Plant Operations Practice Questions for Level 2 · Intermediate

1. Question 1

   During an annual lockout/tagout inspection, the inspector finds an employee using a local stop button instead of the main disconnect. What should be done?

   1. Note it and address it at next year's inspection.
   2. Correct the problem and retrain the employee.
   3. Place a warning tag on the local stop button.
   4. Allow it if the stop button is locked in the off position.
   Show the answer

   Answer: B. Correct the problem and retrain the employee.

   A stop button does not isolate the equipment from its energy source. The problem must be corrected, and the employee must be retrained in the proper lockout/tagout procedure.

2. Question 2

   A plant keeps its safety data sheets in an electronic system. During a network outage, employees cannot open an SDS, and no backup is available. Which requirement is not being met?

   1. SDSs must be available to employees during the work shift.
   2. SDSs must be printed and stored beside every chemical container.
   3. SDSs must be approved by a supervisor before every chemical use.
   4. SDSs must be replaced whenever the electronic system goes offline.
   Show the answer

   Answer: A. SDSs must be available to employees during the work shift.

   Electronic SDS systems are allowed, but employees must still be able to get the information during their shift. A network outage without backup access fails that requirement.

3. Question 3

   An unplanned bypass causes a plant to exceed an NPDES permit limit. Under the general federal requirement, when must the event be reported?

   1. Report it only with the next regular discharge report.
   2. Report it in writing within 24 hours, then orally within 5 days.
   3. Report it orally within 12 hours, then in writing within 30 days.
   4. Report it orally within 24 hours, then in writing within 5 days.
   Show the answer

   Answer: D. Report it orally within 24 hours, then in writing within 5 days.

   The permittee must report the event orally within 24 hours and normally provide a written report within 5 days. The permitting authority may waive the written report in an individual case.

4. Question 4

   A plant security review identifies several possible improvements. How should the plant decide which ones to complete first?

   1. Choose whichever improvement costs the least to install.
   2. Address the highest risks to critical operations first.
   3. Give every improvement the same priority and schedule.
   4. Choose the security upgrade most visible to the public.
   Show the answer

   Answer: B. Address the highest risks to critical operations first.

   Security work should focus first on the risks that could cause the greatest harm to important plant operations. Cost can be considered, but it should not be the only factor.

5. Question 5

   A contractor will enter a permit-required confined space while plant employees do work that could affect the entry. What must the plant do?

   1. Share the hazards and coordinate the work.
   2. Let the contractor use the plant permit without a briefing.
   3. Let both crews follow separate plans without coordination.
   4. Give the contractor an equipment list after the work is complete.
   Show the answer

   Answer: A. Share the hazards and coordinate the work.

   The plant must tell the contractor about the space hazards and entry precautions and coordinate the work when plant and contractor activities may affect one another.

Operator Master has 43 Level 2 · Intermediate plant operations questions, free.

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