- Safety Questions and Answers Prepared by S Kadar M *
TOPICS Industrial Safety & GFPC Policy Importance of Housekeeping Important Phone numbers and Radio Numbers PPE (Personal Protective Equipment) Work Permit System Cold work Permit Hot work Permit Confined Space Permit Excavation Permit Vehicle entry Permit Electrical Lock Out & Tag Out High Elevation Job Radiography Chemistry of Fire Ignition Hazards NFPA code Fire Fighting MSDS Quality Control Safety Electrical Hazards Static Electricity First Aid Tank Farm hazardous Home electricity
IN DUSTRIAL SAFE SAFETY TY AN D GFP G FPC C POLICY P OLICY
1.
Why Industrial Safety is important? With rapid advances in Industrial process, new types of dangers to life, health and environmental are getting increased. Yearly several billions of employees are injured in factories due to mechanical, electrical, chemical and radiation hazards. Many are disabled for life. Few die even. To prevent all these, industrial safety is important.
2.
What is the Safety Policy in GFPC? GFPC Safety Policy: We are committed to safeguard Health, Safety and Environmental interests of all concerned to achieve business success. We believe that all accidents are preventable; we commit to practice Safety as a culture across the organization.
3.
What are the Objectives of HSE? Provide and maintain a safe work place for ourselves, contractors, customers, and community. Comply with all applicable laws, regulations and standards. Continue to expand and enrich our knowledge of Safety, Occupational Health and the working Environment. Conserve natural resources and further increase margins of protection by reducing waste generation and contamination of air, water and land. Ensure that any waste is disposed off off in a safe and environmentally sound fashion. Design, construct and install inherently safe facilities, operation and maintain them in a safe manner to minimize risk.
Use the right tolls, equipment and the appropriate personal protective equipment for the work we perform and always see that they are in a safe working condition. Maintain the highest standards of housekeeping. Set a good example for others by demonstrating a comprehensive level of awareness that will prevent unsafe acts and behavior that could result in an injury i njury,, illness, or loss of property on and off the job. Accept and assure that compliance with this policy is a criterion of personal performance and substantial condition of employment progress in GFPC. We encourage all constructive proposals of continuous improvement. We care about about each other and those around us, and believe that all injuries and occupational diseases ad environmental deviations are avoidable. 4.
What is the main motto of GFPC Safety Policy? The Safety Policy is normally laid down by the employer, which aims at the well being of all the employees both mentally and physically. It declares the commitment (promise) of the top management to Health, Safety and Environment; it also makes arrangements to make the ‘policy’ active.
5.
How Safety can be best achieved in plant operations? Safety can be best achieved by having Safety Standards Procedures and adhering to the SSP’s.
6.
What is the important of the House keeping? Housekeeping Housekeeping is the main tool to preven preventt accidents. A place for everything and everything in its place is the motto to be followed. Poor housekeeping is a source of accidents in industries.
7.
What are the jobs of Housekeeping? Check and ensure the safety equipments are in good condition. Report leaks in the plant.
Avoid oil spillage. Store all the chemicals in safe place. Before closing the permit ensure the equipment and area is clean and safe condition after maintenance. Barricade unsafe/hazardous area with proper sign board. ‘F’ keys kept in proper place. All the hoses are rolled in a proper place. Hang the helmets in a proper place. Keep the files in designated place.
8.
What are the Emergency Telephone numbers of GFPC? Fire
333 (information to Control Room)
Head Count (Admin)
444
Security
555
First aid Centre
666
CCC (Central Command Centre) (Admin Building)
111, 777, 888
ECC (Emergency Command Centre) (Control Room)
222
External Police Ambulance Civil Defense JAMA’A JAMA’A Radio channel Al-Fanteer Al-Fanteer Hospital RC Industrial Security RC Environmental
999 997 998 3411055 7/A 3464000 3404170 3411050 3417777
Neighboring Industries SASREF Aramco Petrokemya SCECO
9.
What are the Radio Numbers of important persons? President Manufacturing Director Operation Head Fire Chief Fire supervisor Fire brigade Shift Supervisor Security Officer Security Supervisor Security control room Mechanical supervisor Electrical supervisor Instrument supervisor Clinic
10.
340 5594 03 874 3009 03 874 3006 357 7111 341 0615 341 5485 03 858 6990
37 38 34 28 12 11 34 27 06 23 10 24 09
What are the important Radio Numbers of the other department? Mechanical Sr. technician Instrument Sr. technician Electrical Supervisor /Technician Unit 100/200/300 Unit 400/700 Unit 500/600 Unit 800 Unit 900 Lab Technician Weigh bridge/Loading area operator
11.
17 24 10/46 19 15 18 13 26 33 41/39
Radio: which mode (group) is used during emergency? Hub # 4.
12.
Where is our Emergency Assembling point?
13.
Ø
Opposite to Fire Station
Ø
Near Administration building
What is an accident? Accident is an unplanned, unexpected incident, which causes damage equipment or life or to both.
14.
What are the basic causes of an accident? The basic causes for an accident are unsafe act (88%), unsafe condition (10%), and natural calamities (2%) personal and proximate (adjacent) causes.
15.
What is reportable accident? If any employee meets with an accident, he should be able to report for duty within 48 hrs from the date of the accident and if not, the accident is termed as Reportable Accident (Lost time Accident).
16.
How do we prevent accidents? Learn and practice SOP & SSP procedures. Practicing & maintaining good house keeping. Reporting unsafe conditions through IR.
17.
What is the importance of accident Investigation? It aims at the objective evaluation of all facts, statements, opinions and related information and action plan to prevent or to control similar occurrences.
18.
What is lost time accident? Should an injured person remain away as a result of accident for more than a day (excluding the day of accident and the day of reporting), it is treated as lost time accident.
19.
What is Emergency planning?
Emergency Planning is nothing but a documented sequence of events to be followed in case of emergencies like fire, explosion, toxic material release etc. The documents clearly specifies whom to do what during emergencies and duties and responsibilities of all those who are involved in the operation and maintenance of the Plants. 20.
Why Emergency Response planning & Mock exercises are important? All major accident hazard units should have an Emergency Response Plan and regular mock exercises have to be carried out on the plan so that any shortcomings that are observed can be overcome.
21.
22.
What are the types of Emergency planning? Ø
On-site Emergency Planning
Ø
Off- site Emergency Planning.
What is an on-site Emergency? On-site emergency: emergency : Negligible effect to neighbor industries from our plant premises and that can be controlled by internal facilities and resources.
23.
What is an off-site Emergency? Off-site emergency: Emergency inside our plant premises affect the neighboring industries and would require substantial assistance and coordination from nearby industries and others like JAMA’A, Police, hospitals, Royal Commission etc.,
24.
What is is JAMA’A JAMA’A? ? What is the abbreviation abbreviation of JAMA’A JAMA’A? ? JAMA’A: is an association association to help and assist affected industry during emergency. JAMA’A: Jubail Area Mutual Aid Association.
25.
What is incident? Unplanned event result in measurable loss or injury
26.
What is Near miss? Undesired event but did not due to chance or circumstance.
27.
What is unsafe condition? Unsafe condition is the situation in an area where there is some danger for a safe working atmosphere.
28.
Identify the unsafe acts, near miss and unsafe conditions: a. Damaged machine guards Unsafe condition b. Smoking in restricted areas Unsafe act c. Oil or chemical spilled areas Unsafe condition d. Corroded ladder steps Unsafe condition e. Ignoring an oil or chemical spill Unsafe act f. Doing unauthorized work Unsafe act g. Damaged pipeline insulation Unsafe conditions h. Improper vehicle operation Unsafe act i. Broken rail guard Unsafe condition
j. Working on an over head pipe line without scaffolding Unsafe act k. Walking over a process pipeline Unsafe act l. Keeping unused unused sample bombs not not in a correct place. Near miss m. Wear the safety harness but forget to tie the rope. Near miss. n. Playing with DCS key board/Panel switches Unsafe act 29.
Who is the reporting authority for incident? Shift Supervisor.
30.
What is Incident Report (IR)? Incident report is to highlight the unsafe conditions, Unsafe acts, Near Miss and HSE i ncident in working place and rectify the problem immediately.
31.
What is the purpose of rising Incident Report? Create awareness and educate all through incident report and set right the Near Miss, Unsafe condition, Unsafe work condition into Safe Condition.
PPE (Personal P r o t e c t i v e E q u i p m e n t ) 32.
What is PPE s? s?
Personal Protective Equipment. 33.
What are all minimum requirement PPE s for entering the plant?
Safety shoe, Goggles, Helmet and Shirt with full sleeve 34.
What is the purpose of PPE? To protect the human from the hazards.
35.
What is the role of PPE s? s?
Personal Protective Equipments is the barrier between the hazard and the worker. First thing is to improve Safety by engineering Design and controls. 36.
What are the types of PPE s? s?
There are 2 types: 1. Respiratory Respirator y Protective type. 2. Non-respiratory Non-respirato ry Protective type. 37.
38.
What are the Respiratory Protective Equipments? Ø
Continuous air supplied Respirators (On-Line Respirators)
Ø
Self Contained Breathing Apparatus
Ø
Canister Masks etc.,
What are the Non-respiratory Protective Equipments? Head
–
Helmet, Hood
Face
–
Face shield, Welding shield, Asbestos hood, PVC hood.
Eyes
–
Goggles, Gas cutting goggles, Arc welding goggles.
Ear
-
Ear plug, Ear muffs.
Hand
-
Cotton, PVC, Leather, Asbestos gloves, electrical Gloves.
Body
-
Fire resistance uniform, Apron (leather, asbestos,
PVC), Overall suits, Lead apron, Safety belt, Bunker Gear (Fire suit)
39.
Leg
-
Safety shoe, boots
Nose
-
Dust respirator (cloth, vinyl type)
What is Bunker Gear? Bunker gear provides thermal protection from radiant heat, as well as thermal protection from conductivity/convection during fire fighting.
40.
What is Dust? How do they enter human body? Dusts are minute particles mainly classified into Respirable and Nonrespirable dusts. Dusts that are less than 10 microns in size are respirable dusts. Dusts mainly gain entry in to human system by inhalation, skin adsorption and ingestion (Oral Consumption)
41.
What are the effects of heat? Heat results in heat heat stress. It also result in heat stroke, heat exhaustion, heat cramps, dehydration, heat fatigue and loss of emotional control etc.,
42.
43.
How to prevent Heat stress? Ø
Intake adequate fluid and salt.
Ø
Wear proper protective and light colored clothing.
Ø
Avoid caffeinated drinks and heavy meals.
What are the Weather categories and its working condition when atmosphere humidity is more? Weather category 0
-
Continuous work outside
Weather category 1
-
75% work outside (each hour)
Weather category 2
-
50% work outside (each hour)
44.
Weather category 3
-
25% work outside (each hour)
Weather category 4
-
No work outside (otherwise no emergency)
Where will we use face shield? In heaters to view flame condition and other areas in which grinding, chipping, cutting, and breaking or drilling work carry on.
45.
Where will we use chemical splash suit? Tasks include breaking of steam line, lines containing hazardous chemical and line having fluid more than 49 oC (120 0F) temperature.
46.
Which PPE will be used to protect hand? Gloves
47.
Which glove is suitable for acid/caustic handling? PVC rubber gloves
48.
Which glove is suitable for Benzene handling? PVC rubber gloves
49.
How noise can be controlled? Solid foundation of machines & use of rubber padding, proper maintenance of machine, suitable sound absorbers, using of acoustic/sound proof construction boards and use of hearing protection like Ear Muffs and Ear Plugs etc.,
50.
When and where will you use hearing protection? During steam blowing and Area having sound more than 85 dBA. Example: Compressor area
51.
Which PPE will be used as hearing protection? Ear plug & ear muffler
52.
How will the underground obstacles be identified?
By probing, utilizing special instruments 53.
What is the minimum height required for body harness? 1.5 meter (5 feet)
54.
Why barricade is needed around job working area? To warn and prevent personal and vehicle entry into a potential hazardous or restricted area
55.
Which type of barricade tape will be used to decline an area not to enter? Red and white with Danger sign
56.
Which type of tape used to decline an area may enter with caution? Yellow and black with Caution sign.
57.
What type of barricade will be used for radiography or X ray? Barricade tape with magenta and yellow color giving signs reading Caution
58.
59.
What is your first action if you see a fire? Ø
Inform to CCR or Supervisor through Radio.
Ø
Break Fire Manual Call Point.
Ø
Call others for help.
Ø
Isolate process side after getting clearance from CCR.
Ø
Try to extinguish the fire if it is small or initial stage.
Which type of alarm indicates fire? long Sound for 25 second with 60 second cycle
60.
Which type of alarm indicates gas release? Continuous long (HF) and short sound (LF) for 60 sec
61.
Which type of alarm indicates All clear?
Lengthy single long sound for 60 sec 62.
What is the role of operator during the Emergency ? Emergency ? Remain calm. Stop all the work and evacuate the workers from the plant area. Terminate all the work permits and evacuate the confined space. Follow ERT leaders’ instruction. Shut down all ignition sources.
63.
How will you communicate during emergencies? Through radio, Manual calls station and phone.
WORK PERMIT SYSTEM 64.
What is work permit? Work permit is a written document describing the work to be carried out, the precautions to be taken, the preparation made and with the signature of the employees connected with (and responsible for) carrying out the work.
65.
What are the advantages of work permit system? Work permit system is practiced and enforced to make sure all the jobs were done in safe manner. Protect the human being. Safe guard the plant equipment & environmental. Eliminate and reduce fire and accidents.
66.
What are the permits systems following in GFPC?
67.
Ø
Cold work
Ø
Hot work
Ø
Confined Space
Ø
Excavation work and
Ø
Vehicle entry
What is JSA? JSA: Job Safety Analysis. Safety evaluation will be done before issuing permit with receiver.
68.
What is the purpose of JSA? To protect the employees from injury by identifying High Potential Hazards and minimize/control the risk of harm to the working crew, others and environment while performing the job.
69.
70.
What are the roles of permit issuer? Ø
Understanding the job.
Ø
Do JSA completion with receiver.
Ø
Rise the permit.
Ø
Execute the permit.
Ø
Monitor the job in 2 hrs once.
After completing the maintenance job who will be the responsible for housekeeping? Work group representative (Receiver)
71.
Who will prepare JSA? Receiver (Work group representative)
72.
What is Take-two Take-two ? ?
‘Take-Two’ means to take two minutes before starting any job to think about (thinking before acting): T – ‘T ‘Talk’ about the upcoming job A – ‘A ‘Actions’ decide what actions will be needed. K - ‘Knowledge’ – decide what knowledge is needed. E - ‘Equipment’ – decide what equipment is needed. 73.
What is the purpose of Take-Two Take-Two ? ?
The ‘Take- Two’ method is used to help employees to think and implement safety precautions before any job is started. 74.
What is LMRA? Last Minute Risk Assessment.
75.
Before closing the permit what is the role of Operator? Check the following: Job completion. Area cleaned. Locks provided by the receivers all removed. Close the permit after signing maintenance person.
76.
Why approval form is needed for excavation permit? To ensure excavation area underground free of Fire Water Piping, Process piping & live electrical cable.
77.
Whose signatures required for excavation (permit) approval form? §
Engineering representative
§
Safety representative
§
Contract representative
§
Shift Supervisor
78.
Whose signatures required for confined space entry permit? Shift Supervisor Area operator Receiver Engineering representative if any excavation job
79.
80.
Whose signatures required for hot work permit? §
Issuer
§
Receiver
§
Shift supervisor
§
Area Operator
Whose signatures required for excavation permit? Shift Supervisor Receiver Area Operator
81.
Who will approve blind list for confined space? Shift supervisor
82.
What is meant by Electrical Lock out? Positive Isolation of electrical breaker, locking and tagging by operator and maintenance team before commencing the job is called Lock Out.
83.
What is the purpose of Electrical Lock out? To safeguard employees while working on electrically powered equipment or electrical circuits from unexpected startup of equipment or energizing of circuits.
84.
What is the color of operation s s Do Do not operate tag?
“Do not operate” tag in Red and white color 85.
What is the color of maintenance tag for electrical lockout? “Do not operate” tag in orange color.
86.
Who will energize and De-energize 4.18 KV Motors? Electrical technician will energize and De-energize the Motors in presence of Area Operator.
87.
What is the color of Maintenance lock for Lock out system? Blue.
88.
What is the color of Contractor s lock for electrical lock out system?
Yellow. 89.
What is the color of Electrical lock for electrical lock out system? Red.
90.
If the work carried out below 50V, require any lock out? Not required lock out.
91.
92.
When will operator remove the lock out? ü
After finishing the job.
ü
After closing the permit.
ü
After removing the maintenance lock.
Maintenance lock can be removed without completing the job? Maintenance lock can be removed at shift end without completing the job. Next shift person will put another lock and continue the job. Until operator’s lock should be in lock out condition.
H I G H E L EV EV A T I ON J OB
93.
What is High elevation job? Any job which is done above 1.5 meters meters from work place level will be a high elevation job. Example: painting in pipe racks, provision of scaffolding over fixed platform in a vessel of column.
94.
What is scaffolding? Scaffolding is a temporary frame work used to support people and material in the construction or repair works in the industries and constructing building works..
95.
96.
What are the hazards of working at heights? Ø
Fall of a person
Ø
Fall of material
Ø
Falling at the same level
Ø
Collapse of structures
Ø
Damage of equipment etc.
Ø
Throwing or dropping material from top.
What are the PPE s used for high elevation job?
Safety Harness Rope grab Vertical fall arrestor, horizontal fall arrestor Crawling board Pipe grabs (manic roach) 97.
How long scaffolding inspection can be carried out? On completion. Every 15 days.
After alteration. After bad weather. 98.
What is the maximum gap between scaffolding platform and work surface? 500mm.
99.
Who will authorized for scaffolding inspection? Scaffolding inspector.
100.
What is the ladder safety rule? For every four meter of height of a ladder the base distance should be meter 4:1
101.
What are the Hazards when climbing ladders? Lack of Awareness Lapse of Concentration Slipping and tripping Over balancing Ladder Instability Rungs failing
102.
What type of safety safety equipment we should use if we go outside the railing around the platform? Safety belt.
103.
What is the function and purpose of pipe line insulation? Pipeline insulation protects person from very hot and very cold pipes.
104.
Before Radiation test, what are the precautions to be taken? Get the permit.
Evacuate the persons nearby. Stopping the other job nearby. Barricade the area with warning tags. Blinking light at night time.
HOSE 105.
Why Hose pressure test carried out? To check the stability of the hose.
106.
What is the test pressure of hose? Test pressure 1.5 times of MAWP (Maximum allowable Working Pressure) specified by the vendor.
107.
What is the color code indicate in in the hose corner? Indicates whether hose has been pressure tested at particular period. (Normally we are conducting pressure test twice in a year)
108.
What is White color code indicates? Pressure tested for 1 st six months
109.
What is red color code indicates? Pressure tested for 2 nd six months.
110.
What are the color codes for Hoses used in GFPC? What is the function? Ø
Blue color for Oxygen.
Ø
Red color hose for Acetylene
Ø
Orange for Propane.
Ø
Black color hose for utility purpose (plant air, water, IA, steam)
Ø
111.
Yellow color hose for Nitrogen handling
Why Yellow color hose used only for Nitrogen handling? To aware all and avoid accidently using nitrogen for other uses. Nitrogen gas is an inert gas and it will dissipate oxygen. Oxygen deficiency is more dangerous for human breathing and lead to death.
112.
What are the properties of Nitrogen? Nitrogen ? Colorless, odorless, inert gas. Boiling point -195.5 oC. Freezing point -210 oC. Will displace oxygen. Non-combustible.
113.
Whether utility plant air (compressed air) can be used for drying hand and cloth? Should not be used. Compressed air may enter the body through small nicks and cuts, if any, and cause stoppage of blood flow, clotting etc – which may have serious consequences.
114.
Why Nitrogen gas is called as Silent Silent Killer ? ?
It will displace oxygen and causes death.
SAFETY SHOWE SHOWER R 115.
What is the purpose of providing safety shower & eye washer in plant area? Safety shower/eye washer is provided when persons are exposed to chemical material that may cause injury to eyes or body.
116.
If a person exposed to chemical how long will he take shower minimum?
He should used shower for at least min 15 minutes. 117.
What type of water (Raw water, Potable water, DM water) is used in safety shower? Potable water
118.
Why safety shower line is insulated? To prevent hot water discharge.
119.
What is the maximum temperature of Safety shower Water temperature? 40oC
120.
What is the temperature range of safety shower water? 15 – 35oC
121.
Incidents to be reported before end of the day or shift True
122.
Excavation work permit required approval plan True
123.
Hot work permit is not extendable after emergency True
124.
Cold work permit is extendable after emergency True
125.
JSA prepared by Shift Supervisor False (By Receiver)
126.
Owning area representative is mechanical technician False (Field Operator)
127.
Area with White and red tape barricade is allowable to be entered
False (not to enter) 128.
Safety representative signature is required for all Hot work permits False
129.
Safety representative signature is required for a Confined space permit False
130.
PVC gloves is suitable for steam service False (Asbestos, Leather)
131.
Confined space permit required for open sumps having more than 1.6M depth True
132.
480V power motor energizing/de energizing will be done by operator True
133.
Approved staircase and grating need body harness/safety belt. False (Not approved stair case, scaffolding having minimum height 1.5M height)
134.
Red color tape barricading for caution and yellow color tape for Danger ”. ”.
False (Red for Danger and Yellow for Caution)
135.
Permit receiver copy will be displayed on work location True
136.
Confined space entry require safety attendant Yes
137.
What is a cold Job? A job where there is no source of ignition.
138.
Name some of the cold jobs in the petrochemical industries? Pump, Compressor repair Strainer cleaning Motor repairs Changing of gaskets, valves, leak arresting etc., Valve gland packing changing Blinding Scaffolding work
139.
What is a hot job? A job in which a source of ignition can be present.
140.
Name some of the hot jobs in the petrochemical industries? Welding Cutting Grinding, Stress relieving, Hot-tapping, Drilling, Chipping, Operation of vehicles and Welding machine, etc,
141.
What are the types of hot work? 2 types:
142.
Open flame and non-flame
What is open flame and non-flame hot works? Give examples:
Open flame hot work: •
Gas cutting & welding.
Non-flame Hot work jobs: Grinding Chipping Concrete cutting Running IC engine Vehicle entry Jobs in restricted area Radiography Taking camera and video Electric soldering Working in electrical more than 50V. 143.
What are the basic steps in preparing a pump for a cold cold job such as mech. Seal repair, strainer cleaning etc.,? Isolate the pump by closing the valves. Put ‘Do not operate’ tags in the valves. Depressurize through the casing vent and keep the vent wide open. Drain the pump through the casing vent and keep the drain wide open. Take electrical lock out. Release the job to the maintenance.
144.
How do you prepare a Column or Vessel for entry? Ø
Prepare lists and procedures
Ø
Decommission the vessel as per procedure
Ø
Isolate by blocking valves
Ø
Depressurize to flare and block off.
Ø
Depressurize to atmosphere at top vents.
145.
Ø
Introduce steam. (Avoid pulling vacuum)
Ø
Drain under positive pressure of steam.
Ø
Steam out thoroughly.
Ø
Install blinds under slight positive pressure of steam.
Ø
Blind off steam after re steaming if necessary.
Ø
Open man ways.
Ø
Water washes the tower.
Ø
Fix air eductors.
Ø
Anticipate pyrophoric iron sulfide.
Ø
Check for gases and oxygen%
Ø
Inspect the tower yourself and ensure it is cool enough and the internals are safe to stand on.
Ø
Prepare entry permit. Note down special special instructions if any.
Ø
Issue permit for entry.
What are the basic steps involved in the preparation preparation for an entry into a furnace? Decommission the furnace as per normal procedure. Open the individual burner’s damper fully. Open the furnace’s stack damper fully. Isolate the furnace by blinding the coil. Open fire box man ways Check O2 inside the furnace from outside. Issue the permit.
146.
What are the preparations for a hot work? Internal Preparation: Isolate by closing valves. Depressurize & drain. Steam-out to expel hydrocarbons. Isolate by blinding. Wedge open blinds if required re-steam Gas test for inflammable. External Preparation: Cleaning up the area. Stop any hydro carbon leaks in the vicinity. Cover sewers effectively. Gas test. Water spray and other firefighting equipment have to be ready. Use steam to purge any gas leak that cannot be tightened. Place firefighting equipment for emergency use. Organize the fire watch. Ensure the welding machine properly earthed. Ensure cylinder opening key on its place. Fill up the fire permit form properly. Ensure all concerned authorities sign the permit. Hence, external preparations are necessary as in the case of a hot job & the movement should be supervised by the operating personnel.
147.
Why the same permit permit is used for "Vessel Entry" as well as "Hot jobs"? The preparations are more or less the same for both jobs.
148.
What is the gas test difference between "Vessel Entries" as well a "Hot jobs"? For vessel entry we have to check gas test for O 2. For hot jobs we have to check gas test for LEL.
149.
Is a hot job job safe safe once it has begun? No. Dangerous situation may develop due to various reasons.
150.
How often the gas test be done? Normally gas test is made within one hour of the beginning of the work. Re test may be necessary in some locations and the frequency will be decided by the supervisor.
151.
What are the values of gas test? Gas (LEL) Oxygen CO
152.
0% 19.5 to 21.5% 5%
Is hot permit required for ordinary hand tools which produce sparks sparks occasionally? No. These sparks are considered too weak for an ignition.
153.
Why entry of vehicles is restricted under a hot permit system? The exhaust of vehicles often spit out red-hot carbon or scale sparks, which can cause a fire in a plant.
154.
What is the maximum maximum speed of the vehicles inside the plant? 30 kmph.
155.
Who is the issuing authority of a hot permit? The Shift supervisor.
156.
Who is the performing authority? Shift supervisor.
157.
Who will request the vehicle entry permit? Maintenance, Operation, Project representative Driver.
EXCAVATION 158.
What is an excavation permit? It is a permit to excavate for laying pipeline and cables or digging for foundation etc.,
159.
What is the purpose of Excavation procedure? To protect personal and plant equipment from hazards that might occur as result of excavating in any plant location.
160.
What are the hazards anticipate during excavation job? Damage or failure of underground pipes and electrical cables. Tripping slipping and falling. Injury from falling material. Collapsing due to cave in. Possibility of explosive, flammable, Suffocation due to toxic or oxygen deficient atmosphere in excavation.
161.
Who is the initiator of Excavation permit? Technical Department Engineer Project Engineer/Representative Maintenance supervisor Maintenance Specialist
Project site Representative Contractor Engineer responsible for excavation. 162.
Who all should sign an excavation permit for authorization? Electrical Engineer Mechanical Engineer Civil Engineer Shift Supervisor Area Operator after completing gas test and working place fulfilling conditions mentioned in the permit.
163.
Who issues an excavation permit and how? The shift supervisor is to give a cold permit on basis of an approved excavation permit. The excavation permit is made in duplicate and one copy is retained in the plant till the job is completed.
CONFI CO NFI NED SPACE 164.
What is confined space entry? A place in which employee is going to enter and perform work or inspect. Confined has has a limitation limitation for entry entry and exit and and it is not designed for continuous human occupancy.
165.
Give some examples for confined space ? space ? Vessel Tanks Furnaces Reactors Fin fan coolers Boilers
Pit and excavation pit have more than 1.2 m depth Man holes Sewers Hoppers Vaults (eq. 900 V 01) Pipes Trenches 166.
What to do check before entered into into the confined space? Oxygen test to be carried out.
167.
What is the Oxygen content inside the confined space? 20.8%
168.
At what oxygen level a person not allowed to inside the confined space? Below 19.5% O2 not permitted to inside the confined space.
169.
What are the potential hazards in the confined spaces? o
Oxygen Deficiency (<19.5 oxygen concentration or too much O 2 )
o
Presence of Combustibles gases and liquids (Methane, Hydrogen, Acetylene, Propane, Gasoline fumes)
o
Presence of Toxic Materials (CO, H2S, Benzene vapors, welding fumes, corrosives etc,)
170.
o
Electricity
o
Process or equipment related Hazards
o
Conditions changing from non-hazardous to hazardous.
What is entrant?
The employee who will physically enter the confined space to perform the work. 171.
Who is attendant? The employee who remains outside the confined space and monitors the entrant(s); guards the space against unauthorized entry; warns the entrants of any unusual conditions; and summons the rescue personnel if needed.
172.
What are the responsibilities of Attendant? To monitor entrants during the job and during entry & exit to help and ensure their safety. To monitor atmospheric conditions in the space prior to and during entry. To control access to the confined space. To call emergency assistance when required. To assess hazards in and around the space, and take action on the same. To keep records of confined space work, such as air test results, personnel entry/exit, etc.
173.
Whether attendant entered into the confined space in case of any emergency? No.
174.
Confined space entry procedure? Isolate the confined space. Ventilate the confined space. Complete the gas test. Complete permit. Enter the space as permit/work procedure.
175.
176.
What are the safe allowable levels of gases before work inside the confined space? Oxygen
20.8%
Hydrocarbons
5% (500 ppm) (@10% not allowed to work)
Toxic material
Allowable concentration of particular material
CO
25 ppm max
CO2
5000 ppm max
If the O 2 2 level is more than 23% what will be effect? Combustion will be fast as O 2 increases.
177.
What is the purpose of air air purging in in confined space? Dilute and remove contaminates (hazardous material) and supply O 2.
178.
What are the responsibilities of Entrant? To assure that the space has been adequately ventilated, isolated, emptied, or otherwise made safe for entry. To immediately exit a space, without question, upon word of the attendant, no matter what the reason. To follow all safety rules and procedures that apply to the job. To be familiar with the work to be performed and the procedures that apply to the job. To use the appropriate PPE whenever necessary
179.
What are the responsibilities of Shift Supervisor? To assure adequate protection is provided to the entrants by verifying verifying adequate lockout and that all hazards are securely isolated. To support the attendant’s authority in controlling access to a confined space.
To verify that all personnel have exited prior to closing the space. To assure that all personnel involved are aware of the hazards associated with the space. To assure that rescue services are available prior to entry. 180.
In a confined space how many volt lighting to be used? 24V with explosive proof fitting.
181.
Normally confined space entry, nitrogen is not allowed inside the vessel. In UF reactor nitrogen positive pressure is maintaining during confined space. Why Why ? ? UF reactor catalyst in pyrophoric stage due to sulfur processing. To avoid pyrophoric fire hazards due to Oxygen ingress into the reactor, Nitrogen positive pressure is maintaining.
182.
Procedure before closing the permit/confined space? Remove all personnel, tools, and debris from the space. Sign off the log. Close the space. Close the permit. Review the job with the host employer (hazards, problems, other employers, etc.)
183.
If the confined space work not started within 30min. after getting permit, can we start work in the confined space? No. Permits shall be invalidated invalidated or cancelled if the work not commenced within 30 minutes.
184.
At what are the conditions the confined confined space space entry permit will closed? Failure to commence work within 30 minutes. Conditions on the permit are not compiled with.
Change of condition. (venting, hydrocarbon spillage etc) Plant fire/gas release emergency. If incident/accident took place. 185.
Confined space entry work not required stand by man (attendant) out side the vessel. True or False. False.
RADIATION 186.
What is radioactive? Radioactivity is the reading of amount of radiation emitted by a source.
187.
What are the effects of radiation? Radiation can cause cancer by killing the cells in our body.
188.
What are the three types (forms) of radiation ? radiation ? Alpha radiation Beta radiation Gamma radiation
189.
190.
What are the characteristics of Alpha Rays? •
Highly ionizing.
•
Travels very little distance.
•
Blocked by paper or a few centimeters of air.
What are the characteristics of Beta Rays? •
Middle ionizing.
•
191.
192.
Blocked by a thin sheet of aluminum.
What are the characteristics of Gamma Rays? •
Travels furthest yet is the least ionizing.
•
Blocked by a few feet of concrete or lead.
Gamma rays are more dangerous than other radiation. Why? Gamma radiation can pass through our body and can kill the cell even if we wear normal PPE.
193.
How do you understand that an X-ray test is being conducted in a process area? The area should be protected with radiation warning signals and proper tapes.
194.
When the permit will be invalid or cancelled? If the condition in the permit are violated. Emergency declared in the plant. If the work not start within 2 hours of issuing the permit.
195.
What is the allowable radiation? 0.7 millirad/hour.
196.
What is the Occupational Exposure Limit of radiation? 20 mSV (200mrem) per year over a period of 5 years. Single dose should not exceed 50mSV (5000 mrem)
197.
What are the color codes codes of the permits in the GFPC? Blue Pink Yellow Green
198.
-
Cold work Hot work Confined space Excavation
Where work permit is not required?
Working in work shop. Working in welding yard. 199.
C H EM E M I ST S T RY R Y O F F I RE RE 200.
What is fire? Fire is a rapid oxidation of fuel with intense liberation of heat and light.
201.
What are the essentials to make a fire triangle? Fuel, air (oxygen), and heat (ignition)
202.
What are the essentials to make a fire tetrahedron? Fuel, air (oxygen), heat (ignition) and chemical chain reaction.
203.
What is the Flash Point of fuel? The Lowest temperature at which the liquid gives off enough vapors to produce momentary flash when an ignition source is introduced.
204.
What is Fire Point? Fire point is slightly higher than flash point at which the temperature; vapors are produced continuously to sustain the flame.
205.
What is Auto ignition temperature? It is the lowest temperature which will cause a fuel air mixture to burn or explode.
206.
What is the ignition temperature range of petroleum products? Petroleum products have ignition temperatures ranges from 200 oC to 650oC
207.
Write flash point temperature classification?
Class ‘A’ Class ‘B’ Class ‘C’ 208.
-
below 23 oC between 23 oc to 65 oC Above 65 oC
In what form the fuel mixture burn? Fuel burns in the form of vapor with air. But solids and liquids also burn as readily as vapor, in finely atomized form. Example: steel wool, carbon dust, wooden dust, steel filing, furnace oil in furnace.
209.
What are the common sources of fuel in a Petrochemical industry? All petroleum products, Hydrogen, NH 3, H2S, Solvents & ordinary combustibles like wooden furniture, paper, cotton waste or rug, dry grass, wooden scaffolding, tarpaulins, synthetic fibers, etc.,
210.
What is the special hazard for light ends ends leaking out? Light ends are invisible & being heavier than air they hug the ground. They can travel great distances to find a source of ignition when the flame travels back at great speed to the fuel source.
211.
What is the composition of Atmospheric air? What is the role of N 2 in the combustion process? About 1/5th O2 and 4/5th N2 with traces of moisture, CO 2 and other inert gases. Nitrogen does not enter into the combustion reaction during a fire. On the other hand, it is smothering agent given by nature, diluting the effect of O 2 which alone reacts with fuels in the event of fire.
212.
What are the effects of fire? Oxygen increases, the fire will increases. Pressure increases, the fire will increases. Temperature increases, the fire will increases.
213.
What is the lean & rich mixtures?
A lean mixture is too little fuel vapor in air to burn & a rich mixture is too much fuel vapor in air to burn. 214.
What is LEL & UEL? LEL: Lower Explosive Limit UEL: Upper Explosive Limit
215.
What do you understand by lower & upper explosive limits of fuels? Lower explosive limit is the percentage by volume in air of a fuel vapor below which it will not burn. Upper explosive limit is the percentage by volume volume in air of o f fuel vapor above which it will not burn.
216.
What is the difference between flammable liquid and inflammable liquids? Flammable liquids: having flash point below 37.8 oC Inflammable liquids: having flash point between 37.8 oC to 93oC.
217.
What is the meaning of flammable range of fuels? It is the percentage of fuel mixture in air by volume, between the lower & upper explosive limits.
218.
Are flammable ranges different for different fuels? Yes. There are different from fuel to fuel.
219.
Does the flammable range of fuel vary with the O 2 content in the air? Yes. The range widens with the increasing O 2 content. Example: Propane in air (20% O 2) flammable range is 2.2 – 9.5 Propane in 100% O 2 flammable range is 2.2 – 57.
220.
What are the impacts of oxygen deficiency? No visible Effect
Increased breathing rate. Accelerated heartbeat. Impaired attention, thinking and coordination. Faulty judgment and poor muscular coordination. Muscular exertion causing rapid fatigue. Intermittent respiration. Nausea, vomiting, Inability to perform vigorous movement, or loss of the ability to move. Unconsciousness, followed by death. Below 6%, Difficulty Diffic ulty breathing. Death in minutes. 221.
Convulsive
movements.
What are the effects of Oxygen Enrichment? When the oxygen concentration rises above 23.5% by volume, the atmosphere is considered oxygen enriched, and is prone to become unstable. As a result of the higher oxygen level, the likelihood and severity of a flash, fire or explosion is significantly increased.
222.
Why are the underground petrol tanks tanks generally safe at service stations? The vapor pressure of gasoline is higher than the atmospheric; hence air cannot cannot normally get get in. Even if some air gets gets in during filling & emptying operations the mixture is too rich to burn.
223.
What are the common sources of ignition in Petrochemical industries? Furnaces Hot lines pyropheric iron Friction Heat Sparks from electrical equipment Stray currents Welding
Cutting Grinding Exhaust from the vehicles. 224.
Are there sources of ignition in petrochemical industries which are too weak to ignite petroleum products? Yes. Sparks produced by hand tools, an ordinary 2 or 3 cell flash light switch and thermocouple junctions are few examples.
IGNITION HAZARDS 225.
What is the ignition hazard? It is a source of hot energy, which can cause flammable mixture to burn or explode.
226.
What are the Ignition sources in the petrochemical industries? Electrical equipment Friction in the running equipment Open flame Smoking and matches Spontaneous combustion Hot surface Static electricity electricity Lightening
227.
What is the definition of Auto-ignition temperature? Are they the same for all fuels? It is the lowest temperature, which will cause a flammable mixture to burn or explode by itself. Ignition temperature varies from fuel to fuel.
228.
What is the range range of Auto Auto ignition temperature of our petroleum products? About 42 to 600 oC
229.
What are the flash point, Auto ignition temperature, Explosive limit and Exposure limit of our handling petro products?
Kerosene nC5 iC8 Paraxylene Hydrogen Hot oil Benzene DMDS L.W.O H.W.O N. Paraffin LAB Diesel H2S 230.
Boiling Point oC
Flash Point oC
Auto Ignition Explosive Temp oC limit %
155-260 37 99.0 13.3 -253 35 9 80 109 85-110 260-290 190-240
42.0 -45 12.6 27
254 260 450 466 571 373 580
170 -11.1 16.0 Below 3.0 115 70 140 55 260 270
160-371 -60.2
1.16 – 6.0% 1.50 – 7.6% 0.84 – 6.0% 1.10 – 7.0% 4.1 – 74.0% 1.1 – 2.6% 1.3 – 7.1% 1.1-16.3
0.6 – 6.5% 0.4 – 5.0% 0.3 – 10.0% 4.3 – 46%
Exposure Limit (TLV ppm)
300
5 0.5
10 10
Which chemical material having wide variation of flammable range? range? Acetylene 2.5 – 100%.
231.
Is the flame of match hot enough enough to ignite the petroleum vapors? Yes. The temperature of a match flame is about 870 C
232.
What is the classification of Hazardous area in the plant area? Hazardous areas are classified into two types: Areas which are considered always hazardous because flammable gases will be present during normal operation. •
Example: Fuel gas, LPG loading
Areas which are considered hazardous only infrequently as a result of failure •
233.
Example: Any process plant area.
Which is more likely to get ignited: Hydrocarbon soaked in insulation or liquid hydrocarbon?
H/C soaked insulation is more hazardous since ignition characteristics of hydrocarbons change drastically when surface area is increased by soaking. 234.
During Air fin cooler fire shall we switch off the fans or keep running running the fans? Why? Switched off the fans. Reason: To cut off continuous oxygen supply to the fire.
235.
What about electric sparks? Ordinary electric sparks can be in the order of 500 oC
236.
What are the common sources of ignition hazards in in a petrochemical industry? Furnaces, hot lines, friction heat. Pyrophoric iron sulfide Hot jobs like welding, cutting, grinding, chipping, hot-tapping, stress relieving. Exhaust from vehicles. Sparks form electrical equipments. Spontaneous ignition. Static electricity electricity Lightening Catalytic effect of fresh metallic surfaces.
237.
A Petrochemi Petrochemical cal industry has to have furnaces, hot lines & rotating equipment, which can frictional heat? How is then, a fire hazard prevented? Furnaces are developed to keep flames inside the boxes. They are located at safe distance. Hot lines are insulated. Insulation serves a personal protection as well as means of conserving heat energy, besides safe guarding against fire hazards. Rotating equipment must be looked after well, under preventive & predictive maintenance program. Operating personnel should should take care of normal lubricating needs and should operate them in the proper manner.
238.
What is pyrophoric iron sulfide?
Supply kerosene contains sulfur in the form of compounds. This sulfur reacts with iron inside vessel and pipelines, to form iron sulfide scales. Iron sulfide ignites spontaneously in presence of air (or oxygen) which in turn can trigger off other fires explosions. Pyrophoric iron sulfide should be anticipated in all sour systems. Particular mention must be made to flare headers. 239.
How does pyrophoric iron sulfide become a source of ignition? Air can come in contact with pyrophoric iron sulfide during shut down maintenance work, when vessels & pipe lines are opened for cleaning & repairs. If the system have not been gas freed already, entry of air can supply both the oxygen & ignition required for the system before admitting air and also to keep the iron sulfide scales wet till they are also to keep the iron sulfide scales wet till they are removed to safe place.
240.
What are the methods to prevent an ignition hazard from the material? Running units are not completely safe from the ignition hazard of pyrophoric iron sulfide. There are plants, which use air or oxygen for the process. Rigorous control on the quantity, special safety interlock systems, avoidance of vapor spaces in vessels & tanks are all necessary precautions in such plants to prevent a fire hazard. Vacuum systems are especially vulnerable. If due to leaks, air gets into the systems, pyrophoric iron sulfide will serve as the source of ignition. Proper vacuum test during start up & periodic checks of the ejector effluents for oxygen will serve as a check to unknown entry of air into the vacuum systems.
241.
How are pyrophoric iron sulfide handled? Keep the scale wet till it is removed to a safe area. It can then be buried or burnt away.
242.
What are the methods to prevent a fire in a plant, while permitting permitting hot jobs? Hot jobs are sources sources of ignition. They are not allowed in the petrochemical industry as a general rule.
All hot jobs are permitted on the basis of a hot permit. Issue of is strictly governed by the hot-permit produce of the petrochemical industry.
FIRE 243.
FIGHTING
How do you report when seeing the fire in the plant? Reporting fire: Location of the fire. Type of the fire. Some indication of its extent (urgency).
244.
Write 4 stages of fire? Ignition Growth Flash over Fully developed and decay.
245.
What are the extinguishing methods methods available for fire put off? Starvation
246.
-
Cut off fuel (elimination) (eliminatio n)
Smothering -
Cut off oxygen (limitation)
Cooling
Removal of temperature
-
What are the extinguishing mediums available? Water Steam Foam Vaporizing liquids (halons) DCP CO2 Sand
Blanketing Beating out 247.
What are all the types of fire fighting equipments we have? Fire tender Extinguishers Monitors Hydrants Hydrants with monitors Hoses with hose reel Deluge system Foam pourer
248.
What is meant by Back draft? In fire decay stage oxygen reduce to 15% and flame suppressed but heat inside the room will still be at flash point and when O 2 is introduced rapid explosion will occurred.
249.
250.
How to avoid back draft? Ø
By proper ventilation.
Ø
By rapid cooling.
What is PASS ? ?
This word easy to remember how to use fire extinguisher. P A S S 251.
-
Pull Aim Squeeze Sweep
How will you prevent a leaking hot hydrocarbon vapor vapor from catching fire until it has been isolated and depressurized? Dilute with steam so that explosive mixture does not form.
252.
What is Fire Water pump? Used to pump water for fire fighting purpose only.
253.
What is the capacity of our fire water tank? 3687 m3
254.
How long we can utilize the water for fire fighting? (prolong fire fighting hours) 8 hours.
255.
Auto cut in and cut off of Fire water pumps? CONTROL SYSTEM
Pump 820 P 02 02 A 820 P 02 02 B
256.
Type Jockey Jockey
Cut in (KSc)
Cut off (KSc)
9. 5 9. 0
10.0 10.6
820 P 01 01 A Ele Electri ctric cal
8.0
*
820 P 01 01 B
Diesel
7.5
*
820 P 01 01 C
Diesel
6.0
*
What is our fire water header pressure? 10.5 Ksc.
257.
What is the purpose of jockey pump? To Keep Fire Water Header pressure during normal operation (Total circulation)
258.
Why there are 2 driven provide for fire water pump electrical and diesel? In case of power failure we can run the fire water pump with diesel.
259.
What type of extinguishing medium medium used for Hydrogen fire? Steam.
260.
Which extinguisher will be used for electrical fire? CO2
261.
Which extinguisher will be used for oil fire? DCP (Dry chemical powder)
262.
What are all the types of extinguishers available? Water, DCP, CO2 and Foam
263.
How does automatic sprinkler (Deluge System) works? Due to high temperature (above 70 oC depends upon the process, quartz bulb design temperature condition) during fire the fluid inside the quartz bulb will expand and will break the bulb and releasing the fire water pressure on the fire water valve thus opening the main valve (deluge valve) due to pressure difference.
264.
What are the safeties to be followed by Fire fighters during fire fighting? Follow the leader’s instruction. Observe to watch hazardous position. Radiation of heat. Care on tank rook, life lines, boil over. Anticipate Pipeline pressurizing. Anticipate Toxic gas may release. Care on insufficient air and CO more.
265.
What are problems may causes during fire fighting? Thermal radiation Heat stress& strain (37 oC sweating, imbalance, heart beat may increases) Heat syncope (dilution of blood cells, BP decrease, blood to brain decrease)
Effect on respiration (50% respiration reduced when exposed to 37 to 50 oC) Thermal equilibrium and environmental changes Heat stroke and physiological effects.
M.S.D.S 266.
What does MSDS stand for? MSDS stands for Material Safety Data Sheet which prepared by the chemical manufacturer.
267.
What is the importance of MSDS? Each Chemical, particularly hazardous chemicals has material safety data sheet which provides information about the physical, chemical properties of the chemical, TLV, first Air Measures in case of exposures, spills, fire Fighting methods etc.,
268.
What is TLV? TLV stands for the Threshold Limit Value, which refers to the air borne concentrations of substances to which workers can be exposed for 8 hours without any harmful effects on their health.
269.
What are the classifications of TLV? It is classifies into TLV- TWA, TLV – STEL, TLE – IDLH.
270.
What is TLV-TWA? TWA - Time Weighted Average of the maximum concentration of the chemical present in the work place to which the workers can have a safe exposure. It is based average concentration obtained from the samples taken every two hours for an 8 hour period.
271.
What is TLV-STEL?
STEL – Short Term Exposure Limit to which a worker can be exposed for duration of 15 minutes, maximum 4 exposures at an interval of 60 minutes from each exposure for a 8 hour period. 272.
What is TLV-IDLH? IDLH – Immediately Dangerous of Life and Health i.e., minimum concentration of the chemical to which the worker is exposed. NH3 TLV 25.0 ppm STEL 35.0 ppm Cl2 TLV 0.5 ppm STEL 3.0 ppm
273.
What are properties of Benzene? Colorless
274.
Melting point
5.5 oC
Boiling point
80 oC
Specific Gravity
0.87
Vapor pressure
74.6 mm Hg @ 20oC
Flash point
-11.0 oC
Explosion limits
1.3 – 8 %
Auto ignition
561 oC
What are the risks of handling benzene? This material is causes carcinogen.
275.
What is the TLV of Benzene? 0.5 ppm.
276.
What are effects of benzene when short-term exposure? Nausea. Vomiting Dizziness Narcosis Reduction in blood pressure
CNS depression Dermatitis when contact with skin. 277.
What are the characteristics of H 2 S? S? Color:
colorless
Smell:
Rotan egg smell
Heaviness: Heavier than air Solubility: 278.
Soluble in water forming corrosive acid
What will happen to a person, if he is working in H 2 S concentration above 100 ppm? He will lose the sense of smell.
279.
What is the threshold Limit value of H 2 S? S? Below 10 ppm. At this level a person can work. Long term exposure limit
280.
What will happen to person, if if he is working in H 2 S concentration above 30 ppm level? Respirator problems and eye irritations.
281.
What type of hazards exists when a sour water handling equipment equipment is opened for maintenance? H2S - toxic gas and iron sulfide which may catch fire when it comes in contact with oxygen.
282.
At what level H 2 2S concentration, a person will get rapid unconsciousness followed by death within minutes? 1000 ppm
N.F.P.A 283.
What is NFPA? National Fire Protection Association.
284.
285.
What are the classifications of Material? Class 1
Explosives
Class 2
LPG/gas under pressure
Class 3
Flammable liquids
Class 4
Flammable solids
Class 5
Oxidizing substance
Class 6
Toxic material (benzene)
Class 7
Radio active
Class 8
Corrosive (HCl)
Class 9
Misc dangerous
NFPA hazard Diamond what is indicate? Blue color Red color Yellow color White color
286.
What are the effects of health according health according the chemical code? Also write protective equipment used? 0 1 2 3 4
287.
Health Fire/Flammability Fire/Flammabil ity Reactivity of the material Any special hazards
Normal Material (no need) Slightly hazardous (may be SCBA) Hazardous (SCBA) Extremely Hazardous (full protective suit and SCBA) Deadly (full protective suit and SCBA)
What are the hazardous of flammable material flammable material on code number? 0 1 2 3 4
No flammable hazard (will not burn) Slightly Flammable (above 93 oC) Moderately Flammable (below 93 oC) Highly Flammable (below 38 oC) Extremely Flammable (below 23 oC)
288.
What are the effects of Reactivity material Reactivity material hazards according the chemical code? 0 1 2 3 4
289.
Significant Reactive hazard (stable) Slightly Reactive (not stable when heated) Moderately Reactive (Violent chemical change) Highly Reactive (May Detonate with heat or shock) Extremely Reactive (May Detonate)
Give some examples for specific hazard code as per NFPA? Radioactive (symbol will displayed) Use no Water (Symbol W) Corrosive (symbol CORR) Alkali (symbol ALX) Acid (symbol ACID) Oxidizer (symbol OX)
290.
MAINTENANCE 291.
SAFETY
What are the safeties to be followed before the work commenced? Preparation of JSA based job condition. Job carried out as per JSA. Using proper PPE’s during work.
292.
What is the minimum PPE s required in work shop?
Helmet Goggles Safety shoes 293.
Work permit needed for working in work shop? No need as per SSP.
294.
What are the General safeties for maintenance person? Use right tools for right jobs. Broken tools should not used. Tools without handle should not be used.
295.
LABORATORY 296.
SAFETY
What is the purpose of Laboratory Safety? The purpose of this standard is to define the minimum requirements for safety of employees working in QC.
297.
What are the minimum PPE s require inside the QC?
Safety glass Chemical goggles/face shields. Gloves (rubber, butyl, latex) based on chemical handling as specified in the MSDS Lab coats, aprons, scrubs Safety shoes Respirators 298.
What are the hazards anticipated in the QC? Chemical splash over Health hazard Inhalation Injection Chemical skin contact Glass cutting Electrical shock
299.
How to avoid hazards inside the QC? Wearing proper PPE. Proper ventilation.
Proper storage of chemicals. Keep the chemicals in a safe, well ventilated and cool place. Proper labeling of chemicals. Keep chemicals separately to avoid dangerous. (example: separating chemicals acid and base apart) Rinse all visible residues and chemicals from glassware. Decontaminate/chemically destroy any biologically active or noxious materials before sending items to glassware. ENSURE that no sharps go in glassware bins. Do not overload glassware bins. Gas cylinders must be secured whether in use or stored. Regulators must be removed and caps used when moving cylinders. Avoid pipetting by mouth. 300.
What are importances s of Chemical storage in the QC?
Do not store food in chemical storage refrigerators Avoid storing liquid chemicals above eye level. Avoid storing chemicals in path ways. Avoid over stocking shelves. Avoid storing heavy containers above shoulder level. Avoid storing chemicals in fume hoods or on counter tops. Avoid storing chemicals near sources of heat or in direct sunshine. Store concentrated acids and bases separately. Keep corrosives away from organic chemicals and combustible materials.
Use secondary catch basins for concentrated acids and bases. Store in approved safety cans or cabinets Segregate from oxidizing acids and oxidizers. Keep away from any source of ignition: flames, heat or sparks. Know where fire fighting equipment is stored and how to use. If volatile flammable liquids are stored in a refrigerator it must be in an explosion-proof (lab-safe) refrigerator. Store oxidizers away from flammable, combustible materials and reducing agents. Water reactive materials should be stored separately Store highly toxic materials in a dedicated storage fume hood. Cyanides should stored separately from acids Store in unbreakable containers or use secondary containers. Label storage areas with designated area signs. Maintain the minimum quantity needed and dispose of unneeded material immediately. 301.
How to handle the chemical and how to avoid hazardous during normal work? Be familiar with chemical properties and products of chemical reactions. Be prepared for chemical spills and clean up spills immediately. Plan ahead – have apparatus and associated equipment ready before chemicals are used. Use the appropriate equipment, such as funnels, beakers and spatulas when transferring chemicals.
Use chemical fume hoods to control exposure as chemicals are transferred. Use chemical fume hoods to control exposure during the experiment. Wear the appropriate personal protective equipment (chemical splash goggles, gloves, etc.). Have disposal containers ready ahead of time. 302.
Chemicals can be segregated as: A. Corrosives B. Flammable Liquids C. Oxidizers D. All the above.
303.
Acids and bases should be stored together? True or false. False. Acids and bases should be stored apart.
304.
Chemical storage information can be found in : in : A. B. C. D.
305.
MSDS. Labels Dictionary Both A & B
Chemical fume hoods can be used to control exposure. True False
306.
ELECTRICAL HAZARDS 307.
What are the Electrical hazards? Shock, Burn, Electric sparks that can cause ignition of flammable mixtures, explosion etc., are the electrical hazards.
308.
At what current a person can withstand?
1mA to 8mA
-
Person can withstand.
Greater than 75mA
-
Cause death.
Tissue will burn when current greater than 200 mA and greater. 309.
Before doing the electrical job job what to check first? Always test a circuit to make sure it is de-energized by using proper PPE, before working on it.
310.
What do you do when co-worker get shocked? Call other people for help Shut off the power supply to the particular circuit. Do not touch the victim. Pry the victim with non-conductor (wood) Call emergency medical team.
311.
How to avoid electrical hazards? Prevent overloading by using correct size and type wire. Prevent exposure of live wire. (provide proper insulation) Prevent exposure of live electrical equipments/parts. Lock out and maintenance.
tag
out
circuits
and
machines
before
Prevent electrical shock by grounding tools while working on it. Prevent too much current in circuits by using over current protection devices. 312.
What are the common ignition hazards in petrochemical industry electrical equipment? Motors, switches & breakers, lamps, cable joints, junction & terminal boxes, welding cables etc.,
313.
What is an electrical sparks? When electricity jumps a gap in air, it is called a spark.
314.
Are all electrical sparks or arcs hot enough to ignite petroleum products? Most of them. But there are certain electrical electri cal devices which may may create sparks or arcs that are too weak to cause ignition. The flash light switches or thermocouple switches are examples of this type. It is however, to be remembered that the intensity of the spark does not depend on the switch but on the amount of current flowing the circuit.
315.
Can the flash light bulb ignite a flammable mixture if exposed? Yes. If the hot-glowing hot-glowi ng filament is exposed due to a broken glass bulb, a fire can start in a flammable mixture.
316.
How are the lamps protected from causing ignition in the plant area? Lamps are provided with vapor tight fittings that is, even if the bulb breaks and the hot filament is exposed momentarily, there will be no fire or explosion since vapors are present inside the glass globe.
317.
What is the meaning of an explosion proof fittings? An explosion proof fitting is designed to withstand the pressure created by a internal explosion & to cool hot gases below the ignition temperature before they reach outside of the explosion proof housing.
318.
What is the basis of the selection of explosion explosion proof electrical equipment in petrochemical industries? Likewise, electrical equipments are classified into two types. Equipment which creates sparks is arcs as a result of normal use. Example: An ordinary light switch. Equipment which create sparks only when there is a failure Example: The common induction motor.
All electrical equipment in continuously hazardous areas must be explosion proof.
319.
STATIC ELECTRICITY 320.
What is Static Electricity? How is it formed? Static electricity is concentration of energy formed due to contact and separation.
321.
What are the hazards of static electricity in petroleum industries? The principal hazard is a spark discharge which can ignite a flammable mixture.
322.
Why petroleum products products which are poor conductors of electricity become charged with static? Good conductors are also better generators of static electricity. But because they are good conductors the Static generated is discharged faster. Refined petroleum products like gasoline, kerosene, jet fuels, etc., are poor conductors. conductors. They are also poor generators generators,, but because their relaxation times are much longer, large charges are accumulated.
323.
How do we avoid static electricity? By providing correct bonding and grounding. Correct bonding and grounding ensures that static electricity does not accumulate and cause a spark.
324.
What is bonding? Bonding is electrically connecting conductive objects to equalize electrical potential and prevent sparks.
325.
What is Grounding?
Grounding is connecting a conductive object to the earth to dissipate electricity. 326.
How do we avoid static electricity during tanker loading? Providing proper earthings. Using downspouts. Avoid splash filling/high velocity filling. Maintain proper filling velocity.
FIRST AID 327.
What is the importance of First Aid? First aid is assistance offered to a person who is affected by a condition which can lead to death, disability.
328.
329.. 329
What are the normal person vital signs? Heart Beat or Pulse
60 – 80 beat/min
Blood Pressure
80 – 120 mmHg/min
Temperature
37 oC
Breathing rate
12 -20 times/min.
What Wh at is bu burn? rn? Wh What at are th the e cau causes ses for th the e burn burn? ? Burns are caused by: Hot liquids and vapors Dry heat Corrosive substances Electric shock Radiation including sun burn
330.
What are the classifications of burns? First degree: involves epidermis epidermi s characterized by redness, severe pain and edema at the burn site. Secord degree: involves all the epidermis characterized by blister (pink color) “Intact or open” sub continuous edema Third Degree: entire epidermis and dermis is involved. involved. It is painless or with slight pain/skin feels leathery, hair fall out easily. (dry, charred, pearly white color)
CAR SEAL 331.
What is Car seal? Car seal is a safety device used to isolation valves that shall remain normally open (CSO) or normally close (CSC) during plant operations, for Safety, Health, Environment considerations. Example: PRV TSV isolation valves valves (CSO) Bypass valve of TSV PRV (CSC)
332.
What is COD? Control of Defeat.
333.
What is MOS? Maintenance Override Switch.
334.
What is SCD? Safety Critical Device. Example: PRV, TSV, Interlock system transmitter, Safety equipment devices etc.,
T A N K F AR A R M H A Z A R DS DS 335.
What is the impact of tank hazards?
Tanks handling flammable liquid constitutes a much greater potential fire hazard than the process unit, probably because they are fragile and easily damaged by slight over pressure or vacuum. They do cause damage, loss of material and interruption of production. 336.
What are the emergencies in a tank farm area? Over filling. Over pressurizing. Collapse due to vacuum. Tank fire due to sinking of the roof. Tank fire during Mechanical work. Unusual occurrences (Lightening, Static charge etc)
337.
What are the causes for over filling? Lack of attention. Errors in level indicators. Wrong setting of valves. Change of service. Gravity filling. Wrong routing of transfer.
338.
What are the causes of over pressurizing? Receiving of liquid rate is high to tank and the vent is not able to take the load of this high filing rate. Over pressurizing by gas: N 2 valve malfunctioning, the vent was not cleaned. cleaned. Or clogged. clogged. Sudden shower cooled the tank causing it to collapse due to condensation of liquid. PVRV not properly working.
339.
What is the purpose of roof drain?
Drain the water during rainy season and avoid roof stress. 340.
What is the impact of water on floating roof? Sinking of roof. Accumulation of rain on the roof roof creates stresses.
341.
Reason for water accumulation of roof floating? Plugged roof drains Plugged roof drain strainer
342.
What are the hazards expected during roof sink? Exposing petroleum vapor to atmosphere, which might find an ignition source outside and result in flash back fire to the tank. Environmental problem.
343.
What is the reason reason for tank fire during mechanical work? Accumulation of explosive material in somewhere. (gauge hatch leg, leg, hollow leg support etc.,) Gas release from nearby tanks.
344.
How lightening affects tanks? In case of floating roof tank, small rim fires have caused by vapor leaking through the seals. The source of ignition was atmospheric electricity due to lightening in the rainy season.
345.
Reason for static electricity during transfer? Pumping rate rather high and lines acquired the charge.
346.
What is TSV and where do we use it? TSV (Thermal safety valve) is used to take care of pressure build up due to thermal expansion. It is provided at places where a liquid can remain in blocked up state with no room for expansion due to temperature rise.
347.
How to avoid static electricity in tanks?
Avoid by keeping pumping rate at lower and avoiding splash filling.
HOME ELECTRICAL ELEC TRICAL SAFE SAFETY TY 348.
How do we prevent electric shock in home? By providing proper earth. By using proper size wire. Avoiding damaged cord. (causes fire and electrical shock) By using proper plug-correct fitting, avoid loose contact, earth plug pin. Not (over) loading extension cord. By providing ELCB.
349.
What is meant by ELCB? Electrical Leakage Circuit Breaker.
350.
What are the things to be avoided during lightening in home? Avoid switching on TV. Avoid using cell phone (unless emergency) Unplug the electrical equipments like refrigerator etc, Don’t take shower/bath. Avoid standing under tree.
The End - But no no End for Safety. Safety.
