Lecture 1

Question 1

In the chemical, petrochemical and most other industries, you will find that all companies are required to have an occupational safety program, with a focus on ________

Answer 1

personal safety.

Question 2

“a discipline that focuses on the prevention of fires, explosions, and accidental chemical releases at chemical process facilities”

Answer 2

Process Safety

Question 3

It is all about the prevention of, preparedness for, mitigation of, response to, or restoration from catastrophic releases of chemicals or energy from a process associated with a facility.

Answer 3

Process Safety

Question 4

an independent commission was created to examine the process safety mindset, or culture, of BPs refinery operations, this commission came to be known as the

Answer 4

Baker Panel

Question 5

Who began the manufacturing of nitroglycerine and what year?

Answer 5

Alfred Nobel, 1864.

Question 6

Alfred Nobel’s major breakthrough was discovering that when mixed with an inert carrier, it became safer to handle. This form of nitroglycerine is called

Answer 6

dynamite

Question 7

In 1976, a runaway reaction occurred near Seveso, Italy that resulted in the release of _____ into residential areas

Answer 7

2,3,7,8-tetrachlorodibenzo-p-dioxin, commonly known as dioxin

Question 7

This incident eventually led to stricter regulations for the process industries in the European Economic Community in 1982, under what is known as the

Answer 7

Seveso Directive

Question 8

a toxic and flammable material, occurred at a chemical plant in Bhopal, India, killing more than 3,000 people.

Answer 8

methylisocyanate

Question 9

The Bhopal incident led to the formation of the

Answer 9

Center for Chemical Process Safety (CCPS)

Question 10

is a not-for-profit organization that is part of the U.S. based American Institute for Chemical Engineers with a mission to improve industrial process safety

Answer 10

Center for Chemical Process Safety

Question 11

is a formally established and documented set of activities and procedures designed to produce specific results in a consistent manner on a sustainable basis.

Answer 11

A management system

Question 12

is a management system that is focused on prevention of, preparedness for, mitigation of, response to, or restoration from releases of chemicals or energy from a process associated with a facility.

Answer 12

Process Safety Management (PSM)

Question 13

Many people developed _________, a skin disease, and a 17 km² (6.6 mile²) area was made
uninhabitable.

Answer 13

Chloracne

Question 14

issued PSM guidelines.

Answer 14

in 1985 the Chemical Manufacturers Association (CMA), which later became the American Chemical Council (ACC)

Question 15

By 1989, the CCPS introduced a set of __ process safety management elements.

Answer 15

12

Question 16

also issued PSM guidelines in 1990.

Answer 16

The American Petroleum Institute (API)

Question 16

issued its own version in 1995 under the authority of the Clean Air Act.

Answer 16

Environmental Protection Agency (EPA)

Question 16

EPA RMP covers the impacts of

Answer 16

hazards off-site.

Question 16

issued the Process Safety Management of Highly Hazardous Chemicals (OSHA HHC) regulation, which had its own, although similar, set of process safety management elements

Answer 16

Occupational Safety and Health Administration (OSHA)

Question 16

the CCPS created _____ as the framework for the next generation of process safety management.

Answer 16

risk-based process safety (RBPS)

Question 16

Managing Risk focuses on four issues:

Answer 16

(1) prudently operating and maintaining processes that pose the risk,
(2) managing changes to those processes to ensure that the risk remains tolerable,
(3) maintaining the integrity of equipment and assuring quality of materials, fabrications, and repairs, and
(4) preparing for, responding to, and managing incidents that do occur.

Question 16

OSHA PSM regulations cover the impacts of

Answer 16

hazards to workers on-site.

Question 16

is “the possibility of loss or injury” or “someone or something that creates or suggests a hazard”

Answer 16

risk

Question 16

This is the cornerstone of process safety excellence.

Answer 16

Commitment to Process Safety

Question 16

Pillars of Process Safety

Answer 16

1. Commit to Process Safety
2. Understand Hazards and Risk
3. Manage Risk
4. Learn from Experience

Question 16

Thus, in the process industries, understanding the risk associated with an activity requires answering the following questions:

Answer 16

1. What can go wrong? (human injury, environmental damage, or economic loss).
2. How bad could it be? (magnitude of the loss or injury).
3. How often might it happen? (likelihood of the loss or injury)

Question 16

The CCPS definition has three elements as opposed to two:

Answer 16

1. the hazard (what can go wrong),
2. the magnitude (how bad can it be), and
3. the likelihood (how often can it happen)

Question 16

There are five elements to the pillar of Commit to Process Safety.

Answer 16

Process Safety Culture
Compliance with Standards
Process Safety Competency
Workforce Involvement
Stakeholder Outreach

Question 16

is widely credited for reductions in major accident risk and in improved process safety performance in the process industry.

Answer 16

PSM