ANSWER piping systems for dry chlorine Example Design Codes and Standards: Peroxides--NFPA 430 - CORRECT ANSWER code for the storage of liquid and solid oxidizers Example Design Codes and Standards: Compressed Gasses--Compressed gas association P-22 - CORRECT ANSWER the responsible management and disposition of compressed gases and their cylinders Example Design Codes and Standards: Fixed equipment--NFPA 85 - CORRECT ANSWER boiler and combustion systems hazard code Example Design Codes and Standards: Fixed Equipment--API 521 - CORRECT ANSWER pressure-relieving and depressuring systems Example Design Codes and Standards: Flammable Liquids: NFPA 77 - CORRECT ANSWER recommended practice on static electricity Plant Building Important Codes to Know - CORRECT ANSWER API 752: management of hazards associated with location of process plant permanent buildings API 753: Management of Hazards associated with location of process plant portable buildings Metrics Important Codes to Know - CORRECT ANSWER API 754: Process Safety PErformance Indicators for the Refining and Petrochemical Industries Pressure Vessels Important Codes to Know - CORRECT ANSWER ASME 510: Pressure vessel inspection code Solids Handling Important Codes to Know - CORRECT ANSWER NFPA 654: standard for the prevention of fires and dust explosions How fixed equipment fails - CORRECT ANSWER (piping, tanks, exchangers, columns, etc.) -anything with a flange and gasket can leak from improper bolting, wrong gasket, pipe stress, etc. -Corrosion (normal, accelerated, incompatible materials, end of useful life, welding technique) -equipment design (e.g. heat exchanger tubes/tube sheets) -valve gaskets, valve bleeders open, etc. How rotating equipment can fail - CORRECT ANSWER (pumps, compressors, turbines, etc.) -anything that rotates can fail mechanically or at sealing surfaces -vibration can tear equipment apart How can instrumentation fail? - CORRECT ANSWER -False signals, wrongs signals, frozen in place causing various problems such as overflow, cavitation etc. How can Electric equipment fail? - CORRECT ANSWER (power, switchgear, etc.) -loss of power (even for micro seconds) can shut down equipment Risks of centrifugal pumps - CORRECT ANSWER have a mechanical seal that can leak Risks of canned motor pumps - CORRECT ANSWER eliminates the seal that a centrifugal pump has, but can fail catastrophically Risks of a positive displacement gear pump - CORRECT ANSWER -can build up very high pressures if deadheaded Common failure modes in rotating equipment chart - CORRECT ANSWER Ways to prevent LOPC in pumps - CORRECT ANSWER -vibration monitor/interlock -amp monitor/interlock -prevent deadhead by monitoring discharge pressure, flow measurement, and having minimal recycle lines -prevent overheating by lubrication rounds -downstream pressure design (downstream equipment designed for max discharge pressure) How to minimize the duration of release in compressors - CORRECT ANSWER -minimize TIH or flammable and interlock -upstream vacuum--equipment pressure design -leaks from vibration can be minimized by vibration monitoring How to prevent human error with Conduct of Operations - CORRECT ANSWER -commissioning -startup reviews -P&ID walk downs -independent verification -limit switch on key valves -line labeling -checklist SOP's -two way communication -abnormal events reporting Potential failures of Shell and Tube heat exchangers - CORRECT ANSWER -potential for tueb leaks create unique design considerations (velocity in shell, material of construction, erosion/corrosion, tube warping, fouling, etc.) Potential failures of plate and frame heat exchangers - CORRECT ANSWER -hard to leak from one stream to another, but they could leak from gasket surface -fouling common failure modes in heat exchangers chart - CORRECT ANSWER Preventing LOPC in heat exchangers - CORRECT ANSWER -inspect for obvious corrosion, tube thickness, seal weld cracks/die penetrant, and hydro test -monitor discharge heating or cooling medium for leaks -cooling water PRD for blocked condition and thermal expansion -high point inert bleed -heating and cooling medium quality -monitor steam quality how to prevent over/underpressure in vessels and tanks - CORRECT ANSWER pressure controls/licks PRD How to prevent spills from vessels and tanks - CORRECT ANSWER dikes how to prevent catastrophic release from vessels and tanks - CORRECT ANSWER -remote isolation -double wall tank how to prevent overfill of vessels and tanks - CORRECT ANSWER level control/ilck How to prevent static buildup in vessels and tanks - CORRECT ANSWER -bonding/grounding -dip tube filling how to prevent runaway reactions in batch reactor control systems? - CORRECT ANSWER -temperature -automatic dump systems -automatic quench systems -explosion panels how to avoid vibration/seal leaks, small bore in batch reactors - CORRECT ANSWER -vibration monitor -min level agitator start and operation -seal oil lube systems What is a maximum credible event? - CORRECT ANSWER a hypothetical explosion, fire, or toxic event that has the potential maximum consequence to the occupants of the building under consideration from among the major scenarios evaluated. The scenarios are realistic and have a reasonable probability of occurrence considering the chemicals, inventories, equipment and piping design, operating conditions, fuel reactivity, process unit geometry, industry incident history, and other factors. Each building may have its own set of MCEs for potential explosion, fire or toxic material release impacts, They are not necessarily the worst case scenario When do we use and MCE? - CORRECT ANSWER -Doing a facility siting study -developing an EPA Risk Management Plan What is a facility siting study? - CORRECT ANSWER Managing the risk from toxic releases, explosions, and fires to personnel in occupied buildings What is and EPA Risk Management Plan (RMP) - CORRECT ANSWER It is concerned with offsite consequence assesment, and the plan must include a worst case scenario. Worst case release means the release of the largest quantity of a regulated substance from a vessel or process line failure that results in the greatest distance to an endpoint Examples of MCE or worst case scenarios - CORRECT ANSWER -maximum contents of a vessel or pipe released -max flow rate through a pipe assuming a full diameter sheer -for toxic gasses, a 2' orifice is released over 10 minutes -the scenario is calculated with a source model, based on the equipment design, process conditions, and HIRA team experience with the process Risk is a function of which 3 elements? - CORRECT ANSWER -What can go wrong? -How bad could it be? -How often might it happen? What can go wrong? - CORRECT ANSWER (human injury, environmental damage, or economic loss) What can go wrong is the chemical or physical conditions that have the potential for causing harm. What could go wrong is the Hazard. How bad could it be? - CORRECT ANSWER (magnitude of the loss or injury) How bad could it be is the consequence if the hazard manifests. Engineers can estimate how bad it could be by estimating the effects of LOPC and fire/explosion overpressures, toxic release consequences, etc. This is called consequence assessment. How often might it happen? - CORRECT ANSWER (likelihood of the loss or injury) The likelihood is expressed as a probability or frequency What are safeguards? - CORRECT ANSWER controls that we design to either prevent the hazard from occurring or reduce the severity of the incident Examples of safeguards for cars at a traffic light - CORRECT ANSWER Preventative -auto stop (engineered) -speed limit (administrative) -traffic light (admin) -deterrent laws (admin) Mitigative -auto construction (passive) -air bags (active) -seat belts ALARP - CORRECT ANSWER as low as reasonably practicable What are the 3 types of process safety incidents? - CORRECT ANSWER Causes of industrial reactive chemical incidents - CORRECT ANSWER -inadequate hazard identification and evaluation -inadequate prcedures and training for storage and hadling of reactive chemicals -inadequate process design for reactive hazards -inadequate design to prevent human errors typical deviations causing runaway reactions - CORRECT ANSWER -loss of cooling -human error -accumulation of reactants -external fire -presence of "hot-spots" common runaway reactions - CORRECT ANSWER -organic peroxide thermal runaways (a self accelerating decomposition) -ethylene thermal decomposition -vinyl acetate polymerization run away what is a chemical reactivity hazard - CORRECT ANSWER a situation with the potential for an uncontrolled chemical reaction that can result directly or indirectly in serious harm to people, property or the environment True or False: An ethylene decomposition can easily be controlled by monitoring the termperature and comparing to the auto decomposition temp. - CORRECT ANSWER False--There is an inflection point making it difficult to predict Based on my knowledge of chemistry, a strong acid/base reaction can cause what type of process consequence? - CORRECT ANSWER over temperature--rapid increase in temp over pressure--from rapid generation of vapor from heat of reaction what does inerting do? - CORRECT ANSWER adds an inert gas like nitrogen so theres less oxygen to feed a fire