CPS - UNIT -4 PRAVIN PATHAK-SAFETY IN PLANT OPERATION MAINTENANCE

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What is the main function of a breather valve (vent) in a chemical plant? *

1 point

To seal the system tightly to prevent any leakage

To allow air into the system for combustion

To release excess pressure and prevent over- pressurization of storage tanks or vessels

In the context of mechanical failure, what does "fatigue" refer to? *

1 point

The immediate failure of equipment

The slow degradation of materials over time

The employee's energy level

The absence of mechanical issues

When implementing pipeline color coding, what should be done in case of changes in pipeline contents? *

1 point

Update the color coding immediately

Remove the color code altogether

No need to update the color coding

Wait for the next scheduled maintenance

In preventive and emergency maintenance work, what is the importance of proper record-keeping? *

1 point

To create extra paperwork

To bypass safety procedures

To provide a historical record and improve future safety and efficiency

To meet industry standards

What is the primary purpose of a "Lockout/Tagout" procedure when working on pipelines in a chemical plant? *

1 point

To isolate energy sources and ensure equipment is safely de-energized

To secure personal belongings

To prevent unauthorized access to the plant

To mark the pipelines with colored tags

During the start-up of a plant, what is the first step to be taken in ensuring safety? *

1 point

Begin the production process immediately

Skip safety checks to save time

Notify the local emergency services

Conduct a safety briefing with all personnel involved

What is the primary purpose of color coding pipelines in a chemical plant? *

1 point

To meet industry fashion trends

To confuse employees

Aesthetic purposes

To improve safety and easily identify the contents of pipelines

In the event of a chemical spill, what is the first step that should be taken to ensure safety? *

1 point

Evacuate the entire plant

Attempt to clean up the spill immediately

Ignore the spill if it's small

Report the spill to the appropriate personnel

In emergency maintenance situations in a chemical plant, what should personnel prioritize? *

1 point

Following standard procedures

Ensuring their own safety and the safety of others

Immediately fixing the issue at any cost

Ignoring safety protocols to save time

In the event of a gas release, what should be the first step before activating a flare system? *

1 point

Activate the flare system immediately

Evacuate the facility

Assess the situation and attempt to fix the issue

Ignore the gas release and continue operations

What is the primary purpose of a pre-shutdown safety review (PSSR) before shutting down a chemical plant? *

1 point

To identify and address safety concerns before shutting down equipment

To delay the shutdown process

To increase production efficiency

To conduct employee performance evaluations

Before initiating a plant shutdown, what should be done to ensure the safety of personnel and equipment? *

1 point

Skip safety checks to save time

Conduct a hazard assessment and implement appropriate controls

Notify local authorities of the shutdown

Evacuate the facility immediately

Who is typically responsible for overseeing the plant shutdown process and ensuring that safety measures are followed? *

1 point

Contractors working on-site

The plant manager only

A designated shutdown team or supervisor

Maintenance personnel only

What is the purpose of a "Permit to Work" system in emergency maintenance situations? *

1 point

To expedite the maintenance process

To eliminate the need for safety documentation

To ensure that necessary precautions and safety measures are in place before work begins

To encourage untrained personnel to perform tasks

What is the primary responsibility of the Safety Data Sheet (SDS) coordinator in a chemical plant? *

1 point

To ensure that SDSs are up-to-date and accessible to employees

To create daily reports on plant operations

To maintain a list of all employees

To keep track of first-aid supplies

When working on emergency maintenance tasks in a chemical plant, what is the importance of communication? *

1 point

To minimize communication to reduce distractions

To ensure that all personnel are informed of the situation and safety concerns

It's not necessary during emergencies

To keep the situation confidential

What role does "vibration" play in mechanical failure leading to a loss of containment? *

1 point

Vibration reduces the risk of material degradation

Vibration has no impact on mechanical failure

Excessive vibration can weaken materials and cause fatigue or stress cracks

Vibration improves the structural integrity of materials

In the event of an emergency situation during plant shutdown, what is the first priority for personnel? *

1 point

Evacuate the facility

Report the emergency to the appropriate authorities

Try to resolve the emergency independently

Continue with the shutdown process

In case of unexpected issues or emergencies during plant start-up, what should personnel do first? *

1 point

Ignore the issues and continue with the start-up process

Attempt to resolve the issues independently

Wait for someone else to take action

Immediately stop and follow emergency shutdown procedures

During plant shutdown, what is the purpose of ensuring proper isolation of energy sources? *

1 point

To expedite the process

To prevent accidental energization and ensure safety

To allow equipment to be easily restarted

To reduce downtime

What is the importance of conducting regular inspections and testing of equipment in a chemical plant to prevent mechanical failure? *

1 point

To meet regulatory requirements only

To reduce the lifespan of equipment

To increase operational costs

To ensure equipment remains in proper working condition, identify potential issues, and prevent catastrophic failures

Which colour is use for identifying pipelines carrying gases, in chemical industry? *

1 point

Voilet

Blue.

Silver.

Canary Yellow.

When working on a pipeline in a chemical plant, what is the purpose of a "Hot Work Permit"? *

1 point

To bypass safety protocols

To speed up the work

To ensure safe procedures for activities like welding, cutting, or grinding

To allow unauthorized personnel to perform work

Which colour is use to identify the pipelne carrying raw water, in chemical industry? *

1 point

Brown

Sea green.

Canary yellow.

Sky blue.

What should be the first step taken when shutting down equipment during a plant shutdown to ensure safety? *

1 point

Conduct a hazard assessment and implement appropriate controls

Notify local authorities

Skip safety inspections to save time

Begin shutting down equipment immediately

What is the primary goal of preventive maintenance in a chemical plant? *

1 point

To perform maintenance only when equipment breaks down

To prevent equipment failures and ensure safe, reliable operation

To increase production output

To reduce the number of employees in the maintenance department

What is the primary reason for documenting the plant shutdown process? *

1 point

To increase the complexity of the shutdown procedure

To save paper and reduce waste

To create a historical record for future reference

To meet regulatory requirements

What does a purple color code on a pipeline typically indicate in a chemica plant? *

1 point

Toxic or radioactive materials

Flammable materials

Non-hazardous materials

What is the purpose of performing equipment and system checks during plant start-up? *

1 point

To identify potential safety hazards

To maximize production output

To save time and resources

To skip unnecessary steps

What is the preferred method of disposal for gases that can be safely recovered and reused in a chemical plant, rather than being flared? *

1 point

Recycling and reusing the gases whenever possible.

Flaring is always the preferred method

In the event that a pressure relief valve (PRV) or breather valve malfunctions or sticks, what is the appropriate action to take? *

1 point

Ignore the issue and continue operations

Wait for the next scheduled maintenance

Attempt to manually adjust the valve without notifying anyone

Report the issue to maintenance and replace the malfunctioning valve

Which of following points are to be considered before shutdown of plant? *

1 point

All flammable material removed from plant.

All vessels are depressurised and drained properly.

All of the given options.

Shutdown activities are performed under the supervision of experienced person.

What is the primary reason for conducting regular inspections and maintenance of flame arresters in a chemical plant? *

1 point

To ensure the arrester remains in proper working condition and can effectively prevent flame propagation

To increase operational costs

To meet regulatory requirements

To decrease the service life of the arrester

Which of following points are to be considered before start up of plant? *

1 point

Fire fighting system is operating properly.

All of given options.

All blinds are removed.

All earthing and bondings are restored.

When initiating the start-up of a chemical plant, why is it important to communicate the start-up plan to all relevant personnel? *

1 point

To avoid any communication with employees

To confuse the employees

To ensure everyone is on the same page and aware of the plan and potential safety concerns

To surprise the employees with a sudden start-up

Which of following document, for material lifting crane, you will check before issuing work permit, in preventive maintenance work, where lifting of heavy vessel with crane, is required? *

1 point

Form 10

Form 12

Form 11

Form 13

What is the primary purpose of a safety briefing before beginning the start- up of a chemical plant? *

1 point

To introduce new employees to the plant layout

To discuss the plant's history

To ensure that all personnel understand the safety protocols and procedures for the start-up

To review the company's financial performance

How can "improper pressure" contribute to mechanical failure and a loss of containment in a chemical plant? *

1 point

Over- pressurization can lead to equipment rupture or failure

Lower pressure always results in safer conditions

Proper pressure management is not relevant to mechanical failure

It has no impact on mechanical failure

Which color is commonly associated with pipelines carrying hazardous materials that pose a health risk or toxicity? *

1 point

Yellow

Green

Brown

Blue

Which colour is use for identifying pipeline carrying "Effluent from plant" in chemical industry? *

1 point

Silver grey.

Red.

Black.

Canary yellow.

In which of following "Emergency maintenance work" you will keep stand by fireman ready with fire extiguisher? *

1 point

Welding work on gas pipeline.

Working at height for tightening of flange on pipe.

Entering into storage tank.

Which colour is use for identifying the pipelines carrying "Acid",in chemical industry? *

1 point

Yellow.

Red

Voilet

Sea green.

Before starting any equipment during plant start-up, what should be done to ensure safety? *

1 point

Increase the operating speed to meet production targets

Bypass safety interlocks for convenience

Ignore warning signs and labels

Perform a hazard assessment and implement appropriate controls

What is "LOTO"? *

1 point

Lock Out Tag Out.

Less overflow Tag Out.

Less overflow tight Out.

Lock Out Task Out.

Which of the following is a common safety precaution when working on pipelines that may contain hazardous materials? *

1 point

Rushing through the job to finish quickly

Wearing shorts and a t-shirt for comfort

Ignoring the type of material in the pipeline

Using appropriate PPE, such as gloves, goggles, and respiratory protection

What is the primary purpose of a flare system in a chemical plant? *

1 point

To provide an aesthetically pleasing display of flames

To safely combust and dispose of excess or potentially hazardous gases

To generate electricity for the plant

To release excess greenhouse gases into the atmosphere

Which colour is use to identify the pipeline carrying "steam" in chemical industry? *

1 point

Canary yellow

Red

Blue.

Silver grey

What is the primary purpose of a pressure relief system in a chemical plant? *

1 point

To prevent pressure build-up that could lead to equipment failure or explosions

To reduce the need for regular inspections

To save energy

To increase pressure within the equipment

What is the primary responsibility of the "Permit to Work" system when working on pipelines in a chemical plant? *

1 point

To expedite the work process

To ensure that necessary precautions and safety measures are in place before work begins

To eliminate the need for safety documentation

To allow untrained personnel to perform tasks

What is the minimum percentage of "Oxygen" required in air, at "confined space", so that person can enter into confined space, for work? *

1 point

0.215

0.195

0.185

0.175

What is the primary purpose of a flame arrester in a chemical plant? *

1 point

To provide emergency lighting during power outages

To ignite flammable gases safely

To prevent the propagation of flames and explosions into pipelines or equipment

To create a decorative flame display

When is a flare system typically activated in a chemical plant? *

1 point

When there's an emergency or the need to relieve excess pressure

During routine maintenance

Only during special events

Whenever operators feel like it

When discussing mechanical failure leading to a loss of containment, what is meant by "corrosion"? *

1 point

Routine maintenance tasks

Employee errors

The gradual deterioration of materials due to chemical reactions or environmental factors

The plant's design

What is the primary safety consideration when conducting maintenance or inspections on a flame arrester in a chemical plant? *

1 point

No special safety precautions are needed

To work on the arrester without any personal protective equipment

To perform maintenance in a hurry to save time

To follow appropriate safety procedures, including using proper PPE and ensuring the system is safely isolated

What does the acronym "H2S" stand for in the context of chemical plant safety? *

1 point

Health and Safety

Hazardous Storage

Hydrogen Sulfide

High-Speed Storage

In pipeline color coding, what color is typically used to indicate the presences of flammable gases or liquids? *

1 point

Blue

Yellow

Green

Red

Which standard is used for colour coding for pipelines in chemical industry?" *

1 point

IS: 3297

IS: 2379

IS:2579

When conducting preventive maintenance, what should be the first step to ensure safety? *

1 point

Conduct a thorough safety assessment of the maintenance task

Avoid using personal protective equipment (PPE)

Begin maintenance immediately to save time

Skip safety inspections

What is the primary mechanism of mechanical failure that can lead to a loss of containment in a chemical plant? *

1 point

Routine maintenance

Corrosion, erosion, or material degradation

Improper paperwork

Employee attire

"Knock out drum", is component of Which of following equipment? *

1 point

Rupture disc.

Breather valve.

Flame arrester.

Flare system.

During plant shutdown, when should a lockout/tagout (LOTO) procedure be implemented? *

1 point

Only at the beginning of the shutdown process

When a piece of equipment or a system needs to be isolated to prevent accidental energization

Only during routine maintenance

Whenever employees want to take a break

Which permit you will issue for working at Height of Five meters, from ground for maintenance work of flowmeter on pipeline? *

1 point

Height work permit.

Excavation workpermit.

Hot work permit.

Confined space work permit.

Which of the following is a common hazard associated with chemical storage in a plant? *

1 point

Adequate ventilation

Corrosion-resistant containers

Chemical spills and leaks

Proper labeling

Which colour is use for identifying, pipelines carrying "air" in chemical industry? *

1 point

Sea green

Sky blue

Red

Canary yellow.

Which valve is used as high pressure protection valve? *

1 point

Safety valve.

Butterfly valve.

Ball valve.

Rotary valve.

Which workpermit you will issue for Emergency maintenance work which requires welding work to be performed? *

1 point

Height work permit.

Confined space entry work permit.

Electrical work permit.

Hot work permit.

During the start-up of a chemical plant, when should personnel prioritize safety inspections and checks? *

1 point

After the plant is fully operational

During lunch breaks

Before any equipment is started

Only during routine maintenance

What role does a pilot flame serve in a flare system? *

1 point

To ensure that the flare system is ready to ignite released gases

To attract wildlife

To generate heat for the plant

To create a decorative display

When working on a pipeline, what should you do if you encounter a leak or spill of hazardous materials? *

1 point

Share the information on social media

Ignore it and continue working

Quickly finish your task before addressing the issue

Report it to the proper authorities and take appropriate actions to contain and mitigate the spill

Which personnel are typically responsible for overseeing the start-up process and ensuring safety measures are followed? *

1 point

A designated start-up team or supervisor

Contractors working on-site

The plant manager only

Plant operators only

Which gases or vapors should never be allowed to pass through a flame arrester? *

1 point

Any flammable gases or vapors, regardless of their properties

Only harmless gases

Gases with a strong odor

Only natural gases

What is the purpose of a Lockout/Tagout (LOTO) procedure in a chemical plant? *

1 point

To secure valuable equipment

To isolate energy sources and prevent equipment from being accidentally started

To prevent unauthorized personnel from entering the plant

To mark chemical containers with tags

What is the primary purpose of a Safety Data Sheet (SDS) in a chemical plant? *

1 point

To communicate information about hazardous chemicals

To outline the plant's budget

To list employee contact information

To provide instructions for plant operation

What is the importance of communication during plant start-up? *

1 point

To share personal stories with colleagues

To provide entertainment for employees

To ensure that all personnel are informed of the plan and any safety concerns

It's not necessary during start-up

What is the importance of regularly inspecting and testing pressure relief systems and breather valves in a chemical plant? *

1 point

To avoid extra work

To ensure they are functioning properly to prevent accidents and equipment damage

To meet regulatory requirements only

Increase the pressure in the equipment

What is the primary purpose of a pre-start safety review (PSSR) before beginning plant start-up? *

1 point

To reduce production eificiency

To document any equipment malfunctions

To ensure that all safety measures are in place and functioning

To delay the start-up process

What should you do if you encounter an unexpected hazardous situation during emergency maintenance work in a chemical plant? *

1 point

Attempt to resolve the situation without assistance

Notify someone else to handle it

Ignore it and continue working

Stop work, report the situation, and take appropriate actions to mitigate the hazard

In the event of a chemical spill during start-up, what should be the immediate response? *

1 point

Delay the start-up for the day

Report the spill, evacuate if necessary, and follow proper spill response procedures

Ignore the spill and continue with the start-up

Attempt to clean up the spill without reporting it

What is the primary objective of a controlled and systematic plant shut- down procedure? *

1 point

To ensure safety and prevent accidents

To expedite the shutdown process

To save energy and resources

To maximize production output

Why Breather valve is fixed on storage tanks for chemicals? *

1 point

To maintain pressure inside storage tank.

To protect tank from lightening stroke.

To provide earthing to tank.

To protect tank from fire.

What is the importance of regularly maintaining and testing a flare system in a chemical plant? *

1 point

To generate additional revenue

To meet regulatory requirements only

To ensure it is ready for safe and effective operation during emergencies

To reduce costs

What is the importance of conducting a safety briefing or communication before initiating the shutdown of a chemical plant? *

1 point

To ensure that all personnel are informed of the plan and any safety concerns

To increase confusion among employees

It's not necessary during shutdown

To expedite the shutdown process

What type of flammable gases or vapors are flame arresters designed to control? *

1 point

All types of gases and vapors

Only non-toxic gases

Specific gases and vapors with known flammability risks

Only gases with a pleasant odor

Which work permit you will issue for preventive maintenance of reactor agitator, which requires entry in reactor vessel? *

1 point

Hot work permit.

Height work permit.

Electrical work permit.

Confined space entry work permit.

Where in a chemical plant is a flame arrester typically installed? *

1 point

At the exit gates

On top of storage tanks

At the entrance of the facility

Inside the break room

What is the primary responsibility of the Safety Data Sheet (SDS) coordinator during plant start-up? *

1 point

To ensure that SDSs are up-to-date and accessible to employees

To maintain a list of all employees

To lead the start-up process

To create daily reports on plant operations

What is the importance of performing a gas test before working on a pipeline in a chemical plant? *

1 point

To check for the presence of valuable gases

To reduce time spent on maintenance

To identify and mitigate potential hazards like flammable or toxic gases

To create a pleasant working environment

Which of the following is a common cause of mechanical failure that can result in a loss of containment? *

1 point

Material strength improvements

Regular inspections

Improper installation or welding

Excessive plant cleanliness

In a chemical plant, which type of fire extinguisher is suitable for extinguishing electrical fires? *

1 point

Class B

Class D

Class C

Class A

In which of following "Emergency maintenance work "the oxygen level mandetory to be measured and same to be written on workpermit? *

1 point

Working on pump for changing impeller.

Working on scaffold to change the gasket in flagejoint.

Entering into reactor for dismantling agitator, in reactor.

Welding work on diesel pipe line.

In the event of unexpected issues or emergencies during plant shutdown, what should personnel do first? *

1 point

Immediately stop and follow emergency shutdown procedures

Wait for someone else to take action

Ignore the issues and continue with the shutdown

Attempt to resolve the issues independently

What is function of "Flare Sytem" in chemical factory? *

1 point

To provide protection from lightening strokes from sky.

It work as overpressure protection.

It liberates smoke from diesel generator in factory.

To control the pollution.

What is the primary reason for using a flare system to burn off gases in a chemical plant? *

1 point

To minimize environmental impact

To increase greenhouse gas emissions

To save money on fuel costs

Before performing maintenance on a pipeline in a chemical plant, what is the first step to take to ensure safety? *

1 point

Start the maintenance immediately

Check your personal protective equipment (PPE)

Skip the pre-maintenance inspection

Ignore safety guidelines to save time

In pipeline color coding, what color is typically used for pipelines carrying non-hazardous or safe materials? *

1 point

Orange

Black

White

Purple

What is the importance of effective communication during plant shutdown? *

1 point

To share personal anecdotes with colleagues

It's not necessary during shutdown

To ensure that all personnel are informed of the plan and any safety concerns

When is it important to install a pressure relief device on a chemical storage tank or vessel? *

1 point

Before pressure exceeds the tank's design limits

Only in extremely hot weather

When the tank is completely empty

Only if the tank is brand new

What is function of "Rupture Disc"? *

1 point

To protect from vibrations.

To protect from friction.

To protect from corrosion.

To protect from overpressure.

What should be done before conducting maintenance on a pressure relief system or breather valve in a chemical plant? *

1 point

Disregard personal protective equipment (PPE)

Proceed with maintenance immediately

Skip safety checks to save time

Conduct a thorough safety assessment of the maintenance task

In the event of a fire or explosion, what is the primary function of a flame arrester? *

1 point

To allow flames to spread

To prevent flames from traveling back into the pipeline and causing further damage

To ensure the safety of nearby personnel

To interisify the fire

Who is responsible for maintaining and ensuring the accuracy of pipeline color coding in a chemical plant? *

1 point

Only the plant manager

Only the maintenance team

All personnel who work with the pipelines

What is the primary purpose of setting the pressure relief valve (PRV) to a specific pressure level? *

1 point

To make the valve look more attractive

To ensure that the valve opens at a safe pressure, preventing over- pressurization

To reduce the need for maintenance

To increase the pressure inside the equipment

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