Professional Documents
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Chemical and Process Management Final
Chemical and Process Management Final
Ans- Purpose: The major objective of process safety management (PSM) of highly hazardous chemicals is to
prevent unwanted releases of hazardous chemicals especially into locations that could expose employees and
others to serious hazards. An effective process safety management program requires a systematic approach to
evaluating the whole chemical process. Using this approach, the process design, process technology, process
changes, operational and maintenance activities and procedures, Non routine activities and procedures,
emergency preparedness plans and procedures, training programs, and other elements that affect the process
are all considered in the evaluation. Application: The various lines of defense that have been incorporated into
the design and operation of the process to prevent or mitigate the release of hazardous chemicals need to be
evaluated and strengthened to ensure their effectiveness at each level. Process safety management is the
proactive identification, evaluation and mitigation or prevention of chemical releases that could occur as a
result of failures in processes, procedures, or equipment. The process safety management standard targets
highly hazardous chemicals that have the potential to cause a catastrophic incident. The purpose of the
standard as a whole is to aid employers in their efforts to prevent or mitigate episodic chemical releases that
could lead to a catastrophe in the workplace and possibly in the surrounding community .To control these types
of hazards, employers need to develop the necessary expertise, experience, judgment, and initiative within their
work force to properly implement and maintain an effective process safety management program as envisioned
in the Occupational Safety and Health Administration (OSHA) standard. Although OSHA believes process safety
management will have a positive effect on the safety of employees and will offer other potential benefits to
employers, such as increased productivity, smaller businesses that may have limited resources to them at this
time, might consider alternative avenues of decreasing the risks associated with highly hazardous chemicals at
their workplaces. Reduction in inventory will result in reducing the risk or potential for a catastrophic incident.
Exceptions :The PSM standard does not apply to the following: Retail facilities; Oil or gas well drilling or
servicing operations; Normally unoccupied remote facilities; Hydrocarbon fuels used solely for workplace
consumption as a fuel (e.g. propane used for comfort heating, gasoline for vehicle refueling), if such fuels are
not a part of a process containing another highly hazardous chemical covered by this standard; or Flammable
liquid stored in atmospheric tanks or transferred, which are kept below their normal boiling point without
benefit of chilling or refrigerating and are not connected to a process.
Q2. What is the role of training in safety? Explain different types of training conducted in industry.
Ans :- Training must include instruction on how to handle upset conditions as well as what operating personnel
are to do in emergencies such as pump seal failures or pipeline ruptures. Communication among operating
personnel and workers within the process area performing Non routine tasks also must be maintained. The
hazards of the tasks are to be conveyed to operating personnel in accordance with established procedures and
to those performing the actual tasks. When the work is completed, operating personnel should be informed to
provide closure on the job. Employee Training: All employees, including maintenance and contractor employees
involved with highly hazardous chemicals, need to fully understand the safety and health hazards of the
chemicals and processes they work with so they can protect themselves, their fellow employees, and the
citizens of nearby communities. Training conducted in compliance with the OSHA Hazard Communication
standard (Title 29 Code of Federal Regulations (CFR) Part 1910.1200) will inform employees about the chemicals
they work with and familiarize them with reading and understanding MSDSs. However, additional training in
subjects such as operating procedures and safe work practices, emergency evacuation and response, safety
procedures, routine and Non routine work authorization activities, and other areas pertinent to process safety
and health need to be covered by the employer's training program. In establishing their training programs,
employers must clearly identify the employees to be trained, the subjects to be covered, and the goals and
objectives they wish to achieve. The learning goals or objectives should be written in clear measurable terms
before the training begins. These goals and objectives need to be tailored to each of the specific training
modules or segments. Employers should describe the important actions and conditions under which the
employee will demonstrate competence or knowledge as well as what is acceptable performance. Contractors
Training: Employers who use contractors to perform work in and around processes that involve highly
hazardous chemicals have to establish a screening process so that they hire and use only contractors who
accomplish the desired job tasks without compromising the safety and health of any employees at a facility. For
contractors whose safety performance on the job is not known to the hiring employer, the employer must
obtain information on injury and illness rates and experience and should obtain contractor references. In
addition, the employer must ensure that the contractor has the appropriate job skills, knowledge, and
certifications (e.g., for pressure vessel welders)..
Q5. Explain the role of hazardous area classification in safety. State its advantages.
Ans- Hazardous area classification is the evaluation and classification of hazardous (classified) locations using
scientific and engineering principles, within facilities where chemicals are manufactured, processed or utilized.
Hazardous areas are classified solely for the purpose of ensuring the safe and proper specification and
installation of electrical/ electronic equipment located within them. Article 500 of the National Electrical Code
(NEC) (reference 1) defines the requirements for the safe and proper specification and installation of
electrical/electronic equipment in hazardous (classified) locations. NEC Article 500.5 (A) states that "Locations
shall be classified depending on the properties of the flammable gas, flammable liquid-produced vapors,
combustible liquid-produced vapors, combustible dust or fibers/flyings that may be present, and the likelihood
that a flammable or combustible concentration or quantity is present. Each room, section, or area shall be
considered individually in determining its classification."
Advantage Hazardous area classification drawings provide a road map that ensures that electrical/electronic
equipment can be safely and properly specified and installed in hazardous (classified) locations such that the
risk of fires or explosions is greatly reduced. Work with a qualified engineering testing lab that has the expertise,
experience and capabilities necessary to perform accurate and practical area classifications for hazardous
(classified) locations within any process facility.
Q6. Explain the selection criteria for plant siting and layout for a major petrochemical plant.
Ans- SITING CRITERIA: There are 4 Siting Criterias as under: General Guidelines : 1. Land availability and its cost.
2. Raw material availability. 3. Labour availability (Also the quality of labor-Strike). 4. Infrastructure availability
(Different for different Products & even Models). 5. Access to market. (Not in Andaman Nikobar) 6. Transport
facilities. 7. Drinking and process water facilities. (Igatpuri Plant laid down pipeline from a river for making water
available) 8. Sewage and Drainage. 9. Place for solid and liquid waste disposal. (Govt. approved facility distance
like Taloja, Pune Ranjangaon) 10. Interlinking with other plants.(Suppliers & Venders & Purchasers) 11.
Surrounding population density and distance from the public.(In case of nuclear plant or MAH Units like one in
Manmad Petroleum unit) 12. Distance from highway and railway and from transport centers.(Cost cutting
Factor) 13. Suitability of climate, environment and factors related to ecology, geology, and micro& macro
biology. 14. Government policy advantages like subsidies (M&M Haridwar –Some taxrelaxation), incentives and
zoning (area reservation eg. SEZ) if prescribed. 15. Other techno-economic criteria.
Q8. Explain any two unit operation in the industry with safety aspects.
Ans- FERTILISER INDUSTRY: Fertilisers are natural (manure) or artificial. Artificial fertilizers are produced in
chemical plants and they may be organic or inorganic, nitrogenous, phosphatic, potash and trace element
fertilizers. In the warehousing stage, phosphate. Potassium-salt and other dusts are released. In chemical
processing plant, air pollution by toxic gases (Fluorine compounds, H2SO4, NO, HCI, CO and NH3, gases) and
dust, high air temperature and noise are noticed. Closed and efficient ventilation is necessary. In finishing
processes, weighing, bagging and storing, gaseous emissions and fluorine compounds are released. Phosphates
and other raw materials contain 10% or more free silica which may cause pneumoconiosis. The dust of soluble
fertilizers causes irritation. The safety measures include: 1. Mechanizations and automation of production
processes, provision of remote control, careful assembly and safe operation of equipment and heat insulation.
2. Process segregation and walls and floor covering to absorb fluorine compounds. 3. Gen. Ventilation, exhaust
ventilation of enclosed plant, cleaning of exhaust air and waste water. 4. Education and personal hygiene. 5. Use
of PPF and safety showers. 6. Safety and sanitary supervision. 7. Pre and post medical examination including
radiographs of the locomotors system and lungs. PESTICIDE INDUSTRY (INSECTICIDE): Pesticide is a chemical
used to destroy an organism detrimental to human interest. It includes insecticides, fungicides, herbicides,
rodenticides, bactericides, miticides, nematocides, moUuscicides. They are generally halogenated (Cyclodienes,
Bischlorophenyls, Cycloparaffins, Organo-chlorines and Chlorinated terpenes) or Organophosphorus (Parathion,
malathion, TEPP, OMPA, DDVP, abate, ciodrin etc. ) type. They are classified as extremely hazardous, highly
hazardous, moderately hazardous, slightly hazardous etc. For these classifications and their details including
Lethal Dose values see Reference No. 1 given at the end of this Chapter. Strict safety rules are necessary during
their processing, handling, packaging etc. Exhaust ventilation and use of PPE are essential.
1. Exposed Side 2. Protected Side 3. Flame stabilized on arrester element 4. Flame arrester element absorbs and
quenches flame front 5. Piping
Q12. What are the safety precaution to be taken in the process and operations involving explosive chemicals?
Ans :- Safety in chemical industry: 1. Study and identify chemical hazards using material safety data sheet
(MSDS) and a system of classification, packaging and labeling should be developed. 2. Select safer technology. 3.
Select safer sitting of chemical industry for minimum loss to men, material, environment etc. 4. Take all safety
precautions at Design and construction stage. 5. Workplace hazards inside the factory should be controlled by
good engineering controls, (SOPs) safe operating procedure and using personal protective equipment. 6. All
requisite safety devices, fittings, instruments, equipment, machines etc., must be provided and well maintained.
7. Workers must be properly Educated & trained for safe operation of the plant such as proper Warning signs,
color codes, Safety Work Permit Systems, fire fighting. 8. Conduct Mock-drills of MAH Unit & Potential
Emergencies due to Chemical Hazards to know everybody their role in emergency planning and control. 9. Safe
Storage, handling & transportation of hazardous chemicals within and out-side factory premises. 10. Safe
Storage, disposal of hazardous wastes within and outside factory premises.(Sewage &Haz-Sludge) 11. Well
monitoring and control of hazardous substances/Waste at work places (Inspection, Audit & Analysis / ETP &
STP) and of occupational ill-effects and diseases by pre and periodical medical examinations of the workers.
Q14. Explain in brief the safety precaution while transfer of flammable chemicals.
Ans :- Avoid accumulation of vapours and to control sources of ignition including: open flames electrical
equipment sources of static electricity Accounts of a few of the fires that have occurred in our laboratories
may be found in Anecdotes(link is external). Pouring flammable liquids can generate static electricity. The
development of static electricity is related to the humidity levels in the area. Cold, dry atmospheres are more
likely to facilitate static electricity. Bonding or using ground straps for metallic or non-metallic containers can
prevent static generation. Whenever possible use plastic or metal containers or safety cans. When working
with open containers, use a laboratory fume hood to control the accumulation of flammable vapor. Use bottle
carriers for transporting glass containers. Avoid using equipment with series-wound motors, since they are
likely to produce sparks. Do not heat flammable liquids with an open flame. Steam baths, salt and sand baths,
oil and wax baths, heating mantles and hot air or nitrogen baths are preferable. Minimize the production of
vapors and the associated risk of ignition by flashback. Vapors from flammable liquids are denser than air and
tend to sink to the floor level where they can spread over a large area. Electrically bond metal containers
when transferring flammable liquids from one to another. Bonding can be direct, as a wire attached to both
containers, or indirect, as through a common ground system. When grounding non-metallic containers,
contact must be made directly to the liquid, rather than to the container. In the rare circumstance that static
cannot be avoided, proceed slowly to give the charge time to disperse or conduct the procedure in an inert
atmosphere.
Q15. State the safety precaution to be taken while handling of acid/alkali chemicals.
Ans- Hydrochloric acid is a hazardous liquid which must be used with care. The acid itself is corrosive, and
concentrated forms release acidic mists that are also dangerous. If the acid or mist come into contact with the
skin, eyes, or internal organs, the damage can be irreversible or even fatal in severe cases. The use of personal
protective equipment is essential. Safety is of utmost importance when handling dangerous chemicals like
hydrochloric acid. The Environmental Protection Agency regulates hydrochloric acid as a toxic substance, and it
should be treated as such. It is recommended that you wear the following protective equipment when using
hydrochloric acid of any concentration: Vapor respirator Rubber gloves Boots Full suit Face shield If
using hydrochloric acid at your workplace, it is highly recommended you have access to an eye-flush station in
case of accidental exposure. You should also review all Hydrochloric Acid MSDS information before making
contact.
Q16. Explain CMV Rule for transportation of hazards chemicals.
Ans- Central Motor Vehicle Rules (CMVR) 1989 to reduce the road disasters carrying chemicals. The
implementation of the Rules 131 to 133 of CMVR, 1989, providing details of responsibility of consignors,
transporters and drivers of the goods carriage transporting HAZCHEM shall be strengthened. Further, the states
can also put additional restrictions in the permit condition while granting permits to the transporters. Training:
Comprehensive training of inspection staff issuing fitness certificates regarding design codes, their requirement
for the inherent safety of the container and the vehicle, etc. Comprehensive training of the traffic inspectors
regarding the applicable of legal requirements. Training of inspectors regarding HAZCHEM as per the CMVR so
as to make them understand the consequences of non-compliance. Elaborate training programmes for
community leaders, panchayats, NGOs and other identified prominent persons in the areas is necessary after a
directory of information (containing the names, addresses, telephone numbers, etc.) is prepared. A small
booklet in the vernacular on dos and don'ts for the local public should be brought out and circulated. The
Regional Transport Officer (RTO) should carry out the proper verification and examination of the tankers/trucks
before issuing a new license/permits. Check driver's license for its validity, provide a certificate to the effect that
he has successfully undergone the requisite training for transportation of hazardous goods and endorse his
license, authorising him to drive vehicles carrying HAZCHEM. 1. Check documents and inspect vehicles with
check lists. 2. Implement vehicle entry, loading/unloading check list. 3. Check compatibility with material last
transported with the one intended to be loaded. 4. Place appropriate fire extinguishers. 5. Provide separate
earthing to tank and hoses. 6. Provide stop blocks to prevent rolling of vehicles. Loading/unloading operation to
be carried out under supervision. 7. Make the driver read the Transport Emergency Card (TREMCARD) while the
loading/unloading operation is carried out. 8. Seal and lock valves after loading. The Emergency Information
Panel (EIP) should be checked and if found inappropriate, new panels should be pasted on all three places.
Appropriate class labels should be pasted. 9. Communicate the route and scheduled halts to driver and
transporter. 10. Implement a computerised system for records. Although it may not be possible for all the units
to implement such computerised systems, alert security staff and proper maintenance of records can easily
achieve the objective. Train security staff in checking the documents and vehicles. 11. Selection of transporters
should be on the basis of their credibility rather than solely on quotes.
Q18. Explain the safety precaution in storage of flammable gases. Ans :- Follow these seven general safety
recommendations: 1. Know and understand the properties, uses, and safety precautions before using any gas or
gas mixture. Consult the Air Products Safety Data Sheet (SDS) and Safetygrams for safety information on the
gases and equipment you will be using. 2. Determine the appropriate equipment required to use the product
and know how to safely operate the equipment. 3. Be aware of potential hazards and develop plans to cover
possible emergencies. 4. Provide personal protective equipment (PPE) and the required training for its use.
Require personnel to wear the proper PPE for each task 5. Follow all national, state, and local regulations
pertaining to the storage, use, and disposal of compressed gases and cryogenic liquids.6. If you are unfamiliar
with the hazards associated with a particular gas, contact your supplier for additional information. 7. Use
appropriate equipment when handling portable cylinder banks. Storage Take the following precautions to
prevent injuries caused by asphyxiation, fire, explosion, high pressure, and improper handling of compressed
gas cylinders. NEVER • Allow storage temperature to exceed 125°F (52°C). • Permit smoking or open flames in
oxidizer or flammable gas storage areas. • Expose cylinders to corrosive materials such as ice melting
compounds. • Store only the amount of compressed gas required for the specific application. • Store cylinders
away from heavily traveled areas and emergency exits. • Provide adequate access for cylinder handling. •
Visually inspect stored cylinders on a routine basis, or at least weekly, for any indication of leakage or problems.
• Restrict access to cylinder storage areas. • Protect cylinders from wet or damp ground. ALWAYS • Store
cylinders in accordance with ISO Standard 11625 or CGA Pamphlet P-1. • Store cylinders upright with valve
outlet seals and valve protection caps in place. See Air Products’ Safetygram-14, “Don’t Turn a Cylinder Into a
Rocket.” • Secure cylinders when in storage, transit, or use. • Store cylinders in areas designated for that
purpose. • Segregate full and empty cylinders. • Store cylinders in a dry, cool, wellventilated, secure area
protected from the weather and away from combustible materials. • Ensure that there is adequate separation
from combustibles as specified by national regulations.
ANS- The hazardous chemicals/dangerous goods are divided by United Nation Committee of Experts on the
Transport of dangerous goods into the following classes: CLASS 1 : Explosive
Division 1 – Substances and articles which have a mass explosion hazard.
Division 2 – Substances and articles which have a projection hazards but not a mass explosion hazards.
Division 3 – Substances and articles which have a fire hazard and either a minor blast hazard or a major
projection hazard or both, but not a mass explosion hazard.
Division 4 – Substances and articles which present no significant hazard.
Division 5 – Very insensitive substances which have a mass explosion hazard.
CLASS 2 : Gases compressed, liquefied, dissolved under pressure or deeply refrigerated.
CLASS 3 : inflammable liquids.
CLASS 4 : Inflammable solids, substances liable to spontaneous combustion substances which on contact with
water emit inflammable gases.
Division 4.1 – Inflammable solids.
Division 4.2 – Substances liable to spontaneous combustion.
Division 4.3 – Substances which on contact with water, emit inflammable gases.
CLASS 5 : Oxidising substances, organic peroxides.
Division 5.1 – Oxidising substances.
Division 5.2 – Organic peroxides.
CLASS 6 : Poisonous (toxic) and Infectious substances.
Division 6.1 Poisonous (toxic) substances.
Division 6.2 Infectious substances.
CLASS 7 : Radioactive substance.
CLASS 8 : Corrosives.
CLASS 9 : Miscellaneous dangerous substance. See IS:1446 for classification of dangerous goods.
Arrangement for loading and unloading of the liquid have to be well designed. It is preferred to load toxic and
flammable material from the bottom. It is preferable to provide a discharge pump on the tank.
Q20. What are the safety aspects in plant start up and shutdown?
Ans:- 4.1 Safe Start-up & Shutdown Procedures: Start-up or restart operation after a short or long shutdown and
shutdown procedures need special precautions.Starting sequence should be well defined, written and known to
the workers involved in this work. Starting in sequence of utilities like water, air, power; purging, charging, slow
and gradual heating, monitoring of pressure, temperature, flow and reaction rate, cooling if necessary, starting
of exhaust system, scrubber or condenser etc., observing noise, vibration, speed, alignment, synchronizing etc.
are all important. During start-up if drains remain open, vent valves remain closed, wrong valves are operated,
unwanted material enters e.g. oxygen instead of nitrogen as blanketing over flammable reaction, water where it
is incompatible, air instead of steam or steam instead of air, excess or less charging of material or catalyst,
delayed cooling or heating, not starting of any pump or instrument, no indication or alarm due to failure or
malfunctioning of instrument in the beginning, no starting of local exhaust or scrubber when it is essential and
failure of interlock or trip resulting in unwanted mixing or reaction, mixing of air with hydrocarbons, contacting
hot oil and water, thermal or mechanical shocks etc. are some of the examples of possible disorders. Correct
identification of pipelines, valves and gauges, correct sequence of control operation, correct charging or
addition-rate and instead of relying on instruments only Counter-check of other parameters and strict manual
observation and satisfaction are requisite precautions for safe start-up procedure.
Q22. Inspecting the workplace - a checklist for health and safety representatives
Ans - When inspecting the workplace, health and safety representatives are encouraged to include the
inspection regime as well. Often that will involve asking for the risk assessments and records. You should also
check the accident book. Among the things you should be looking out for are: Does your employer have a
maintenance programme for all buildings and equipment? Are all routine or standard maintenance tasks risk
assessed and are the risk assessments up to date? Have all control measures that arise from the risk
assessment been put in place and are they working? What procedures are in place to ensure that non-routine
maintenance work is risk assessed? Is maintenance activity logged and monitored? Are all maintenance
workers fully trained and provided with the appropriate equipment and PPE? Are other workers trained on
how maintenance work can affect them? Are all potential hazards (such as asbestos) identified and clearly
marked so that maintenance workers will be aware of them? What arrangements are in place to ensure that
external contractors are competent and informed about any potential risks within the workplace? Have there
been any injuries, illnesses or near misses reported relating to maintenance activities, or a lack of maintenance
work, since your last inspection?
Q23. Explain colour code system. What are its advantages in safety?
Ans - Colour Coding identification of contents:: Indian Standards : IS to be followed are : Code of practice for
safety colours and safety signs 9457, Pipelines, identification, colour code 2379, Standard colours for building
and decorative finishes 1650, pipelines in thermal power plants 9404, Identification for canisters and cartridges
8318 and Gas cylinders and related medical equipment 3933. Colours to Identify Hazards :Colour coding is most
desirable and useful for safety purposes. Standard colours are used to identify hazards as follows : Red - Fire
protection, prohibition, danger, emergency stops on machines, red cross on medical facilities. Yellow - Risk,
danger or caution, hazards of slipping, falling, striking etc., flammable liquid storage, yellow band on safety cans,
material handling equipment viz. lift trucks, cranes, crane hooks, caution, transport equipment, obstructions,
change in floor level, stair nosing etc. Green - Safety equipment not identified elsewhere, safety board, safe
condition. Blue - Warning and information signs, bulletin boards, rail road uses. It indicates safety colour only if
used with a circular sign. Orange - Dangerous parts of machines or energized equipment such as exposed edges
of cutting devices, inside of movable guards, enclosure doors, transmission guards, electric installations. Purple -
Radiation Hazards Black & White - Housekeeping and traffic markings. Also used as contrast colours. 4 Benefits
of Colour-Coded Equipment: 1. Prevent Cross Contamination 2. Identify high risk, low-risk areas 3. Hygienic
Waste Management 4. Safe Segregation of Cleaning Equipment Colour-coded equipment can assist in
minimising the risk of product cross-contamination from bacteria, allergens and foreign bodies. Consequently
this improves food safety, saves on expensive recalls and protects business reputation.
Q27. What is fire? Explain different types of fire. & Types of Extinguisher
Ans - Classes of Fire and Extinguishers Class of fire Description Extinguishing Medium IS No. A Fires involving
ordinary combustible materials like wood, paper, textiles, fibres and vegetables etc. where the cooling effect of
water is essential for the extinction of fires. Water type (Soda acid) 934 Water type (gas pressure) 940 Water
type (constant air pressure), 6234 Anti – freeze types and Water buckets B Fire in flammable liquids like oils,
grease, solvents, Petroleum products, varnishes paints etc. where a blanketing effect is essential. Chem. Foam
933 Carbon dioxide 5507 10474 2878 8149 Dry Powder 2171 4308 Dry Powder Mechanical foam 10658 10204
Halon 1211 11108 Sand buckets C Fires involving gaseous substances under pressure where it is necessary to
dilute the burning gas at a very fast Carbon dioxide 2878 8149 Dry powder 2171 rate with an inert gas or
powder. Dry powder 4308 Halon 1211 11108 D Fire involving metals like magnesium, aluminum,zinc, potassium
etc., where the burning metal is reactive to water and which requires special extinguishing media or technique.
Dry powder 2171 Special dry powder for metal fire 4861 11833 Sand buckets E Fires involving electrical
equipment where the electrical non-conductivity of the extinguishing media is of first importance. Carbon
dioxide 2878 Dry chemical powder 2171 4308 Halon 1211 11108 When electrical equipment is deenergized,
same as for Classes A & B Sand buckets. * Class E is omitted is some literature (eg. IS: 2190) Class K is suggested
for fire involving cooking oils. Types of Extinguishers and suitability for Fire (IS:2190) Type of Extinguisher IS
No. For type of Fires A B C D 1. Water type (Soda acid) 934 4406 S * NS * NS NS 2 Water type (gas cartridge) 940
S NS NS NS 3 Water type (stored pressure) 6234 S NS NS NS 4 Chemical foam type 933 5507 10474 NS S NS NS 5
Mechanical foam type 10204 NS S NS NS 6 Dry powder type 2171 10658 NS S NS NS 7 Dry powder type 11833
NS NS NS S 8 CO2 type 2878 8149 NS S S NS 9 Halon 1211 type 11108 NS S S NS
Q31. Explain the role of fire detection and alarm system in safety.
Ans - Fire Detection and Alarm Systems: Various types of detectors are available operating on principles of
thermal expansion, thermoelectric sensitivity, thermo conductivity or photosensitivity to detect presence of
smoke, increase in temperature, light intensity or total radiation. Their types are: Thermal expansion detectors.
Radiant energy detectors. Light interference detectors and ionization detectors. They should be properly
located depending upon their range. They simply give alarm and cannot extinguish fire. They make us alert for
fire fighting. Though fire detection and alarm systems are separate systems but the latter has to operate just
after the former operates. Therefore they are considered together. IS 2175 and 2189 also deal with them
together. Two main functions of any fire detection system are 1. To give alarm to start up extinguishing
procedure, and 52 2. To give early warning to area occupants to escape. Selection of the type of detector is
important For example, low risk areas need thermal detectors, a ware house may have infrared and ionization
detectors and a computer area requires ionization or combination detectors.
Q32. Explain the role of firefighting system in industry.
Ans - The fire fighting system is most probably important for all building services. The main aim of the fire
fighting system is to protect human life and property of human and other important documents. It consists of
three parts are listed below:
Large storage of water tanks either in the underground or top of the building which is called fire tanks.
Pumping system.
A large network of pipes like hydrants and sprinklers.
Importance of fire fighting equipment
Safety against fire is a very important thing to be considered at all workplaces and homes. Every year a large
number of people die due to fire accidents. Fire fighting systems AMC services involves in creating awareness
among the people about fire safety and it can be easily ensured by having proper fire protection and fire
fighting system. The importance of a fire fighting system is an indispensable one to ensure maximum protection
against fire. The fire fighting system also ensures the safety of firefighters who risk their lives to save others life.
Q39. Explain the different types of pressure relief systems provided in your plant.
Ans - The two primary types of relief devices are the relief valve and rupture disk. Relief valves The three basic
types of pressure-relief valves are conventional spring loaded, balanced spring loaded, and the pilot operated.
Conventional spring loaded. In the conventional spring-loaded valve (Fig. 1), the bonnet, spring, and guide are
exposed to the released fluids. If the bonnet is vented to the atmosphere, relief-system backpressure decreases
the set pressure. If the bonnet is vented internally to the outlet, relief-system backpressure increases the set
pressure. The conventional spring-loaded valve is used in noncorrosive services and where backpressure is less
than 10% of the set point. Balanced spring-loaded. The balanced spring-loaded valve incorporates a means to
protect the bonnet, spring, and guide from the released fluids and minimizes the effects of backpressure. The
disk area vented to the atmosphere is exactly equal to the disk area exposed to backpressure. These valves can
be used in corrosive or dirty service and with variable backpressure. Pilot operated. The pilot-operated valve
is combined with and controlled by an auxiliary pressure pilot. The resistance force on the piston in the main
valve is assisted by the process pressure through an orifice. The net seating force on the piston actually
increases as the process pressure nears the set point. Rupture disk devices The rupture-disk device is a
nonreclosing differential-pressure device actuated by inlet static pressure. The rupture disk is designed to burst
at set inlet pressure. The device includes a rupture disk and a disk holder. The rupture disk may be used alone,
in parallel with, or in conjunction with pressure-relief valves. They are manufactured in a variety of materials
with various coatings for corrosion resistance. Pilot-operated-valve considerations. Pilot-operated valves should
be considered for all clean services within their temperature limitations. They are well suited for pressures
below 15 psig and are available with the pilot-pressure sensing line connected to either the valve inlet or to a
different point. Pilotoperated valves provide tight shutoff with very narrow margins between operating
pressure and set pressure.
Q40. . Explain the fire-fighting system provided in your plant.
Ans- General Fire Fighting Equipment Fire fighting systems and equipment vary depending on the age, size, use
and type of building construction. A building may contain some or all of the following features: fire
extinguishers fire hose reels fire hydrant systems automatic sprinkler systems. Fire extinguishers Fire
extinguishers are provided for a 'first attack' fire fighting measure, generally undertaken by the occupants of the
building before the fire service arrives. It is important that occupants are familiar with which extinguisher type
to use on which fire. Most fires start as a small fire and may be extinguished if the correct type and amount of
extinguishing agent is applied whilst the fire is small and controllable. Fire hose reels Fire hose reels are
provided for use by occupants as a 'first attack' fire fighting measure but may, in some instances, also be used
by firefighters. When stowing a fire hose reel, it is important to first attach the nozzle end to the hose reel valve,
then close the hose reel valve, then open the nozzle to relieve any pressure in the wound hose, then close the
nozzle. This achieves two principle objectives: A depressurised hose and hose reel seal will last longer than if
permanently pressurised. When the hose reel is next used, the operator will be forced to turn on the isolating
valve, thus charging the hose reel with pressurised water supply, before being able to drag the hose to the fire.
A potential danger exists if the operator reaches the fire and finds no water is available because the hose reel
valve is still closed. Because hose reels are generally located next to an exit, in an emergency it is possible to
reach a safe place simply by following the hose. Fire hydrant systems Fire hydrant systems are installed in
buildings to help firefighters quickly attack the fire. Essentially, a hydrant system is a water reticulation system
used to transport water in order to limit the amount of hose that firefighters have to lay, thus speeding up the
fire fighting process. Fire hydrants are for the sole use of trained firefighters (which includes factory fire fighting
teams). Because of the high pressures available serious injury can occur if untrained persons attempt to operate
the equipment connected to such installations. Automatic Sprinkler Systems A sprinkler head is really an
automatic (open once only) tap. The sprinkler head is connected to a pressurised water system. When the fire
heats up the sprinkler head, it opens at a pre-set temperature, thus allowing pressurised water to be sprayed
both down onto the fire and also up to cool the hot smoky layer and the building structure above the fire. This
spray also wets combustible material in the vicinity of the fire, making it difficult to ignite, thereby slowing down
or preventing fire spread and growth.
Q45. Disasters
Seveso disaster (1976):
The Seveso disaster was an industrial accident that occurred around 12:37 pm on July 10, 1976, in a small
chemical manufacturing plant approximately 20 kilometres (12 mi) north of Milan in the Lombardy region
of Italy. It resulted in the highest known exposure to 2,3,7,8-tetrachlorodibenzo-p-dioxin (TCDD) in residential
populations,[1] which gave rise to numerous scientific studies and standardized industrial safety regulations.
The EU industrial safety regulations are known as the Seveso II Directive. The Seveso disaster was named
because Seveso, with a population of 17,000 in 1976, was the community most affected. Other affected
neighbouring communities were Meda (19,000), Desio (33,000), CesanoMaderno (34,000) and to a lesser
extent Barlassina (6,000) and Bovisio-Masciago (11,000).[2] The industrial plant, located in Meda, was owned by
the company ICMESA (IndustrieChimicheMedaSocietàAzionaria), a subsidiary of Givaudan, which in turn was a
subsidiary of Hoffmann-La Roche (Roche Group). The factory building had been built many years earlier and the
local population did not perceive it as a potential source of danger. Moreover, although several exposures of
populations to dioxins had occurred before, mostly in industrial accidents, they were of a more limited scale.
Q47. MSDS
Ans- A safety data sheet (SDS), material safety data sheet (MSDS), or product safety data sheet (PSDS) is a
document that lists information relating to occupational safety and health for the use of various substances and
products. SDSs are a widely used system for cataloguing information on chemicals, chemical compounds, and
chemical mixtures. SDS information may include instructions for the safe use and potential hazards associated
with a particular material or product, along with spill-handling procedures. The older MSDS formats could vary
from source to source within a country depending on national requirements; however, the newer SDS format is
internationally standardized.
SECTION 1: Identification of the substance/mixture and of the company/undertaking
1.1. Product identifier 1.2. Relevant identified uses of the substance or mixture and uses advised against 1.3.
Details of the supplier of the safety data sheet1.4. Emergency telephone number SECTION 2: Hazards
identification 2.1. Classification of the substance or mixture 2.2. Label elements 2.3. Other hazards SECTION 3:
Composition/information on ingredients 3.1. Substances 3.2. Mixtures SECTION 4: First aid measures 4.1.
Description of first aid measures 4.2. Most important symptoms and effects, both acute and delayed 4.3.
Indication of any immediate medical attention and special treatment needed SECTION 5: Firefighting measures
5.1. Extinguishing media 5.2. Special hazards arising from the substance or mixture SECTION 6: Accidental
release measure 6.1. Personal precautions, protective equipment and emergency procedures 6.2.
Environmental precautions SECTION 7: Handling and storage 7.1. Precautions for safe handling 7.2. Conditions
for safe storage, including any incompatibilities SECTION 8: Exposure controls / personal protection 8.1. Control
parameters 8.2. Exposure controls SECTION 9: Physical and chemical properties 9.1. Information on basic
physical and chemical properties 9.2. Other information SECTION 10: Stability and reactivity 10.1. Reactivity
10.2. Chemical stability SECTION 11: Toxicological information 11.1. Information on toxicological effects
SECTION 12: Ecological information 12.1. Toxicity 12.2. Persistence and degradability SECTION 13: Disposal
considerations 13.1. Waste treatment methods SECTION 14: Transport information 14.1. UN number 14.2. UN
proper shipping name SECTION 15: Regulatory information 15.1. Safety, health and environmental
regulations/legislation specific for the substance or mixture 15.2. Chemical safety assessment SECTION 16:
Other information 16.2. Date of the latest revision of the SDS
Q48. HAZCHEM Code
Ans - The HAZCHEM code (also called Emergency Action Code) gives vital information to fire brigade and
other emergency services on the action to be taken to combat spillage, leakage or fire in an emergency
involving a hazardous substance. The letters signify 4 aspects viz.
1. Method of controlling spillage a) by diluting or b) by containing
2. Personal protective equipment to be worn by fire fighters
3. Reactive nature of Chemical, and Need for evacuation.
4. It is important to note here that the objective of the HAZCHEM code is not to identify the chemical carried
in the vehicle. The purpose of HAZCHEM code is only to provide guidance on the basic approach to dealing
with an emergency.
In interpreting the HAZCHEM code, the following points will be useful:
1. If necessary, a fire fighting medium represented by a higher number than that shown may be used, but not
represented by a lower number.
2.Where the letter appears as white on black, police and other non-fire service personnel need to wear
breathing apparatus only for a fire and not for a spillage, but firemen are required to wear it in both cases.
3. Letter E indicates that the officer in charge should consider civil evacuation of the area
The Indian Chemical Manufacturers Association (ICMA), in their publication "Code for Safe Transportation of
Hazardous Substances by Road" recommends that at least the area within a radius of 300m should be
considered for evacuation wherever 'E' appears in HAZCHEM code. For example for ethylene oxide with UN
number 1040 and HAZCHEM code is 2PE and would be decoded as:
2- Fog equipment is recommended (through extinguishing agents corresponding to higher number may also
be used).
P- Can be violently (V) reactive. Full body clothing with breathing apparatus is necessary. The substance may
be diluted and washed to drain.
E- Consider evacuation as first priority.
Every goods carriage used for transporting any dangerous or hazardous goods shall be legibly and conspicuously
marked with an emergency information panel in each of the three places as specified, so that the emergency
information panel faces to each side of the carriage and to its rear and such panel shall contain the information.
Q51. Chemistry of fire. Brief corresponding actions for fire extinguishing with respect to components of fire
triangle.
Ans - Oxygen, heat, and fuel are frequently referred to as the "fire triangle." The important thing to
remember is: take any of these four things away, and you will not have a fire or the fire will be
extinguished. All fires can be extinguished by cooling, smothering, starving or by interrupting the
combustion process to extinguish the fire. Cooling: limiting temperature by increasing the rate at
which heat is lost from the burning material Smothering: limiting oxygen by preventing air from
reaching the seat of the fire to allow the combustion process to reduce the oxygen content in the
confined atmosphere until it extinguishes itself Starving: limiting fuel by removing potential fuel
from the vicinity of the fire, removing the fire from the mass of combustible materials or by dividing
the burning material into smaller fires that can be extinguished more easily
Interrupting: inhibiting the chemical chain reaction by applying extinguishing media to the fire that
inhibit the chemical chain reaction at the molecular level)
Q1 Role of PSM Advantage and Dissadvan Q25 Flare & role in Safety
Role of Training in safety Different
Q2 types Q26 Safety working on pipelines
Role of Instrumentation in Safety and Fire & Fire Types & Types of
Q3 advantage Q27 Extinguisher
Q4 Bhopal Gas Tragedy Q28 Deflagration & Detonation
Hazardous area classification and
Q5 advantage Q29 BLEVE & VCE
Plant siting and layout Major
Q6 petrochemical plant Q30 Dust Explosion
Fire Detection and alarm
Q7 HIRA & IMPORTANCE Q31 system
Two unit operation with safety
Q8 Fertilizer, Pesticide Q32 Fire Fighting system in Industry
Pressure Vessels Hazards and
Q9 P & ID in safety and advantages Q33 Controls
Q10 Flame Arrestor & Diagram Q34 Safety in bulk storage of gasses
Q11 Pesticides safety measures Q35 Corrosion & types
Safety in process & operation explosive
Q12 chemical Q36 Safety in bulk storage of acid
Q13 Vapour cloud Explosion & UVC Q37 Steam Explosion
Safety in transfer of flammable
Q14 chemical Q38 Liquefied Flammable gas
Safety in handling acid & Alkali Different types of pressure
Q15 chemicals Q39 relief system
CMV rule for transportation of hazard Fire Fighting system in your
Q16 Chemical Q40 plant
Q17 Compatibility in safety Q41 Statutory for Pressure vessels
Nitrogen blanketing of Storage
Q18 Safety storage of flammable gases Q42 tank
Sprinkler system for a
Q19 UN classification of Hazard Chemical Q43 flammable tank
Q20 Safety in startup and shutdown Q44 Safety of LPG tank Farm
Q21 Role of Maintenance in Safety Q45 Disasters
Inspecting the workplace- checklist of
Q22 H&S rep Q46 TREM Card
Q23 Colour Code System & Advantages Q47 MSDS
Q24 Safety Relief System Q48 HAZCHEM Code
Q25 Flare & role in Safety Q49 MOC and how to
Q26 Safety working on pipelines Q50 Emergency Information Panel
Q51 Fire Triangle and Starvation Cooling & Smooth