Process Safety Management Overview

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Questions and Answers

What is a primary purpose of Process Safety Information in a PSM program?

To create emergency response plans for chemical spills

To ensure all employees receive training on safety protocols

To provide a resource for various users including hazard analysis teams (correct)

To conduct regular safety drills and simulations

What must be included in a comprehensive risk assessment?

Analysis of system component failures and their risks (correct)

The opinions of all employees regarding risk

Only the historical performance of safety measures

General industry standards without specific data

Which factor influences the selection of a process hazard analysis methodology?

The size of the office where the process is managed

The amount of existing knowledge about the process (correct)

The number of employees involved in the process

The geographical location of the facility

What components must be considered in both quantitative and qualitative risk analysis?

Severity and probability of undesirable events Signup and view all the answers

What does acceptable risk depend on according to the risk analysis framework?

The probability and severity of events Signup and view all the answers

Which of the following is NOT a part of Process Safety Information?

Analysis of employee training needs Signup and view all the answers

What type of approach is a process hazard analysis?

Organized and systematic Signup and view all the answers

What must be done if a risk is deemed unacceptable during risk analysis?

Modify the system to reduce probability or severity Signup and view all the answers

What is the primary benefit of conducting a process hazard analysis for new processes?

It helps improve the design and construction from a reliability standpoint. Signup and view all the answers

Which of the following is NOT an element of a mechanical integrity program?

Regularly scheduled breakdown maintenance Signup and view all the answers

When should initial startup procedures be evaluated?

As part of the pre-startup safety review. Signup and view all the answers

What must management ensure when making changes during a shutdown of an existing process?

That any changes go through management of change procedures. Signup and view all the answers

How should non-routine work in process areas be managed?

Through consistent management control and clear communication of hazards. Signup and view all the answers

Which aspect of a mechanical integrity program involves assessing the reliability of equipment?

Identification and categorization of equipment. Signup and view all the answers

What is a key requirement for equipment handling highly hazardous chemicals?

It must be constructed to minimize the risk of chemical releases. Signup and view all the answers

What constitutes a critical part of the pre-startup safety review?

The evaluation of operating procedures and startup processes. Signup and view all the answers

What must be included in a work authorization notice or permit?

A procedure describing steps for clearance Signup and view all the answers

A GFCI opens the circuit in which of the following time frames after detecting a difference?

0.02 to 0.03 seconds Signup and view all the answers

What is meant by 'management of change'?

The identification and review of process alterations before implementation Signup and view all the answers

Which fall protection systems are designed to absorb the energy of an actual fall?

Fall arrest systems Signup and view all the answers

Which operation is most likely to produce ozone as a byproduct?

Electric arc welding Signup and view all the answers

What is the primary goal of incident investigation?

To identify underlying causes and prevent future incidents Signup and view all the answers

Hexavalent chromium is most likely produced during which operation?

Welding stainless steel Signup and view all the answers

What actions might management decide regarding emergency situations involving hazardous chemicals?

Evacuate the area and involve local emergency services Signup and view all the answers

In a ventilation system, total pressure is equal to the sum of which two types of pressure?

Velocity pressure and static pressure Signup and view all the answers

When is it necessary for an operator to seek review and approval in their operations?

When operating outside established parameters Signup and view all the answers

Who is responsible for auditing the process safety management system?

A trained individual or a team of trained people Signup and view all the answers

Which marking indicates that a product meets health and safety standards in Europe?

CE Signup and view all the answers

Under DOT regulations, which drivers are prohibited from consuming alcohol within four hours before their shift?

All drivers Signup and view all the answers

What is crucial for effective emergency preparedness related to highly hazardous chemicals?

Pre-planned procedures and adequate employee training Signup and view all the answers

What type of changes fall under the management of change definition?

All changes except replacement in kind Signup and view all the answers

The type of liability insurance that protects individuals offering professional services from negligence claims is called what?

All of the above Signup and view all the answers

What is expressed by the value of the compression stress divided by the shear stress?

Value of the compression stress divided by the tensile stress Signup and view all the answers

Which statement best defines the term 'creep' in material science?

Slow but permanent deformation of a material under a given load Signup and view all the answers

Under what condition is shoring not required for a trench more than 4 feet deep?

If they are sloped to an angle of repose Signup and view all the answers

Which of the following best describes a trench?

Deeper than it is wide Signup and view all the answers

What is the most critical function of the guard on a grinding wheel?

To completely enclose the wheel Signup and view all the answers

Which organization is recognized for having the most standards for unfired pressure vessels?

ASME Signup and view all the answers

In indoor warehousing, which type of powered truck is generally preferred?

Electric trucks Signup and view all the answers

One of the main issues with safety inspections is that hazards can:

Increase in severity between inspections Signup and view all the answers

What is one disadvantage of an external safety inspection?

High cost Signup and view all the answers

What should you do if you witness an unsafe act by an employee during a safety inspection?

All of the above Signup and view all the answers

An unsafe act by an employee that results in an accident is classified as which type of accident cause?

Direct Signup and view all the answers

Which option is NOT an advantage of fixed guards?

Adjustment and repair may require removal Signup and view all the answers

Which type of machine guard shuts off power when it is opened?

Interlocked Signup and view all the answers

Which of the following does NOT require machine guarding according to OSHA standards?

Vibrating parts Signup and view all the answers

Which statement about Class A hard hats is NOT true?

They provide limited impact protection but good voltage protection Signup and view all the answers

Which of the following statements about Class B hard hats is NOT true?

They do not have to meet ANSI standards Signup and view all the answers

Study Notes

Domain IV: Advanced Safety Concepts

This domain covers advanced safety concepts, including process safety management.
Process safety management is crucial for complex, high-energy hazardous processes.
Catastrophic events can be prevented through proper application of process safety management techniques.
Examples include the Flixboro explosion, Seveso Dioxin release, and Bhopal toxic plume release.

4.1 Process Safety Management

The objective is to prevent unwanted releases of hazardous chemicals.
A systematic approach is needed to evaluate the entire process.
This includes process design, technology, operations, maintenance, and emergency preparedness.
Evaluating and strengthening lines of defense against chemical releases is key.
This approach identifies, evaluates, and mitigates or prevents chemical releases.

Elements of Process Safety Management (PSM)

Employee Participation: Teamwork between management and employees is essential.
Management must consult employees in developing and implementing the PSM program.
Employees should have access to process information and influence decisions.
Process Safety Information: A complete, accurate, written record of process definition, design, risk management, protective systems, normal/upset conditions, chemical & occupational health hazards is vital.
This information is necessary for a successful PSM program.
Process Hazard Analysis: This is a systematic effort to identify and analyze potential hazards associated with handling hazardous chemicals.
Choosing the right methodology (considering existing knowledge and process complexity) is crucial.

4.2 Personal Protective Equipment (Respirators)

Employers need written respiratory protection programs for respirator use.
These programs include SOP's for selection/use, training, disinfection, storage, and inspection.
Respirators are categorized as Air Purifying Respirators and Atmosphere Supplying Respirators.
Air Purifying Respirators only remove specific contaminants.
Atmosphere Supplying Respirators supply independent air.
Respirators should not be used in atmospheres with unknown contaminant types or concentrations.
- Immediate danger to life and health (IDLH) atmospheres are a contraindication.
Supplied Air Respirators (SAR) have their own air supply and are independent of the surrounding atmosphere.

4.3 Example Questions (General Safety)

Topics covered include: engineering controls, insurance company types, reducing chemical exposure, controlling noise, and various aspects of insurance.

4.3 Example Questions (Specific Safety Topics)

Topics cover: emergency preparedness, audits, safety review, mechanical integrity, work permissions, and equipment maintenance.

12 Emergency Preparedness

Management needs to address what actions employees are to take in case of release of hazardous materials.
Planning/procedures/training for employees are crucial.
Options to handle unwanted releases, such as employee responses to small releases, mobilization of plant resources, or evacuation, need to be considered.

13 Audits

Audits assess the design and effectiveness of the process safety management system/program.
Procedures describe steps for supervisors or contractors to gain authorization.
Audits involve evaluations of safety/health condition considerations, thorough reviews, and documentation.

14 Mechanical Integrity

This program aims to minimize the risk of hazardous chemical releases through a well-defined equipment and instrumentation program.
This includes categorization, inspections, testing, and maintenance of equipment.
It also involves creating and maintaining documentation of tests and inspections.

10 Management of Change

This element details the management of changes to processes, chemicals, technology, equipment, and facilities.
Change involves all modifications, not just replacement.
This includes a formal method/process for defining, reviewing, and implementing modifications
This requires procedures, proper notification, and a review process.

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Description

Test your knowledge on the essential components of Process Safety Management (PSM) programs, including Process Safety Information, risk assessment, and hazard analysis methodologies. This quiz covers critical aspects of ensuring safety in industrial processes.