MCQs

1) Head Quarters of ILO- Geneva

2) Safety & Risk phrases are to be marked on- Bottles/small containers
3) Act which governs the periodic testing of process pressure vessels- Petroleum
act
4) Chemical which was involved in Flixborough disaster- Cyclohexane
5) Most commonly observed loss of containment facility in tank farms- Bund walls
6) Public liability insurance scheme is a relief for- Neighborhood
7) Most important emergency control available with road Tankers- TREM Card
8) Year, Month & Date of Bhopal disaster- 2nd December 1984
9) One Hazardous material generated on the walls affected by with ‘Sick Building
Syndrome”- Molds
10) One Bio hazard which is very commonly observed in industrial installations-
11) One substitute being used in place of Halon- Inergen (Nitrogen + Argon +
CO2)
12) One Non-Destructive Inspection technique- Dye penetration test/
Radiography
13) The chemical involved in Seveso disaster- 2,3,7,8- Tetra Chloro Dibenzo Para
Dioxin (TCDD)
14) Internal Organization to Fire Safety- National Fire Protection Association
15) DISH equivalent American Statutory body- OSHA
16) Environment related Risk assessment technique- Environmental Impact
Assessment
17) Apex Safety institute in India which deals exclusively with Hydrocarbon
industries- Oil Industry Safety Directorate (OISD)
18) Storage facility which is maintained in Sub Zero temperature conditions-
Cryogenic Storage tank / Cryo tank
19) Phrase notifying hazardous characteristic of a material packed and issued for
domestic consumption- Store in cold and dry place/ Keep away from direct
sunlight
20) One Standard guide word to depict “Deviation” about “Pressure condition” in a
HAZOP study- more than
21) Device which is installed on Steam piping to prevent ‘Water Hammering’-
Steam trap valves
22) Device installed on High level vent points to warn about hazardous levels of
gas/ vapor/ dust emissions-

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 Abbreviations
FTA – Fault Tree Analysis
FMEA – Failure Mode and Effect Analysis
ETA – Event Tree Analysis
MORT- Management Oversight Risk Tree
HAZOP- HAZard OPerability
HAZAN- HAZard ANalysis
PHA- Preliminary Hazard Analysis
PSM- Process Safety Management
LTA- Latent Transitional Analysis
FR- Frequency Rate
SR- Severity Rate
DII- Disabling Injury Index
TQ- Threshold Quantity
BLEVE- Boiling Liquid Expanding Vapor Explosion
CCR- Central Control Room
MCAA- Maximum Credible Accident Analysis
MSIHCR- Manufacturing, Storage and Import of Hazardous Chemicals Rule
MAH- Major Accident Hazard
DISH- Director of Industrial Safety and Health
PESO- Petroleum and Explosive Safety Analysis
RA- Risk Assessment
OHSAS- Occupational Health and Safety Assessment Series
ALARP- As Low As Reasonably Practicable
GFR- Gujarat Factory Rule
CCE- Chief Controller of Explosives
BIS- Bureau of Indian Standards
ALARA- As Low As Reasonably Achievable
JSA- Job Safety Analysis

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P&ID- Piping and Instrumentation Diagram
EPPRR- Emergency Planning Preparedness and Response Rule
HIRA- Hazard Identification and Risk Analysis
WCA- Workmen Compensation Act
WCR- Workers' Compensation Regulator
SOP- Standard Operating Procedure
ISO- International Organization for Standardization
FAFR- Fatal Accident Frequency Rate
UVCE- Unconfined Vapor Cloud Explosion

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 Definitions
 Sick Building Syndrome (SBS): Situations in which building occupants
experience acute health and comfort effects that appear to be linked to time
spent in a building, but no specific illness or cause can be identified.

 Mounded Storage: A storage vessel which may constructed above ground or

partly buried and which is completely covered by a mound of earth or similar
inert material.

 Cryogenic Storage: A storage below - 40°C is referred as cryogenic storage.

 Linear Heat Detection: A heat sensing cable which monitors and detects
changes in temperature at ANY and ALL points along its length.

 Inherently Safer Plant: A plant in which hazard control is done by minimizing

hazardous inventory or use of alternative less hazardous process instead of
just using PPE alone.

 Safety Integrity Level: A relative level of risk-reduction provided by a safety

function, or to specify a target level of risk reduction.

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 Short Notes
1. ILO:
 A specialized agency associated with UN, established in 1919, to improve the
labour conditions, raise living standards and promote economic as well as
social stability as the foundation for lasting peace throughout the world.
 ILO has 186 member countries.
 It is headed by a Director General appointed by a Governing Body of 24
government representatives, 12 representatives of management and 12
representatives of labour, which meets three times a year.
 ILO has published over 250 studies and publications dealing with safety and
health.
 Main activities of the ILO in the field of Safety, Health and welfare are as under:
 Carries out technical co-operation, international supervision, ensuring effective
application, labour inspection, occupational health services, meetings,
symposia, activities in the field of ergonomics, expert consultancy service etc.
 Expert advice and technical assistance in matters connected with labour and
social policy.
 Publishing conventions and recommendations regarding rights of labour,
employment and training, conditions of work, social security and protection at
work etc.

2. OSHA:
 OSHA is the government regulatory body for occupational safety, Industrial
Health and Environmental protection for USA.
 Similar to the factory inspectorates or Directorates Industrial safety & health
(DISH) in India.
 Objective of an OCCUPATIONAL SAFETY & HEALTH ADMINISTRATION
is to assure safe and healthful working conditions to working men & women.
 Its mission is to implement an effective safety & health management system
in every work place in America.
 OSHA determines which standards apply to your workplace and requires
you to follow these standards and requirements.
 OSHA offers an extensive Web site at osha.gov that includes sections
devoted to training, state programs, small businesses, construction, as well
as interactive eTools to help employers and employees.
 OSHA also offers training programs for employers and employees to get
hazard recognition.
 OSHA provides standards in 4 categories viz. General industry,
Construction, Maritime and Agricultural.
 These standards are related to work place hazards

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3. NFPA:
 National Fire Protection Association is a non-profit organization, established in
1896, to reduce the world wide burden of fire & other hazards.
 NFPA develops, publishes and disseminates standards and codes indented to
minimize the cause, possibility and effects of fire and other risks.
 Out of various codes of NFPA most important one is ‘NFPA Diamond’
 Draw NFPA diagram and write details regarding it viz. rating, colour indication,
location etc.

4. NSC:
 National Safety Council generate, develop and sustains a voluntary
movement of health, Safety and environment at the national level.
 Managed by 51 members independent Board of Governors headed by the
chairman who is nominated by Government of India.
 Board comprises 16 members elected by the general body of NSC, 32
members elected by the NSC, 2 experts nominated by immediate past
chairman
 NSC has 13 chapters covering 16 states 1 union tertiary and 23 action
centres.
 NSC maintains active liaison with international institutions and agencies in
the field of Safety, Health and Environment.

 NCS carry out following activities:

 Conducting specialised training Courses, Conferences, Seminars &
Workshops all over the Nation
 Conducting consultancy studies such as Safety Audits, Hazard Evaluation,
Emergency Management Planning & Risk Assessment
 Designing and developing HSE promotional materials & publications
 Facilitating organisations in celebrating various campaigns e.g. Road safety
week, Safety Day, Fire Service Week etc.
 Organizes many national and international conferences

5. NIOSH:
 The National Institute for Occupational Safety and Health (NIOSH) is the
United States federal agency responsible for conducting research and making
recommendations for the prevention of work-related injury and illness.
 NIOSH is headquartered in Washington, D.C.
 NIOSH is a professionally diverse organization with a staff of 1,200 people
representing a wide range of disciplines including epidemiology, medicine,
industrial hygiene, safety, psychology, engineering, chemistry, and statistics.
 Mission of NIOSH is to develop new knowledge in the field of occupational
safety and health and to transfer that knowledge into practice.

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  NIOSH does following major activities:
 Conduct research to reduce worker illness and injury, and to advance worker
well-being.
 Promote safe and healthy workers through interventions, recommendations
and capacity building.
 Enhance worker safety and health through global collaborations.

6. HAZCHEM Code:
 The HAZCHEM code for any chemical consists of three parts on an orange
background:
1) A number 1 to 4
2) A capital letter P to T or W to Z (except Q)
3) An optional letter E
 Significance of Numbers 1 to 4 (types of extinguishers to be used)
1)Water jet
2)Water fog produced by a high pressure atomizing jet direct
3)Foam (normal protein foam as used by all fire brigades)
4)Dry agents – commonly known as Dry Chemical Powder and vaporizing
liquids are also in this category
 Significance of Letter P to T and W to Z (except Q)
 P to T are those which may in an emergency be diluted and flushed down
the nearest drain.
 W to Z may not be diluted and must be contained.
 P & R and W & X are those whose vapour or products of combustion are
injurious to the human skin and for which full impervious protective clothing
(generally nitrile rubber) as well as (self-contained breathing apparatus
SCBA) must be provided
 S & T and Y & Z are those which Breathing apparatus (BA) alone is
necessary.
 P, S, W and Y are capable of reacting, violently either alone or with some
other substances with which it may come in contact
 Final and optional letter E calls for evacuation of all persons other than the fire
brigade to a minimum distance of 200 meters form the incident spot, whether
fire or spillage.

7. Halon Substitute:
 The United States, is offering Inergen fire suppression systems as an
alternative to halon-based fire protection systems.
 Inergen is environmentally friendly, has no global warming potential, does not
deplete ozone and has zero atmospheric lifetimes. This high pressure agent is
stored in cylinders similar to CO2. The new agent comprises three naturally
occurring gases – nitrogen, argon and CO2.

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 FM-200 is a new halon alternative, which is safe to use in normally occupied
areas.
 FE-13 (trifluoromethane) is the newest clean agent, it is the safest of all.

Advantages:

 No cleanup is required after discharge of the agents.

 Such agents does not form corrosive or abrasive residues, hence suitable
for use on delicate, expensive assets that might otherwise be destroyed by
non-clean agents such as foam or water.
 Non-conductive in nature and hence can be employed for the protection of
sensitive electrical and electronic equipment.
 Nontoxic at their typical design levels

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 Descriptive Question
1. Bhopal Gas Tragedy:
 In the early morning hours of December 3, 1984, a poisonous grey cloud from
Union Carbide India Limited’s pesticide plant at Bhopal spread throughout the
city.
 Major cause behind the accident was entering of water leakage into a MIC tank-
610.
 Metal within leaking water acted as a catalyst and speeded up the exothermic
reaction between MIC and water.
 As a result temperature inside the tank increased to over 200 °C, raising the
pressure to a level the tank was not designed to withstand.
 This forced the emergency venting of pressure from the MIC holding tank,
releasing a large volume of toxic gases.
 Around 5 lakh people got affected and around 3787 deaths were officially
reported.

 Factors that contributed to this disaster:

 Use of hazardous chemicals (MIC) instead of less dangerous ones
 Storing chemicals in large tanks instead of over 200 steel drums.
 Corroded pipelines
 Poor maintenance after the plant ceased production in the early 1980s
 Failure of several safety systems (due to poor maintenance and regulations).
 Safety systems shut down to save money - including the MIC tank refrigeration
system which alone would have prevented the disaster.
 Vent gas scrubber was under designed, not repaired and not connected.
 Water curtain jets were under designed to reach the maximum height.
 The computerized pressure / temperature sensing system, a warning device to
give alarm and to control the situation at the time of abnormal condition was not
installed.
 Neighboring community was not told about significance of the danger.
 Correct antidote and medical treatments were not suggested to surrounding
doctors.
2. Chernobyl Disaster:
 On April 26, 1986, a major accident occurred at Unit 4 of the nuclear power
station at Chernobyl, Ukraine, in the former USSR.
 The accident destroyed the Chernobyl-4 reactor and killed 30 people,
including 28 from radiation exposure.
 209 people on site and involved with the clean-up were treated for acute
radiation poisoning.
 On 25 April, prior to a routine shut-down, the reactor crew at Chernobyl-4 began
preparing for a test to determine how long turbines would spin and supply power
following a loss of main electrical power supply.
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  A series of operator actions, including the disabling of automatic shutdown
mechanisms, preceded the attempted test early on 26 April.
 As flow of coolant water diminished, power output increased. When the operator
moved to shut down the reactor from its unstable condition arising from previous
errors, a peculiarity of the design caused a dramatic power surge.
 The fuel elements ruptured and the resultant explosive force of steam lifted off
the cover plate of the reactor, releasing fission products to the atmosphere.
 A second explosion threw out fragments of burning fuel and graphite from the
core and allowed air to rush in, causing the graphite moderator to burst into
flames.
 Accident wasn’t due to absence of safety systems but due to the fact that most
of these protective systems were turned off by the plant operators as they
conducted a fatal experiment.
 Major lesson from this disaster was, need for a SOP and strict monitoring over
any bypassing or shutting down of safety system.

3. Seveso Disaster:
 On Saturday 10 July 1976, in the Milan suburb of Seveso, a reactor safety
valve vented 2, 3, 7, 8 – Tetra Chloro Dibenzo Para Dioxin (TCDD) a toxic gas
and the air was filled with a toxic cloud.
 Cloud drifted over the adjacent town and come down to earth due to heavy rain
 Management tried to inform the local authority but they face a communication
problem due to weekend holidays
 One of the plant reactors had overheated, causing the release into the
atmosphere of one of the most toxic chemicals known to man, dioxins.
 The first detectable human health effect was chloracne, a pustular skin
eruption resulting from exposure to dioxins, which appeared in a number of
individuals, including 193 schoolchildren.
 Dioxin contamination has long term effects and effects are carried on with
generations.
 People living in contaminated areas at the time of the accident have suffered
significantly elevated rates of blood, liver and bone cancers, and higher death
rates.
 The accident make it clear that the manufacturers should not be reluctant or
publicize what they are doing and assess their process very carefully to ensure
that there are no similar hidden hazards.
 Seveso disaster suggested need for continuous monitoring of process, use of
proper control instrumentation, various hazard analysis techniques.

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4. Bio Hazard:
 Bio hazards are biological substances that pose a threat to the health of living
organisms, primarily that of humans, known as pathogens.
 They include bacteria, viruses, and fungi as well as larger organisms such as
parasites and plants.

Route of entry:
 Biological agents enter the body by inhalation, by ingestion or by absorption
through the skin. The possible routes of entry are limited by the characteristics
of the agent.
 Once inside the body, infectious agents can multiply and be passed from one
person to another.
 The route they follow is referred to as the route of transmission, it may be direct
or indirect.
 Direct transmission takes place when there is physical contact between an
infected and a non-infected person.
 Direct transmission might also occur if a person is injected or punctured with an
infected needle or other sharp object which is infected.
 Indirect transmission may occur when infectious agents attach themselves to
materials or objects such as food and water or cooking and eating utensils.
 An infectious agent may also be transmitted by an insect. The insect may carry
the infectious agent from the source to an uninfected person.

Health Hazards:
 Bacterial diseases include tuberculosis, tetanus and food poisoning.
 Infection through the skin can cause boils or blood poisoning.
 Common fungal diseases are ringworm, which is a skin infection, and thrush,
which infects the skin and mucous membranes.
 Viral diseases include hepatitis, mumps, German measles and rabies.

Control Measures:
 Biological hazards may be recognized by examining the materials used in the
workplace or by a history of illness in workers.
 May be controlled at the source of the hazard, along the path from the source
to the worker, and at the worker.
 Controls at the source involve eliminating or reducing exposure through
elimination, isolation or containment of the hazard.
 Especially ventilation systems, which might harbour biohazards must be
regularly maintained, cleaned and sterilized.
 Controls along the path include cleaning and disinfecting as well as the safe
disposal of waste.

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  It is important that all bio-hazardous materials, including waste, are labelled,
handled and disposed of in a manner that avoids contamination of the handler
or the environment.
 Control at the worker may involve personal protective equipment such as gloves
and masks.
 Immunization programs may be appropriate in some circumstances.

Precautions

 All contaminated equipment or material should be contained, labelled and

isolated.
 Spills should be cleaned up immediately.
 No one should eat, drink or smoke in a potentially hazardous work area.
 Showers, lockers and laundry facilities should be used to prevent hazards from
leaving the workplace.
 Safe procedures should be designed to deal with the specific hazards of each
workplace.

5. Advanced Fire Protection System:

 Advance fire protection system involves use of helon alternatives, gas & fire
detection system, linear heat detection system, fire training group and
upcoming standards from international organizations like NFPA, OISD etc.

 Halon Alternatives:
 Generally CO2 based fire extinguishers are used. But as CO2 being major
greenhouse gas, it’s usage as an extinguishing agent is matter of concern.
 So as an alternative halon came into picture. Unique capabilities of halon allows
it to extinguish fire without harming the surrounding area.
 Suitable for class B and C fires.
 Non-conductive and leaves no traces when applied.
 Lighter in comparison to CO2.
 Most commonly used halon are Halon 1211 and Halon 1301, but one major
issue with it is their high ozone depletion potential.
 As an alternative to such halon, ingern (N2 + Ar + CO2) is being accepted as an
alternative.

 Gas and Fire detection system:

 Such system provides early and reliable detection of fire or gas, alerts
personnel and initiates protective actions automatically or manually upon
operator activation.
 Such system consists of field mounted detection equipment and manual alarm
stations, a system logic unit for processing of incoming signals, alarm and HMI
units.

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  Firefighting systems can be integrated with such detection system to take
preventive actions.

 Linear heat detection system:

 System in which a heat sensing cable which monitors and detects changes in
temperature at ANY and ALL points along its length.
 It will be bit costly because of long length of wire required in large installations
but its specific advantage is it will detect overheat conditions means when flame
is not even visible we can predict the occurrence of fire.
 Use of higher sensitive cable will lead to accurate detection of even a small
temperature difference.
 Such system can be integrated with alarm system and firefighting system for
preventive measures.

 Recent advancement in technology has brought automated fire extinguishing

systems like water sprinkler system, water curtain system etc. which are
intelligent fire fighting systems.
 From training and education, related to firefighting, point of view technological
advancement has made it efficient and more practical and easy to learn
approach.

6. Environmental Impact Assessment:

 As per “Environmental protection Act, 1986” it is mandatory for all
hazardous chemical units to conduct an EIA through a competent
independent agency and submit a report prior to the execution of a project
for new installation or expansion / addition / alteration of an existing facility.
 Objective of an EIA is to identify & assess the environmental consequences
of plant under consideration.
 Identification & assessment of these impact require collection /
manipulation of large amounts of data.
 It should be undertaken early enough in the planning stage of projects for
selection of environmentally compatible sites, process technologies and
such other environmental safe guards.

Important information to be furnished to facilitate an EIA Report:

 Detailed description of the process activity
 Discussion on the probable impact on the environment
 Any adverse environmental impact that cannot be controlled or avoided
 Alternatives to the proposed action that might avoid some or all the adverse
environmental effects
 Assessment of the cumulative, long term effect of the proposed action

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7. Ambient Air and Stack emission Monitoring:
 Basic need of sampling, monitoring and analysis is to find the level of pollution
and to work out strategy to reduce it.
 It statutory requirement by Form No.37 U/R 12B, GFR 1963
 Monitoring is more than air sampling, it includes a series of actions to assess
the protection necessary.
Ambient Air Monitoring:

 Mostly it is done by two methods viz. Personal monitoring and Area monitoring.
 Air monitoring can be done for 8 hours, 15 minutes or instantaneous.
 The results are then compared with exposure indices such as TLV, STEL and
ceiling limits.
 Area air monitoring is often conducted by placing sampling device near
contaminant emission areas.
 First, permissible exposure limits should be found and kept as target. Then
actual level should be measured and compared with the target.
 If the measure level is higher than the permissible, bring down them down to
the permissible level.
 In personal air monitoring purpose is to find individual exposure.
 In personal air monitoring sampling device (dosimeter) is positioned as close
as possible to the breathing zone of the worker so the data collected closely
approximates the concentration inhaled.
 After personal air monitoring is completed the sampling media is analysed in a
laboratory using analytical methods.

Stack Emission Monitoring:

 Under Environmental (protection) Act 1986, monitoring of stack emissions in
terms of temperature, particulate matter, suspended solids, SOX, NOX, CO and
concentrations of many gases is statutory requirement.
 Pollution Control Board officers can take samples of air or emission and sent
them to laboratory for analysis. Board can prescribe stack height and air
sampling point.
 If stack emission has more pollutants then prescribed limits by PCB, then its
duty of owner to bring them down under limits. Else PCB may issue order of
closure.

8. Safe Siting of Hazardous Industries:

 Appropriate site selection through careful planning and loss control studies at
the initial stages of a project formulation is must.
 Points to be considered with respect to a site selection could be summarized
as;

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o Type, size and magnitude of installation
o Land availability and its cost
o Raw material, labour and infrastructure availability
o Operational and maintenance convenience
o Hazards to employees, transporters and service providers
o Hazards to nearby community
o Access to market (marketing and distribution)
o Solid and liquid Waste disposal responsibilities
o Waste water treatment & effluent discharge / disposal
o Surrounding population density and distance from the public
o Distance from highways, railways and transport facilities
o Adequate distance, separating plants, utilities, hazardous material storage,
loading / unloading, warehouse, supply chains, furnaces etc.
o Suitability of climate, environment and factors related to ecology, geology,
meteorology, micro & macro biology
o Internal and external security availability
o Emergency preparedness and response plan
o Suitability for industrial use and located away from residential and other
public occupied areas
o Availability of electricity or other prime movers and other utilities
o Sufficient spacing must be available to develop green belt zone as per
Environmental guidelines
o Internal access, working and movement space for men, material, machines,
tools, maintenance facilities
o Convenient and quick access to the provisions like firewater, pump house,
hydrant, monitors, portable extinguishers, emergency squads, occupational
health centre etc.

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