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AIChE CCPS Process Safety Professional Certification Sample Questions:

1.
During a field inspection of the process piping in a production unit, a section of piping is identified as containing a dead leg in which stagnant liquid is trapped. It is determined that this dead leg branch line is used very infrequently. Assume that the plant is in a location where winter temperatures drop below 20°F (-7°C) and summer temperatures can exceed 90°F (32°C). Which of the following are valid process safety reasons to remove the line? (Select all that apply)

A) The cost of removing the line will be greater if done at a later time
B) Stagnant liquids in piping could result in accelerated corrosion
C) The current position of the line may be a tripping hazard
D) Water could accumulate in the line and freeze during colder weather, potentially rupturing the piping

2. A company has done a statistical/metric study on root causes of incidents over the last dozen years. It shows a steady, marked increase in the number of incidents with root cause being insufficient operator knowledge of the process. Which two of the following statements are most reasonable?

A) Facility audits are not detecting the issue
B) Better writing of operating procedures will compensate for insufficient process knowledge by the operators
C) The company's training program might need improvement
D) The incident investigation element is clearly deficient
E) The company's process safety competency could be deteriorating

3.
This heater was severely damaged during startup as a result of a firebox explosion. The operator had difficulty with the instrumentation and decided to complete the startup by bypassing the interlocks. The main gas valve was opened and gas filled the heater while the pilots were off.
Upon lighting of the pilots, the heater exploded destroying the casing and damaging several tubes. Identify and discuss what elements of Risk-Based Process Safety, had they been implemented more effectively, could have reduced or eliminated the likelihood of this event occurring or reduced the consequences.

A) No RBPS elements could have prevented this incident
B) Multiple elements including Operating Procedures, Management of Change, Training, Asset Integrity, and Process Safety Culture were involved
C) Only Mechanical Integrity was involved
D) Only Emergency Management was involved

4. A field operator contacted the control room about a leaking connection on a heat exchanger. The control room operator instructed the field operator to bypass the heat exchanger. However, unknown to the control room operator, additional piping had recently been installed upstream of the heat exchanger, and had not been recorded on the P & ID. When the field operator incorrectly opened a valve in the new piping, the process stream was routed to an unintended location.
Which of the following groups of Risk Based Process Safety elements, if properly implemented, could have prevented this incident?

A) Process Knowledge Management - Management of Change - Training and Performance Assurance
B) Process Knowledge Management - Safe Work Practices - Management of Change
C) Asset Integrity - Training and Performance Assurance - Management of Change
D) Management of Change - Conduct of Operations - Emergency Management

5. Which of the following criteria would justify not performing a periodic review of operating procedures?

A) There is very low turnover of plant operators
B) The process is only operated a few times per year
C) The process has been indefinitely suspended at this facility
D) The facility is heavily automated
E) The site has an effective Management of Change program that covers procedures
F) There are no regulatory requirements to review the procedures

Solutions: