December
Process Safety Management, SDS
and Cold Stress
This month’s curriculum focuses on the two hazards that cause the most serious winter-season incidents: the chemicals and the cold. In our PSM environments—where one wrong move can trigger a release—over 30% of chemical injuries come from misread SDS warnings, and extraction-area vapors like hexane can ignite from tiny static pops. Add winter conditions, where slips and tool drops jump more than 70% and cold strips 25–30% of your grip strength, and you’ve got a season where mistakes multiply fast. That’s why December reviews the essentials: how PSM changes the field, how chemicals actually behave, how to spot warnings before they escalate, and how cold exposure slows reaction time in dangerous ways. It’s not a textbook—it’s high-hazard, high-stakes survival training designed to keep crews from becoming statistics.
Hexane Insane
creeps along the process floor—tank pads, pump alleys, and tight corners where low-lying vapor slithers faster than your eyes can track. He’s the master of invisible chaos, drifting under doors, filling pockets of dead air, and waiting for the smallest spark to set him off. One loose fitting, one unventilated space, and Hexane Insane flips from quiet haze to catastrophic blast in seconds.
Weakness: ventilation, sealed connections, gas monitoring, hot-work controls, and crews trained to respect what they can’t see—or smell.
“If you didn’t notice me… perfect. That’s when I blow up the show.
December
Stay sharp—because the Cold and Chemical Villains never take a day off.
Frost-Bite
hunts the winter jobsite—open yards, rooftops, and wind-blasted work areas where the cold cuts deeper than you think. He’s the master of silent damage, numbing fingers, stiffening joints, and stealing judgment before you even feel the danger. One exposed cheek, one soaked glove, and Frost-Bite sinks in, freezing you from the outside in.
Weakness: layered PPE, dry gear, warm breaks, steady hydration, and watching each other for early signs of cold stress.
“Hold still… I only need a second to chill you to the bone."
Sulfuric Sorrow
stalks the process lines—acid tanks, transfer stations, and pump skids where one splash can erupt into heat, fumes, and permanent damage. He’s the master of corrosive chaos, eating through gloves, steel, and skin with equal hunger. One cracked fitting, one rushed dilution, and Sulfuric Sorrow melts anything in his path.
Weakness: face shields, chemical-resistant PPE, slow dilutions (“acid to water”), emergency showers, and workers who treat every drop as a threat.
“I don’t break things… I dissolve ‘em.
Static Specter
haunts loading racks, transfer hoses, dry air, and walkways where moving product silently builds charge. He’s the master of hidden ignition, slipping across steel surfaces, sliding through unbonded lines, and waiting for one rushed connection to let him snap loose.
Weakness: grounding, bonding, anti-static PPE, intrinsically safe tools, humidity control, and crews who zap themselves to safety before Static Specter can.
“Relax… it’s just a little spark—unless the vapors are listening.”
WEEK 1
PSM
When this site crosses OSHA’s chemical line, the field tilts, the hazards rush, and suddenly you’re playing for keeps—every decision, every step, every move. In Week 1, we don’t drown you in technical jargon; we review it, break it down, and make sure every contractor understands what actually matters when a jobsite turns into a PSM Field. Hexane, sulfuric acid, pressure systems, and invisible vapors transform routine work into high-hazard operations, and we walk crews through how to recognize that shift instantly, spot early warning signs most workers miss, and follow the PSM playbook with zero shortcuts or guessing. If you work around high-hazard chemicals, this isn’t just more paperwork—it’s the difference between reacting too late and going home safe.
Multiple Guess 1.What is the most reliable way for a contractor to confirm they are entering a PSM-covered area? A) Someone in the break room mentions it B) You see a fire extinguisher C) Posted signage, boundary markings, and confirmation with supervision D) You smell chemicals 2.Before starting any task in a PSM area, contractors must: A) Start working if they “don’t see anything leaking” B) Wait for someone else to check the area C) Assume it’s safe unless told otherwise D) Confirm hazards, isolations, permits, and exact boundaries before touching equipment 3.Which situation is an early warning sign of a dangerous process upset? A) A toolbox talk starting late B) Someone yelling nearby C) A pressure gauge jumping unexpectedly or equipment temperature rising D) A forklift honking 4.Hot work in a PSM area can ONLY begin if: A) The weather is clear B) Gas testing, permitting, area prep, and an assigned fire watch are all complete — NO PERMIT = NO WORK C) The supervisor “gives a quick verbal” D) The welder says it’s safe 5.A contractor hears a high-pitched alarm in a PSM unit but doesn’t see anything unusual. What’s the correct response? A) Ignore it until someone radios in B) Keep working and wait for confirmation C) Stop work, move to a safe location, and communicate immediately — alarms trigger BEFORE visible danger D) Attempt to silence the alarm Closed-answer 1.Contractors must verify ________ and isolations themselves before breaking a line. 2.Abnormal vibration, heat, or pressure requires an immediate ________-work action. 3.Hexane is dangerous because it gives no early ________ cues to the senses. 4.Hot work requires a permit, gas testing, area prep, and a ________ watch. 5.In an emergency, contractors must evacuate using routes that keep them ________ of the release. Discussion question What information do you want BEFORE stepping into any tank farm, pump deck, or chemical line-up?
WEEK 2
SDS Review
Week 2 cuts the fluff and gets real about SDS and pictograms—we’re not teaching chemistry here, we’re reviewing the hazard cues that actually keep you alive on the field. When a container hits your hands, you need to read the warnings fast: the signal words, the pictograms, the PPE calls, and the sections that matter when things go sideways. This week gives crews the quick-glance skills to spot the real danger behind every label, avoid bad reactions, and choose the right protection without guessing. It’s not a science lesson—it’s the playbook for staying one step ahead of the hazard.
Multiple Guess 1.The flame pictogram tells a contractor the chemical can: A.Only burn when heated to high temperatures B.Ignite easily from sparks, static, or hot surfaces C.Cause long-term cancer risk only D.Be stored anywhere indoors 2.A container shows the flame-over-circle symbol. This means: A.Flammable B.Oxidizer — can make fires burn hotter or longer C.Corrosive D.Not reactive 3.The skull-and-crossbones pictogram indicates: a.Minor irritation b.Acute toxicity — small exposure can be fatal c.Slippery floors d.Low hazard 4.Which of the following is TRUE about SRLs (Self-Retracting Lifelines)? a.They must be inspected monthly b.They do not limit free fall distance c.They engage immediately after fall begins d.They replace harnesses 5.The health hazard pictogram (silhouette with star in chest) means: a.Explosive b.Flammable c.Long-term health damage — cancer, organ failure, respiratory issues d.Static buildup only Closed-Answer 1.The pictogram showing a test tube burning a hand means the chemical is __________. 2.Section 2 of the SDS lists pictograms, hazards, and the __________ word. Discussion Point 1.Which pictogram do you personally think gets ignored the most — and why do you think that happens in the field?
WEEK 3
Extraction and Hexane
Week 3 drops you into the extraction zone, where hexane moves fast, stays invisible, and leaves zero room for guessing. We’re not teaching chemistry—we’re reviewing the real warning signs contractors must catch: low-lying vapor, equipment tone changes, ignition risks, and why “intrinsically safe” isn’t optional. This week shows crews how hexane behaves, why warm solvent becomes a vapor missile, and how to read the field before the hazard hits. Short, sharp, and survival-focused—this is the film review that keeps you safe inside a live extraction unit.
Multiple Guess 1.In the extraction process, hexane is used because it: A.Reduces temperature B.Dissolves oil from material and carries it away C.Neutralizes acids D.Creates steam 2.Hexane vapor is especially dangerous in extraction areas because it is: A.Colorful and obvious B.Dispersed upward C.Slow to ignite D.Invisible, fast-moving, and heavier than air 3.Which action is REQUIRED before entering an extraction zone? A.Wearing insulated work boots B.Bringing your cell phone C.Raising the ventilation system D.Confirming all electronics are intrinsically safe (approved for the zone) 4.Which area of the extraction process is MOST likely to develop low-lying hexane vapor? A.Drying ovens B.Upper catwalks C.Wash, evaporator, and liquid transfer points D.Forklift aisles 5. Contractors performing hot work near extraction equipment must: A.Keep a fire extinguisher nearby and continue B.Never perform hot work without a permit, gas test, and authorized fire watch C.Allow sparks as long as they are contained D.Only worry if hexane odor is strong Closed Answer 6. Electronics must be ________ safe before entering a hexane zone. 7.Hexane vapor is ________ than air, so it sinks and travels along low areas. Discussion 8.What’s your personal checklist before stepping into a hexane area?
WEEK 4
Cold Stress
Week 4 hits the reality of cold stress—where numb hands, slow reactions, and frozen metal turn normal tasks into high-risk moments. We’re not teaching weather science; we’re reviewing the signs crews must catch early: stiff fingers, slowed thinking, icy surfaces, and the danger of shivering suddenly stopping. This week shows workers how cold strips grip strength, wrecks dexterity, and doubles the chance of slips, drops, and bad decisions. Quick, practical, and no-nonsense—this is the cold-weather film study that keeps you upright, aware, and alive when the temperature sinks.
Multiple Guess 1.You watch a coworker repeatedly miss the alignment on a small bolt because their hands are stiff and slow. What should you do FIRST? A.Tell them to warm up later B.Offer to finish the bolt for them C.Stop the task and get them warmed up — loss of fine motor control is a cold-stress warning D.Ask them to switch gloves 2.A worker on a fixed ladder hesitates and re-grips twice. You know cold reduces grip strength 25–30%. The biggest immediate risk is: A.Frostbite B.A fall from height due to weak grip C.Dehydration D.Eye strain 3.A worker’s skin on their fingertips turns pale and firm. What stage of cold injury is this? A.Trench foot B.Early frostbite C.Dehydration D.Advanced hypothermia 4.On an extreme cold windy day your coworker becomes unusually quiet, sluggish, and slow to respond. What could you assume? A.They’re distracted B.Cognitive impairment from cold stress C.They skipped breakfast D.Their PPE is too tight 5. A worker is in the cold for an hour, stops shivering, becomes confused, and stumbles. Immediate action: A.Give warm sports drink and continue working B.Let them rest outside C.Call for a supervisor and wait D.Treat as an emergency — move them to heat, call for medical support immediately Closed Answer 6. When shivering stops during cold exposure, ________ is advancing and it becomes an emergency. 7.Cold reduces reaction time, leading to increased ________ risk on ladders and catwalks. Discussion 8.What mistakes have you seen people make in the cold that led to near misses?
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