Safety Procedures in Industrial Operations

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Questions and Answers

What is one consequence of Incorrect Isolation mentioned in the procedures?

Enhanced safety protocols

Improved operational efficiency

Injury to people and damage to equipment (correct)

Increased production output

Which personal protective equipment must be worn at all times in the plant?

Safety shoes, high visibility jackets & safety goggles (correct)

Dust mask and gloves only

Apron and ear plugs

Surgical mask

Which precaution should be taken to ensure safe manual handling?

Handle all materials without any lifting techniques

Move items quickly to save time

Always use your back when lifting heavy items

Follow good manual handling practices (correct)

What is the recommended cutting direction when using a safety knife?

Away from the body Signup and view all the answers

During HOPT operation, what should be the main safety focus?

Maintaining line of fire Signup and view all the answers

What type of gloves should be used when handling substances that come into contact with paint?

Nitrile gloves Signup and view all the answers

What should be checked to prevent electrical shock during operations?

Inspect earthing cables for loose connections Signup and view all the answers

What is one hazard associated with the stirring operations of mixers?

Noise Signup and view all the answers

What is the primary purpose of the Standard Operating Procedure manual for the High Speed Dispersor (HSD)?

To ensure safe handling and operation of HSD 1 and HSD 2. Signup and view all the answers

Who is primarily responsible for the safe handling and operation of HSD 1 and HSD 2?

Trained and Authorized Person Signup and view all the answers

Which of the following is a potential hazard associated with the High Speed Dispersor?

Static Fire Hazard from failure of continuity of earthing. Signup and view all the answers

What does the abbreviation *TA stand for in this context?

Trained & Authorized Person Signup and view all the answers

What could be a consequence of a malfunctioning Limit Switch?

Damage to equipment and potential injury. Signup and view all the answers

Which role in the responsibilities section is listed as secondary for the safe operation of HSD 1 and HSD 2?

Production Officer Signup and view all the answers

What is included in the scope of this SOP?

Both operation and cleaning of HSDs. Signup and view all the answers

What is a potential risk associated with malfunctioning hydraulic systems?

Spills and injury to personnel. Signup and view all the answers

What personal protective equipment (PPE) is mandatory when operating in the plant?

Helmet, safety shoes, safety glasses, hand gloves, and mask Signup and view all the answers

What should be ensured regarding waste management before starting operations?

That waste bins are available for effective segregation of waste Signup and view all the answers

What is the maximum batch size allowed for the high-speed dispersor?

800 Liters Signup and view all the answers

Which action should be taken before starting the batch of food contact products?

Inspect equipment for contamination after QC clearance Signup and view all the answers

What should be done regarding the vessel before charging raw materials?

The vessel should be empty and cleaned Signup and view all the answers

What is the maximum RPM for the machine during operation?

1200 RPM Signup and view all the answers

What should be done with the vessel before it is weighed?

Ensure the vessel bottom valve is closed Signup and view all the answers

What systems must be ON when the machine is operating?

Both fume and dust extraction systems Signup and view all the answers

What is the procedure for charging solvents through a mass flow meter?

Set weights in batch controllers and charge through the mass flow meter. Signup and view all the answers

Why is it important to ensure earthing is connected during material transfer?

To avoid electrical hazards. Signup and view all the answers

What should be done before placing the portable under the High Speed Dispersor (HSD)?

Check that local isolation is in place. Signup and view all the answers

What is the first step when starting the impeller?

Remove local isolation by issuing the local isolation key. Signup and view all the answers

What height must the shaft reach before it can be lowered?

The maximum allowed height. Signup and view all the answers

What must be checked before operating the impeller?

The earthing and that the green light is on. Signup and view all the answers

How should the vessel be secured before starting the mixing process?

Using strapping belts and clamps. Signup and view all the answers

What should be done after the operation of the impeller is complete?

Return the local isolation key to the PO. Signup and view all the answers

What should be done immediately after a splash or exposure?

Inform the supervisor and consult the medical center if required. Signup and view all the answers

What is the correct procedure when shutting down the High Speed Dispersor (HSD)?

Ensure all portable containers are closed and turn off HSD properly. Signup and view all the answers

What action should be taken in the event of a power failure?

Release the emergency switch and complete the remaining work when power resumes. Signup and view all the answers

Who is authorized to operate the machine under a breakdown situation?

Only authorized and trained persons are allowed to operate the machine. Signup and view all the answers

What is a crucial step to follow after a normal shutdown of the equipment?

Verify that the operation lock is in place and the key is secured. Signup and view all the answers

What should be done immediately in case of spillage?

Start cleaning and inform the SO Signup and view all the answers

What is the first step to take if the impeller needs to be stopped?

Press the Stop push button Signup and view all the answers

Which action should be taken if the cutter is found to be broken or not working?

Report to engineering and obtain a new one Signup and view all the answers

What is the procedure for collecting a sample during operation?

Ensure the shaft has stopped and clean the sampler after use Signup and view all the answers

What should be done in the event of a fire alarm or an emergency shutdown?

Push the emergency shut off switch and report the incident Signup and view all the answers

What should be done if the stirrer experiences a breakdown or issue during operation?

Turn off the stirrer switch and inspect the issue Signup and view all the answers

What action should be taken if the lid is stuck during lifting and lowering?

Report the issue to engineering immediately Signup and view all the answers

What is required before adding the required raw materials (RM) during the operation?

Refer back to the batch card for the sequence Signup and view all the answers

Study Notes

Standard Operating Procedure Manual - Operations

Document Title: High Speed Dispersor (HSD 1 & 2)
Revision Number: Rev. No.7
Issue Date: 28/11/2019
Review Date: 19/01/2022
Scope: Applies to operating and cleaning HSDs (High Speed Dispersors) 1 and 2.

Purpose

To ensure safe handling and operation of HSD 1 and HSD 2.

Definitions/Abbreviations

TA: Trained & Authorized Person
QO: Quality Officer
PO: Production Officer
PM: Production Manager
ETF: Emergency Task Force

Responsibilities

Primary: TA, PO, PM
Secondary: TA, PO, PM

Hazards

Static Fire Hazard: Failure of portable earthing/bonding clamp could cause fire.
Limit Switch (Injury): Malfunctioning could damage equipment and cause body injury.
Hydraulic Failure: Could cause a spill.
Injury to People: Incorrect isolation could result in injury and equipment damage.
VOC Exposure: Exposure to volatile organic compounds could be harmful to health.
Ergonomic Risk Hazard: Manual handling needs to be performed according to good practice.

Personal Protective Equipment (PPE)

Safety shoes, high-visibility jackets, safety goggles must be worn at all times in the plant.
Cut-resistant hand gloves for handling wooden pallets, buckets, HOPTs, and other materials.
Vapor mask, helmet, long sleeves, and face shield during solvent charging.
Nitrile gloves for contact with paint.

Line of Fire during HOPT Operation

HOPT operation should be performed inline with pallet movement on the floor.

Noise

Stirring and AODD pump operation create noise.

Electrical Shock

Machine panels should be locked, and earthing cables checked for defects and breakage.

Hygiene

Ensure vessels are in a sealed condition.

Cut Injury

Use approved safety knives for bag cutting during charging.
Ensure cutting direction is away from the body.

LOPC (Loss of Containment Procedures)

Follow SOP for spill management regarding materials from height.
Use of helmets is mandatory when using the equipment.

Initial Start-Up

Use safety gear (PPE).
Be mindful of pinch points when working with drums and vessels.
Implement waste segregation by providing waste bins for efficient waste handling.
Ensure chilled water circulation is turned on.
Ensure fume/dust extraction system is operational.
Using yellow-printed food-contact batch cards.
Ensure equipment is clean before starting batch production from the QC department.

Machine RPM

Max machine RPM to be 1200.

Solvent Charging

Method for charging solvents into the vessel (e.g., mass flow meter).

HSD Operations

Procedures for lifting the shaft of the HSD, attaching earthing clamps, and lowering it.

Abnormal Conditions

Issues in stirrer operation, spillage, equipment breakdown.
Reporting breakdowns to Engineering and supervisors is essential.

Abnormal Conditions (Spill/Leakage)

Immediate reporting to superiors in case of spillage and immediate actions to mitigate.

Emergency Shutdown

Procedures for shutting down the HSD in case of fire, or spillage.
Reporting and action plan for external emergencies.

Normal Shutdown

Procedures for proper HSD shut down process, outlet valve closure, and handover procedures.

Measures in Case of Utility Loss

Steps and procedures to take in case of electrical, air pressure, or chiller failure.

Authorization for Work

Only trained and authorized personnel can operate the HSD during breakdown or repair.

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Description

Test your knowledge on safety procedures and personal protective equipment in industrial operations. This quiz covers important aspects like handling machines safely, proper usage of safety knives, and precautions for electrical safety. Ensure you know the protocols for High Speed Dispersor operations and manual handling techniques.