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Questions and Answers
Questions and Answers
In the context of process safety, what does the term "loss prevention" primarily encompass?
In the context of process safety, what does the term "loss prevention" primarily encompass?
- Hazard identification, technical evaluation, and new engineering designs to prevent loss (correct)
- Accident prevention through reactive measures after incidents
- Using hard hats and safety shoes
- Implementing strict rules and regulations
A 'latent hazard' exhibits an immediate adverse effect.
A 'latent hazard' exhibits an immediate adverse effect.
False (B)
What are the three elements of Process Safety?
What are the three elements of Process Safety?
Behavior, systems and process
The Bhopal, India incident in 1984 involved the release of the highly toxic substance ______.
The Bhopal, India incident in 1984 involved the release of the highly toxic substance ______.
Match the incident with the corresponding location and year:
Match the incident with the corresponding location and year:
Which of the following best describes the concept of 'inherently safer design'?
Which of the following best describes the concept of 'inherently safer design'?
Statistical methods are not used in documenting accidents and loss.
Statistical methods are not used in documenting accidents and loss.
What does the acronym OSHA stand for?
What does the acronym OSHA stand for?
The formula to calculate OSHA Injury & Illness Rate is (# of Injuries & Illness * 200,000) / (Total hrs all ______)
The formula to calculate OSHA Injury & Illness Rate is (# of Injuries & Illness * 200,000) / (Total hrs all ______)
Match the following strategies with their descriptions in the context of Inherently Safer Design:
Match the following strategies with their descriptions in the context of Inherently Safer Design:
What is the main goal of safety or loss prevention?
What is the main goal of safety or loss prevention?
An OSHA incidence rate based on lost workdays does NOT need to account for diminished long term performance.
An OSHA incidence rate based on lost workdays does NOT need to account for diminished long term performance.
What is the basic difference between Safety Program and Safety Management System?
What is the basic difference between Safety Program and Safety Management System?
In 1984, an explosion in ______, Mexico resulted in hundreds of fatalities and significant damages.
In 1984, an explosion in ______, Mexico resulted in hundreds of fatalities and significant damages.
Match the following Process Safety milestone practices with their time periods:
Match the following Process Safety milestone practices with their time periods:
According to the provided material, what is considered when defining 'Risk'?
According to the provided material, what is considered when defining 'Risk'?
The Flixborough disaster in England (1974) was caused due to a Cyclone.
The Flixborough disaster in England (1974) was caused due to a Cyclone.
In the context of 'inherently safer design', list one of the key strategies.
In the context of 'inherently safer design', list one of the key strategies.
An explosion and fire in Pasadena, TX in 1989, which caused over $800M in damage, was trigged by flammable vapors of what compound: ethylene/______?
An explosion and fire in Pasadena, TX in 1989, which caused over $800M in damage, was trigged by flammable vapors of what compound: ethylene/______?
Match S-A-F-E-T-Y model values to their definitions
Match S-A-F-E-T-Y model values to their definitions
Which of the following events is associated with the release of 'flammable hydrocarbon vapors'?
Which of the following events is associated with the release of 'flammable hydrocarbon vapors'?
Large area of Russia, Ukraine and Belarus evacuated and resettled after the Henderson, Nevada incident in 1988, resulting in approximately 360,000 people evacuated.
Large area of Russia, Ukraine and Belarus evacuated and resettled after the Henderson, Nevada incident in 1988, resulting in approximately 360,000 people evacuated.
What is a key difference between 'active' and 'latent' hazards in a chemical plant?
What is a key difference between 'active' and 'latent' hazards in a chemical plant?
The T2 Laboratories Inc. incident in Jacksonville, FL in 2007 involved a reactor explosion in the manufacture of gasoline ______.
The T2 Laboratories Inc. incident in Jacksonville, FL in 2007 involved a reactor explosion in the manufacture of gasoline ______.
Match the given event with the type of hazard involved:
Match the given event with the type of hazard involved:
Which statistic is calculated using (# of Fatalities X 10^8)/(Total hrs worked by all employees)?
Which statistic is calculated using (# of Fatalities X 10^8)/(Total hrs worked by all employees)?
In fatality rate, the total number of people exposed is divided by the number of fatalities each year.
In fatality rate, the total number of people exposed is divided by the number of fatalities each year.
For a car traveling 50 mph, write the equation to properly calculate deaths per million miles travel by car.
For a car traveling 50 mph, write the equation to properly calculate deaths per million miles travel by car.
According to the material, the FAR for travel by air is indicated as ______.
According to the material, the FAR for travel by air is indicated as ______.
Match the description to the rate
Match the description to the rate
Questions and Answers
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Flashcards
Flashcards
Safety or Loss Prevention
Safety or Loss Prevention
The prevention of accidents using appropriate technologies to identify and eliminate plant hazards.
Hazard
Hazard
A chemical or physical condition with the potential to cause damage to people, property, or the environment.
Risk
Risk
A measure of potential loss considering both the likelihood and magnitude of the incident.
Mechanical Hazards
Mechanical Hazards
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Chemical Hazards
Chemical Hazards
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Active Hazard
Active Hazard
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Latent Hazard
Latent Hazard
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Inherently Safer Design
Inherently Safer Design
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Substitute (Safety Strategy)
Substitute (Safety Strategy)
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Minimize (Safety Strategy)
Minimize (Safety Strategy)
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Moderate (Safety Strategy)
Moderate (Safety Strategy)
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Simplify (Safety Strategy)
Simplify (Safety Strategy)
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Accident Statistics
Accident Statistics
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OSHA Incidence Rate
OSHA Incidence Rate
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Fatal Accident Rate (FAR)
Fatal Accident Rate (FAR)
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Fatality Rate
Fatality Rate
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Study Notes
Study Notes
Process Safety Engineering: Introduction & Overview
- Loss prevention emerged to include hazard identification, technical evaluation, and new engineering designs
The Rising Case for Change
- In 1974, Flixborough, England experienced a cyclohexane explosion, resulting in 29 fatalities and offsite effects
- In 1984, Bhopal, India experienced a toxic material release, resulting in 2,500 immediate fatalities and 20,000+ total, as well as many other offsite injuries from methyl isocyanate
- In 1984, Mexico City, Mexico experienced an explosion causing 300-650 fatalities, mostly offsite, and $20M in damages; the LPG explosion was caused by a leak at a marketing terminal pipeline
- In 1986, Chernobyl had a large area of Russia, Ukraine, and Belarus evacuated and resettled, affecting 336,000 people, with fewer than 50 immediate deaths and thousands of cancer-related cases, plus extensive environmental damage
- In 1988, Norco, LA, experienced an explosion, resulting in 7 onsite fatalities, 42 injuries, and $400M+ in damages
- In 1988, Henderson, Nevada, experienced an incident
- In 1989, Pasadena, TX, had an explosion and fire, resulting in 23 fatalities, 130 injuries, and $800M+ in damages
- T2 Laboratories Inc. in Jacksonville, FL, 2007, experienced a reactor explosion in manufacture of gasoline additive, resulting in 4 killed and 13 wounded
- BP America Refinery in Texas City, TX, 2005, experienced an isomerization unit explosion and fire, resulting in 15 killed and 180 wounded
- West Pharmaceutical Services in Kinston, NC, 2003 had a dust cloud explosion and fire from release of fine plastic powder, resulting in 6 killed and dozens wounded
Safety & Loss Prevention
- The older strategy of accident prevention involved hard hats, safety shoes, rules, and regulations
- Safety has been replaced by loss prevention, which includes hazard identification, technical evaluation, and the design of new engineering features
Safety, Hazard, and Risk
- Safety or loss prevention uses appropriate technologies to identify and eliminate chemical plant hazards before accidents occur
- A hazard is a chemical or physical condition with the potential to damage people, property, or the environment
- Risk measures human injury, environmental damage, or economic loss based on incident likelihood and loss/injury magnitude
Hazards in Chemical Plants
- Mechanical hazards in chemical plants can cause worker injuries due to tripping, falling, or moving equipment
- Chemical hazards include fire, explosion, reactivity, and toxic hazards
- Active hazards are immediately adverse effects and are similar to "unsafe acts"
- Latent hazards may not be noticeable for some time, and unforeseen trigger conditions can activate risk
S-A-F-E-T-Y
- S is Management Systems
- A is Proper Attitude
- F is Understand Fundamentals
- E is Experience
- T is Time to do things safely
- Y is Your Participation
- Safety Programs identify and eliminates existing safety hazards
- Safety Management Systems prevent the existence of safety hazards
Three Elements of Process Safety
- The three elements are Behavior, Systems and Process
Process Safety Milestone Practices
- Pre-1930's: Identify who caused the loss and punish the guilty
- Pre-1970's: Find breakdown in and fix man-machine interface
- 1970's, 80's: Development of risk assessment techniques and systematic approaches
- 1980's +: Performance-, risk-based standards, regulations; 'green' and 'inherent' designs
Inherently Safer Design
- Definition: designing the chemical process to eliminate hazards rather than controlling the hazard
Inherently Safer Design Strategies
- Minimize
- Moderate
- Substitute
- Simplify
- Replace material with a less hazardous substance, which is an example of substitute
- Use smaller quantities; eliminate unnecessary equipment; reduce size of equipment or volumes processed, which is an example of minimize
- Use less hazardous conditions, a less hazardous form of material or facilities which minimize the impact of a release, which is an example of moderate
- Design facilities which eliminate unnecessary complexity and make operating errors less likely, which is an example of simplify
Accidents and Loss Statistics
- Statistical methods include:
- OSHA incidence rate
- Fatal accident rate (FAR)
- Fatality rate, or deaths per person per year
OSHA Incidence Rate
- OSHA stands for the Occupational Safety and Health Administration of the US govt
- OSHA Injury & Illness Rate = (# of Injuries & Illness*200,000)/(Total hrs all employees)
- OSHA Incidence Rate (lost WD) = (# lost workdays * 200,000)/ (Total hrs worked)
- Lost Workdays are those days which the employee would have worked but could not because of occupational injury or illness
Fatal Accident Rate (FAR)
- FAR= (# of Fatalities X 108)/(Total hrs worked by all employees)
Fatality Rate
- FatalityRate = (# Fatalities / yr) / (Total # PeopleExposed)
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