Loss prevention is forward looking. The system must be designed to eliminate the hazard or reduce its impact before the plant is built. True or false?
True
What are the five areas covered by loss prevention?
Loss of manufacturing time
Loss of equipment
Loss of materials
Loss of lives
Loss of reputation
What are the 3 main types of chemical plant accidents
Fire, explosions and toxic releases.
Fire has a high probability of occurrence, but low potential for fatalities and moderate economic losses.
Explosions has a moderate probability of occurrence, moderate potential for fatalities, but high economic losses.
Toxic releases have a low probability of occurrence, a high potential for fatalities, but low potential for economic losses.
What is the most significant cause of losses in a chemical plant?
Mechanical losses
What are the 3 stages of a process life cycle to implement loss prevention at?
R&D and Process Development
Plant Design and Layout
Plant Operation and Maintenance
What are the two main toolkits for designing for loss prevention?
- Implementing inherently safer design strategies (ISD)
2. Implementing chemical process safety strategies (CPSS)
“A process reactor has thickness and strength of material that can
withstand 10 bar pressure, which is above the maximum possible pressure of 5 bar in
case of a runaway reaction in the reactor.” Which loss prevention strategy is this?
Passive strategy, under CPSS
Use flanged pipes instead of welded pipes. What inherent safety design strategy is this?
Substitute
Use equipment that requires less maintenance. What ISD strategy is this?
Simplify
Use more reliable equipment over less reliable ones where possible. What ISD strategy is this?
Siplify
What are the 5 design aspects under loss prevention for Plant Layout?
- Reactor system design. Design cooling system for exothermic reactions.
- Equipment reliability. Select equipment according to established engineering standards and right MOC.
- Layout. Divide the pant into separate areas in order to reduce risk of injury. Have minimum distance.
- Control & protective systems. Use automatic BPCS and SIS systems to control the plant.
What are the 5 design aspects under loss prevention for Plant Operations?
- Quality of Personnel. Plant personnel must have necessary qualifications and be
capable in the event of an emergency - Training. Periodic reassessment & retraining very important.
- Operating Instructions & Procedures. English should be simple and clear.
- Maintenance. Plant shutdowns are usually planned well in advance to cover equipment
overhaul and safety inspections. - Management of Change
What are the 5 requirements of a Management of Change procedure?
- Inform and train affected personnel before changes has occurred
- Evaluate the technical basis of each change
- Develop written procedures for carrying out the change
- Inspect for potential safety and health impacts of the change
What is the main purpose of a MOC
Ensure that proposed modifications
to both equipment and procedures will produce the benefits sought without unforeseen
and undesirable side effects.
What are other names for SIS?
Trip and Alarm System
Emergency Shut Down
Safety Shutdown System
Safety Interlock System
Safety-related System (more general term for any system that maintains a safe
state for Equipment Under Control)
Safety-related Electrical Control System (the term used in machinery safety for any
electrical system that performs a safety function)
What is the 5th and 6th LOPA layer?
Physical Protection (Relief Devices) and Physical Protection (Dikes)
What are the requirements for SIS and BPCS systems?
Both must be separate and independent from each other. The failure of one should not affect the other.
