1. Chapter 9 – 10 Test Review

2. Chapter 9 – 10 Test Review
Describing the different permitting systems used by the chemical processing industry is a difficult process. Variations between plants are enormous with only a few common permit systems. There are three that are common between the industry: government mandated
Hot Work Permits
Confined Space Entry
Control of Hazardous Energy (Lock Out Tag Out)

3. Chapter 9 – 10 Test Review
Hot work is defined as any maintenance procedure that produces a spark or excessive heat, or requires welding or burning. Examples include: grinders, open fires, welding equipment, energized electrical circuits, internal combustion engines, electric motors, and so on.
According to the PSM standard, employers are required to have a permit for hot work operations. The permit must include the following topics:
Fire prevention and protection measures in place before work begins
Date permit is approved for
Location, equipment, and item where hot work is performed
Fire watch posted and in place during procedure and 30 minutes after work is complete
Permit must be displayed at the work site until the work is complete

4. Chapter 9 – 10 Test Review
A confined space is defined as a space large enough so a person can enter, has restricted entry, and is not designed for continuous occupancy.
Examples include:
excavations, sewers, pits, reactors, boilers, furnaces, distillation columns, strippers, absorbers, vessels, tanks, silos, blenders, drums, piping, pumps compressors, heat exchangers, extruders or any space that entry or allows the head of he worker to go below the top of the confined space.

5. Chapter 9 – 10 Test Review Preparing the space for entry
The process operator will secure the vessel or area by isolation. Example: pipe entering and exiting the vessel will be isolated and blinded.
Any remaining chemical must be removed. This may require water washing, purging, or inerting. All electrical equipment must be de-energized, lock-out and tagged before entry.
Blower may be required to ventilate the vessel. Oxygen concentration must be between 19.5% and 23.5%.
A standby attendant is required.

6. Chapter 9 – 10 Test Review
The purpose of the hazardous energy standard is to protect employees from the hazards associated with the accidental release of uncontrolled energy.
The lockout/tagout procedure is a standard designed to isolate a piece of equipment from its energy source.

7. Chapter 9 – 10 Test Review
The chemical processing industry harnesses energy from 7 basic form: electrical, pneumatic, hydraulic, compressed gases and liquids, gravity and spring tension. The two most common classifications of energy are kinetic and potential.
Kinetic is closely associated with movement while potential is related to stored energy.

8. Chapter 9 – 10 Test Review
OSHA established a 6-step procedure for locking out a piece of equipment.
Preparation for shutdown – identify type of energy and hazards
Shut down the equipment
Isolation of equipment – closing valves, shut down main disconnect and circuit breakers, electric, hydraulic, etc
Apply lockout/tagout devices to breakers, valves switches, and energy isolating devices
Control of stored energy – relieve pressure
Verification step – lock-tag-try
All of this information should be recorded on a lockout logbook.

9. Personal Protective Equipment
Chapter 9 – 10 Test Review
Personal Protective Equipment
The human body has over 19 square feet of surface area and inhales over 3,000 gallon of air per day. Chemical exposure comes through what means?
PPE provides an effective means for protecting employees.
The primary purpose of PPE is to prevent exposure to hazards when engineering or environmental controls cannot be used.
Most of the hazards found in the chemical processing industry have been assessed and have PPE that will provide some degree of protection

10. Personal Protective Equipment
Chapter 9 – 10 Test Review
Personal Protective Equipment
Many of the gloves used by chemical technicians have a wide variety of operational limitations; one type of glove cannot be used for every job.
the primary difference in gloves can be determined by:
chemical resistance
Type of material
Thickness of material
compatibility to toxic and hazardous substances

11. Personal Protective Equipment
Chapter 9 – 10 Test Review
Personal Protective Equipment
Over 70,000 injuries occur each year in the U.S. from accidental falls, slips, trips, and heavy object impact. Many of these injuries could have been prevented with the proper footwear.
Safety shoes are designed to protect the foot from impact and compression forces. Approved footwear must meet the following guidelines:
soles must be chemical resistant, puncture proof, slip resistant, abrasion resistant, and provide cushioning support, have leather uppers.
footwear must pass performance test for impact and compression according to ANSI Z (American National Standards Institute)

12. Personal Protective Equipment
Chapter 9 – 10 Test Review
Personal Protective Equipment
Hard hats requirements have developed in response to hazards found in the work place
the hard hat should be replaced if it is cracked, chipped, worn, or outside of reasonable age limits
nothing should be stored between the suspension and the shell
do not use solvents or chemicals to clean hard hat. Water and soap should be used.

13. Personal Protective Equipment
Chapter 9 – 10 Test Review
Personal Protective Equipment
Flame-retardant clothing is designed to protect the worker for a limited amount from a flash fire or heat source. The clothing will resist bursting into flames upon contact but will not protect a worker during sustained periods of exposure. The material does not breathe like cotton and can be uncomfortable.

14. Personal Protective Equipment Emergency Response – Four Levels of PPE
Chapter 9 – 10 Test Review
Personal Protective Equipment
Emergency Response – Four Levels of PPE
LEVEL A
Highest level of PPE
Requires totally encapsulating chemical protective suit (TECP)
Provides maximum protection

15. Personal Protective Equipment Emergency Response – Four Levels of PPE
Chapter 9 – 10 Test Review
Personal Protective Equipment
Emergency Response – Four Levels of PPE
LEVEL B
Chemical exposures not considered toxic unless absorbed through skin
Requires non-airtight chemical protective suit with taped sleeves

16. Personal Protective Equipment Emergency Response – Four Levels of PPE
Chapter 9 – 10 Test Review
Personal Protective Equipment
Emergency Response – Four Levels of PPE
LEVEL C
Hazard will not adversely affect skin
Hazards must be identified. PPM tested, correct respiratory equipment identified, PPE listed

17. Personal Protective Equipment Emergency Response – Four Levels of PPE
Chapter 9 – 10 Test Review
Personal Protective Equipment
Emergency Response – Four Levels of PPE
LEVEL D
Minimal amount of protection
Typical work uniform and standard PPE satisfies level D standards

18. Personal Protective Equipment
Chapter 9 – 10 Test Review
Personal Protective Equipment
The Occupational Safety and Health Administration requires employers who use and issue respirators to develop a written respiratory protection program
The purpose of respiratory protection is to protect employees from environments that could be hazardous.
Fit testing is a procedure that ensures the respirator forms a good seal on the technician’s face.

19. Personal Protective Equipment
Chapter 9 – 10 Test Review
Personal Protective Equipment
During fit test training the technician learns:
which respirators will be used in their assigned area
which respirators fit their face
how to properly don a respirator
how to select a respirator
specific hazards in their assigned units
Process tech use two types of respirators:
Air-purifying
Air-supplying

20. Personal Protective Equipment
Chapter 9 – 10 Test Review
Personal Protective Equipment
Air purifying respirators come in two designs, half face and full face
designed to remove specific contaminants or organic vapors from the air
designed for specific contaminants
Filter life of a respirators is determined by service time and contaminant
overpowering is used to describe atmospheric conditions that exceed the limitations of the respirator
Not designed for atmospheres containing less than 19.5% oxygen

21. Personal Protective Equipment
Chapter 9 – 10 Test Review
Personal Protective Equipment
Air supplying respirators come in two designs:
self contained breathing apparatus (SCBA)
hose line respirators
Designed to be used in oxygen deficient atmospheres and also provide protection from dust, mist, fumes, organic vapors, ammonia, and acid gases

22. Personal Protective Equipment
Chapter 9 – 10 Test Review
Personal Protective Equipment
Because respirators are selective in what they will remover, a number of issues must be addressed before selecting a respirator:
Type of contaminant
Airborne chemicals or contaminants present
Hazards associated with the chemicals
Physical characteristics of chemical
Air-purifying or air-supplied respirators
Oxygen deficient atmosphere
Length of time to perform task
Exposure time limit
Concentration of chemical present

23. Personal Protective Equipment
Chapter 9 – 10 Test Review
Personal Protective Equipment
When a respirator is used it is the responsibility of the technician to:
Carefully clean and disinfect the device
Return respirator to plastic bag
Ensure elastomer around face piece seal is not folded or bent
Visually inspect for damage
Properly dispose of spent filters and cartridges
When a respirator is used a positive and negative fit test should be performed. To perform negative fit test, ensure a tight seal by pulling the straps snug.

24. Personal Protective Equipment
Chapter 9 – 10 Test Review
Personal Protective Equipment
When a respirator is used a positive and negative fit test should be performed.
To perform negative fit test, ensure a tight seal by pulling the straps snug. By placing an open palm over the respirator’s inlet, you should be able to create a vacuum when you inhale. Hold for 10 seconds.
The positive fit test is performed by exhaling and covering the exhaust ports. If the respirator has a good seal, a positive pressure will fill the face piece.

25. Self-Contained Breathing Apparatus (SCBA)
Chapter 9 – 10 Test Review
Self-Contained Breathing Apparatus (SCBA)
SCBA’s provide a self-contained air supply that will last 30 to 60 minutes.
Air supply will vary depending upon a number of factors:
physical condition of the tech
physical size of the tech
training and experience of the tech
total charge of the cylinder
atmospheric pressure
environmental conditions (fear, excitement, emotional factors, physical exertion
carbon dioxide concentration greater than .04% in the compressed air cylinder

26. Chapter 9 – 10 Test Review Hose Line Respirators
Typically hose line respirators are used in environments that are immediately dangerous to life and health.
Hose line operators are required to wear emergency escape units (provide 5 minutes or more of emergency air)