CA1 Process safety and environmental quality

MCQs chose the correct answer. (1.5pts)

1) Process Safety incidents can cause
a) Multiple injuries and/or fatalities
b) Massive asset damage
c) Environmental consequence
d) Reputation impact
e) All of the above

2) Process Safety incidents are generally caused by failure of

a) A single barrier
b) Multiple barriers
c) Sometimes single but sometimes multiple barriers
d) None of the above

3) Who is responsible for managing process safety and asset integrity

a) Operations and Maintenance Staff
b) Projects and Engineering Staff
c) Contracts and Procurement Staff
d) All of us either directly or indirectly

Q1- Define the terms: Process safety, Industrial safety, Hazard, first aid.(2pts)

Q2 list 4 important of industrial process safety (2pt)

Q3) several hazards are encountered in industries resulting to an accident. List 2 causes of
accident in mining industry (2pt)

Q4) what do you understand by PPE? , list 2 types of EYE and Chemical/Gases PPE (2,5pts)

Q5) cite and briefly explain 2 non-auditary effect of noise pollution (2pts)

Q6) In short note, explain the environmental effect of industrial accident on :(4pts)

Q7) Gases are the most common ignition sources of hazardous accident in oil and gas
industries: list the general classes of such gases and give the appropriate techniques for fire
and explosion preventive measures. (3pts)

Q8) list the classes of fire and the associated ignition source(s)(2pts)
 Correction of CA 1Process safety and environmental quality

MCQ (1,5pts) 1)e, 2)b, 3)d,

Q1)

 Process Safety is defined as “a discipline that focuses on the prevention of fires, explosions,
and accidental chemical releases at chemical process facilities
 Industrial safety; Industrial safety is primarily a management activity that is concerned with
reducing, controlling, and eliminating hazards from the industries or industrial units.
 Hazard; Any real or potential condition that can cause injury, illness, or death to personnel,
damage to or loss of a system, equipment, or property, or damage to the environment.
 First aid; First aid is immediate skilled assistance given to the victim by a certified first aider
in case of an accident, injury, or illness before medical aid is available.

Q2- list 4 important of industrial process safety (2pt)

 Safety is important as it safeguards human life, especially in high risk areas such as
nuclear, aircraft, chemical, oil and gases, and mining industries, where a fatal mistake
can be catastrophic.
 Industrial process safety reduces risks to people, and processes.
 The basic need for safety in industry or any other field is to prevent the occurrence of
mishaps and hazards that sometimes causes heavy loss of life, property, and
environment.
 Each and every employee in the industry desire to work in a safe and protected
atmosphere and it is the moral responsibility of the industry to look toward employee
protection.
 Safety is important for protecting the environment against damage from industrial
accidents and also for minimizing financial losses, property damage, accident, injury,
and even death.

Q3)- several hazards are encountered in industries resulting to an accident. List 2 causes of
accident in mining industry (2p)

 release of poisonous gases such as hydrogen sulphide or explosive natural gases

especially firedam or methane
 collapsing of mine stopes, mining induced seismicity, flooding or general mechanical
errors from improperly used or malfunctioning mining equipment.
 The use of improper explosives underground can also cause methane and dust
explosions.

Q4) Personal protective equipment, commonly referred to as “PPE”, is equipment worn to

minimize exposure to a variety of hazards: EYE(General safety glasses,Laser safety
glasse,Chemical splash goggles,Impact goggles,Face shields), Chemicals/gases (Respirator
cartridges, Full-face respirators, Half-mask respirators,Surgical masks)

Q5) cite and briefly explain 2 non-auditary effect of noise pollution(2pts)

  Irritation and annoyance: Noise, sometimes, leads to emotional disturbances and
makes people lose their temper. It can interfere with proper rest and sleep. Annoyance
seems to increase with the loudness of the sound
 Trouble Communicating: High decibel noise can put trouble and may not allow people
to communicate freely. Constant sharp noise can give you severe headache and disturb
your emotional balance.
 Effect on Animals: Animals rely heavily on sounds to communicate, to find food,
avoid predators etc. Pets react more aggressively due to exposure to constant noise.
They become disoriented more easily and face many behavioral problems.
Overexposure to high intensity of noise affects the hearing ability of many animals.
Man-made noise affects mating calls and echolocation. This leads to reduction in
survival and reproduction rates. At an ecosystem level, noise pollution could lead to
migration of animals. Their migration can affect the crop production. Because many
animals such as bats pollinate bananas, peaches, agave and other cash crops.
 Effect on non-living things: The noise booms cause cracks in walls of buildings as
well as in hills. Sonic boom can break window panes and buildings.

Q6) Gases are the most common ignition sources of hazardous accident in oil and gas
industries: list the general classes of such gases and give the appropriate techniques for fire
and explosion preventive measures. (3pts)

Gases are grouped as follows: (Compressed gas, Liquefied gas,Cryogenic gas)

Preventive measures:

 use of containers, fitting regulators, valves, and piping that have been approved for use
with a given gas; •
 preventing the overpressurization of the storage container, regulator, valves, and
piping; •
 preventing the storage container from overheating;
 limiting the amount of storage at a given location;
 segregation of storage to prevent interreaction among gases;
 ventilation to prevent the accumulation of vapors;
 exclusion of ignition sources;
 proper training for persons employed in handling gases; and installation of systems,
regulated as to qualification of installers

Q8) list the classes of fire and the associated ignition source(s)(2pts)
Class A:Ordinary Combustibles (paper, wood, plastics..) ,Class B: Flammable liquids and gas
Class C: Electrical, Class D: Metal ,Class K: Cooking oils
 CA2 Process safety and environmental quality

Q1- Define the terms: Process safety, Industrial safety, Hazard, first aid.(2pts)

Q2- list 3 impacts of industrial ventilation (3pts)

Q3- Define PPE, list 3 types of hand protective equipment and their uses (3.5pts)

Q4- list 5 important of process safety (2.5pt)

Q5a) what do you understand by fire safety plan?(1pts)

b) List the appropriate items that should be considered in a safety plan (3pts)

Q6- several hazards are encountered in industries resulting to accident. List 2 causes of
accident in mining industry (2pt)

Q7- Definition of risk.What do you understand by pure risk and speculative risk? (3pts)
 Correction of CA2 Process safety and environmental quality

Q1- Define the terms: Process safety, Industrial safety, Hazard, first aid.(2pts)

 Process Safety is defined as “a discipline that focuses on the prevention of fires, explosions,
and accidental chemical releases at chemical process facilities
 Industrial safety; Industrial safety is primarily a management activity that is concerned with
reducing, controlling, and eliminating hazards from the industries or industrial units.
 Hazard ;Any real or potential condition that can cause injury, illness, or death to personnel,
damage to or loss of a system, equipment, or property, or damage to the environment.
 First aid; First aid is immediate skilled assistance given to the victim by a certified first aider
in case of an accident, injury, or illness before medical aid is available.

Q2- list 3 impacts of industrial ventilation (3pts)

 Large amounts of dust or fumes are generated.
 Increased heating costs from ventilation in cold weather are a concern.
 Emission sources are few in number and near the workers’ breathing zones.

Q3- Define PPE, list 3 types of hand protective equipment and their uses (3.5pts)
 Light latex, vinyl or nitrile gloves(Working with biological hazards and chemical splash
hazards)
 Light chemical resistant gloves(Working with small volumes of corrosive liquids, organic
solvents, flammable compounds)
 Light to heavy chemical resistant gloves(Using apparatus under pressure, air or water reactive
chemicals)
 Insulated gloves(Working with hot liquids and equipment, open flames, water bath, oil bath;
Handling cryogenic liquids)
 Wire mesh gloves(Working with live animals and exposed to potential cuts)

Q4- list 5 important of process safety (2.5pt)

 Safety is important as it safeguards human life, especially in high risk areas such as
nuclear, aircraft, chemical, oil and gases, and mining industries, where a fatal mistake
can be catastrophic.
 Industrial process safety reduces risks to people, and processes.
 The basic need for safety in industry or any other field is to prevent the occurrence of
mishaps and hazards that sometimes causes heavy loss of life, property, and
environment.
 Each and every employee in the industry desire to work in a safe and protected
atmosphere and it is the moral responsibility of the industry to look toward employee
protection.
 Safety is important for protecting the environment against damage from industrial
accidents and also for minimizing financial losses, property damage, accident, injury,
and even death.
Q5a) what do you understand by fire safety plan?(1pts)

b) List the appropriate items that should be considered in a safety plan (3pts)

Q5a) A fire safety plan is also known as the fire emergency evacuation plan(FEEP) is a
written document which include the action to be taken by all staff in the event of fire and
the arrangement for calling the fire brigade.

b) The following items should be considered where appropriate: Fire evacuation strategy; action
on discovering a fire; action on hearing the fire alarm; calling the fire brigade; power/process
isolation; identification of key escape routes; assembly point; firefighting equipment provided;
personnel emergency evacuation plan etc…(0.5 x 6)

Q6- several hazards are encountered in industries resulting to accident. List 2 causes of
accident in mining industry (2pt)

 including release of poisonous gases such as hydrogen sulphide or explosive natural

gases especially firedam or methane
 collapsing of mine stopes, mining induced seismicity, flooding or general mechanical
errors from improperly used or malfunctioning mining equipment.
 The use of improper explosives underground can also cause methane and dust
explosions.

Q7- Definition of risk.What do you understand by pure risk and speculative risk? (3pts)

 Risk is the combination of likelihood and consequence of a specific hazard event

occurring or
 Risk can simply be defined as the unlooked for, unwanted event in the future.

Pure risk; These are risks that can result only in loss or damage to goods by fire or theft or the
incurring of legal liability to pay damages by negligently causing bodily injury to someone or
damage to the property of others, Pure risks are insurable because they are capable of
statistical measurement.

Speculative Risks – Speculative risks may result in either a profit or a loss, which may be
either large or small. These risks are uninsurable because there is no way of measuring their
effect.
 Exams(1): Process safety and environmental quality

MCQ (2pts)
1) A safe plant is the one in which
a) Integrity is established at the design stage
b) Technical integrity is maintained throughout the life cycle of the asset
c) Operating integrity is maintained all the time
d) All of the above

2) Who is responsible for managing process safety and asset integrity

a) Operations and Maintenance Staff
b) Projects and Engineering Staff
c) Contracts and Procurement Staff
d) All of us either directly or indirectly

3) If you see any leaks or spills what should you do

a) Walk past as it is not your job to report it.
b) Report the leak immediately
c) Report only if the leak seems to be getting worse
d) Report only if the leak is big

4) Process Safety incidents are generally caused by failure of

a) A single barrier
b) Multiple barriers
c) Sometimes single but sometimes multiple barriers
d) None of the above

Q1) Define the terms: Process safety, Hazard, Pakistan factory act, fire safety plan (2pts)

Q2)
a) What is the definition of risk(0,5pt)
b) What do you understand by the term insurance? (1pt)
c) What do you understand by pure risk and speculative risk? (2pts)
d) Distinguish between an insurance company and a re-insurance company. (2pt)

Q3) list 3 objectives of the Workmen’s compensation acts (2pts)

Q4) Industrial ventilation systems are necessary requirements for the health and safety of
workers across many industries, enumerate the effect of this system (1,5pts)

Q5) Hazardous chemicals like flammable and combustible liquids exist and are used in all
types of occupancies; list 4 technical preventive measures to avoid chemical fire (4pts)

Q6) list 4 common causes of fire accident (2pts)

Q7) When to use a fire extinguisher? (1pts)

 Correction of Process safety and Environmental Quality EXAM(1)

MCQ (2pts) 1d, 2d, 3b, 4b

Q1) Define the terms: Process safety, Hazard, Pakistan factory act, fire safety plan (2pts)
Process Safety is defined as “a discipline that focuses on the prevention of fires, explosions,
and accidental chemical releases at chemical process facilities
Hazard: Any real or potential condition that can cause injury, illness, or death to personnel,
damage to or loss of a system, equipment, or property, or damage to the environment.
The Pakistan factory act is an act to consolidate and amend the law regulating labour in
factories.
A fire safety plan is a written document which include the action to be taken by all staff in the
event of fire and the arrangement for calling the fire brigade

Q2)

a) Definition of risk(0,5pt)
 Risk is the combination of likelihood and consequence of a specific hazard event
occurring or
 Risk can simply be defined as the unlooked for, unwanted event in the future.
b) What do you understand by the term insurance? (1pt)

Insurance is an arrangement by which one party (the insurer) promises to pay another party
(the insured) a sum of money if something should happen which causes the insured to suffer
financial loss. By so doing, the responsibility for paying for such losses is then transferred
from the insured to the insurer. In return for accepting the burden of paying for losses when
they occur, the insurer charges the insured a price called premium.

c) What do you understand by pure risk and speculative risk? (2pts)

Pure risk; These are risks that can result only in loss or damage to goods by fire or theft or the
incurring of legal liability to pay damages by negligently causing bodily injury to someone or
damage to the property of others, Pure risks are insurable because they are capable of
statistical measurement.

Speculative Risks – Speculative risks may result in either a profit or a loss, which may be
either large or small. These risks are uninsurable because there is no way of measuring their
effect.

d) Distinguish between an insurance company and a re-insurance company. (2pt)

Insurance Companies – Insurance companies are risk takers. They accept risks transferred to
them by individuals, corporate bodies, government and their agencies/corporations etc.
Insurance companies are required to be registered by the National Insurance Commission.
Re–Insurance Companies ; Re–insurance is therefore a form of insurance whereby an
insurance company can transfer to another insurer all or part of its liabilities in respect of
claims arising under the contracts of insurance that it writes.

Q3) list 3 objectives of the Workmen’s compensation acts (2pts)

1) Provide workmen and/or their dependents some relief or to consider compensation

payable by an employer to his workmen in case of accidents arising out of and in the
course of employment and causing either death or disablement of workmen as a measure
of relief and social security.
2) Provide for payment by certain classes of employers to their workmen compensation for
injury by accident.
3) To enable a workmen to get compensation irrespective of his negligence.
4) It lays down the various amounts payable in case of an accident, depending upon the type
and extent of injury. The employer now knows the amount of compensation he has to pay
and is saved of many uncertainties to which he was subject before the Act came into force.

Q4) Industrial ventilation systems are necessary requirements for the health and safety of
workers across many industries, enumerate the effect of this system (1,5pts)

 Large amounts of dust or fumes are generated.

 Increased heating costs from ventilation in cold weather are a concern.
 Emission sources are few in number and near the workers’ breathing zones.

Q5) Hazardous chemicals like flammable and combustible liquids exist and are used in all
types of occupancies; list 4 technical preventive measures to avoid chemical fire (4pts)

 Educating persons in the area where the chemical is handled as to its hazard,
precautionary procedures, danger signals, and proper steps to take in case of an
emergency.
 Providing reference sources, knowing where to look for help in finding the answers to
problems beyond your area of knowledge, and knowing how experts can be contacted.
 Controlling and confining the chemical so that the toxic material cannot be contacted,
swallowed, or inhaled in dangerous quantities during normal operations. • Providing
automatic toxic gas indicators and alarms.
 Keeping combustible materials and packaging away from the storage area.
 Providing a storage building of noncombustible or resistive construction.

Q6) list 4 common causes of fire accident (2pts): Humman Error, Arson, Combustible on site,
Clutter, Faulty equipment

Q7) When to use a fire extinguisher? (1pts)

An extinguisher is used when the fire is contained and not spreading; the extinguisher is
readily available; you know how to use it properly; personal safety is not compromised and
there is a clear path for escape.
 Exams (2): Process safety and environmental Quality

Q1) Define the following terms: Injury, mishap.(1pt)

Q2) Explain the environmental effect of industrial accident on: Ecosystem and Health of
Biota (3pts)
Q3) Complete the table with the appropriate preventive measures. (4pts)

 Use appropriate headgear and avoid wearing loose-fitting cloths during work with
moving machinery.
 Install effective exhaust ventilation and air conditioning to prevent air contamination
and heat stress; if necessary, use odor neutralizing chemicals.
 Protect the skin of the hands (with barrier cream, or chemical-resistant gloves) when
in contact with solvents and cleaning agents; use specific soaps for cleaning the skin
of the hands, at the end of the work shift.
 Wear safety shoes with non-skid soles.
 Wear appropriate ear protection ; consult a safety supervisor or a supplier

Accident hazards Preventive measures

Slips and falls on the level on slippery floors
Capture of clothes in the grinding and mixing equipment
while preparing dyes
Exposure to vapours of solvents, paints, and lacquers can
cause irritation and damage to eyes and mucous membranes,
to the respiratory and digestive tracts, and to the skin.
Exposure to organic substances (toluene, n-hexane,methyl-
alcohol etc.) may damage the nervous system
Exposure to organic substances may cause allergic reactions
such as irritation of the respiratory tract and of eyes and skin
Exposure to excessive noise levels in grinding of pigments

Q4) List 4 types of fire extinguishers and their mode of applications (4pts)

Q5) several hazards are encountered in industries resulting to an accident. List 2 causes of
accident in mining industry (2pt)
Q6) several hazards are encountered in industries resulting to an accident. List 4 causes of
accident in petroleum industry.(2pts)

Q7) what do you understand by PPE? list 2 types of EYE and Chemical/Gases PPE(1.5pts)

Q8) Distinguish between an insurance company and a re-insurance company. (2pts)

 Exams(2): Correction of Process safety and environmental Quality

Q1) Define the following terms. Injury, mishap.

 What is an injury? Injury is a physical harm or damage to the body resulting from an
exchange of (usually acute, mechanical, chemical, thermal, or other environmental)
energy that exceeds the body’s tolerance.
 What is a mishap? An unplanned event or series of events resulting in death, injury,
occupational illness, damage to or loss of equipment or property, or damage to the
environment

Q2) Explain the environmental effect of industrial accident on:

a. Eco-system

The fallout dust or the gaseous clouds or dispersed toxicants are several pollutants that may
spread through the environment. It may migrate to the neighboring places or effect the local
fauna or flora by interacting with the living systems. The caustic gases wilt cause necrosis,
chlorosis or prohibit the plants from photosynthesis causing low productivity. These gases
may also lead to acid-rain formation which ultimately damages the environment including soil
and water.

b. Health of biota

The people will be subjected to shock and may be traumatized due to an unwarned accident.
In such situations, people may be confused and sometimes run towards the direction of the
accident in haste. Thus they may lose their lives in the process. In some cases the people due
to curiosity would go close to the area of accident. If the gaseous concentration is beyond
threshold limit value (TLV) it enters the body system impairing the functions. The evacuation
procedures should be meticulous on the implements to protect the people in the accident area
from inhaling the obnoxious gases such as SO, NH etc. should be available with the industry
or with the people themselves.

Q3) Complete the table with the appropriate preventive measures.

Accident hazards Preventive measures

Slips and falls on the level on slippery floors Wear safety shoes with non-skid soles.
Capture of clothes in the grinding and mixing Use appropriate headgear and avoid
equipment while preparing dyes wearing loose-fitting cloths during work
with moving machinery.
Exposure to vapours of solvents, paints, and -Install effective exhaust ventilation and air
lacquers can cause irritation and damage to eyes conditioning to prevent air contamination
and mucous membranes, to the respiratory and and heat stress; if necessary, use odor
digestive tracts, and to the skin. Exposure to neutralizing chemicals.
organic substances (toluene, n-hexane,methyl-
alcohol etc.) may damage the nervous system
Exposure to organic substances may cause allergic - Protect the skin of the hands (with barrier
reactions such as irritation of the respiratory tract cream, or chemical-resistant gloves) when
and of eyes and skin in contact with solvents and cleaning
agents; use specific soaps for cleaning the
skin of the hands, at the end of the work
shift.
Exposure to excessive noise levels in grinding of -Wear appropriate ear protection ; consult a
pigments safety supervisor or a supplier

Q4) List 4 types of fire extinguishers and describe their mode of applications
 Dry Chemical: Dry Chemical is the most widely used type of fire extinguisher and is also
recognized as a multi-purpose ABC fire extinguisher. The agent works by interrupting the
chemical chain reaction. Also, on a class A fire it creates a barrier between the fuel and the
oxygen.
 Carbon Dioxide: Works by separating oxygen and heat. Usually ineffective against class A
fires.
 Water/Foam: Works by cooling the fire and coating the fuel. Foam extinguishers create a
foam barrier preventing the fuel from coming in contact with oxygen. They can cause shock
hazard on class C fires. Can cause liquids in class B fires to spread but effective on class A
fires.
 Dry Powder: They works by separating fuel from oxygen and/or removing heat. Effectiveness
is based on the type of class D fire it is designed to extinguish. Ineffective on class A,B,C
fires (metal fires) only.
 Wet Chemical: Works by forming a soapy foam blanket over the burning material and cooling
it below its ignition temperature.

Q5) several hazards are encountered in industries resulting to an accident. List 2 causes of
accident in mining industry (2pt)

 including release of poisonous gases such as hydrogen sulphide or explosive natural

gases especially firedam or methane
 collapsing of mine stopes, mining induced seismicity, flooding or general mechanical
errors from improperly used or malfunctioning mining equipment.
 The use of improper explosives underground can also cause methane and dust
explosions.

Q6) several hazards are encountered in industries resulting to an accident. List causes of
accident in petroleum industry.
 Explosions and Fires;
 High Pressure Lines and Equipment;
 Electrical and Other Hazardous Energy;
 Machine Hazards;
 Falls;
 Confined Spaces.

Q7) what do you understand by PPE? List 2 types of EYE and Chemical/Gases PPE

Personal protective equipment, commonly referred to as “PPE”, is equipment worn to

minimize exposure to a variety of hazards
EYE (General safety glasses,Laser safety glasse,Chemical splash goggles,Impact
goggles,Face shields)
Chemicals/gases (Respirator cartridges, Full-face respirators, Half-mask respirators,Surgical
masks)

Q8) -Insurance Companies – Insurance companies are risk takers. They accept risks
transferred to them by individuals, corporate bodies, government and their
agencies/corporations etc. Insurance companies are required to be registered by the National
Insurance Commission.

-Re–Insurance Companies ; Re–insurance is therefore a form of insurance whereby an

insurance company can transfer to another insurer all or part of its liabilities in respect of
claims arising under the contracts of insurance that it writes.