2nd Lec. - pg. 1-2

Question 1

• Unexpected ______, _______ , or flammable liquids and gases in processes involving highly hazardous chemicals have been ________.
• Opportunity for ____ and _______.

Answer 1

• releases of toxic, reactive; reported for many years
• accident, disaster

Question 2

Major disaster in chemical industry

Answer 2

1984 Bhopal India
1989 Phillips Petroleum
1990 BASF
1991 IMC Sterlington

Question 3

Minimum elements required from employers in relation to PSM:
1. Develop and maintain ________ identifying workplace chemical and process hazards, equipment used in the processes, and technology used in the processes;

Answer 3

written safety information

Question 4

2. Perform a workplace hazard
   assessment, including, _______, ___________, identification of any previous release within the facility that had a potential for catastrophic consequences in the workplace, estimation of workplace effects of a range of releases, and estimation of the health and safety effects of such a ______ ,

Answer 4

• as appropriate, identification of potential sources of accidental releases ; range on employees

Question 5

3. Consult with employees and their representatives on the development and ________ and the development of _______ and provide access to these and other records required under the standard;

Answer 5

• conduct of hazard assessments; chemical accident prevention plans

Question 6

4. Establish a system to respond to the workplace hazard assessment
   findings, which shall address _____, ______, and ______;
5. Review periodically the workplace _____ and _______;

Answer 6

4. prevention, mitigation, emergency responses
5. hazard assessment, response system

Question 7

6. Develop and implement written
   operating procedures for the ______, including procedures for each _____, ______, and _______;

Answer 7

• chemical processes; operating phase, operating limitations, safety and health considerations

Question 8

7. Provide _______ and _______ for employees and employee training in operating procedures, by emphasizing ________ that must be developed and made available.

Answer 8

7. written safety, operating information; hazards and safe practices

Question 9

8. Ensure _____ and _____ are provided with appropriate information and training;
9. Train and educate employees and contractors in emergency response procedures in a manner as comprehensive and effective as that required by the regulation
   promulgated pursuant to _______.

Answer 9

8. contractors, contract
   employees
9. section 126(d) of the Superfund Amendments and Reauthorization Act;

Question 10

10. Establish a quality assurance program to ensure that initial process-related equipment, ______, and _______ and installed consistent with design specifications;

Answer 10

• maintenance materials, spare parts are fabricated

Question 11

11. Establish maintenance systems for critical process-related equipment, including _____, _______, _______, equipment to ensure ongoing mechanical integrity; and testing of such equipment to ensure ongoing mechanical integrity

Answer 11

11. written procedures, employee training, appropriate inspections

Question 12

12. Conduct ________ of all newly installed or modified equipment;
13. Establish and implement written procedures managing _______, ________, _______, and facilities; and

Answer 12

12. pre-startup safety reviews
13. change to process chemicals, technology, equipment

Question 13

14. Investigate every incident that results in or could have resulted in a major accident in the workplace, with findings to be reviewed by ________ and ________, if appropriate.

Answer 13

operating personnel, modifications made

Question 14

PSM mainly applies to manufacturing industries-particularly, those
pertaining to ____

Answer 14

chemicals, transportation equipment, and fabricated metal
products.

Question 15

PSM applies to those companies that deal with (______) specific toxic and reactive chemicals in listed quantities

Answer 15

any of more than 130

Question 16

Information on the hazards of the
highly hazardous chemicals in the
process shall consist of at least the
following:

Answer 16

-Toxicity,
- Permissible exposure limits,
- Physical data,
- Reactivity data,
- Corrosivity data, and
- Thermal and chemical stability data, and hazardous effects of Inadvertent mixing of different materials.

Question 17

A careful review of what could
go wrong and what safeguards must be implemented to prevent releases of hazardous chemicals.

Answer 17

PHA - Process Hazard Analysis

Question 18

Information on the technology of the process must include at least the following:

Answer 18

• A block flow diagram or simplified
  process flow diagram,
• Process chemistry,
• Maximum intended inventory,
• Safe upper and lower limits for such items as temperatures, pressures, flows or compositions, and
• An evaluation of the consequences of deviations, including those affecting the safety and health of employees.

Question 19

Information on the equipment in the process must include the following:

Answer 19

• Piping and instrument diagrams
  (P&IDs),
• Electrical classification,
• Relief system design and design basis,
• Ventilation system design,
• Design codes and standards
  employed,
• Material and energy balances for
  processes built after May 26,1992,
  and
• Safety systems (e.g., interlocks, detection, or suppression systems).

Question 20

The employer must perform an initial _____ (hazard evaluation) on all processes covered by PSM.

Answer 20

process hazard analysis