Safety Procedures in Industrial Operations
45 Questions
0 Views

Choose a study mode

Play Quiz
Study Flashcards
Spaced Repetition
Chat to Lesson

Podcast

Play an AI-generated podcast conversation about this lesson

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?

<p>Away from the body (D)</p> Signup and view all the answers

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

<p>Maintaining line of fire (A)</p> Signup and view all the answers

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

<p>Nitrile gloves (B)</p> Signup and view all the answers

What should be checked to prevent electrical shock during operations?

<p>Inspect earthing cables for loose connections (A)</p> Signup and view all the answers

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

<p>Noise (A)</p> Signup and view all the answers

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

<p>To ensure safe handling and operation of HSD 1 and HSD 2. (C)</p> Signup and view all the answers

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

<p>Trained and Authorized Person (A)</p> Signup and view all the answers

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

<p>Static Fire Hazard from failure of continuity of earthing. (C)</p> Signup and view all the answers

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

<p>Trained &amp; Authorized Person (C)</p> Signup and view all the answers

What could be a consequence of a malfunctioning Limit Switch?

<p>Damage to equipment and potential injury. (B)</p> 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?

<p>Production Officer (C)</p> Signup and view all the answers

What is included in the scope of this SOP?

<p>Both operation and cleaning of HSDs. (C)</p> Signup and view all the answers

What is a potential risk associated with malfunctioning hydraulic systems?

<p>Spills and injury to personnel. (A)</p> Signup and view all the answers

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

<p>Helmet, safety shoes, safety glasses, hand gloves, and mask (C)</p> Signup and view all the answers

What should be ensured regarding waste management before starting operations?

<p>That waste bins are available for effective segregation of waste (C)</p> Signup and view all the answers

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

<p>800 Liters (D)</p> Signup and view all the answers

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

<p>Inspect equipment for contamination after QC clearance (A)</p> Signup and view all the answers

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

<p>The vessel should be empty and cleaned (D)</p> Signup and view all the answers

What is the maximum RPM for the machine during operation?

<p>1200 RPM (B)</p> Signup and view all the answers

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

<p>Ensure the vessel bottom valve is closed (D)</p> Signup and view all the answers

What systems must be ON when the machine is operating?

<p>Both fume and dust extraction systems (B)</p> Signup and view all the answers

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

<p>Set weights in batch controllers and charge through the mass flow meter. (C)</p> Signup and view all the answers

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

<p>To avoid electrical hazards. (D)</p> Signup and view all the answers

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

<p>Check that local isolation is in place. (B)</p> Signup and view all the answers

What is the first step when starting the impeller?

<p>Remove local isolation by issuing the local isolation key. (B)</p> Signup and view all the answers

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

<p>The maximum allowed height. (D)</p> Signup and view all the answers

What must be checked before operating the impeller?

<p>The earthing and that the green light is on. (B)</p> Signup and view all the answers

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

<p>Using strapping belts and clamps. (D)</p> Signup and view all the answers

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

<p>Return the local isolation key to the PO. (B)</p> Signup and view all the answers

What should be done immediately after a splash or exposure?

<p>Inform the supervisor and consult the medical center if required. (C)</p> Signup and view all the answers

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

<p>Ensure all portable containers are closed and turn off HSD properly. (A)</p> Signup and view all the answers

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

<p>Release the emergency switch and complete the remaining work when power resumes. (A)</p> Signup and view all the answers

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

<p>Only authorized and trained persons are allowed to operate the machine. (D)</p> Signup and view all the answers

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

<p>Verify that the operation lock is in place and the key is secured. (B)</p> Signup and view all the answers

What should be done immediately in case of spillage?

<p>Start cleaning and inform the SO (D)</p> Signup and view all the answers

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

<p>Press the Stop push button (C)</p> Signup and view all the answers

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

<p>Report to engineering and obtain a new one (A)</p> Signup and view all the answers

What is the procedure for collecting a sample during operation?

<p>Ensure the shaft has stopped and clean the sampler after use (B)</p> Signup and view all the answers

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

<p>Push the emergency shut off switch and report the incident (B)</p> Signup and view all the answers

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

<p>Turn off the stirrer switch and inspect the issue (B)</p> Signup and view all the answers

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

<p>Report the issue to engineering immediately (C)</p> Signup and view all the answers

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

<p>Refer back to the batch card for the sequence (D)</p> Signup and view all the answers

Flashcards

Standard Operating Procedure (SOP)

A document outlining the correct steps and procedures for safely operating a particular piece of equipment, in this case, the High Speed Dispersor (HSD 1 & 2).

Trained and Authorized Person (TA)

A person who has been trained and authorized to operate a specific piece of equipment.

Static Fire Hazard

The potential for a fire that is caused by static electricity building up due to a lack of proper grounding.

Limit Switch

A safety switch that prevents machinery from operating beyond a certain point, potentially causing injury or damage.

Signup and view all the flashcards

Hydraulic System

A system that uses pressurized fluids to move and control machinery. Malfunctioning can lead to leaks and potential injury.

Signup and view all the flashcards

Production Officer (PO)

A person responsible for overseeing the production processes in a factory or plant.

Signup and view all the flashcards

Production Manager (PM)

The responsible individual for leading and coordinating the manufacturing operations within a company.

Signup and view all the flashcards

Emergency Task Force (ETF)

A team designated to handle emergency events and situations within a company.

Signup and view all the flashcards

What is a SOP?

A document that instructs on the correct steps for operating a piece of equipment safely. It often outlines procedures, safety precautions, and other important details.

Signup and view all the flashcards

What are the operating limits of the HSD?

The maximum amount of material that can be safely processed within a specific piece of equipment. In this case, it's 800 liters for the High Speed Dispersor.

Signup and view all the flashcards

What is the purpose of the fume/dust extraction system?

A system used to remove harmful fumes or dust during the manufacturing process. It helps protect workers from potential hazards.

Signup and view all the flashcards

What is a batch card?

The step-by-step instructions for preparing a specific batch of product, including required ingredients, quantities, and manufacturing steps.

Signup and view all the flashcards

What are pinch point hazards?

A safety hazard that involves sharp edges or points on machinery. It poses the risk of cuts or punctures.

Signup and view all the flashcards

What is a chilled water circulation system?

A system used to cool down materials during the production process. It helps maintain the desired temperature for manufacturing.

Signup and view all the flashcards

What is a helmet used for?

A type of protective gear worn by workers to prevent injury from falling objects or impact.

Signup and view all the flashcards

What does PPE stand for?

Personal Protective Equipment, encompassing items like safety shoes, helmets, gloves, and masks that protect workers from various hazards.

Signup and view all the flashcards

Weighing Method

A method of transferring materials into a vessel by carefully weighing them on a scale before adding them. This ensures accurate measurements and prevents overdosing.

Signup and view all the flashcards

Earthing

An electrical connection that prevents the buildup of static electricity, which can cause dangerous sparks and fires. This is crucial when dealing with flammable liquids.

Signup and view all the flashcards

Drum Lifter

A mechanical device used to safely lift and move heavy items, like 200 kg drums, to prevent strain and potential injury.

Signup and view all the flashcards

High Speed Dispersor (HSD)

A specialized machine with high-speed rotating blades that are used to effectively mix and disperse liquids. They are essential for creating consistent blends.

Signup and view all the flashcards

Batch Card

The instructions that detail the specific steps, quantities, and times required to produce a particular product batch.

Signup and view all the flashcards

Air Receiver Tank

A system using compressed air to move and control the shaft of the HSD, allowing for accurate height adjustments during the mixing process.

Signup and view all the flashcards

Local Isolation

A safety measure where the power input to the HSD is isolated, preventing accidental operation. This is crucial before moving the HSD.

Signup and view all the flashcards

RM Sequence

The order in which raw materials (RMs) are added to the HSD, as specified in the batch card.

Signup and view all the flashcards

Emergency Shut Off Switch

A safety feature that allows the machine to be stopped immediately in an emergency.

Signup and view all the flashcards

Sampler

A specialized device used to collect samples from the HSD for quality analysis.

Signup and view all the flashcards

Sampling Point

A designated area within the HSD where samples are taken for analysis.

Signup and view all the flashcards

Line Manager

The person responsible for dealing with incidents and reporting them to the appropriate authorities.

Signup and view all the flashcards

HSES Staff

The team responsible for creating and updating Standard Operating Procedures (SOPs).

Signup and view all the flashcards

Incorrect Isolation

Working alone without proper safety precautions can lead to bodily harm or equipment damage.

Signup and view all the flashcards

VOC Exposure

Exposure to VOCs (Volatile Organic Compounds) can cause health problems.

Signup and view all the flashcards

Ergonomic Risk Hazard

Handling heavy items without proper techniques can cause injuries.

Signup and view all the flashcards

PPEs (Personal Protective Equipment)

Always wear appropriate protective equipment to prevent injuries.

Signup and view all the flashcards

Line of Fire

HOPT operation should be conducted with the pallet on the floor to avoid any accidents.

Signup and view all the flashcards

Noise

Loud machines like mixers and pumps can cause hearing damage.

Signup and view all the flashcards

Electrical Shock

Check for loose connections and broken wires in electrical panels to prevent electric shocks.

Signup and view all the flashcards

Hygiene

Maintain good hygiene to prevent contamination of materials and products.

Signup and view all the flashcards

Cut Injury to Hand

Always use approved safety knives for cutting bags and cut away from your body.

Signup and view all the flashcards

Cutting Direction

Cutting bags should be done with the knife pointed away from the body to prevent injury.

Signup and view all the flashcards

Vessel in Close Condition

All vessels should be closed to prevent spills, leaks, and contamination.

Signup and view all the flashcards

Approved Safety Knife

Always use a knife approved for safety to cut bags when charging materials.

Signup and view all the flashcards

Cutting Direction

Always cut materials away from your body when using a knife.

Signup and view all the flashcards

Hygiene

Maintain a clean and hygienic environment to prevent contamination of materials.

Signup and view all the flashcards

Electrical Shock

Inspect and maintain electrical equipment regularly to prevent electric shock.

Signup and view all the flashcards

Nitrile Gloves

Always wear gloves when handling paint to protect your hands.

Signup and view all the flashcards

Face Shield, Helmet, Long Sleeves

Wear a face shield, helmet and long sleeves when handling solvents for protection.

Signup and view all the flashcards

Vapor Mask

Use a vapor mask to protect your respiratory system when handling solvents.

Signup and view all the flashcards

Cut Resistance Gloves

Use cut resistance gloves for handling materials that can cause cuts.

Signup and view all the flashcards

Safety Shoes

Always wear safety shoes in the plant to protect your feet from hazards.

Signup and view all the flashcards

High Visibility Jackets

Wear a high visibility jacket in the plant for increased safety.

Signup and view all the flashcards

Safety Goggles

Always wear safety goggles in the plant for eye protection.

Signup and view all the flashcards

Safety Gear in Plant

Always wear safety equipment while working in the Plant

Signup and view all the flashcards

Good Manual Handling

Always use proper manual handling techniques to prevent injuries.

Signup and view all the flashcards

Noise

Loud machines like mixers and pumps can increase noise levels.

Signup and view all the flashcards

Electrical Safety

Using proper electrical safety practices, avoid using damaged wires to prevent Electric Shock.

Signup and view all the flashcards

Vessel in Close Condition

Ensure all vessels should be in close conditions to prevent leaks & spills.

Signup and view all the flashcards

Approved Safety Knife

Always use a knife approved for safety to cut bags.

Signup and view all the flashcards

Cutting Direction

Always cut materials away from your body to prevent injuries.

Signup and view all the flashcards

HSD Splash/Exposure

In case of a liquid splash or exposure to the HSD, immediately wash the affected area with plenty of water and inform the supervisor (SO). If necessary, seek medical attention.

Signup and view all the flashcards

HSD External Emergency

If an external emergency arises, the HSD operation can be stopped at any point and resumed later following the original sequence. Immediately follow the emergency evacuation procedure.

Signup and view all the flashcards

Normal HSD Shutdown Procedure

When shutting down the HSD normally, ensure all portable containers containing material are closed with lids, outlet valves are closed and capped, and the HSD is turned off properly. Confirm the operation lock is in place, handover the key to the issuer, and press the emergency switch.

Signup and view all the flashcards

HSD Startup After Shutdown

After a normal shutdown, release the emergency switch, remove the lids from vessels or containers, and start work.

Signup and view all the flashcards

HSD Power Failure

In case of a power failure, release the emergency switch of the HSD once power resumes, complete the remaining work, and follow the normal operation procedure.

Signup and view all the flashcards

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.

Studying That Suits You

Use AI to generate personalized quizzes and flashcards to suit your learning preferences.

Quiz Team

Related Documents

SOP.PRD.001 HSD 1 & 2 PDF

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.

More Like This

4AE3 U4 C1 Obj 2
60 questions

4AE3 U4 C1 Obj 2

Reusl avatar
Reusl
Personal Protective Equipment (PPE) in Wood Processing Machinery
10 questions

Personal Protective Equipment (PPE) in Wood Processing Machinery

TenaciousGnome avatar
TenaciousGnome
Taller Safety Norms
29 questions

Taller Safety Norms

LongLastingAsh avatar
LongLastingAsh
Eye and Face Protection in Industry
40 questions

Eye and Face Protection in Industry

ExtraordinaryAphorism avatar
ExtraordinaryAphorism
Use Quizgecko on...
Browser
Open
Browser
Browser