Safety Ques & Ans

8/3/2019 Safety Ques & Ans

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- Safety Questions and Answers Prepared by S Kadar M*

TOPICS

Industrial Safety & GFPC PolicyImportance of HousekeepingImportant Phone numbers and Radio NumbersPPE (Personal Protective Equipment)Work Permit SystemCold work PermitHot work PermitConfined Space PermitExcavation PermitVehicle entry PermitElectrical Lock Out & Tag OutHigh Elevation JobRadiographyChemistry of FireIgnition HazardsNFPA codeFire FightingMSDSQuality Control SafetyElectrical Hazards

Static ElectricityFirst AidTank Farm hazardousHome electricity


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IN DUSTRIAL SAFETY AND GFPC POLICY

1. Why Industrial Safety is important?

With rapid advances in Industrial process, new types of dangers tolife, health and environmental are getting increased. Yearly severalbillions 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 Environmentalinterests of all concerned to achieve business success. We believethat all accidents are preventable; we commit to practice Safety as aculture 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 ofprotection by reducing waste generation and contamination ofair, water and land. Ensure that any waste is disposed off in asafe and environmentally sound fashion.

Design, construct and install inherently safe facilities,operation and maintain them in a safe manner to minimize risk.


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Use the right tolls, equipment and the appropriate personalprotective equipment for the work we perform and always seethat they are in a safe working condition.

Maintain the highest standards of housekeeping.

Set a good example for others by demonstrating acomprehensive level of awareness that will prevent unsafeacts and behavior that could result in an injury, illness, or lossof property on and off the job.

Accept and assure that compliance with this policy is acriterion of personal performance and substantial condition ofemployment progress in GFPC.

We encourage all constructive proposals of continuous

improvement. We care about each other and those around us,and believe that all injuries and occupational diseases adenvironmental deviations are avoidable.

4. What is the main motto of GFPC Safety Policy?

The Safety Policy is normally laid down by the employer, which aimsat the well being of all the employees both mentally and physically.It declares the commitment (promise) of the top management toHealth, Safety and Environment; it also makes arrangements to makethe policy active.

5. How Safety can be best achieved in plant operations?

Safety can be best achieved by having Safety Standards Proceduresand adhering to the SSPs.

6. What is the important of the House keeping?

Housekeeping is the main tool to prevent accidents. A place foreverything 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 goodcondition.

Report leaks in the plant.


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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) 111, 777, 888(Admin Building)

ECC (Emergency Command Centre) 222(Control Room)

External

Police 999Ambulance 997Civil Defense 998JAMAA 3411055JAMAA Radio channel 7/AAl-Fanteer Hospital 3464000RC Industrial Security 3404170RC Environmental 3411050

3417777


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Neighboring Industries

SASREF 340 5594Aramco 03 874 3009

03 874 3006Petrokemya 357 7111SCECO 341 0615

341 548503 858 6990

9. What are the Radio Numbers of important persons?

PresidentManufacturing Director 37Operation Head 38

Fire Chief 34Fire supervisor 28Fire brigade 12Shift Supervisor 11Security Officer 34Security Supervisor 27Security control room 06Mechanical supervisor 23Electrical supervisor 10Instrument supervisor 24Clinic 09

10. What are the important Radio Numbers of the other department?

Mechanical Sr. technician 17Instrument Sr. technician 24Electrical Supervisor /Technician 10/46Unit 100/200/300 19Unit 400/700 15Unit 500/600 18Unit 800 13Unit 900 26Lab Technician 33Weigh bridge/Loading area operator 41/39

11. Radio: which mode (group) is used during emergency?

Hub # 4.

12. Where is our Emergency Assembling point?


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Opposite to Fire Station

Near Administration building

13. What is an accident?

Accident is an unplanned, unexpected incident, which causesdamage 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%), unsafecondition (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 reportfor duty within 48 hrs from the date of the accident and if not, theaccident 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, opinionsand related information and action plan to prevent or to controlsimilar occurrences.

18. What is lost time accident?

Should an injured person remain away as a result of accident formore than a day (excluding the day of accident and the day ofreporting), it is treated as lost time accident.

19. What is Emergency planning?


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Emergency Planning is nothing but a documented sequence ofevents 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 areinvolved in the operation and maintenance of the Plants.

20. Why Emergency Response planning & Mock exercises areimportant?

All major accident hazard units should have an EmergencyResponse Plan and regular mock exercises have to be carried out onthe plan so that any shortcomings that are observed can beovercome.

21. What are the types of Emergency planning?

On-site Emergency Planning

Off- site Emergency Planning.

22. What is an on-site Emergency?

On-site emergency: Negligible effect to neighbor industries from ourplant premises and that can be controlled by internal facilities andresources.

23. What is an off-site Emergency?

Off-site emergency: Emergency inside our plant premises affect theneighboring industries and would require substantial assistance andcoordination from nearby industries and others like JAMAA, Police,hospitals, Royal Commission etc.,

24. What isJAMAA? What is the abbreviation ofJAMAA?

JAMAA: is an association to help and assist affected industryduring emergency.

JAMAA: Jubail Area Mutual Aid Association.

25. What is incident?

Unplanned event result in measurable loss or injury


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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 somedanger 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


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j. Working on an over head pipe line without scaffolding

Unsafe act

k. Walking over a process pipeline

Unsafe act

l. Keeping unused sample bombs 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 incident in working place and rectify the problemimmediately.

31. What is the purpose of rising Incident Report?

Create awareness and educate all through incident report and setright the Near Miss, Unsafe condition, Unsafe work condition intoSafe Condition.

PPE (Personal Protec t i ve Equipment)

32. What is PPEs?

Personal Protective Equipment.

33. What are all minimum requirement PPEs for entering the plant?


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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 PPEs?

Personal Protective Equipments is the barrier between the hazardand the worker. First thing is to improve Safety by engineeringDesign and controls.

36. What are the types of PPEs?

There are 2 types:

1. Respiratory Protective type.

2. Non-respiratory Protective type.

37. What are the Respiratory Protective Equipments?

Continuous air supplied Respirators (On-Line Respirators)

Self Contained Breathing Apparatus

Canister Masks etc.,

38. What are the Non-respiratory Protective Equipments?

Head Helmet, Hood

Face Face shield, Welding shield, Asbestos hood, PVChood.

Eyes Goggles, Gas cutting goggles, Arc weldinggoggles.

Ear - Ear plug, Ear muffs.

Hand - Cotton, PVC, Leather, Asbestos gloves, electricalGloves.

Body - Fire resistance uniform, Apron (leather, asbestos,


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PVC), Overall suits, Lead apron, Safety belt,Bunker Gear (Fire suit)

Leg - Safety shoe, boots

Nose - Dust respirator (cloth, vinyl type)

39. What is Bunker Gear?

Bunker gear provides thermal protection from radiant heat, as wellas thermal protection from conductivity/convection during firefighting.

40. What is Dust? How do they enter human body?

Dusts are minute particles mainly classified into Respirable and Non-

respirable dusts.

Dusts that are less than 10 microns in size are respirable dusts.

Dusts mainly gain entry in to human system by inhalation, skinadsorption and ingestion (Oral Consumption)

41. What are the effects of heat?

Heat results in heat stress. It also result in heat stroke, heatexhaustion, heat cramps, dehydration, heat fatigue and loss ofemotional control etc.,

42. How to prevent Heat stress?

Intake adequate fluid and salt.

Wear proper protective and light colored clothing.

Avoid caffeinated drinks and heavy meals.

43. What are the Weather categories and its working condition whenatmosphere humidity is more?

Weather category 0 - Continuous work outside

Weather category 1 - 75% work outside (each hour)



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Weather category 4 - No work outside (otherwise noemergency)

44. 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 hazardouschemical and line having fluid more than 49oC (1200F) 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, propermaintenance of machine, suitable sound absorbers, using ofacoustic/sound proof construction boards and use of hearingprotection 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?


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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 potentialhazardous or restricted area

55. Which type of barricade tape will be used to decline an area not toenter?

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 readingCaution

58. What is your first action if you see a fire?

Inform to CCR or Supervisor through Radio.

Break Fire Manual Call Point.

Call others for help.

Isolate process side after getting clearance from CCR.

Try to extinguish the fire if it is small or initial stage.

59. 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?


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Lengthy single long sound for 60 sec

62. What is the role of operator during the Emergency?

Remain calm.

Stop all the work and evacuate the workers from the plantarea.

Terminate all the work permits and evacuate the confinedspace.

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 carriedout, the precautions to be taken, the preparation made and with thesignature 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 allthe 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?


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Cold work

Hot work

Confined Space

Excavation work and

Vehicle entry

67. What is JSA?

JSA: Job Safety Analysis. Safety evaluation will be done beforeissuing permit with receiver.

68. What is the purpose of JSA?

To protect the employees from injury by identifying High PotentialHazards and minimize/control the risk of harm to the working crew,others and environment while performing the job.

69. What are the roles of permit issuer?

Understanding the job.

Do JSA completion with receiver.

Rise the permit.

Execute the permit.

Monitor the job in 2 hrs once.

70. After completing the maintenance job who will be the responsible forhousekeeping?

Work group representative (Receiver)

71. Who will prepare JSA?

Receiver (Work group representative)

72. What isTake-two?


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Take-Two means to take two minutes before starting any job tothink about (thinking before acting):

T Talk about the upcoming job

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 ofTake-Two?

The Take- Two method is used to help employees to think andimplement 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


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78. Whose signatures required for confined space entry permit?

Shift Supervisor

Area operator

Receiver

Engineering representative if any excavation job

79. Whose signatures required for hot work permit?

Issuer

Receiver

Shift supervisor

Area Operator

80. Whose signatures required for excavation permit?

Shift SupervisorReceiverArea 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 byoperator and maintenance team before commencing the job is calledLock Out.

83. What is the purpose of Electrical Lock out?

To safeguard employees while working on electrically poweredequipment or electrical circuits from unexpected startup ofequipment or energizing of circuits.

84. What is the color of operationsDo not operate tag?


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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 Motorsin presence of Area Operator.

87. What is the color of Maintenance lock for Lock out system?

Blue.

88. What is the color of Contractors 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. When will operator remove the lock out?

After finishing the job.

After closing the permit.

After removing the maintenance lock.

92. Maintenance lock can be removed without completing the job?

Maintenance lock can be removed at shift end without completingthe job. Next shift person will put another lock and continue the job.Until operators lock should be in lock out condition.

HIGH ELEVATI ON J OB


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93. What is High elevation job?

Any job which is done above 1.5 meters from work place level will bea high elevation job.

Example: painting in pipe racks, provision of scaffolding over fixedplatform in a vessel of column.

94. What is scaffolding?

Scaffolding is a temporary frame work used to support people andmaterial in the construction or repair works in the industries andconstructing building works..

95. What are the hazards of working at heights?

Fall of a person

Fall of material

Falling at the same level

Collapse of structures

Damage of equipment etc.

Throwing or dropping material from top.

96. What are the PPEs 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.


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After alteration.

After bad weather.

98. What is the maximum gap between scaffolding platform and worksurface?

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 shouldbe 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 equipment we should use if we go outside therailing 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 coldpipes.

104. Before Radiation test, what are the precautions to be taken?

Get the permit.


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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 WorkingPressure) specified by the vendor.

107. What is the color code indicate in the hose corner?

Indicates whether hose has been pressure tested at particularperiod.

(Normally we are conducting pressure test twice in a year)

108. What is White color code indicates?

Pressure tested for 1st six months

109. What is red color code indicates?

Pressure tested for 2nd six months.

110. What are the color codes for Hoses used in GFPC? What is thefunction?

Blue color for Oxygen.

Red color hose for Acetylene

Orange for Propane.

Black color hose for utility purpose (plant air, water, IA, steam)


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Yellow color hose for Nitrogen handling

111. 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. Oxygendeficiency is more dangerous for human breathing and lead to death.

112. What are the properties ofNitrogen?

Colorless, odorless, inert gas.

Boiling point -195.5oC.

Freezing point -210oC.

Will displace oxygen.

Non-combustible.

113. Whether utility plant air (compressed air) can be used for dryinghand and cloth?

Should not be used. Compressed air may enter the body throughsmall nicks and cuts, if any, and cause stoppage of blood flow,clotting etc which may have serious consequences.

114. Why Nitrogen gas is called asSilent Killer?

It will displace oxygen and causes death.

SAFETY SHOWER

115. What is the purpose of providing safety shower & eye washer in

plant area?

Safety shower/eye washer is provided when persons are exposed tochemical material that may cause injury to eyes or body.

116. If a person exposed to chemical how long will he take showerminimum?


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He should used shower for at least min 15 minutes.

117. What type of water (Raw water, Potable water, DM water) is used insafety shower?

Potable water

118. Why safety shower line is insulated?

To prevent hot water discharge.

119. What is the maximum temperature of Safety shower Watertemperature?

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


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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 spacepermit

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 height1.5M height)

134. Red color tape barricading forcautionand yellow color tape forDanger.

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.


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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: Open flame and non-flame

142. What is open flame and non-flame hot works? Give examples:


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Open flame hot work:

Gas cutting & welding.

Non-flame Hot work jobs:

GrindingChippingConcrete cuttingRunning IC engineVehicle entryJobs in restricted areaRadiographyTaking camera and videoElectric soldering

Working in electrical more than 50V.

143. What are the basic steps in preparing a pump for a cold job such asmech. 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 wideopen.

Drain the pump through the casing vent and keep the drainwide open.

Take electrical lock out.

Release the job to the maintenance.

144. How do you prepare a Column or Vessel for entry?

Prepare lists and procedures

Decommission the vessel as per procedure

Isolate by blocking valves

Depressurize to flare and block off.

Depressurize to atmosphere at top vents.


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Introduce steam. (Avoid pulling vacuum)

Drain under positive pressure of steam.

Steam out thoroughly.

Install blinds under slight positive pressure of steam.

Blind off steam after re steaming if necessary.

Open man ways.

Water washes the tower.

Fix air eductors.

Anticipate pyrophoric iron sulfide.

Check for gases and oxygen%

Inspect the tower yourself and ensure it is cool enoughand the internals are safe to stand on.

Prepare entry permit. Note down special instructions ifany.

Issue permit for entry.

145. What are the basic steps involved in the preparation for an entry intoa furnace?

Decommission the furnace as per normal procedure.

Open the individual burners damper fully.

Open the furnaces 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.


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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 concernedauthorities sign the permit.

Hence, external preparations are necessary as in the case of ahot job & the movement should be supervised by theoperating personnel.


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147. Why the same permit is used for "Vessel Entry" as well as "Hotjobs"?

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 O2.

For hot jobs we have to check gas test for LEL.

149. Is a hot job 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 thework. Re test may be necessary in some locations and thefrequency will be decided by the supervisor.

151. What are the values of gas test?

Gas (LEL) 0%Oxygen 19.5 to 21.5%CO 5%

152. Is hot permit required for ordinary hand tools which produce sparksoccasionally?

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 scalesparks, which can cause a fire in a plant.

154. What is the maximum speed of the vehicles inside the plant?

30 kmph.

155. Who is the issuing authority of a hot permit?

The Shift supervisor.


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156. Who is the performing authority?

Shift supervisor.

157. Who will request the vehicle entry permit?

Maintenance, Operation, Project representativeDriver.

EXCAVATION

158. What is an excavation permit?

It is a permit to excavate for laying pipeline and cables or digging forfoundation etc.,

159. What is the purpose of Excavation procedure?

To protect personal and plant equipment from hazards that mightoccur 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 inexcavation.

161. Who is the initiator of Excavation permit?

Technical Department Engineer

Project Engineer/Representative

Maintenance supervisor

Maintenance Specialist


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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 approvedexcavation permit.

The excavation permit is made in duplicate and one copy is retainedin the plant till the job is completed.

CONFINED SPACE

164. What is confined space entry?

A place in which employee is going to enter and perform work orinspect. Confined has a limitation for entry and exit and it is notdesigned for continuous human occupancy.

165. Give some examples for confined space?

VesselTanksFurnacesReactorsFin fan coolersBoilers


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Pit and excavation pit have more than 1.2 m depthMan holesSewersHoppersVaults (eq. 900 V 01)

PipesTrenches

166. What to do check before entered 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 confinedspace?

Below 19.5% O2 not permitted to inside the confined space.

169. What are the potential hazards in the confined spaces?

o Oxygen Deficiency

(


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The employee who will physically enter the confined space toperform the work.

171. Who is attendant?

The employee who remains outside the confined space and monitorsthe entrant(s); guards the space against unauthorized entry; warnsthe entrants of any unusual conditions; and summons the rescuepersonnel if needed.

172. What are the responsibilities of Attendant?

To monitor entrants during the job and during entry & exit tohelp 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 actionon the same.

To keep records of confined space work, such as air testresults, personnel entry/exit, etc.

173. Whether attendant entered into the confined space in case of anyemergency?

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.


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175. What are the safe allowable levels of gases before work inside theconfined space?

Oxygen 20.8%

Hydrocarbons 5% (500 ppm) (@10% not allowed to work)

Toxic material Allowable concentration of particularmaterial

CO 25 ppm max

CO2 5000 ppm max

176. If the O2level is more than 23% what will be effect?

Combustion will be fast as O2 increases.

177. What is the purpose of air purging in confined space?

Dilute and remove contaminates (hazardous material) and supply O2.

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 ofthe 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 theprocedures 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 byverifying adequate lockout and that all hazards are securelyisolated.

To support the attendants authority in controlling access to aconfined space.


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To verify that all personnel have exited prior to closing thespace.

To assure that all personnel involved are aware of the hazardsassociated 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 thevessel. In UF reactor nitrogen positive pressure is maintainingduring confined space. Why?

UF reactor catalyst in pyrophoric stage due to sulfur processing. Toavoid 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 gettingpermit, can we start work in the confined space?

No. Permits shall be invalidated or cancelled if the work notcommenced within 30 minutes.

184. At what are the conditions the confined space entry permit willclosed?

Failure to commence work within 30 minutes.

Conditions on the permit are not compiled with.


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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) outside the vessel. True or False.

False.

RADIATION

186. What is radioactive?

Radioactivity is the reading of amount of radiation emitted by asource.

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?

Alpha radiation

Beta radiation

Gamma radiation

189. What are the characteristics of Alpha Rays?

Highly ionizing.

Travels very little distance.

Blocked by paper or a few centimeters of air.

190. What are the characteristics of Beta Rays?

Middle ionizing.


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Blocked by a thin sheet of aluminum.

191. What are the characteristics of Gamma Rays?

Travels furthest yet is the least ionizing.

Blocked by a few feet of concrete or lead.

192. Gamma rays are more dangerous than other radiation. Why?

Gamma radiation can pass through our body and can kill the celleven if we wear normal PPE.

193. How do you understand that an X-ray test is being conducted in aprocess area?

The area should be protected with radiation warning signals andproper 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 of the permits in the GFPC?

Blue - Cold workPink - Hot workYellow - Confined spaceGreen - Excavation

198. Where work permit is not required?


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Working in work shop.

Working in welding yard.

199.

CHEMISTRY OF FIRE

200. What is fire?

Fire is a rapid oxidation of fuel with intense liberation of heat andlight.

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 vaporsto 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 200oC to650oC

207. Write flash point temperature classification?


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Class A - below 23oCClass B - between 23oc to 65oCClass C - Above 65oC

208. In what form the fuel mixture burn?

Fuel burns in the form of vapor with air. But solids and liquids alsoburn as readily as vapor, in finely atomized form.

Example: steel wool, carbon dust, wooden dust, steel filing, furnaceoil in furnace.

209. What are the common sources of fuel in a Petrochemical industry?

All petroleum products, Hydrogen, NH3, H2S, Solvents & ordinary

combustibles like wooden furniture, paper, cotton waste or rug, drygrass, wooden scaffolding, tarpaulins, synthetic fibers, etc.,

210. What is the special hazard for light 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 theflame travels back at great speed to the fuel source.

211. What is the composition of Atmospheric air? What is the role of N2in the combustion process?

About 1/5th O2 and 4/5th N2 with traces of moisture, CO2 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, dilutingthe effect of O2 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?


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A lean mixture is too little fuel vapor in air to burn & a rich mixture istoo 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 fuelvapor below which it will not burn.

Upper explosive limit is the percentage by volume in air of fuel vaporabove which it will not burn.

216. What is the difference between flammable liquid and inflammableliquids?

Flammable liquids: having flash point below 37.8oC

Inflammable liquids: having flash point between 37.8oC to 93oC.

217. What is the meaning of flammable range of fuels?

It is the percentage of fuel mixture in air by volume, between thelower & 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 O2content in the air?

Yes. The range widens with the increasing O2 content.

Example:

Propane in air (20% O2) flammable range is 2.2 9.5

Propane in 100% O2 flammable range is 2.2 57.

220. What are the impacts of oxygen deficiency?

No visible Effect


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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, orloss of the ability to move.

Unconsciousness, followed by death.

Below 6%, Difficulty breathing. Convulsive movements.Death in minutes.

221. What are the effects of Oxygen Enrichment?

When the oxygen concentration rises above 23.5% by volume, theatmosphere is considered oxygen enriched, and is prone to becomeunstable. As a result of the higher oxygen level, the likelihood andseverity of a flash, fire or explosion is significantly increased.

222. Why are the underground petrol tanks generally safe at servicestations?

The vapor pressure of gasoline is higher than the atmospheric;hence air cannot normally get in. Even if some air gets in duringfilling & emptying operations the mixture is too rich to burn.

223. What are the common sources of ignition in Petrochemicalindustries?

FurnacesHot linespyropheric ironFrictionHeatSparks from electrical equipmentStray currentsWelding


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CuttingGrindingExhaust 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 flashlight 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 toburn or explode.

226. What are the Ignition sources in the petrochemical industries?

Electrical equipmentFriction in the running equipmentOpen flameSmoking and matchesSpontaneous combustionHot surfaceStatic electricityLightening

227. What is the definition of Auto-ignition temperature? Are they thesame for all fuels?

It is the lowest temperature, which will cause a flammable mixture toburn or explode by itself. Ignition temperature varies from fuel tofuel.

228. What is the range of Auto ignition temperature of our petroleum

products?

About 42 to 600oC

229. What are the flash point, Auto ignition temperature, Explosive limitand Exposure limit of our handling petro products?


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BoilingPoint oC

FlashPoint oC

Auto IgnitionTemp oC

Explosivelimit %

ExposureLimit(TLVppm)

Kerosene 155-260 42.0 254 1.16 6.0%

nC5 37 -45 260 1.50 7.6%iC8 99.0 12.6 450 0.84 6.0% 300Paraxylene 13.3 27 466 1.10 7.0%Hydrogen -253 571 4.1 74.0%Hot oil 359 170 373 1.1 2.6% 5Benzene 80 -11.1 580 1.3 7.1% 0.5DMDS 109 16.0 1.1-16.3L.W.O 85-110 Below 3.0H.W.O 260-290 115N. Paraffin 190-240 70 0.6 6.5%LAB 140 0.4 5.0%

Diesel 160-371 55 260 0.3 10.0%H2S -60.2 270 4.3 46% 10

230. Which chemical material having wide variation of flammable range?

Acetylene 2.5 100%.

231. Is the flame of match hot 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 becauseflammable gases will be present during normal operation.

Example: Fuel gas, LPG loading

Areas which are considered hazardous only infrequently as aresult of failure

Example: Any process plant area.

233. Which is more likely to get ignited: Hydrocarbon soaked ininsulation or liquid hydrocarbon?


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H/C soaked insulation is more hazardous since ignitioncharacteristics of hydrocarbons change drastically when surfacearea is increased by soaking.

234. During Air fin cooler fire shall we switch off the fans or keep 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 500oC

236. What are the common sources of ignition hazards in a petrochemical

industry?

Furnaces, hot lines, friction heat.Pyrophoric iron sulfideHot jobs like welding, cutting, grinding, chipping, hot-tapping, stressrelieving.Exhaust from vehicles.Sparks form electrical equipments.Spontaneous ignition.Static electricityLighteningCatalytic effect of fresh metallic surfaces.

237. A Petrochemical industry has to have furnaces, hot lines & rotatingequipment, which can frictional heat? How is then, a fire hazardprevented?

Furnaces are developed to keep flames inside the boxes. They arelocated at safe distance.

Hot lines are insulated. Insulation serves a personal protection aswell as means of conserving heat energy, besides safe guardingagainst fire hazards.

Rotating equipment must be looked after well, under preventive &predictive maintenance program. Operating personnel should takecare of normal lubricating needs and should operate them in theproper manner.

238. What is pyrophoric iron sulfide?


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Supply kerosene contains sulfur in the form of compounds. Thissulfur reacts with iron inside vessel and pipelines, to form ironsulfide 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 shutdown maintenance work, when vessels & pipe lines are opened forcleaning & repairs. If the system have not been gas freed already,entry of air can supply both the oxygen & ignition required for thesystem 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 areremoved to safe place.

240. What are the methods to prevent an ignition hazard from thematerial?

Running units are not completely safe from the ignition hazard ofpyrophoric iron sulfide. There are plants, which use air or oxygenfor the process.

Rigorous control on the quantity, special safety interlock systems,avoidance of vapor spaces in vessels & tanks are all necessaryprecautions in such plants to prevent a fire hazard.

Vacuum systems are especially vulnerable. If due to leaks, air getsinto the systems, pyrophoric iron sulfide will serve as the source ofignition. Proper vacuum test during start up & periodic checks of theejector effluents for oxygen will serve as a check to unknown entryof 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 beburied or burnt away.

242. What are the methods to prevent a fire in a plant, while permitting hotjobs?

Hot jobs are sources of ignition. They are not allowed in thepetrochemical industry as a general rule.


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All hot jobs are permitted on the basis of a hot permit. Issue of isstrictly governed by the hot-permit produce of the petrochemicalindustry.

FIRE FIGHTING

243. 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 available for fire put off?

Starvation - Cut off fuel (elimination)

Smothering - Cut off oxygen (limitation)

Cooling - Removal of temperature

246. What are the extinguishing mediums available?

WaterSteamFoamVaporizing liquids (halons)DCPCO2Sand


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BlanketingBeating 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 butheat inside the room will still be at flash point and when O2 isintroduced rapid explosion will occurred.

249. How to avoid back draft?

By proper ventilation.

By rapid cooling.

250. What isPASS?

This word easy to remember how to use fire extinguisher.

P - PullA - AimS - SqueezeS - Sweep

251. How will you prevent a leaking hot hydrocarbon vapor from catchingfire until it has been isolated and depressurized?

Dilute with steam so that explosive mixture does not form.


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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 firefighting hours)

8 hours.

255. Auto cut in and cut off of Fire water pumps?

CONTROL SYSTEM

Pump Type Cut in(KSc)

Cut off (KSc)

820 P 02 A Jockey 9.5 10.0

820 P 02 B Jockey 9.0 10.6

820 P 01 A Electrical 8.0 *

820 P 01 B Diesel 7.5 *

820 P 01 C Diesel 6.0 *

256. 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 (Totalcirculation)

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 used for Hydrogen fire?

Steam.


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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 70oC 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 thefire water pressure on the fire water valve thus opening the mainvalve (deluge valve) due to pressure difference.

264. What are the safeties to be followed by Fire fighters during firefighting?

Follow the leaders 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 (37oC sweating, imbalance, heart beat mayincreases)

Heat syncope (dilution of blood cells, BP decrease, blood tobrain decrease)


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Effect on respiration (50% respiration reduced when exposedto 37 to 50oC)

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 safetydata sheet which provides information about the physical, chemicalproperties of the chemical, TLV, first Air Measures in case ofexposures, spills, fire Fighting methods etc.,

268. What is TLV?

TLV stands for the Threshold Limit Value, which refers to the airborne concentrations of substances to which workers can beexposed 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 thechemical present in the work place to which the workers can have asafe exposure.

It is based average concentration obtained from the samples takenevery two hours for an 8 hour period.

271. What is TLV-STEL?


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STEL Short Term Exposure Limit to which a worker can beexposed for duration of 15 minutes, maximum 4 exposures at aninterval 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., minimumconcentration 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

Melting point 5.5oC

Boiling point 80oC

Specific Gravity 0.87

Vapor pressure 74.6 mm Hg @ 20oC

Flash point -11.0oC

Explosion limits 1.3 8 %

Auto ignition 561oC

274. 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.VomitingDizzinessNarcosisReduction in blood pressure


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CNS depressionDermatitis when contact with skin.

277. What are the characteristics of H2S?

Color: colorless

Smell: Rotan egg smell

Heaviness: Heavier than air

Solubility: Soluble in water forming corrosive acid

278. What will happen to a person, if he is working in H2S concentrationabove 100 ppm?

He will lose the sense of smell.

279. What is the threshold Limit value of H2S?

Below 10 ppm.

At this level a person can work. Long term exposure limit

280. What will happen to person, if he is working in H2S concentrationabove 30 ppm level?

Respirator problems and eye irritations.

281. What type of hazards exists when a sour water handling equipmentis opened for maintenance?

H2S - toxic gas and iron sulfide which may catch fire when it comesin contact with oxygen.

282. At what level H2S concentration, a person will get rapidunconsciousness followed by death within minutes?

1000 ppm

N.F.P.A

283. What is NFPA?

National Fire Protection Association.


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284. 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

285. NFPA hazard Diamond what is indicate?

Blue color HealthRed color Fire/FlammabilityYellow color Reactivity of the materialWhite color Any special hazards

286. What are the effects ofhealthaccording the chemical code? Alsowrite protective equipment used?

0 Normal Material (no need)1 Slightly hazardous (may be SCBA)2 Hazardous (SCBA)3 Extremely Hazardous (full protective suit and SCBA)4 Deadly (full protective suit and SCBA)

287. What are the hazardous offlammablematerial on code number?

0 No flammable hazard (will not burn)1 Slightly Flammable (above 93oC)2 Moderately Flammable (below 93oC)3 Highly Flammable (below 38oC)4 Extremely Flammable (below 23oC)


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288. What are the effects ofReactivitymaterial hazards according thechemical code?

0 Significant Reactive hazard (stable)1 Slightly Reactive (not stable when heated)

2 Moderately Reactive (Violent chemical change)3 Highly Reactive (May Detonate with heat or shock)4 Extremely Reactive (May Detonate)

289. 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 SAFETY

291. 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 PPEs during work.

292. What is the minimum PPEs required in work shop?

HelmetGogglesSafety 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.


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LABORATORY SAFETY

296. What is the purpose of Laboratory Safety?

The purpose of this standard is to define the minimum requirementsfor safety of employees working in QC.

297. What are the minimum PPEs require inside the QC?

Safety glass

Chemical goggles/face shields.

Gloves (rubber, butyl, latex) based on chemical handling asspecified 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.


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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 ornoxious 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 movingcylinders.

Avoid pipetting by mouth.

300. What are importancess 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 directsunshine.

Store concentrated acids and bases separately.

Keep corrosives away from organic chemicals andcombustible materials.


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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 mustbe in an explosion-proof (lab-safe) refrigerator.

Store oxidizers away from flammable, combustible materialsand 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 ofunneeded material immediately.

301. How to handle the chemical and how to avoid hazardous duringnormal work?

Be familiar with chemical properties and products of chemicalreactions.

Be prepared for chemical spills and clean up spillsimmediately.

Plan ahead have apparatus and associated equipment readybefore chemicals are used.

Use the appropriate equipment, such as funnels, beakers andspatulas when transferring chemicals.


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Use chemical fume hoods to control exposure as chemicalsare transferred.

Use chemical fume hoods to control exposure during theexperiment.

Wear the appropriate personal protective equipment (chemicalsplash goggles, gloves, etc.).

Have disposal containers ready ahead of time.

302. Chemicals can be segregated as:

A. CorrosivesB. Flammable LiquidsC. 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:

A. MSDS.B. LabelsC. DictionaryD. Both A & B

305. Chemical fume hoods can be used to control exposure.

TrueFalse

306.

ELECTRICAL HAZARDS

307. What are the Electrical hazards?

Shock, Burn, Electric sparks that can cause ignition of flammablemixtures, explosion etc., are the electrical hazards.

308. At what current a person can withstand?


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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 what to check first?

Always test a circuit to make sure it is de-energized by using properPPE, 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 tag out circuits and machines beforemaintenance.

Prevent electrical shock by grounding tools while working onit.

Prevent too much current in circuits by using over currentprotection devices.

312. What are the common ignition hazards in petrochemical industryelectrical equipment?

Motors, switches & breakers, lamps, cable joints, junction & terminalboxes, welding cables etc.,


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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 petroleumproducts?

Most of them. But there are certain electrical devices which maycreate sparks or arcs that are too weak to cause ignition. The flashlight switches or thermocouple switches are examples of this type. Itis however, to be remembered that the intensity of the spark doesnot depend on the switch but on the amount of current flowing thecircuit.

315. Can the flash light bulb ignite a flammable mixture if exposed?

Yes. If the hot-glowing filament is exposed due to a broken glassbulb, 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 bulbbreaks and the hot filament is exposed momentarily, there will be nofire 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 pressurecreated by a internal explosion & to cool hot gases below the ignitiontemperature before they reach outside of the explosion proofhousing.

318. What is the basis of the selection of explosion proof electricalequipment 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.


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All electrical equipment in continuously hazardous areas must beexplosion proof.

319.

STATIC ELECTRICITY

320. What is Static Electricity? How is it formed?

Static electricity is concentration of energy formed due to contactand separation.

321. What are the hazards of static electricity in petroleum industries?

The principal hazard is a spark discharge which can ignite aflammable mixture.

322. Why petroleum products which are poor conductors of electricitybecome charged with static?

Good conductors are also better generators of static electricity. Butbecause they are good conductors the Static generated isdischarged faster.

Refined petroleum products like gasoline, kerosene, jet fuels, etc.,are poor conductors. They are also poor generators, but becausetheir relaxation times are much longer, large charges areaccumulated.

323. How do we avoid static electricity?

By providing correct bonding and grounding.

Correct bonding and grounding ensures that static electricity doesnot accumulate and cause a spark.

324. What is bonding?

Bonding is electrically connecting conductive objects to equalizeelectrical potential and prevent sparks.

325. What is Grounding?


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Grounding is connecting a conductive object to the earth todissipate 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 acondition which can lead to death, disability.

328. What are the normal person vital signs?

Heart Beat or Pulse 60 80 beat/min

Blood Pressure 80 120 mmHg/min

Temperature 37oC

Breathing rate 12 -20 times/min.

329. What is burn? What are the causes for the burn?

Burns are caused by:

Hot liquids and vapors

Dry heat

Corrosive substances

Electric shock

Radiation including sun burn


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330. What are the classifications of burns?

First degree: involves epidermis characterized by redness, severepain 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. It is painlessor 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 remainnormally open (CSO) or normally close (CSC) during plantoperations, for Safety, Health, Environment considerations.

Example:

PRV TSV isolation 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.,

TAN K FARM HAZARDS

335. What is the impact of tank hazards?


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Tanks handling flammable liquid constitutes a much greaterpotential fire hazard than the process unit, probably because theyare 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 ableto take the load of this high filing rate.

Over pressurizing by gas: N2 valve malfunctioning, the ventwas not cleaned. Or clogged.

Sudden shower cooled the tank causing it to collapse due tocondensation of liquid. PVRV not properly working.

339. What is the purpose of roof drain?


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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 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 for tank fire during mechanical work?

Accumulation of explosive material in somewhere. (gauge hatch 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 vaporleaking through the seals. The source of ignition was atmosphericelectricity 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 updue to thermal expansion. It is provided at places where a liquid canremain in blocked up state with no room for expansion due totemperature rise.

347. How to avoid static electricity in tanks?


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Avoid by keeping pumping rate at lower and avoiding splash filling.

HOME ELECTRICAL SAFETY

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, earthplug 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,

Dont take shower/bath.

Avoid standing under tree.

The End

- But no End for Safety.


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