(PDIS-103) SAFETY IN CHEMICAL INDUSTRY

2007 May-June

Q-1 a What are the different sections, Describe in MSDS of a chemical Describe health
hazrds and fire explosion data regarding chemicals.

Ans. For proper identification of material hazards, MSDS should be prepared & supplied
with each chemical so that it safety precautions can be well understood.
Following are the different sections in MSDS (total 10 sections)

1. Chemical identity : -

1. Name of the chemical

2. Formula
3. Synonyms
4. Trade name
5. Chemical classification
6. Regulated identification
7. Shipping name, codes / lable
8. CAS number – Chemical Abstracts Service
9. UN no. – United Nations number
10. ADR no. – Agreement Concerning carriage of dangerous goods
11. Hazchem (EAC) no. – Emergency Action Code
12. Hazardous waste ID no.
13. Hazardous ingredients & CAS no.

2. Physical & Chemical Data : -

1. Appearance, state, odour etc..

2. Specific gravity (water = 1)
3. Vapour density (air = 1)
4. Boiling point
5. Melting point / Freezing point
6. Vapour pressure
7. Solubility in water
8. Scrubbing / Neutralising / Inactivating Media
9. PH
10. others

3. Fire & Explosion Hazard Data : -

1. Flash point
2. Autoignition Temperature
3. Flammable limits : LEL / UEL
4. TDG flammability – Transport of Dangerous Goods
5. Explosion sensitivity to impact
6. Explosion sensitivity to static Elect.
7. Explosive material
 8. Flammable material
9. Combustible and flammable liquid
10. Pyrophoric material
11. Hazardous combustion products
12. Hazardous polymerization
13. Corrosive material
14. Organic peroxide
15. Oxidizers
16. Others

4. Reactive Data : -

1. Chemical stability
2. Incompatibility (materials to avoid)
3. Reactivity
4. Hazardous reaction products

5. Health Hazards Data

1. TLV
2. STEL / SET
3. LC 50 or LD 50
4. Odour threshold
5. Carcinogen ? Poison ? Liberates poisonous fume?
6. Routs of entry
7. Body parts that may be affected
8. Effects of exposure and symptoms
9. Emergency and first aid treatment
10. Engineering controls necessary for safe handling
11. NFPA hazard signals
12. Special Health hazards

6. Preventive Measures : -

1. Ventilation required and type

2. Personal protective equipment required and type
3. Handling and storage precautions

7. Emergency and first-aid measure : -

1. Step to be taken in case material is released or spilled

2. Waste disposal method for solid, liquid and gaseous waste
3. Fire, extinguishing media, special procedures and unusual hazards
4. Explosive First-aid measures, Antidotes, Dosages

8. Additional Information / References

9. Manufacture / supplier’s Data

1. Name of firm
2. Mailing address
3. Telephone / Telex / Fax nos.
 4. Telegraphic address
5. Contact person in emergency
6. Local bodies involved
7. Standard packing
8. Tremcard details / Ref.
9. Others

10. Disclaimer (A repudiation , claim, connection)

Q-2 What are the various hazards in chemical industry? Describe the UN
classification of chemicals in details giving examples of each class.

Ans. Following are the hazards in chemical industry

1. Flammable 2. Radioactive
3. Toxic 4. Asphyziants
5. Explosive 6. Poisonous
7. Corrosive 8. Carcinogens
9. Reactive 10. Irritating
11. Oxidizing agents

UN classification of chemicals : -

Class–1 Explosives : - Substances which may explode under the effect of flame, pressure,
heat or petrochemical conditions or which are more sensitive to shocks / impacts or
friction than dinitrobenzene. The substance which is not itself an explosive but
which can form an explosive mixture of gas, vapour or dust is not generally
included in class 1. e.g. Black powder, Nitro Glycerin etc.

Class–2 Gases : - Compressed, liquefied, dissolved under pressure or deeply refrigerate.

Some gases are flammable, others non-flammable e.g. chlorine, oxygen, nitrogen.

Class-3 Flammable liquids : - There are liquids or mixture of liquids containing solids in
solution or suspension having flash point of not more than 60.5 oc (closed cup) or
not more than 65.6 oc (open cup). e.g. petrol, acetone, LDO, FO etc.

Class-4
1. Inflammable solids
2. Substances liable to spontaneous combustion
3. Substances, which, on contract with water, emit flammable gases.
e.g. Naphthalene, sulphure, aluminium powder etc.

Class-5
1. Oxidizing substances
2. Organic peroxides
e.g. Sodium peroxide, sodium nitrate

Class-6 1. Poisonous (toxic) substances

2. Infectious substances
e.g. Aniline, phenol, phosgene
Class-7 Radioactive substances
e.g. Monazite

Class-8 Corrosive substances e.g. Acids, oleum alkali etc.

Class-9 Miscellaneous dangerous substances not covered by other classes.

e.g. Cinematographic films

SHORT NOTE

Q-2 1 HAZCHEM code :- (EAC – Emergency Action Code)

Ans. HAZCHEM code is an emergency code confirmed by the Health & Safety
Executive,UK.

Hazchem code is a very useful and simple device, which enables one to know at once
what action is necessary in case of a spillage, leakage, as fire. Hazchem code
simplifies handling of such emergencies. It consists of only a numeral and one or two
letters, which indicate the action to be taken in case of an emergency involving a
dangerous substances without having to know the name or the properties of the
substance.

Hezchem code uses one of the numerals 1,2,3 or 4 followed by one or two letters
which signify.
- Types of fire extinguisher required
- Types of PPE required
- Whether the substance is violently reactive
- Spillage should be contained or diluted with water
- Weather the material is reactive
- Weather evacuation of surrounding as on necessary.

Hazchem No. of
Petrol – 3YE LPG – 2WE
Ammonia – 2PE Acetic Acid – 2P
Sodium Cyanide – 4X AN – 1S

2. Hazard Communication System (including Safety & Risk Phrases)

Ans
1. Qualitative description like health hazards, flammability hazard, reactivity hazards,
Electrical, machinery, fall or slipping hazard etc.
2. Display of hazard, warning and control indicating signs and posters
3. Safe permissible limits of hazards like TLV, STEL, LD, LC, dBA etc.
4. Threshold quantities of hazardous chemicals as given in manufacture, storage and
important of Hazardous Chemical Rules, 1989.
5. CAS No., UN No., HAZCHEM, DUT, SOLAS etc.
6. Class label and emergency information panel.
7. TREM CARD (Haz. Information to be given to drivers of haz. Goods.)
8. Index like DOW and MOND. (Energy hazard in facility)
9. Hazards prioritization by numbers as given by NFPA.
10. Safety and Risk phrases.
Q-2 Write hazards in Unit operation & unit processes.

Ans. In such operations, there is no chemical reaction to form a new product. It indicates
no chemical change but mechanical or physical change.

Some general unit operations are as follows.

[1] Steam distillation :- Live steam is passed in the still to recover the solvent, cooled
distillate are taken in a separator where solvent and water separate out.
[2] Heating : - It is done either directly or indirectly. Direct heating (steam passed directly)
or indirectly (by coil, jacket)
[3] Cooling : - Directly cooled by water addition or indirectly (exchanger, chiller, water)
[4] Diluting : - (Drowning) e.g. dilute acid, dilute alkali etc.
[5] Filtration :- This operation is far separating solids and liquids. Filteration can be done
either under vaccume, pressure or at atmospheric pressure.
[6] Pulverization : - This operation is done to reduce size of the material, usually crushes,
palverises.
[7] Blending :- A blender to mix thoroughly two or more dried products.
[8] Washing :- Presses notches or centrifuge to remove soluble impurities and acid / alkali
from product.
[9] Packing :- Filling up of finished product in the containers.
[10] Storing of liquid raw material :- Bulk liquid raw materials which are received in
tanker loads are emptied out in storage provided for this purpose.

 Hazards associated with unit processes / operations are.

1. Mechanical hazards e.g. pressure release, leaks, burns, noise, equipment or utility
failure.
2. Reaction haz. Failure to control exotherms, incompatible materials, side reactions,
feed ratio or rate vibration etc.
3. Environmental haz. E.g. air pollution, odour problems, spills etc.
4. Toxicity and health effects.
5. Flammability haz. Due to explosive mixture, static change, auto ignition etc.

Q-3 a Safety measures for storage tanks of chlorine and ammonia.

Ans. Chlorine Storage tanks safety measure

Properties: - greenish yellow gas
Liquid or rhombic crystals
Melting point – 101 oC
Boiling point – 34.5 oC
Density – 1.47 at 0 oC
TLV – 1 PPM STEL – 3 PPM
When heated, emits toxic fumes. When reacted with water or steam produces toxic
and corrosive fumes of HCL.

Storage tank safety.

1. Storage area should be cool, dry, well ventilated, clean and protection from
external heat source.
2. It should be remote from elevators, gangways or ventilating systems.
 3. Ventilation must be sufficient to prevent accumulation of vapor pockets. All fan
switches should be outside the storage area.
4. Storage building should be entirely of non-combustible construction & should be
at ground floor with at least two exits opening.
5. Person affected with asthma, bronchitis, chronic lung dieses should not employed
in c/2 storage exposure area.
6. Being compressed gas, all installations and tank vehicles used for storage and
transport of liquid and gaseous chlorine have to be approved and licensed under the
static & mobile pressure vessels (unfired) Rules 1981.
7. Pressure indicator with alarm should be available in the control room.
8. The tank has to be installed entirely above ground (on roller)
9. The bulk storage tanks for chlorine should be installed near waste air system.
10. Repair all leaks promptly, systematic inspection and maintenance.
11. Neutralizing scrubber is required when large amounts are used or stored.
12. Only experienced, trained & competent personnel should undertake all operations
of connecting process.
13. Flexible seamless copper tubes used for handling of chlorine services.
14. Pressure indicator with alarm should be available in clr & also safety valve (two)
should be connected with waste air system.
15. Put all PPE’s emergency kits, BA set, near tank area & in case of large leakage to
absorb the chlorine in an alkaline medium such as caustic soda, soda or lime slurry
near tank storage area.

 Safety measure for Ammonia storage tanks.

Colour less gas, pungent odour, MP – 77.7 oC, bp – 33.35 oC, (LEL – 16%, UEL – 25%)
d- 0.771 9/1 at oC., VP10 atm at 25.7 oC, TLV – 25 PPM, STEL 35 PPM

Explosive hazard moderate when exposed to flame. When heated emits toxic fumes to
fight fire, stop flow of gas.

1. Storage should be cool, dry, well ventilated and protected from external heat
sources.
2. The location should be away from any flammable liquid storage.
3. Storage area should be protected at least by one standard fire hydrant.
4. Gauge of glass should be provided with excess flow check valves.
5. Storage tank construction should be of integrity and double wall type known as
‘Can in tank’ type.
6. Tank shall be equipped with two relief valves mounted on a 3-way hand valve to
provide means for repair of faulty valve.
7. Installed remote controlled valves at the bottom of ammonia storage tank.
8. Facilities for creating water curtains around the ammonia storage tanks.
9. Non-refrigerated NH3 shall be stored in gas tight containers.
10. Diesel generating sets provision should be made in case of power failure.
11. A flare stack should be provided to burn ammonia vapour in case of safety valve
fails to release amm. Pressure.
12. Provide necessary showers, eye baths and oxygen administration apparatus.
13. Preventive maintenance & inspection.
Q-3 b Safety of storing and using gas cylinders
Gas Cylinders

Ans. In factories we find the use of gas cylinders of oxygen, nitrogen, LPG, acetylene,
CO2, Chlorine, Sulphure dioxide etc. The gases are filled with pressure therefore
when they leak, they come out with force and pass hazards of fire, explosion while
handling them.

Safety in storing & using of gas.

1. Normally to identify and classified cylinders are painted with colors.
1. Acetylene - Maroon
2. Air, N2, NH3, CO2 - French grey
3. O2, Phosgene, Argon, HCN- peacock blue
4. H2, coal gas - signal red
5. Chlorine - Golden yellow
6. Ethylene, EO - Dark violet
7. Helium, Neon - middle brown
8. SO2 - light Brunswick green
 A mistake in colour, handling can cause serious accidents.
2. First verify the marking, number, company, pressure, weight, capacity and date on
the cylinder before their use.
 Should be store in dry, cool & well-ventilated place.
 Mark empty cylinder “Empty”.
 A hammer should never be used for opening valve.
3. Cylinder should be handled in its special trolley or gently rolled on its bottom
edge but not on the whole surface.
4. While carrying a chlorine toner (or any heavy cylinder) in a forklift, it should be
tied with a chain to prevent rolling.
5. Long vertical cylinder should be kept upright in its stand or tied with a chain to
prevent falling.
6. No flammable material should be allowed nearby. Source of ignition, spark,
flame, electricity, molten metal etc. must be kept away.
7. When not in use, the valve should be kept closed and covered with cap &
protected in handling.
8. Pressure regulator, Pressure gauge and non-return valve (NRV) should be
maintained in working order. Special spanner may be used to close or open the valve
keeping the thread direction in mind.
9. Grease or lubricating oil should not be applied on valves of oxygen cylinders.
10. A storeroom of gas cylinders should be well ventilated.
11. Quantity of cylinders should be restricted. It toxic and flammable cylinders are
kept in the same shade, a partition wall should be provided.
 Slings must not be used for lifting.
 Lighting must be flameproof in the cylinder storage area.
 No employment below 18 years.
12. While connecting or changing a cylinder necessary respirator and eye goggles
shall be worn.
13. Use gas detector with alarm.
14. FFE & PPE nearby.
15. Cylinders are safely arranged.
 16. Notice of operating / handling instruction.
17. Proper training & handling of cylinder must be given to workers.
 Cylinder should not be transported on two wheelers.

Q-5 (iv)Flare System

Ans. In plant where highly toxic or flammable gases are generated in bulk or continuously,
a flare system becomes necessary for their collection and safe discharge by burning at
height, The flare should be designed to vent the gases during normal operations and
emergency conditions.

Maximum possible discharge at a time should be considered for safer venting and
preventing pollution of the environment.

A flare system consists of a flare stack and piping to collect the gases to be vented. At
the flare tip, steam nozzles are provided for air entertainment and seals to prevent
flashback of the flame. At the base a knock out drum is provided to collect the liquid
from the gases passing to the flare.

A low level and a high level flare can be combined together so that normal operating
and start up loads are handled by the low level flare, while both flares are used to
handle occasional high volume emergency loads. Thus an environmental impact of
flaring can be kept to a minimum.

Efficient combustion in the flame is necessary otherwise a smoky flame will result.
Liquid carryover can also result in smoky flame.

A fuel gas is used as a purge gas to maintain positive pressure in the system to
disallow air inside. This can be confirmed (no air intake) by monitoring oxygen
content.

It chlorine & sulphur are burned in flares; they will emit HCL & SO2. This requires
more height of the stack so that ground level concentrations of these toxic gases may
come down to permissible level.

Figure

(Collection of liquid from gas)

Hazard of flare system :-

1. Internal explosion
2. Liq. Carry over from flare stack
3. System obstruction
4. Haz. During maintenance of system
 5. Presence of pyrophoric material inside system.

Q-5 Safety and Risk Phrases (Sequence of words intend to have meaning)

Ans. Regulation 9 of the CHIP (Chemical Hazards Information and Packing)

Regulation.1943 gives requirements for the labeling of substances and preparations
dangerous for supply. These include the name and address of the supplier, information
about the substance, symbols and risk and safety phrases. Gives guidelines
particularly as
1. the classification by physico-chemical properties, health effects and
environmental effects and
2. Labeling by risk and safety phrases.
These phrases are represented by number and their specific meaning indicating type
of hazard in brief.
1. Safety phrases
- Keep locked up
- Keep out of the reach of children.
- Keep away from living quarters.
- Keep away from heat.
2. Risk phrases
- Explosive when dry
- May cause fire.
- Highly flammable
- Reacts violently with water
- Harmful by inhalation
Q-6 NDT testing of pressure vessel (Non Destructive Tests)

Ans. Rule 61 of the Gujarat Factories Rules says that if external internal or hydro test is not
possible, NDT in service test shall be carried out for metal thickness and other
defects.

By visual inspection, external or internal, it is impossible to see under surface or inner

defects, cracks, porosity, thickness reduction etc. Hydraulic test can check the overall
integrity (soundness) of the vessel but it cannot show the above defects.

A way of finding the weakest part by hydraulic bursting, or a test piece cutting is
destructive test. There fore, NDT are developed to test boilers, pressure vessels and
nuclear components.

NDT can defect

1. Inherent metal defects like porosity, shrinkage, non-metalic inclusions.
2. Processing defects like residual stresses, cracks caused by grinding of casting and
forging, spruing.
3. In service defects like corrosion, erosion, change in section etc.

Limitations of NDT are

They can measure, thickness, cracks, flaws, porosity, discontinuities, soundness etc.
but not the overall integrity of the material against permissible pressure as a proof
test. From the measured thickness, permissible pressure can be calculated. Overall
integrity of a vessel can be tested by pressure (hydraulic) test only.
PEL = Permissible Limit Value
TREM = Transport Emergency Card
PLC = Programmable Logic Control
PFD = Process Flow Diagram
NFPA = National Fire Protection Association
TDG = Transport of Dangerous Goods.

April / May – 2006

Q-2 a Explain the purpose and design of dyke or Bund

Ans. Dyke is required to restrict the spread of the leaking material to safely contain within
its periphery and to restrict the surface area of the leaking material in order to reduce
its evaporation and for case of fire fighting or other emergency control activity. The
contained material can be safely disposed off or if it is burning, it can be extinguished
easily be reaching up to dyke wall. If there is no dyke (or bund) the leaking material
can come on the road or go in the plant and make more damage.

Dyke wall should be safe, sound and leak proof. Its floor should have a slope with a
pit in corner to provide a discharge valve, which should be opened only when the
rainwater or the stored (leaked) chemical is to be safely discharged.

Design – The volume of the dyke should be slightly more than the biggest tank inside wall
height should be less than 2 Mt. (mostly 1 Mt.) for case of fire fighting and
maintenance work. Steps should be provided to go inside. Acid proof lining should be
provided where required.

Dyke is always required if the liquid is stored at the atmospheric or low pressure and
temperature. Refrigerated chemical when leaks, it remains liquid till it reaches its BP.
There fore dyke is required for it. e.g. refrigerated ammonia.

While opening dyke discharge valve of a flammable material, Spark should be

avoided otherwise fire can travel inside the dyke and catch the tank.

Q-2 c ii Give list of four pairs of incompatible chemicals

Ans. Incompatibility means disability to co-exist permanently. There fore incompatible

materials should not be stored or kept together. for example.
1. Toluene – acid, plastic or rubber
2. Ammonia – chlorine, bromine, iodine
3. Aniline – Nitric acid, hydrogen peroxide
4. H2SO4 – chlorate, perchlorates
5. Nitric acid – AA, acetone, alcohol, aniline

In comp. mat. Can cause a fire, explosion, toxic release, violent reaction, and
polymerization or destroy the structure or function of a product. This information is
useful for storage & handling purposes.

Q-3 a Discuss about the safe design of process vessels & their fittings.
Ans. Rule 61 of the Gujarat Factories Rules. The terms design pressure, maximum
permissible working pressure (MPWP), plant and pressure vessel are defined.

Design pressure – means the maximum pressure that a pressure vessel or plant is
designed to withstand safely when operating normally.

Max. Permissible Working Pressure (MPWP) – means the maximum pressure at

which a pressure vessel or plant is permitted to be operated or used under this rule and
is determined by the technical requirement of process.
Every pressure vessels or plant should be
1. Properly designed on sound engg. Practice
2. of good construction, sound material, adequate strength and free from patent
defects.
3. Properly maintained in a safe condition.
4. A certificate from the Mfg. or competent person shall be obtained and produced
before an Inspector.
 Safety Devices –
1. Suitable safety valve or pressure reliving device of adequate capacity to ensure
that MPWP shall not be excess.
2. Suitable pressure gauge with dial range 1.5 times MPWP and red mark
indicating MPWP.
3. Stop or isolation valve to shutoff the pressure source.
4. Drain cock (valve) to drain the vessel.
5. Suitable pressure reducing valve (PRV) or automatic pressure regulator to
disallow the pressure greater than the MPWP. A safety valve shall be fitted on low
pressure side of such device.
 List of fittings –
- Safety valve – pressure gauge
- Temp. gauge – second safety valve
- Steam pr. Reducing valve necessary
- Flame – proof motor / fitting necessary
- Earthing – Temp. cut device
- Feed / charge control
- Drain / dich pipe – manhole
- Structure, foundation, position safe
- Surrounding space open
- Pressure test report available
- Platforms, stairs, fencing, guarding
- Rupture disc necessary
- Precaution against static charges.
- Proper drainage facility
- Proper reuse / neutralize / safe disposal
- Rain water drain facility
Q-3 b Enumerate precautions for safe working in laboratory

Ans. Following are precautions for safe working in laboratory.

1. Hand free eye wash station
2. Deluge safety showers
3. Safety shields with heavy base.
 4. Fire extinguishers (Dep & CO2)
5. Sand bucket. Fire buckets
6. Emergency lights.
7. Emergency signs & play cards
8. Fire detection or alarm system with pull stations
9. First-aid kits
10. Absorbent & neutralizing agents
11. Chemical storage cabinet
12. Laboratory chemical hood.
13. Ground fault interrupter electrical outlets
14. Container for broken glass & sharps
15. Material safety data sheets
16. Emergency action plan for the institution
17. PPE like, chemical splash goggles, face shields, lab coat, lab apron, gloves etc.
18. Room exhaust (ventilation)
19. Waste collection bins
20. Fuming cupboards
21. Gas cylinders kept up right
22. House keeping

Q-3 c Explain Vent scrubber Header

Ans. VENT - While filling a tank air has to come out. A vent pipe at the top
is required for this purpose. It is also useful to depressurize the vessel before opening
it. Its diameter should be sufficient for easy escape of the air. Vent pipe may have a
bend or roof to prevent outside thing (rain, bird etc) going inside. Vent pipe should
have wire mesh, flame arrester or breather valve if any flammable content is in the
tank. They should be kept clean to avoid chocking.

When explosive air mixture with vapour pr. Is inside the tank, breather valve and
flame arrester both are required inside.

When the content is flammable, N2 blanketing is necessary otherwise inhalation of the

breather valve will take air inside which may form explosive air mixture.

If the gas or vapour is toxic or corrosive, vent is connected with an appropriate

scrubber, flare or incinerator.

Where there is a possibility of vent chocking due to sublimation or polymerization of

the content inside, instead of vent pipe, safety valve or other device is necessary. Vent
shall be provided at all high paints of the vessel.
 Scrubber – TREATED GAS
BLOWER
DEMISTER

VPC STACK
THERMAL TRAY
WATER SPRAY

PACKINGRASCHING

SALT+DUST+AIR

HNO3

LEVEL AN RECOVERY

PUMP

 Main purpose of scrubber is to avoid or to reduced / to control dusting problem in air.

 For preventing of air pollution.
 Packing (Ranching rings), water spray, Thurman ray, demister & at bottom layer of
liquid used from bottom to top of column.
 Water spray provide to remove dust from air (remaining dust from air)
 Tharman tray is used in which VPC (vapor process condensate) is provided to
remove solute from gas (air)
 Demister packing is provided at top of the column. Wire mesh gauge type demister
packing is used to remove AV droplets. Water droplets and hence, dust free air is fed
to atm. Via stack (chimney)
 Liquid collected at the bottom of the column and this liquid is partially recycle to
spray over air with dust from blowers and dust are dissolved in liquid and it is
partially sent to AN recovery.
 Nitric acid is used to prevent the different density layer of liquid at the bottom of the
column.
  Header – Condensate

SHAFT JACKITING CONDENSATE STEAM HEADER COND

EAST
WEST
ER
CONDENSATE
HEADER

DRAIN

1 2 3 4 5

STEAM HAEDER

TO DIFF LOCATION

(1)

Diff. type of steam used & each have header from where it is distributed to many places.

Q-3 d Explain with neat sketch central measure for exothermic reaction

Ans. In exothermic reactions, heat is given out as reaction proceeds. This release of heat
raises the temp. of reaction mass.
 Vessels of such reactions should be regularly tested by a competent person.

For highly exothermic reactions since temp. has to be increased very gradually,
automatic programme are provided which maintain & predetermined rate of rise in
temp. and thus prevent the reaction from reaching runaway stage.

In addition to safety valve, a rupture disc with drowning i.e.dump or surge vessel is
provided to receive the entire reaction mass in case of open pressure and bursting of
the rupture disc. The pressure gauge, temp gauge, high pressure / temp. alarm and
heat source cut off device, quenching or process – killing device, safety valve, rupture
disc, drowning tank, cooling device, agitator, feed control, pressure controller, drain
valve etc should be regularly checked and properly maintained.

Alternate water, power and pumps are required to maintain the necessary cooling
system.

A process or chemical reaction, which is accompanied by evolution of heat.

Approximately for every 10 oC rise in temp. Reaction rate doubles.

 Safety measures : -
1. Automatic programmers are provided which maintain a predetermined rate of rise
in temp. and thus prevent the reaction from machine runway stage.
2. Safety valve, rupture disc with surge vessel is provided to reactive the entire
reaction mass in case of reaction reaching runway stage.
3. The pressure gauge, temp. Gauge, safety valve, rupture disc, drowning tank,
cooling device, agitator, feed control, drain valve etc. should be regularly checked
and properly maintained.
4. Cascade controllers are provided for quenching & control of temp.
5. PIC – provided to control pressure. It will relieve the pressure to blast stack.
6. Safety valve A/B provided & connected to flare stack.
7. Plant trip switch provided E S/D
8. Process parameters in field & gas detection meters (portable).
9. Periodical NDT tests, press-test, hydrostatic tests & inspection will be carried out.
10. Leak test taken before start-up.
11. Positive isolation will be made.
12. Safety permit system, PPE will be followed.

Q-4 a Write about safety consideration while designing a piping layout.

Ans. Following are the safety consideration while designing a piping layout.
1. Material of construction is selected depending on nature (corrosively, toxicity,
flammability etc.)
2. Other parameters like weight, flow, pressure, temp., viscosity, colour, expansion etc.
3. Thickness of pipe, its quality, welding pattern, flanging are to be considered while
selecting a high pressure & temp. Piping.
4. Minimize pipe length, branches and joints and flanges on vaccume line.
5. Good gaskets and gland packing.
6. Flange guard to defect leak downward.
7. Flexibility to allow thermal expansion, bellows subjected to axial movement.
8. Drains & traps at visible places.
9. Removable plugs on sample paints.
10. Adequate pipe supports, walkways, platforms or working place.
11. Ergonomic design for valves to be operated and gauges to be seen.
12. Earthing & bonding to remove static change due to flow, overflow etc.
13. Painting with colour coding (IS : 2379) and cathodic protection where required.
14. Flammable or toxic chemical should not be laid in tunnel, as its leak may spread from
one area to another.
15. Electric cables on hot lines and flammable gas or liquid lines should not run side by
side.
16. Solvent line should not be laid below the corrosive line.
17. Piping arrangement should be such that in case of failure at any paint, closing valves
can quickly isolate the system.
18. Flushing arrangement should be provided for easy start up and maintenance.
19. To allow thermal expansion special joints or loops should be provided.
20. By-pass valve should be within easy reach.
21. Pressure relief device, liquid seal, manual vent valve etc. should be provided to
depressurize the system where necessary.
22. Board of sign, safety should be provided at various locations like road crossing, river,
drainage, and gas underground line.

Q-3 b Describe safety precautions to be taken while transporting flammable liquid by

road tanker.

Ans. Following are safety precautions.

1. Stop the engine of tanker
2. No naked lights, No smoking
3. Mark roads & warn other road users.
4. Keep public away from danger area.
5. Use explosion proof electrical equipment.
6. Keep up wind.
7. First aid kit in road tanker.

Road tankers are constructed in a wide variety of materials like steel, stainless steel,
lined material and FRP construction.

Road tankers and their fastenings should be capable of absorbing following forces.
1. In the direction of travel-twice the total weight.
2. Vertically downwards – twice the total weight
3. Vertically upwards – total weight.
4. Trem cards should be with driver.
5. Emergency kit with driver.
6. Tool kit, emergency lighting
7. Fire extinguishers, protective clothing, PPE.
8. B A sect & first aid kit.
9. Phone no. of transporters, suppliers address and all documents ready with driver.
10. Need special labels or notice on vehicles, display of correct technical name of
chemical, special signs on plates, instruction in writing.
11. Driver should be trained to handle small emergencies.
12. Position of tanker parts like tyre, side light, front light, servicing, horn all are in good
condition.
Q-5 b Safe start up of oil refinery

Ans.
1. Starting sequence should be well defined, written and known to the all workers &
other involved.
2. Check for sufficient amount of raw material, utilities, services, ancillaries etc.
3. Check all blinds removes or not.
4. Purging, changing, elimination of air, water as per plant requirement.
5. Leak testing, atmosphere testing, noise, vibration, speed, alignment, synchronizing
etc.
6. During start-up if drains remain open, vent valves remain closed.
7. During s/y maintain all the process parameters like temp. pressure, flow rate under
control.
8. Effluent & relief system should be enough to handle any abnormal emergency
discharge.
9. Under control.
10. Effluent & relief system should be enough to handle any abnormal emergency
discharge.
11. Counter check of other parameters and strict manual observation and satisfaction are
requisite precautions for safe start up procedure.
12. Removal of S/D blinds, providing running blinds, opening all vessel, reaction, drum.
Disch. Line, safety valves should be checked.
13. Readiness of fire lighting equipment, leak detection etc.
14. Safe opening of all valves.
15. Observation of all levels, overflows, temp., press. If any.
16. Safe increase in loading.
17. Removing air from vaccum equipment.
18. Verifying all steam traps working for condensate discharge.
19. Check all sample & purity of all liquid, gas solid etc.
20. Check all valves opening, closing struck, PA system, internal phones.
21. Oil cup of pump before start up.
22. Line up air, C.W., steam, chiller stream properly.
23. Proper planning of s/u is required.
24. Ensure proper job allocation with diff. agency process dept. inst. Dept. mech. Dept. &
elect. Dept.
25. Check all interlocks control valve opening & closing before s/u.
26. Carry out detailed leak test.
27. Establishment of quality control lab for analysis the raw material as well as utility
used & product.
Q-5 b(2) Ultrasonic testing

Ans. IS 2417, 9346 & 11630 are on this subject.

Ultrasonic is an inspection technique to test both metallic and non-metallic products

such as welds, castings, forging, sheet, tubing, plastics and ceramics by using sound
waves (vibrations).

It discloses the soundness, thickness or physical property of the material or nature of

discontinuities without impairing the material and by exposing its one side only.
Ultrasonic waves i.e. vibrations are created by an electronic generators and passed
through a material due to its elastic properties. Vibrations above the human hearing
range (20000 H2) are called ultrasonic vibrations. An ultrasonic testing limit uses
vibrations of about 5 X 106 Hz (5 mega best).

These are two types of test systems pulse – echo reflection and through
transmission as shown in fig.

A third system known as “Resonant frequency” is rarely used because its functions of
“thickness measurement” and “band or lamination inspection” are also performed by
the pulse-echo system.

Q-5 c i Types of corrosion

Ans. Corrosion : - Corrosion is an electrochemical reaction between a metal and its

environment. It results in a loss of metal or weakening of it. Corrosion reaches deeply,
creates maintenance problems and incurs cost of loss in lacs of rupees over the years.

Scaling : - Corrosion due to oxidation at high temperature is called scaling. e.g.

steam boilers, general corrosion takes place due to a corrosive chemical or impurity
over the exposed surface.

Types of corrosion.
1. Inter granular corrosion : - occurs in stainless steel heated upto 500-800 oC and
then exposed to corrosive conditions.
2. Galvanic corrosion : - happens due to current flowing between two dissimilar
metals which form a galvanic cell. It occurs when two such metals are joined
together at a weld. A typical pair is iron and copper.
3. Pitting corrosion : - results from electrochemical potential setup by differences
of oxygen concentration inside and outside the pit. The oxygen bean part act as
anode and the metal surface as cathode.
4. Knife – line corrosion : - takes place between parent and weld metals. E.g.
austenitic stainless steels.
5. Crevice or contact corrosion : - occurs at the paint of contact of a metal and non
– metallic material. E.g. threaded joints.
6. Erosion : - is a type of corrosion and is caused by flow restriction or change of
direction. E.g. elbows, tees, baffles, nozzles and valves and paint opposite to inlet
nozzle. It is increased if the flow contains solid particles or by bubbles in liquids
 and by two phase flow. Wet steam flow, air jet flashing flow and pump cavitation
can cause severe erosion.
7. External corrosion : - occurs by material of insulation. Leaking of chloride salts
from insulation can corrode pipe work.
8. Under ground piping corrosion : - can be corroded by soil due to
electrochemical action and cathodic protection is used to control it.
9. Stress corrosion : - cracking is the result of corrosion and static tensile stresses.
Corrosion fatigue is caused by corrosion and by alternating fatigue stresses.
Chlorides are a common cause of stress corrosion cracking.

Q-5 c ii Preventive & breakdown maintenance.

Ans. P.M. compromise, all techniques which must be adopted in order to keep all
machinery equipments & plants in well operating condition all time. P.M. is the
system of inspection lubrication & repairing to minimize unscheduled down time &
max. efficiency & production.

P.M. is always more economical than ordinary break down maint.

Benefits of P.M. –
1. Reduce the down time
2. Life of machinery & equipment increase
3. Healthy condition of plant
4. Rate of accident is decreased
5. Higher efficiency & full utilization of machinery
6. Stock inventory maintained.
7. Noise level can be maintained.

 Any successful P.M. involve following factors

- Regular & systematic inspection
- Record & inspection findings
- Stock & spare parts
- Replacement of damaged parts
 List of job under P.M.
- Gasket replacement – calibration of S. Valves
- Suction strainer cleaning – pump alignment
- Pump vibration – valve overhauling & gland packing repair – lubrication – guard
checking – loose alignment.

Q Haz. and control of solvent distillation.

Ans. Solvent disti. Should be carry out at a low press. Or under vaccum or inlet blanketing.
Even as dist. Vessel a safety valve or explosion vent should be provided to be care of
any accidental press. Flare condenser vent gas condenser or incinerator should be
provided if required.

Another danger to flammable solvents come from smoke and electric sparks. All
electric fittings should be flame proof including lighting. During maintenance use of
ferrous tools should be avoided as it can give rise to spark flame arrester and smoke
detector should be provided. Fire extinguishers should be kept ready.
 As far as possible flammable substance should be proceed at low temp. and press. Dip
feed pipe, slow and controlled addition inlet blanketing, vaccum spares flame
avoidance, spark / flame detectors with alarm, no smoking habit, good ventilation and
training to workers necessary.

Q-2 c ISafety measures for bulk storage of conc. Sulfuric acid (H2SO4)

Ans.
1. Large quantities of H2SO4 should be stored in tanks or drums of mild steel or cast iron.
2. Storage tanks should be in the open. They should be protected from external corrosion
by coating them with a suitable material such as bitumen, epoxy paint etc.
3. It should be provided with level indicators with high level alarm & the high level
alarm should automatically shut off the valve in the filling line.
4. Stand by arrangements equal to the biggest container shall always be available to
transfer the acid quickly into the standby storage facility.
5. Storage vessels should be provided with an acid proof adequate size Bund / Dyke and
collecting sump.
6. Storage containers shall be labeled or marked to identify the contents of the container,
the physical and toxicological hazard.
7. Naked flames, hot elements and all other ignition sources should be eliminated.
Smoking should be prohibited.
8. Electrical installation should be of acid resistant type electrical equipment should be
segregate as far as possible from tank storage. It should be protected against corrosion
by plastic coating or painting.
9. Regular and frequent inspection, testing and maintenance is essential.
10. Inventory shall be kept as minimum as possible.
11. Authorized persons only shall be permitted to enter in storage area.
12. Suitable type of fire extinguishers shall be placed near storage.
13. Acid fumes leaking from any paint can cause corrosion. Therefore other installation in
near area should be well protected by paint of the appropriate type.
14. Storage level & period should be kept optimum & minimum.
15. Bulk storage tank must be mounted on foundation lined with acid proof material.
16. Provide acid proof basin with proper drainage to prevent seepage of acid into the
ground thus endangering the foundation.
17. Tanks should be fitted with overflow pipes leading to an adjacent container and
located within the bunds that will retain the total contents of the tanks in the event of
leakage or spillage.
18. Equipped with vents of such size as to maintain the tanks at atmospheric pressure
during filling and emptying. Vent should be connected to a caustic pot.
19. The top of the tank should be accessible by an independent metallic ladder for
inspection.
20. Put all PPE’s near tank. Near all PPE’s.
21. Pill box, first aid kit ready near tank.
22. House keeping maintains in area dry vegetables, grass should be removed.
23. Stores may new to be heated in winter and heating systems using low-pressure hot
water, LP steam as warm air are suitable.
24. Proper lighting – flameproof
25. Fencing of storage area.
26. Restricted and authorized entry.