Exam 1

Question 1

What are the 4 operational components of managing process safety?

Answer 1

1. Management of Change
2. Emergency Management
3. Operational Readiness
4. Conduct of Operations

Question 2

What would cause a management of change to occur?

Answer 2

If something is not an exact replacement (replacement in-kind) a risk evaluation must be performed before implementing the change

Question 3

What is the process of a Management of Change?

Answer 3

requires a written request, some form of risk evaluation, and some level of management approval.

Question 4

What is the key issue of Management of Change?

Answer 4

Change Recognition

Question 5

Who must be involved in the management of change evaluation?

Answer 5

Operators, maintenance, training department, process safety department, environmental department, metallurgists, and design engineers

Question 6

What is a lagging metric?

Answer 6

Number of incidents that had MOC as a root cause

Question 7

When are MOC leading metrics applied?

Answer 7

before an incident to track safety performance.

Question 8

What are the 5 MOC leading metrics?

Answer 8

1. Number of MOCs performed per month.
2. % of work orders/requests that were misclassified as replacement-in-kind but were really changes.
3. % of temporary MOCs for which temporary conditions were not restored to the original state by the deadline.
4. % of MOCs for which the workers were not informed or trained
5. % of MOCs reviewed that did not have adequate hazard and risk assessment.

Question 9

You are monitoring a facility tracking system for change management and see a trend of gradually decreasing MOC requests. How can this be interpreted?

Answer 9

1. The workers might need more training because they are not recognized when MOC requests are needed.
2. There could be a safety culture issue when people feel MOC requests are a bother and they don’t submit them.
3. The facility might be showing more stability with less change being needed.

Question 10

True/False: Small changes can have surprising impacts

Answer 10

True

Question 11

True/False: Organization changes can also have
adverse effects

Answer 11

True

Question 12

What are examples of organizational changes?

Answer 12

1. Changes in working conditions
2. Personnel changes
3. Task allocation changes
4. Organizational structure changes
5. Policy changes

Question 13

True/False: Accidents involving nitrogen asphyxiation are rare because nitrogen sensors can accurately measure the concentration of nitrogen.

Answer 13

False

Question 14

True/False: A chemical process must involve chemicals with low hazards for the process to have an acceptable level of risk.

Answer 14

False

Question 15

True/False: A gas mixture with a fuel concentration above the upper flammable limit can form a flammable mixture when released into the air

Answer 15

True

Question 16

True/False: If the calculated wall thickness to hold the pressure inside a process vessel is less than the minimum wall thickness for mechanical integrity, the
calculated Fp will be greater than 1.0.

Answer 16

False

Question 17

True/False: The Chemical Engineering Plant Cost Index is used to correct equipment cost estimates for different materials of construction.

Answer 17

False

Question 18

True/False: A minimum thermal driving force of 10°C between the hot and cold streams of a heat exchanger is required for heat exchanger safety

Answer 18

False

Question 19

True/False: The steam pressure used in a distillation column reboiler is selected to ensure that the saturation temperature of the steam is at least 10C lower than the
process fluid temperature.

Answer 19

False

Question 20

True/False: The stream factor is used to correct for stream impurities.

Answer 20

False

Question 21

True/False: The factor for material of construction has little impact on
equipment cost estimates.

Answer 21

False

Question 22

True/False: If a mixture forms a minimum-boiling azeotrope, the azeotrope has a boiling temperature lower than one of the components in the azeotrope.

Answer 22

False

Question 23

True/False: For a gas phase reaction, lowering the reactor pressure without making any changes to the reactor configuration in Aspen will reduce the
residence time for the reactor.

Answer 23

True

Question 24

True/False: The number of stages required for a separation will increase if the feed flow rate is increased.

Answer 24

False

Question 25

True/False: To make a gas mixture nonflammable, the oxygen concentration in the gas mixture must be above the limiting oxygen concentration.

Answer 25

False

Question 26

True/False: Electrical bonding of equipment prevents all possible ignitions

Answer 26

False

Question 27

True/False: If a reaction is thermodynamically possible, the reaction rate will always be fast at high temperature.

Answer 27

False

Question 28

True/False: Procedural controls to enhance process safety are more reliable than passive controls.

Answer 28

False

Question 29

True/False: If a 0.007 Torr per tray pressure drop is mistakenly entered for a distillation column, the simulation results will give an unrealistically high temperature of the bottom product stream.

Answer 29

False

Question 30

True/False: A runaway reaction is a potential hazard only for endothermic reactions.

Answer 30

False

Question 31

True/False: All process vessels are made to hold both internal pressure and vacuum.

Answer 31

False