What is the primary goal of chemical and process safety management? a) Minimize environmental impact b) Prevent accidents and protect personnel c) Increase production efficiency d) Reduce raw material costs Answer: b
Who of the following is required to supply safety data sheet? a) Manufacturer b) Supplier c) Distributer d) All of the above. Answer: d
What is the importance of safety data sheets to an employer? a) They are designed to provide employers with all the information they need to adequately assess the risks inherent with using a hazardous chemical during a workplace task, allowing the employer to implement adequate control measures and emergency procedures. b) They can be used as a risk assessment c) So they can show the Health and Safety Executive that they're legal d) Just something you need to have because the law says so. Answer: a
How many sections should a safety data sheet have? a) 5 b) 16 c) 32 d) 22 Answer: b
What is the purpose of Section 1 of a safety data sheet? a) To inform you of the potential hazards b) To inform you of the identity of the substance and the contact details of the manufacturer or supplier who marketed the product c) To inform you of the spillage, storage and waste procedures d) To provide you with the workplace exposure limits (WELs) Answer: b
From the following, please select the incorrect statement? a) A safety data sheet contains exposure controls b) A safety data sheet can also be called a risk assessment c) A safety data sheet contains toxicological information d) A safety data sheet is needed even if you are only storing a chemical. Answer: b
Which organization provides guidelines for Process Safety Management (PSM)? a) EPA b) OSHA c) FDA d) CDC Answer: b
What is the purpose of a Hazard and Operability Study (HAZOP)? a) Assess ergonomic hazards b) Identify potential process hazards c) Investigate workplace injuries d) Evaluate employee performance Answer: b
In the context of chemical safety, what does "LFL" stand for? a) Lower Flammability Limit b) Liquid Fuel Level c) Long Flame Lifetime d) Low Fire Level Answer: a
What type of safety control aims to prevent overpressure in process equipment? a) Relief systems b) Inherent safety c) Hazardous waste disposal d) Routine maintenance Answer: a
What is the purpose of a Safety Data Sheet (SDS)? a) Provide marketing information b) Outline company profits c) Detail chemical hazards and handling procedures d) Summarize production goals Answer: c
Which of the following is an example of an engineering control in chemical safety? a) Wearing personal protective equipment (PPE) b) Installing ventilation systems c) Conducting safety meetings d) Creating emergency response plans Answer: b
What is the "Four P's" of chemical safety? a) Predict, Prevent, Protect, Practice b) Process, Personnel, Probability, Pressure c) Plan, Prepare, Prevent, Protect d) Product, Price, Promotion, Place Answer: a
What is the function of a flame arrestor in process safety? a) Enhance chemical reactions b) Prevent the spread of fire and explosion c) Increase pressure in equipment d) Filter air pollutants Answer: b
What does "PHA" stand for in the context of process safety? a) Process Hazard Analysis b) Potential Hazard Assessment c) Pressure Handling Authority d) Process Handling Assessment Answer: a
What is the primary objective of conducting a Quantitative Risk Assessment (QRA)? a) Improve employee morale b) Reduce manufacturing costs c) Analyze potential hazards quantitatively d) Optimize supply chain logistics Answer: c
What is the purpose of a "safety shower" in a laboratory or workplace? a) To cool down overheated equipment b) To provide drinking water for employees c) To rinse off hazardous chemicals from the skin d) To clean laboratory glassware Answer: c
What is the purpose of a "lockout/tagout" procedure in process safety management? a) To track employee attendance b) To authorize hazardous tasks after a safety assessment c) To grant employees vacation leave d) To manage employee payroll Answer: b
Which of the following is NOT a common type of chemical hazard? a) Thermal hazards b) Chemical reactions c) Fire and explosion hazards d) Ergonomic hazards Answer: d
What does the term "inherently safer design" refer to in process safety? a) Designing processes with no hazards b) Eliminating all chemicals from the process c) Minimizing hazards by using safer technologies and materials d) Increasing the complexity of process equipment for safety Answer: c
Which type of hazard analysis focuses on identifying potential human errors in a process? a) FMEA (Failure Modes and Effects Analysis) b) HAZID (Hazard Identification) c) HAZOP (Hazard and Operability Study) d) HUMAN (Human Error and Mitigation Analysis) Answer: d
Which chemical hazard is associated with the risk of oxygen deficiency? a) Flammable gases b) Corrosive liquids c) Reactive chemicals d) Asphyxiants Answer: d
What does the "RAGAGEP" principle in process safety stand for? a) Reducing All Greenhouse Gas Emissions Promptly b) Recognized and Generally Accepted Good Engineering Practices c) Restricting Access to Hazardous Areas with Gates and Enclosures d) Reacting Appropriately to Gas Accidents with Gas Extraction Procedures Answer: b
Which of the following statements is true about the hierarchy of controls? a) Administrative controls are the most effective and reliable b) Engineering controls are the least effective but most cost-efficient c) Personal protective equipment (PPE) is the most effective control measure d) Elimination of the hazard is the most effective control measure Answer: d
What is the purpose of a "safety integrity level" (SIL) assessment? a) Assess the competence of safety personnel b) Determine the efficiency of manufacturing processes c) Evaluate the reliability of safety instrumented systems d) Calculate the financial cost of safety incidents Answer: c
Which type of hazard analysis involves evaluating the potential consequences of various failures? a) PHA (Process Hazard Analysis) b) FMEA (Failure Modes and Effects Analysis) c) HAZID (Hazard Identification) d) LOPA (Layer of Protection Analysis) Answer: d
What is the primary purpose of a "process safety incident investigation"? a) To identify opportunities for cost reduction b) To determine employee promotions c) To establish liability for legal action d) To understand the root causes of incidents and prevent recurrence Answer: d
What does the term "inerting" process involve in chemical safety? a) Introducing an explosive substance into a process to control reactions b) Removing all chemicals from the process to prevent hazards c) Replacing air or oxygen with an inert gas to reduce flammability d) Enhancing chemical reactions by increasing temperature and pressure Answer: c
Which type of fire extinguisher is suitable for flammable liquid fires? a) Class A b) Class B c) Class C d) Class D Answer: b
What does the acronym "ATEX" stand for in the context of chemical safety? a) Atmospheric Temperature and Extreme Exposure b) Atmosphere and Toxicity Exchange c) Atmospheres Explosibles d) Advanced Technology for Environmental X-rays Answer: c
What is the purpose of a "permit to work" in process safety management? a) To track employee attendance b) To authorize hazardous tasks after a safety assessment c) To grant employees vacation leave d) To manage employee payroll Answer: b
What is the primary purpose of a "process hazard analysis" (PHA)? a) Increase production efficiency b) Identify and assess potential process hazards c) Develop marketing strategies d) Implement cost-cutting measures Answer: b
What is the main objective of conducting a Management of Change (MOC) review? a) Evaluate employee performance b) Improve marketing strategies c) Assess financial performance d) Ensure that process changes are managed safely Answer: d
What does the "Triple Bottom Line" concept consider in chemical and process safety management? a) Safety, security, and sustainability b) Profit, production, and personnel c) Price, promotion, and profits d) Process, performance, and potential hazards Answer: a
Which of the following is an example of an "administrative control"? a) Personal protective equipment (PPE) b) Machine guarding c) Ventilation system d) Standard operating procedures (SOPs) Answer: d
What does "LOPA" stand for in the context of process safety? a) Layer of Protection Analysis b) Liquid Oxygen Production Assessment c) Low Operating Pressure Analysis d) Loss of Process Automation Answer: a
What is the purpose of a "safety audit" in chemical and process safety management? a) To review employee salaries b) To ensure compliance with safety regulations and procedures c) To assess the financial performance of the company d) To calculate production efficiency Answer: b
Which type of hazard analysis is often used to evaluate the potential consequences of a hazardous event? a) PHA (Process Hazard Analysis) b) FMEA (Failure Modes and Effects Analysis) c) HAZOP (Hazard and Operability Study) d) SIL (Safety Integrity Level) Assessment Answer: b
Which chemical hazard involves substances that can react violently with air, water, or other chemicals? a) Flammable hazards b) Corrosive hazards c) Reactive hazards d) Toxic hazards Answer: c
What does the acronym "PSM" stand for in chemical safety management? a) Public Safety Measures b) Process and System Management c) Process Safety Management d) Personal Safety Management Answer: c
Which of the following is a principle of good chemical storage practices? a) Store chemicals in direct sunlight for easy identification b) Keep incompatible chemicals together for efficient access c) Store chemicals alphabetically to simplify inventory management d) Store chemicals separately based on compatibility Answer: d
What is the primary purpose of a "root cause analysis" in process safety management? a) To identify opportunities for cost reduction b) To determine employee bonuses c) To establish blame for incidents d) To uncover underlying causes of incidents for prevention Answer: d
What does the acronym "CPR" stand for in chemical and process safety? a) Chemical Process Response b) Cardiopulmonary Resuscitation c) Chemical Production Regulation d) Chemical Process Risk Answer: b
Which type of personal protective equipment (PPE) is used to protect the eyes from chemical splashes? a) Respirators b) Earplugs c) Goggles d) Hard hats Answer: c
What is the primary purpose of a "safety management system" (SMS)? a) To reduce production output b) To maximize employee bonuses c) To systematically manage safety risks and hazards d) To increase employee turnover Answer: c
What is the purpose of a "safety barrier" in process safety management? a) To restrict employee access to certain areas b) To increase process complexity c) To prevent the use of personal protective equipment (PPE) d) To provide an additional layer of protection against hazards Answer: d
What is the primary purpose of a "lockout/tagout" procedure? a) To secure equipment during routine maintenance b) To limit access to restricted areas c) To isolate electrical equipment from the power source d) To prevent unauthorized personnel from entering the facility Answer: a
Which type of chemical hazard involves substances that can release toxic fumes when heated or mixed with other chemicals? a) Flammable hazards b) Corrosive hazards c) Inhalation hazards d) Reactive hazards Answer: d
What is the purpose of a "confined space entry permit" in process safety management? a) To authorize personnel to access all areas of the facility b) To restrict employee access to certain areas c) To facilitate employee training sessions d) To ensure safety when entering confined spaces Answer: d
What does the term "process hazard analysis" refer to in chemical safety? a) A systematic review of the company's financial performance b) An assessment of employee attendance records c) A comprehensive analysis of process-related hazards d) A review of marketing strategies Answer: c
What is the primary purpose of a "pre-startup safety review" (PSSR)? a) To review employee attendance records b) To assess the efficiency of manufacturing processes c) To ensure that equipment and processes are safe before startup d) To calculate employee bonuses Answer: c
What does the term "inert gas" refer to in process safety management? a) A gas that is highly flammable and explosive b) A gas that is chemically reactive with most substances c) A gas that does not support combustion and reduces fire risk d) A gas that is harmful to the environment Answer: c
Which type of chemical hazard involves substances that can catch fire and burn in the presence of an ignition source? a) Flammable hazards b) Corrosive hazards c) Reactive hazards d) Toxic hazards Answer: a
What is the purpose of a "buddy system" in hazardous work environments? a) To facilitate teamwork b) To assign tasks to employees c) To promote healthy competition d) To ensure that employees work alone Answer: a
What does the term "Process Safety Management (PSM)" encompass? a) Ensuring quality control of products b) Preventing chemical reactions c) Managing risks associated with process facilities d) Regulating employee working hours Answer: c
Which type of hazard analysis involves identifying potential hazards based on previous incidents and experiences? a) PHA (Process Hazard Analysis) b) FMEA (Failure Modes and Effects Analysis) c) HAZID (Hazard Identification) d) LOPA (Layer of Protection Analysis) Answer: c
What is the purpose of a "work permit" in process safety management? a) To increase employee wages b) To authorize and control hazardous work activities c) To facilitate employee promotions d) To assign routine tasks to employees Answer: b
Which chemical hazard involves substances that can cause harm through inhalation or absorption? a) Flammable hazards b) Corrosive hazards c) Inhalation hazards d) Reactive hazards Answer: c
What does the acronym "MSDS" stand for in chemical safety? a) Manufacturing Safety Data Sheet b) Material Safety Data Sheet c) Manufacturing Safety Design System d) Material Safety Design Sheet Answer: b
What is the purpose of a "safety integrity level" (SIL) in the context of safety instrumented systems? a) To determine the profitability of a company b) To assess the performance of personal protective equipment c) To measure the efficiency of a chemical process d) To specify the reliability required of safety instrumented systems Answer: d
Which type of hazard analysis involves systematically evaluating the potential consequences of various failures? a) PHA (Process Hazard Analysis) b) HAZID (Hazard Identification) c) FMEA (Failure Modes and Effects Analysis) d) LOPA (Layer of Protection Analysis) Answer: c
What is the purpose of a "safe operating limit" in chemical and process safety? a) To set performance targets for employees b) To determine equipment maintenance schedules c) To ensure that process conditions remain within safe limits d) To calculate employee salaries Answer: c
Which of the following is an example of a "passive" safety control measure? a) Providing safety training to employees b) Using personal protective equipment (PPE) c) Installing fire detection systems d) Developing emergency response plans Answer: c
Which chemical hazard involves substances that can cause harm through skin contact or ingestion? a) Flammable hazards b) Corrosive hazards c) Inhalation hazards d) Toxic hazards Answer: d
What does the term "inherently safer design" refer to in process safety? a) Designing processes with no hazards b) Eliminating all chemicals from the process c) Minimizing hazards by using safer technologies and materials d) Increasing the complexity of process equipment for safety Answer: c
What is the primary objective of a "pre-startup safety review" (PSSR)? a) To review employee attendance records b) To assess the efficiency of manufacturing processes c) To ensure that equipment and processes are safe before startup d) To calculate employee bonuses Answer: c
What does the term "Process Hazard Analysis (PHA)" involve? a) Determining financial risks for a process b) Analyzing potential chemical reactions c) Identifying potential hazards in a process d) Optimizing production efficiency Answer: c
Which type of hazard analysis involves evaluating the potential consequences of different initiating events? a) PHA (Process Hazard Analysis) b) FMEA (Failure Modes and Effects Analysis) c) HAZID (Hazard Identification) d) LOPA (Layer of Protection Analysis) Answer: d
What does the acronym "MSDS" stand for in chemical safety? a) Manufacturing Safety Data Sheet b) Material Safety Data Sheet c) Manufacturing Safety Design System d) Material Safety Design Sheet Answer: b
What is the purpose of a "safety audit" in process safety management? a) To review employee salaries b) To ensure compliance with safety regulations and procedures c) To assess the financial performance of the company d) To calculate production efficiency Answer: b
Which of the following is an example of an "administrative control"? a) Personal protective equipment (PPE) b) Machine guarding c) Ventilation system d) Standard operating procedures (SOPs) Answer: d
What does "LOPA" stand for in the context of process safety? a) Layer of Protection Analysis b) Liquid Oxygen Production Assessment c) Low Operating Pressure Analysis d) Loss of Process Automation Answer: a
What is the purpose of a "safety audit" in chemical and process safety management? a) To review employee salaries b) To ensure compliance with safety regulations and procedures c) To assess the financial performance of the company d) To calculate production efficiency Answer: b
Which type of hazard analysis is often used to evaluate the potential consequences of a hazardous event? a) PHA (Process Hazard Analysis) b) FMEA (Failure Modes and Effects Analysis) c) HAZOP (Hazard and Operability Study) d) SIL (Safety Integrity Level) Assessment Answer: b
What is the primary objective of a "process safety incident investigation"? a) To identify opportunities for cost reduction b) To determine employee promotions c) To establish liability for legal action d) To understand the root causes of incidents and prevent recurrence Answer: d
What does the term "inert gas" refer to in process safety management? a) A gas that is highly flammable and explosive b) A gas that is chemically reactive with most substances c) A gas that does not support combustion and reduces fire risk d) A gas that is harmful to the environment Answer: c
Which type of chemical hazard involves substances that can release toxic fumes when heated or mixed with other chemicals? a) Flammable hazards b) Corrosive hazards c) Inhalation hazards d) Reactive hazards Answer: d
What is the purpose of a "work permit" in process safety management? a) To increase employee wages b) To authorize and control hazardous work activities c) To facilitate employee promotions d) To assign routine tasks to employees Answer: b
What does the term "process hazard analysis" refer to in chemical safety? a) A systematic review of the company's financial performance b) An assessment of employee attendance records c) A comprehensive analysis of process-related hazards d) A review of marketing strategies Answer: c
What is the primary purpose of a "pre-startup safety review" (PSSR)? a) To review employee attendance records b) To assess the efficiency of manufacturing processes c) To ensure that equipment and processes are safe before startup d) To calculate employee bonuses Answer: c
Which type of hazard analysis involves identifying potential hazards based on previous incidents and experiences? a) PHA (Process Hazard Analysis) b) FMEA (Failure Modes and Effects Analysis) c) HAZID (Hazard Identification) d) LOPA (Layer of Protection Analysis) Answer: c
What is the purpose of a "work permit" in process safety management? a) To increase employee wages b) To authorize and control hazardous work activities c) To facilitate employee promotions d) To assign routine tasks to employees Answer: b
Which type of chemical hazard involves substances that can cause harm through inhalation or absorption? a) Flammable hazards b) Corrosive hazards c) Inhalation hazards d) Reactive hazards Answer: c
What does the acronym "MSDS" stand for in chemical safety? a) Manufacturing Safety Data Sheet b) Material Safety Data Sheet c) Manufacturing Safety Design System d) Material Safety Design Sheet Answer: b
What is the purpose of a "safety audit" in process safety management? a) To review employee salaries b) To ensure compliance with safety regulations and procedures c) To assess the financial performance of the company d) To calculate production efficiency Answer: b
Which type of hazard analysis is often used to evaluate the potential consequences of a hazardous event? a) PHA (Process Hazard Analysis) b) FMEA (Failure Modes and Effects Analysis) c) HAZOP (Hazard and Operability Study) d) SIL (Safety Integrity Level) Assessment Answer: b
What is the primary objective of a "process safety incident investigation"? a) To identify opportunities for cost reduction b) To determine employee promotions c) To establish liability for legal action d) To understand the root causes of incidents and prevent recurrence Answer: d
What does the term "inert gas" refer to in process safety management? a) A gas that is highly flammable and explosive b) A gas that is chemically reactive with most substances c) A gas that does not support combustion and reduces fire risk d) A gas that is harmful to the environment Answer: c
Which type of chemical hazard involves substances that can release toxic fumes when heated or mixed with other chemicals? a) Flammable hazards b) Corrosive hazards c) Inhalation hazards d) Reactive hazards Answer: d
What is the purpose of a "work permit" in process safety management? a) To increase employee wages b) To authorize and control hazardous work activities c) To facilitate employee promotions d) To assign routine tasks to employees Answer: b
What does the term "process hazard analysis" refer to in chemical safety? a) A systematic review of the company's financial performance b) An assessment of employee attendance records c) A comprehensive analysis of process-related hazards d) A review of marketing strategies Answer: c
What is the primary purpose of a "pre-startup safety review" (PSSR)? a) To review employee attendance records b) To assess the efficiency of manufacturing processes c) To ensure that equipment and processes are safe before startup d) To calculate employee bonuses Answer: c
Which type of hazard analysis involves identifying potential hazards based on previous incidents and experiences? a) PHA (Process Hazard Analysis) b) FMEA (Failure Modes and Effects Analysis) c) HAZID (Hazard Identification) d) LOPA (Layer of Protection Analysis) Answer: c
What is the purpose of a "work permit" in process safety management? a) To increase employee wages b) To authorize and control hazardous work activities c) To facilitate employee promotions d) To assign routine tasks to employees Answer: b
Which type of chemical hazard involves substances that can cause harm through inhalation or absorption? a) Flammable hazards b) Corrosive hazards c) Inhalation hazards d) Reactive hazards Answer: c
What does the acronym "MSDS" stand for in chemical safety? a) Manufacturing Safety Data Sheet b) Material Safety Data Sheet c) Manufacturing Safety Design System d) Material Safety Design Sheet Answer: b
What is the purpose of a "safety audit" in process safety management? a) To review employee salaries b) To ensure compliance with safety regulations and procedures c) To assess the financial performance of the company d) To calculate production efficiency Answer: b
Which type of hazard analysis is often used to evaluate the potential consequences of a hazardous event? a) PHA (Process Hazard Analysis) b) FMEA (Failure Modes and Effects Analysis) c) HAZOP (Hazard and Operability Study) d) SIL (Safety Integrity Level) Assessment Answer: b
What is the primary objective of a "process safety incident investigation"? a) To identify opportunities for cost reduction b) To determine employee promotions c) To establish liability for legal action d) To understand the root causes of incidents and prevent recurrence Answer: d
What does the term "inert gas" refer to in process safety management? a) A gas that is highly flammable and explosive b) A gas that is chemically reactive with most substances c) A gas that does not support combustion and reduces fire risk d) A gas that is harmful to the environment Answer: c
Which type of chemical hazard involves substances that can release toxic fumes when heated or mixed with other chemicals? a) Flammable hazards b) Corrosive hazards c) Inhalation hazards d) Reactive hazards Answer: d
What is the purpose of a "work permit" in process safety management? a) To increase employee wages b) To authorize and control hazardous work activities c) To facilitate employee promotions d) To assign routine tasks to employees Answer: b
What does the term "process hazard analysis" refer to in chemical safety? a) A systematic review of the company's financial performance b) An assessment of employee attendance records c) A comprehensive analysis of process-related hazards d) A review of marketing strategies Answer: c
What is the primary purpose of a "pre-startup safety review" (PSSR)? a) To review employee attendance records b) To assess the efficiency of manufacturing processes c) To ensure that equipment and processes are safe before startup d) To calculate employee bonuses Answer: c
Which type of hazard analysis involves identifying potential hazards based on previous incidents and experiences? a) PHA (Process Hazard Analysis) b) FMEA (Failure Modes and Effects Analysis) c) HAZID (Hazard Identification) d) LOPA (Layer of Protection Analysis) Answer: c

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Thursday, 20 July 2023

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Friday, 31 March 2023

Subject   : Fatal Accident on Rapid KL Depot Expansion Project adjacent to SCOMI                             Bombardier compound (lesson learnt)
When   : 17th May 2010
Time   : 11:00 am
Venue : Rapid KL Subang Depot compound adjacent to Scomi site office (KLJ Project)
HSE Comment:    Workers without / less supervision
                               Incorrect tool
                               None of us will cut the manhole.
                               Not clear instruction

Visited the incident site and managed to gather some information from RKL personnel on the incident, listed below is what caused the above fatal accident;

The worker was trying to open a man hole steel cover that is located at the accident site, As they did not have the right tool to open the steel cover, they tried opening it with other tools but failed to open it and also damaged the slot used to insert the actual tool to open it, the worker finally decided to cut the manhole steel cover using a hand grinder.

They initially tried cutting it with the normal 6 inch disc but it did not work, so finally the worker decided to try and use a 12 inch disc (still under investigation who actually gave this instruction?) although the report states the supervisor was present at site. As the 12 inch disc could not fit into the hand grinder as the protective guard only allows the right size disc to be fitted on it, he decided to remove the guard to allow a 12 inch disc to be fitted onto the hand grinder.

Once the 12 inch disc was fitted onto the grinder (not sure how it was done, still being investigated) the worker started cutting the manhole steel cover which approximately has a thickness of 0.5 to 1cm. He managed to cut through to a length 3/4 of the cover's diameter, all of a sudden most probably, due to long duration and extreme force applied or the quality and durability of the disc that was being used cracked and struck his face and threw him to the ground.

A portion of the broken disc was lodged on his right temple till his right chin killing him 15 minutes after its occurrence.

This above fatal accident could been avoided if the work had been closely supervised, the right tool used, proper PPE, had the hazard been identified, assessed and the control measures disseminated to all the employees before work is commenced at site.

We will come up with a some guidelines on usage power tools, will distribute it to all concerned accordingly as soon as possible . In the meantime discuss or retrain your staff during the morning brief or tool box talk, especially those work that requires usage of power tools to prevent any untoward incident.

Accident Site

Blood loss of Grinder Man

Victim cutting the manhole using 7’’ Angel grinder (disc size maximum 7 inch)

Accident Photographs of Victim

Another Grinding Machine Accident

Grinding Accident Video Link:

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Tuesday, 28 February 2023