QUESTIONS AND ANSWERS

PART I. OBJECTIVE TYPE QUESTION

A chemical or physical condition that has the potential to cause damage is the
meaning of?
1.

A.
B.
C.
D.

Safety
Hazard
Risk
HAZOP

What is the total back pressure?

2.

A. superimposed divided by built-up back pressures

B. superimposed multiply with built-up back pressures
C. minus of superimposed and built-up back pressures
D. the sum of superimposed and built-up back pressures

What the guide word none of mean in HAZOP study?

3.

A.
B.
C.
D.

Quantitative Increase
Negation of Intention
Quantitative Decrease
Qualitative Increase

What the guide word More of mean in HAZOP study?

4.

5.

6.

7.

8.

E. Quantitative Increase
F. Negation of Intention
G. Quantitative Decrease
H. Qualitative Increase
What the guide word Less of mean in HAZOP study?
A. Quantitative Increase
B. Negation of Intention
C. Quantitative Decrease
D. Quantitative Decrease
What the guide word Part of mean in HAZOP study?
A. Negation of Intention
B. Quantitative Decrease
C. Qualitative Decrease
D. Quantitative Decrease
What the guide word As well as mean in HAZOP study?
A. Negation of Intention
B. Quantitative Decrease
C. Qualitative Increase
D. Quantitative Decrease
What the guide word Reverse mean in HAZOP study?
A. Complete Substitution

B. Logical Opposite
C. Negation of Intention
D. Quantitative Decrease
What the guide word Other than mean in HAZOP study?
A. Complete Substitution

9.

B. Logical Opposite
C. Negation of Intention
D. Quantitative Decrease
What are the typical material characteristic?

10
.

11
.

A. Reactivity, Flammability, Toxicity, Stability

B. Castability, permeability, Flammability, Toxicity
C. Reflectivity, Luminosity, Reactivity, Toxicity
D. Stability, permeability, Reflectivity, Flammability
What is the Attenuation step in inherent safety?
A. choosing and using smaller amounts of hazardous material.

B. replacing a hazardous material by a less one

C. using hazardous materials in the least hazardous form
D. made a system not only modest by its look but also from its function
What is the Simplification / error tolerance step in inherent safety?

12
.

A. choosing and using smaller amounts of hazardous material.

B. replacing a hazardous material by a less one

C. using hazardous materials in the least hazardous form
D. made a system not only modest by its look but also from its function.

What is the Substitution of effects step in inherent safety?

13
.

A. choosing and using smaller amounts of hazardous material.

B. replacing a hazardous material by a less one

C. using hazardous materials in the least hazardous form
D. made a system not only modest by its look but also from its function
Where should an air cooler exchangers take place from fired heaters?

14
.

A. at least 20 m vertically from fired heaters.

B. at least 10 m vertically from fired heaters.
C. at least 20 m horizontally from fired heaters.

D. at least 10 m horizontally from fired heaters.

What is recommended space for pump and wide foundation?

15
.
16
.

A.
B.
C.
D.

0.5 - 1.0 meter and 2 meters center to center

1 - 1.5 meter and 2 meters center to center
0.5 - 1.0 meter and 3 meters center to center
2.0 3.0 meter and 3 meters center to center

The lowest temperature at which a liquid exposed to the air gives off sufficient vapor
to form a flammable mixture near the surface of the liquid is the meaning of?
A. Flash point
B. Back Pressure

C. Bonding
D. Operating pressure
What is the minimum spacing between gas compressor and an open flames

17
.

A. 10 meters
B. 20 meters

C. 30 meters
D. 40 meters
Where is discharge check valves for an air compressors must be installed

18
.

A.
B.
C.
D.

as near as possible to the comppressor

as far as possible to the compressor
30 m from compressor
50 m form compressor

What diameter of tank that a separate bounded compound should be provided?

19
.

A.
B.
C.
D.

above 48 m
above 68 m
above 18 m
above 98 m

Where is the control rooms, and substation shall be spaced?

20
.

A. as far as possible to the process equipment surface

B. 30 m from process equipment surface

C. at least 15 m from the nearest process equipment surface

D. as near as possible to the process equipment surface
What lader should be serviced for Horizontal vessels 3.70 m or less?

21
.

A. unportable ladder

B. portable ladder
C. automatic ladder
D. permanent ladder
why Intakes and discharges shall be separated?

22
.

23
.

24
.
25

A. to prevent cross contamination by recirculation

B. to convenience in daily operation.
C. to minimize the length of electrical and instrument cables entering and
leaving therefore
D. to maintain the aerodynamic oscillations, piping platforms and ladders
What the suitable storage tank for environmental emissions controls?
A. Floating roof tanks
B. Pressure spheres tank
C. Fixed tank
D. Domed or cone roof tanks with internal floaters
What the suitable storage tank for liquids or gases requiring high pressure
A. Floating roof tanks
B. Horizontal storage tanks on saddles
C. Fixed tank
D. Domed or cone roof tanks with internal floaters
What the suitable storage tank for pressurized liquids

26
.

A. Floating roof tanks

B. Fixed tank
C. Domed or cone roof tanks with internal floaters
D. Pressure spheres
What the spacing between tanks exceed 45.7 meters (150 ft.) in diameter?
A.
B.
C.
D.

minimum of 1 1/2 the diameter of the largest tank

minimum of 1/2 the diameter of the largest tank
minimum of 1/4 the diameter of the largest tank
minimum of 3/4 the diameter of the largest tank

What the spacing between hot oil tanks heated above 65.6 OC (150 OF),
excluding flash asphalt, slop oil and emulsion breaking tanks?
27
.

A. spaced apart by the diameter of the largest tank in the group

B. minimum of 1/2 the diameter of the largest tank
C. spaced apart by the diameter of the smallest tank in the group
D. minimum of 1/4 the diameter of the largest tank
How to increasing inherent safety in reactor?

28
.

A. Provide a welded pipe

B. Use less toxic substance for solvent
C. Choose equipment that requires high maintenance
D. reducing the reactor size and inventories of all materials.
What media which used in heat transfer system?
A. water or other nonammable heat transfer media
B. oil
C. saturated liquid
D. hydrocarbon
What the maximum liquid velocities in plastic or rubber-lined piping?

29
.

30
.

31

A. 40 ft/s
B. 30 ft/s
C. 20 ft/s
D. 10 ft/s
what the function of Double-walled piping
A.
B.
C.
D.

to provide secondary containment for selected hazardous materials

to prevent cross contamination by recirculation
to convenience in daily operation.
to minimize the length of electrical and instrument cables entering and
leaving therefore

What equipment should be provided to prevent the risk of explosion to the

flare?
32

A.
B.
C.
D.

seal drums; header purging; a dry seal such as a molecular seal

Some tanks, wastewater treatment facilities
Pressure relief headers, multiple relief valves
steam coil, jacket, wastewater treatment facilities

Where the flare knock drum, flare ignition and pumpout pump system should
be located?
33

34
.

35

36

37

A. minimum at 90 meters from other facilities

B. at periphery of the clear area
C. 18 in. (457 mm) upstream or downstream of a heating coil
D. the nearest shut down valve
What the maximum allowable working pressure of relieving pressure for fire
contingency?
A. 15%
B. 35%
C. 21%
D. 43%
Rupture disk structure consists of?
A. a thin diaphragm
B. a spring
C. a nozzle
D. a valve
What the defined of terms inherent?
A. the essential characteristic that not explicitly occured (intrinsic)
B. A chemical or physical condition that has the potential to cause
damage
C. a measure of human injury, environmental damage, or economic loss
in terms of both the incident likelihood
D. Decreasing process pressures and temperatures
What are types of relief device are commonly used?
A. Conventional relief valve, balanced relief valves, pilot-operated relief
valves, rupture disk
B. Globe valve, Checked valve, balanced relief valves, relief valve
C. Gate valve, angel globe valve, rupture disk, balanced relief valves
D. Ball valve, Gate valve Globe valve, Check valve
What is the intensification step in inherent safety?
A. choosing and using smaller amounts of hazardous material.

38

B. replacing a hazardous material by a less one

C. using hazardous materials in the least hazardous form
D. made a system not only modest by its look but also from its function
What is the Substitution step in inherent safety?

39

40

A. choosing and using smaller amounts of hazardous material.

B. replacing a hazardous material by a less one

C. using hazardous materials in the least hazardous form
D. made a system not only modest by its look but also from its function
what should be used to prevent the possibility of feeding the fire in case of a
tube rupture or break in the distribution piping?
A. Automatic sprinklers
B. fire detection

C. automatic fire suppression system

D. Automatic and remotely operated valves and pump shutoffs

PART II. SHORT TYPE QUESTIONS

What is Materials Safety Data Sheet (MSDS)?

1.

The information of material. The MSDS contains the information needed to

begin analyzing materials and process hazards, to understand the hazards to
which the workforce is exposed, and to respond to a release of the material or
other major incident where emergency response personnel may be exposed to
the material.
What is the Flash point?

2.

The lowest temperature at which a liquid exposed to the air gives off sufficient
vapor to form a flammable mixture near the surface of the liquid, or within the
test apparatus used, that can be ignited by a suitable flame.
What is the Inherently Safe?

3.

A system is inherently safe if it remains in a nonhazardous situation after the

occurrence of nonacceptable deviations from normal operating conditions
What is the top-level architectural design In safety-related applications?

4.

to allocate the various safety requirements, identified in early phases of the

development, to appropriate safety-related systems or subsystems.
What the rule thumb for reactor layout that should be considered for safety?

5.

6.

Adequate space should be created for handling and storing catalysts,

chemicals, hydrogen, nitrogen, any other reactans, and also mobile equipment
like truck and forklift.
How the tower should be located?
Location of the tower and its complementary equipment should be arranged
adjacent each other and provide a space for assembling and disassembling
tower internals such as tray, demister, etc. If there is more than one tower
installed, the center-lines should be aligned parallel with the piperack.
What the good location for boilers and furnaces?

7.

For boilers and furnaces must be located on the windward side of the plant. For
common stack employed, suitable barriers or isolating barriers may be provided
in individual ducting. Heaters must located near the edge of process area.
What is recommended layout for Vessels and Drums?

8.

Vessels recommended laid out as close as possible to other related equipment.

Where horizontal drums are arranged near a pipe way, the horizontal centerline
of the drums should be located at right angles to the pipe way.
What is Fatality Accident Rate (FAR)?

9.

FAR is generally used for the British Chemical Industry. This statistics reports
the number of fatalities based on 1000 employees working their entire lifetime.

The employees are assumed to work a total of 50 years. Hence, the FAR is
based on 108 working hours
What is the fatality rate?
10.

11.

an independent of the number of hours actually worked and reports only the
number of fatalities expected per person per year. This approach is useful for
performing calculations on the general population, where the number of
exposed hours is poorly defined.
What is the Hazard and Operability Analysis (HAZOP)?
Hazard and Operability Analysis (HAZOP) is one of the most used safety
analysis methods in the process industry. It is one of the simplest approaches to
hazard identification. HAZOP involves a vessel to vessel and a pipe to pipe
review of a plant. HAZOP is based on guide words such as no, more, less,
reverse, other than, which should be asked for every pipe and vessel
What is the HAZOP study focuses on?

12.

A HAZOP study focuses on specific points of a process called "study nodes,"

process sections, or operating steps. Depending on the experience of the study
leader, the portion of a process included in a single study node can vary. The
HAZOP team examines each study node for potentially hazardous process
deviations.
What is the hazard analysis?

13.

The identification of undesired events that lead to the materialization of a

hazard, the analysis of the mechanisms by which these undesired events could
occur and usually the estimation of the consequences
What is the Maximum Allowable Working Pressure (MAWP)?

14.

the maximum (gauge) pressure permissible at the top of a vessel in its normal
operating position at the designated coincident temperature and liquid level
specified for that pressure.
What is the Process Safety Management?

15.

16.

A program or activity that involves the application of management principles and

analytical techniques to ensure process safety in chemical facilities. The focus is
on preventing major accidents rather than dealing with classic worker health
and safety issues
What is good layout for reactor?

Adequate space should be created for handling and storing catalysts,

chemicals, hydrogen, nitrogen, any other reactans, and also mobile equipment
like truck and forklift
17.

Where the tanks that designed for 20 kPa or less containing flammable and
combustible liquids should be located?

Tanks should be located in areas remote from process units and must be
arranged in rows not more than two deep.
18.

air intake and discharges should not be located in what area?

They shall not be located in any area classified as zone 0, 1 or 2 (except for gas

19.

turbine air intakes which shall be in accordance with manufacturers

requirement), nor located above or below an area classified as zone 0, or 1.
What are should be consider fir site layout?

20.

The site layout is considering the site constraints include topographical and
geological features; weather; people, evacuation routes, activities and buildings
in the vicinity; access to utilities; treatment of effluents; and laws and regulations
What are floating roof tanks used for?

21.

Floating roof tanks are typically used where the vapor pressure of the stored
fluid would be excessive for a cone roof tank or where collection of emissions
from the tank is not required but it is still desirable to minimize them
What are fixed tank used for?

22.

The fixed tank is preferred in applications where it is desirable to collect and

treat all emissions from the tank or where an inert gas is used to reduce the
possibility of fire, explosion, or chemical reaction
What the worst safety problem that can occur with reactors?
The worst safety problem that can occur with reactors occurs when an
exothermic reaction generates heat at a faster rate than the cooling system can
remove it

23.

What the worst safety problem that can occur with reactors?
The worst safety problem that can occur with reactors occurs when an
exothermic reaction generates heat at a faster rate than the cooling system can
remove it

24.

What is the function of jacketed or heated piping in heated fluid?

to prevent solidification and when close temperature control of the process fluid
is required

25.

what the function of flare?

26.

A flare provides a means for disposing of flammable, toxic or corrosive gaseous

effluents by burning them under controlled conditions and converting them to
less objectionable compounds.
what causes a flare header may collapse?

27.

Flare headers may collapse if a large volume of liquid is inadvertently

discharged into the header, exceeding the capacity of the piping supports
what to do to prevent flare headers collapse?
use criteria such as specifying the pipe as half-full of liquid or otherwise ensure
that the header can support the weight of the liquid, and absorb the impact of
any liquid slugs.
what is the function of knockout drums in flare system?

28.
29.

to prevent the hazards associated with flaring gas containing liquid droplets. The
flare knockout drum collects relief loads and separates liquid droplets from
vapor releases
What the purpose of the seal drum in flare system?

to prevent air ingress into the flare system thus providing flashback protection.
Below is discussed that should be considered to design seal drum
what the function of relief system to safety?
30.

Relief system is used when inherently safe design simply cannot eliminate
every pressure hazards and passive design can be exceedingly expensive and
cumbersome
What the function of Pressure relief system?

31.

to protect piping and equipment against excessive over-pressure and personnel

safety
how does pressure relief device work?

32.

A pressure relief device is designed to open and relieve excess pressure; it is

re-closed after normal conditions have been restored to prevent the further flow
of fluid (except rupture disk)
How the work of conventional relief valve?

33.

the inlet pressure to the valve is directly opposed by a spring. Tension on the spring is
set to keep the valve shut at normal operating pressure but allow the valve to open
when the pressure reaches relieving conditions.

What the function of balanced relief valves?

34.

35.

36.

Balanced relief valve Is a spring loaded pressure relief valve that incorporates a
bellows or other means for minimizing the effect of back pressure on the
performance characteristics opening pressure, closing pressure, lift, and
relieving capacity.
When the balanced relief valves can be used?
when the built-up pressure is too high for conventional pressure relief or when
the back pressure varies from time to time
When the pilot-operated relief valves are frequently chosen?
when operating pressures are within 5 percent of set pressures and a close
tolerance valve is required

37.

where the rupture disk can be used?

Rupture disks can be used in gas processing plants, upstream of relief valves,
to reduce minor leakage and valve deterioration

38.

what is hazard term mean?

an inherent physical or chemical characteristic that has the potential for causing
harm to people, the environment or property.

39.

What is the meaning of Inherent in Chemical Process Safety Strategies?

Inherent condition is where the hazards (if feasible) eliminate or greatly reduce
by changing the process including the use of materials and its reaction / process
conditions[]\

40.

What is the meaning of Passive in Chemical Process Safety Strategies

In the term of passive is describes as a tools that could minimized hazards
using process which greatly reduce the intensity of an incident without activating
any device

41.

What are the factor selected to represent the inherent safety in Preliminary
Process Design?
Heat of Reaction, Hazardous Substances, Corrosiveness, Chemical Interaction,
Temperature, Pressure, Equipment safety, Safe Process Structure

42.

What the effect of corrosion?

Corrosion reduces the reliability and integrity of plant. It reduces the strength of
materials and causes leaks. Corrosion products affect process materials,
moving parts, process efficiency and cause fouling

43.

Describe the safe process structure?

The safe process structure means which operations are involved in the process
and how they are connected together. It also describes how auxiliary systems
such as cooling, heating or relief systems should be configured and connected
to the main process
Where the tanks that designed for 20 kPa or less containing flammable and
combustible liquids should be located?

44.

Tanks should be located in areas remote from process units and must be
arranged in rows not more than two deep.
What engineer should be consider in the ISD for a specific plant design?

45.

(1) Location of the plant due to the surrounding population, (2) Plant Layout, (3)
Applied System relative to the plant size

PART III. LONGTYPE QUESTIONS

What the typical factors in plant sitting?

1.

2.

Population density around the site

Occurrence of natural disasters, such as earthquake, flood, hurricane
Accessibility to raw materials
Accessibility to markets
Transportation
Availability of land
Availability of power and utilities
Labor
Interface required with other plants
Government policies, such as sitting permits and investment incentives
Means of effluent disposal

What are the safety benefits of a good layout

Minimal explosion damage, since explosion overpressure falls off rapidly

with distance from the center of the explosion.
Minimal thermal radiation damage, as the intensity of thermal radiation also

falls off with the distance.

Less property damage caused by a given incident.
Easier access for emergency services such as fire fighting.
Easier access to equipment for maintenance and inspection.
Efficient and safe construction.
Optimum balance among loss control, maintenance, and operation
requirements.

What are the effectiveness of a HAZOP will depend on?

3.

The accuracy of information (including process and instrumentation

diagrams P&IDs) available to the team information should be complete and
up-to-date

How well the team is able to use the systematic method as an aid to
identifying deviations

The maintaining of a sense of proportion in assessing the seriousness of a

hazard and the expenditure of resources in reducing its likelihood

The competence of the chairperson in ensuring the study team rigorously

follows sound procedures.

What are the informations should be included in physical and chemical

properties?

Toxicity information

Permissible exposure limits

Physical data such as boiling point, freezing point, liquid/vapor densities,

vapor pressure, flash point, autoignition temperature, flammability limits,
solubility, appearance, and odor

Reactivity data, including potential for ignition or explosion

Corrosivity data, including effects on metals, building materials, and organic

tissues

Identified incompatibilities and dangerous contaminants

Thermal data (heat of reaction, heat of combustion).

4.

5.

What are the important factors in plant layout development?

Containment of accidents

High hazard operations

Segregation of different risks

Exposure to possible explosion overpressure

Exposure to fire radiation

Minimization of vulnerable piping

Drainage and grade sloping

Prevailing wind direction

Future expansions

What are the important factors in sitting central services, such as the boiler
house, cooling towers, power station?

6.

7.

Central services should not be put out of action by fire or explosion or

flood.

Central services should not constitute a source of ignition.

Cooling towers should be located to minimize water drift to avoid

corrosion of other units.

Flare stacks should be located upwind to minimize the ignition of vapor

cloud releases and should be analyzed for intensity of thermal radiation
and noise.

What are the rule thumbs for layout and spacing of the waste treatment facilities?
Location of the waste treatment area should be at a refinery/plant low
point to insure gravity flow from all unit process areas. The lift stations
could also be provided.
The waste treatment area must be remoote from the process and utility
area and arranged to permit future expansion of the system.
The layout of the area must involving vehicle accessibility for
maintenance purposes
what are the items that should be check in distillation?

8.

9.

Levelness
Downcomer clearance

Weir heights

Inlet weir clearance

Bolt tightness

Feed and reflux piping

Fabrication Errors
What are the rule thumbs for layout and spacing of flare?

Keep the radiant flux below allowable limits by mainting them with a
sufficient space.
Flare stack must be placed remote from offsite and process facilities,
preferably down widn from any areas where personnel are required for

cntinuous operation.
Flare stack must be located minimum at 90 meters from other facilities
and have a clear perimeter surrounding them.

1
0.

Mentioned and explain four major categorize of strategies for designing

inherently safer design processes which published by Center for Chemical
Process Safety (CCPS)?
Subtitute: Including use less hazarous materials, chemistry and
processes
Minimize: Minimze means only use a small quantities of hazardous
materials or it could be also reducing the size of equipment operating if it
is under high-risk operation such as High Temperature and High
Pressure
Moderate: This term lead to the reducing hazards by applying less
hazardous operation such as Refrigeration, Dilution, or any other process
alternatives
Simplify: Simplify is to eliminate unneccesary complexity and design user
friendly plants, such as removing old piping installation due to the
modification process.

1
1.

Mention option to decreasing transportation risk?

Ship concentrate to reduce the number of containers, then dilute the
concentrate at the user site.
Refrigerate and ship material should transported at atmospheric pressure
or at reduced pressure.
Shipping transportation preferably for the material in diluted form such as
aqueos ammonia.
Shipping transportation is used for intermediates rather than raw
materials.

1
2.

Mention the inherently safer human systems for each stage of chemical
processing life cycle?
Appropriate training.
Reviews and Audits.
Error correction cycles.

1
3.

Mention option to decreasing transportation risk?

Ship concentrate to reduce the number of containers, then dilute the
concentrate at the user site.
Refrigerate and ship material should transported at atmospheric pressure
or at reduced pressure.
Shipping transportation preferably for the material in diluted form such as
aqueos ammonia.
Shipping transportation is used for intermediates rather than raw
materials.

1
4.

What are the most used systems to characterize accident and loss performance?
OSHA incident rate.

Fatal Accident Rate (FAR).

Fatality rate or deaths per person per year

What is an inherent safe plant relies on?

1
5.

An inherent safe plant relies on chemical and physical parameter to prevent

accidents rather than on control systems, interlocks, redundancy, and special
operating procedures to prevent accidents. Inherently safer plants are also more
tolerable of errors and are often the most cost effective system that usually
applied in plant