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8. What accounts for 30–40% of the initial investment when creating a new
facility?
A. Training
B. Compressors
C. Cooling towers
D. Pipes, tubing, hoses, and fittings
9. What is the most common type of valve in the process industries?
A. Ball valve
B. Plug valve
C. Gate valve
D. Globe valve
10. Which of the following do companies use tanks for?
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A. Intermediate storage between process steps
B. Residence time for reactions or fractionation to occur
C. Settling and filtering for process fluids
D. All of the above
11. What type of pump uses pistons, diaphragms, gears, vanes, lobes, or screws to
deliver a constant volume of fluid with each rotation or stroke?
A. Axial pump
B. Centrifugal pump
C. Dynamic pump
D. Positive placement pumps
12. What system of separation is most widely used in the process industries?
A. Reactor
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B. Distillation
C. Absorption
D. Crystallization
13. When working with process equipment, which of the following factors should
process technicians be aware of that can have an impact on worker safety or
the environment?
A. Excess vibration
B. Lack of proper PPE
C. Not complying with government regulations
D. All of the above
14. Which of the following is expected of process technicians?
A. Develop new standard procedures that are quicker to complete without all the safety
regulations
B. Focus on company profits over safety
C. Look for ways to reduce waste and improve efficiency
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D. All of the above
1. What is an integrated group of process equipment used to produce a specific
product?
A. Unit
B. Vessel
C. Process drawing
D. Process standards
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2. Which of the following are included in the role of the process technician?
A. Monitoring and controlling the process
B. Equipment troubleshooting
C. Obeying safety, health, and environmental regulations
D. All of the above
3. Which is an element of quality?
A. Free of deficiencies
B. Improves process uptime
C. Meets quantity goals
D. Improves safety performance
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4. What is the benefit of standardization of symbols found in process drawings?
A. Reduces cost
B. Reduces confusion and mistakes
C. Increases efficiency and quality
D. Increases profit and revenue
5. What are machines that are used in place of electric drivers to produce power
and rotate shaft-driven equipment?
A. Pumps
B. Turbines
C. Compressors
D. Process vessels
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APPENDIX, Chapter 1
Table of Contents
Contents
Page
Safety Minute — Back Injuries (Example)
28
Safety Minute Topics — Sign-Up Sheet
29
Safety Minute Outline (Instructor Copy)
33
Safety Minute Outline (for the students)
34
Checking Your Knowledge Answer Key
35
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Safety Minute – Back Injuries
Example
Do’s and Don’ts When Lifting
Do’s
♦ Lift mentally first, foresee hazards and clear them
♦ Lift in a smooth continuous motion
♦ Develop good posture
Don’ts
♦ Don’t try to jerk a load off a shelf or the ground
Proper Lifting Technique
♦ Plan your lift before you start
• Where are you going to grip it?
• Where are you going to take it?
• How are you going to put it down?
♦ Lift only an edge of the load to see how heavy it is
• If the load is too heavy, use a mechanical device
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Safety Minute Topics—Sign-Up Sheet
SAFETY TOPICS
Student Name
Date of
Presentation
Working Safely Outdoors: Preventing Heat Stress
Keeping House Where You Work
A Clean Worksite Is a Safe Worksite
Accidents: Avoid Shortcuts
Accidents: Learn from Near Misses
Alcoholism
Arc Welding Safety
Arson: Be on the Alert
Asbestos: Entering/Exiting Large Class I Regulated
Areas
Asbestos: Personal Protective Clothing
Asbestos: What You Need to Know About
Regulated Areas
Back Safety for Construction Workers
Bad Housekeeping Is Kid Stuff
Beware of Battery Hazards
Beware of Big Bottles
Beware of Broken Glass
Beware the Pinch Point
Blood-Borne Pathogens: Minimizing Exposure Risk
for Healthcare Workers
Caution—Gasoline!
Chain Saw Safety
Check Floor Load Capacities
Chemical Burns Also Burn
Chlorine Bleach: Cleaner or Killer?
Chock and Block
Clamp-Type Lifting Devices
Clean It Up and Keep It Clean
Clean Out Accidents with Good Housekeeping
Close Encounters of the Dangerous Kind
Cold Chisel Work
Color Coding
Combustible Dust: Preventing Dust Explosions
Commercial Driver Safety: Hours of Service for
Passenger-Carrying Drivers
Commercial Driver Safety: Hours of Service for
Property-Carrying Drivers
Commercial Driver Safety: Vehicle Inspections
Compressed Air
Compressed Air Is for Machines, Not People!
Confined Space Attendant: Understanding Your
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Responsibilities
Confined Space Escape and Rescue
Confined Space Hazardous Atmospheres: Tips to
Recognize Them and Work Safely
Confined Space Supervisor: Know Your
Responsibilities
Confined Spaces in Construction: Potential
Hazards for the Entrant
Controlling High Blood Pressure
Conveyor Safety
Coping with Stress
Crane and Hoist Safety Practices
Crystalline Silica: Controlling Silica Dust in
Construction
Cutting Down on Cholesterol
Cutting Tools
Dangers of Carbon Monoxide
Dermatitis: It’s Not “Just a Little Rash”
Detergents and Cleaning Agents: Familiar but
Dangerous
Dipping and Coating
Dirty Secrets About Trash
Do’s and Don’ts of Lifting
Don’t Get Burned!
Driving and Pulling Nails
Drum Safety
Electric Portable Tools
Electrical Hazards
Electrical Shock
Emergency Preparedness: Emergency Chain of
Command
Emergency Preparedness: Fire Drill!
Emergency Preparedness: Portable Generator
Safety
Emergency Preparedness: Safe Storm Cleanup
Empty Skids and Pallets
Ergonomics: Safe Use of Mobile Devices
Everything Doesn’t Cause Cancer
Excuses, Excuses
Exercise for Health
Explosion Prevention
Extension Cords: Choose the Right One
Extension Cords: Use Them Safely
Eye and Face Protection from Chemical Splashes
Fall Protection: Construction: Fall Arrest: Do’s and
Don’ts
Fall Protection: Construction
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Fall Protection: Preventing Falls in General Industry
Falling Objects
Find a Better Word than “Carelessness”
Fire Safety
First Aid for First-Aid Kits
First Aid: Always Treat Cuts or Scrapes
Fitting Jobs to People
Flammable Liquid Hazards
Flammable Liquids: Handling Them Safely
Fluorescent Lamps
Focusing on Lasers
Food Safety in the Workplace
Foot Protection: Choosing the Right Type
Forge Press Safety
Forklift Operator Safe Practices for Traveling,
Maneuvering, and Parking
Forklift Operator Tips to Prevent Tipovers
Forklift Tips for Inspections
Forklift Tips for Safe Operations at Loading Docks
Forklifts: Operating Safely Around Pedestrians
Fuse Boxes
Golden Rule for Safety
Good Housekeeping
Good Tools Are Safety Devices
Grounding Electricity
Grounds for Caution
Hand Protection
Hand Protection: Cut-Resistant Gloves
Hand Protection: Selecting Chemical-Resistant
Gloves
Hand Tool Safety
Hand Tools: There’s a Safe Way
Handling Hand Tools
Hand-Truck Safety
Hand Trucks
Hazard Communication: Training for Supervisors
Hazard Communication: Workplace Labeling for
Employees
HazCom: Elements of the GHS-Compliant Label
HazCom: What Does the Skull and Crossbones
Pictogram Mean?
HazCom: The SDS—What to Do When a Worker Is
Exposed
HazCom: What Is a Safety Data Sheet?
HazCom: Workplace Labeling
Head Protection: Inspecting and Maintaining Your
Hard Hat
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Help Prevent Workplace Fires
Hidden Hazards
Hints for Preventing Headaches
Hold on to Your Hands
How Should You Use Chemicals? Carefully!
How to Be a Chiseler—A Safe One
Industrial Housekeeping
Injury & Illness Recordkeeping: Employee
Information and Anti-Retaliation
Job Knowledge: A Key to Job Safety
Job Safety Analysis
Keeping Electricity on Your Side
Keeping Fit an Any Age
Kitchen Hazards
Knife Safety: Safety Tips to Avoid the Most
Common Injuries
Knuckle Down on Hand Safety
Laboratory Safety: Handling Arboviruses Safely
Lead: The Cumulative Killer
Lead: Preventing Lead Exposure at Construction
Jobsites
Leading Causes of Industrial Fires
Lessening Your Cancer Risks in the Workplace
Lift Sling Safety to New Heights
Lifting with Cranes and Hoists
Listen Up!
Loading Dock Safety: Using Dockboards
Loading Docks and Warehouses
Locker Room Safety
Lockout/Tagout Affected Employee: Purpose and
Use of Lockout Devices
Lockout/Tagout Authorized Employee: Common
Mistakes to Avoid
Lockout/Tagout for Other Employees: How to
Identify Locks, Tags, Isolation Devices
Lockout/Tagout: The Case of the Jammed Machine
Low-Cost Ergonomic Solutions
Low-Voltage Hazard
Lubricating Machines: The Safe Way
Machine Guarding: Protect Against Amputations
Machine Guarding: Safe Use of Grinding Wheels
Machine Guarding: The Case of the Inadequate
Guard
Machine Safety
Machine Tool Safety
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Safety Minute Outline
(Instructor Copy)
Purpose:
There are numerous reasons for starting every class with a Safety Minute. First
and foremost, this process will start engraining safety as a way of life that
transcends the boundaries of work. The students will hopefully realize the
importance of environmental, health, and safety issues, and take this home with
them. Also, the safety minutes will accomplish several of the objectives of the
Intro course:
• Practice attitudes of safety awareness in their daily affairs.
• Apply basic safety, health, and environmental standards relative to
Process Industry situations.
Content:
The content of each Safety Minute can be different depending on the topic the
student decides to cover. The only requirement for each Safety Minute will be for
the students to incorporate a real life or real world example pertaining to the
topic. The example could be an antidote or story about the topic, a
demonstration, etc. Other material to be included in the Safety Minute can be:
• Background information
• Definition
• Consequences
• Qualities of the topic (ex. Asbestos is fireproof)
• Personal Protective Equipment
• Potential benefit or detriment
• Do’s and Don’ts
• Proper techniques
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Safety Minute Outline
Purpose:
This class will incorporate a Safety Minute into each class meeting for several reasons:
● Often in industry the work shift will start with a Safety Minute,
● We want to encourage you to practice attitudes of safety awareness in your daily
life, as well as on the job.
● You will need to apply basic safety, health, and environmental standards relative
to Process Industry situations.
Content:
The content of your Safety Minute will probably be different from someone else’s
depending on the topic you’ve chosen or been assigned.
Most Important: Be sure to include a real-life example pertaining to the top you’ve
chosen. If you don’t know one personally, you can probably find some examples on the
Internet, or perhaps in your text.
What else should you include? Here are some items that will make your presentation
more meaning and valuable to you, and to the other students.
• Background information – does this pertain to a specific process industry, or is it
standard for all?
• Definition – what are you talking about in this presentation?
• Consequences — what can happen if safety precautions are not taken?
• Qualities of the topic (ex. Asbestos is fireproof)
• Personal Protective Equipment — what PPE specifically relates to this safety topic?
• Potential benefit or detriment – What is the benefit of following this safety practice,
what can happen if you don’t?
• Do’s and Don’ts – A bulleted list of do’s and don’ts is always helpful
• Proper techniques — Are there proper techniques to follow related to your topic?
Can you demonstrate them?
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Chapter 1 Introduction to Process Equipment
Checking Your Knowledge Answer Key
1. Define the following terms:
a. Process drawings
b. Process industries
c. Process technician
d. Troubleshooting
e. Unit
2. (True or False) A process technician controls mechanical, physical, and/or
chemical changes throughout many processes to produce a final product
made from raw materials.
3. (True or False) Process technicians analyze data and communicate data to the
appropriate employees.
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6. In an operations role, a process technician may be required to perform the
following maintenance activities (select all that apply):
a. Lubricate equipment
b. Replace a unit compressor
c. Monitor and analyze equipment performance
d. Change or clean filters
7. List five items of personal protective equipment that a process technician
wears for safety.
8. List four factors that process technicians must be aware of that can impact
worker safety or the environment.
9. A mechanical piece of equipment used to move materials through a piping
system within various processes is a:
a. Heat exchanger
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b. Compressor
c. Burner
d. Pump
10. Drivers that convert electrical energy into useful mechanical work and provide
power for rotating equipment like pumps, compressors, and conveyor drives
are:
a. Reactors
b. Solids handling equipment
c. Motors
d. Furnaces
11. Equipment used to move nonfluid material within a process facility includes:
a. Environmental control equipment
b. Solids handling equipment
c. Separation equipment
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d. Auxiliary equipment
12. How are raw materials sorted?
a. By plant unit
b. By their end products
c. By process requirements
d. By physical requirements