HSE PRACTICES FOR OFFSHORE AND PETROLEUM

INDUSTRIES

HAZARD CONTROL

TUTORIAL: 07

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COURSE CORDINATOR
Prof. SRINIVASAN CHANDARSEKARAN
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B.E (civil engg)., M.Tech (Structural engg- IIT Delhi); Ph.D (IIT Delhi).,
MiUR fellow (Min of Italian University Research, Italy)., M.ASCE
Professor, Dept of Ocean Engg.,
Indian Institute of Technology Madras, INDIA 600036
Tel: (Off) 91-044-22574821, Fax: +91-044-22574802
email: drsekaran@iitm.ac.in
Home page: http://www.drsekaran.com/
Tutorial: 01 Max marks: 20

Part A (2 Marks each)

1. Difference between full recording and recording with exception

2. What is a weak link and what methods is used to detect them?
3. The objective of FMEA is on _________ and not on _________
4. What are different types of FMEA and where is it applicable
5. Write a short notes on risk priority number (RPN)

Part B (5 Marks each)

1. Carryout an FMEA on a projector lamp, with a function “Provide reliable light for image
transfer at a minimum of 1000 lumens for 2000 hours of operation".

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2. Carryout an FMEA study for centrifugal pump with components mechanical bearing, seal,
shaft and impeller.

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 SOLUTIONS
Part A
1. Recording with exception - Earlier HAZOP are carried out only for potential deviations with
negative consequences, as it was used for internal purposes and handwritten. It is asswumed
that deviations not included are presumed to be satisfactory.
Full recording - Over period of time it was observed the need for recording all deviations
irrespective of their potential. Each keyword applied to the system in the HAZOP report has
to be clearly stated. Even statements like no cause could be identified or no consequences
arose from the cause recorded are to be reported.
2. Weak Link: It is the one having the highest chance of failure. A detailed analysis of the

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components in the weak link are carried. The components if needed has to be redesigned
such that the failure rate decreases to ALARP. One of the method used to identify the weak

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link is FMEA.
3. Failure prevention, detection
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4. Two types of FMEA
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Design FMEA: Identifies the potential failure modes of components, sub-components etc of
a main system
Process FMEA: Identifies the potential failure modes of processes deployed in making the
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components
5. Risk priority number (RPN)
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Risk priority number identifies the important areas of concern. It evaluates a severity rating,
the occurrence rating, and the detection rating for a potential failure mode
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RPN = Severity X Occurrence X Detection

Part B
1. FMEA report

Potential
Potential
Function Effect(s) Potential
Failure Controls Recommended Action(s)
of Cause(s)
Mode
Failure
hot spots on
glass due to Designed as
over per Implement new glass
touching Guidelines coating to minimize
gas leak at and tested for impact of touching on
base of glass environmental bulb durability

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due to and durability
lamp burns overheating

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no light
out Change lamp base to less
on image
prematurely corrosive material.
Provide py
inadequate Revise the interface
reliable Sneak circuit
voltage to between bulb base and
light for analysis on
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lamp due to electrical connection to
image projector
corrosion of ensure positive
transfer at system
base connection, with
a
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increased connection
minimum
force.
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of 1000
Install additional plastic
lumens
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shield on projector to
for 2000
ensure no injury to user if
hours of
glass shatters.
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operation
Designed as Modify projector lamp
no light, over per Design Guide to include
lamp potential pressure in Guidelines correct bulb gas.
shatters for injury amp due to and tested for Conduct Design of
to user wrong gas environmental Experiments on projector
and durability bulb gas to determine the
optimum gas
specification to
desensitize bulb pressure
to gas variation.
 Potential
Potential
Function Effect(s) Potential
Failure Controls Recommended Action(s)
of Cause(s)
Mode
Failure
Modify Lamp durability
test to include induced
gas pressure build up.
lamp
filament has
low
resistance Designed as
user may
due to per Modify lamp durability
have
low light wrong Guidelines test to include moderate

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difficulty
output filament and tested for customer abuse during
viewing
material environmental installation process.

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image
slow gas and durability
leak due to
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2. FMEA for centrifugal pumps

S No Components Failure mode Failure effect Comments

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Mechanical Leaking though 1. Fluid leakage

1 Periodic
seal seal 2. Losses of pumping efficiency
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maintenance and
1. Excessive pump vibration replacement as per
Worn out: shaft 2. Increased In shaft radial schedule
2 Bearing
and seal broken movement
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3. Eventual pump shutdown

1. Using non
1. Vibration
corrosive material
3 Shaft Corroded 2. Possible bearing damage
and corrosion-
3. Eventual coupling failure
resistant paints
Worn out: 1. Pump low efficiency
4 Impeller decreasing 2. Vibration
pump capacity 3. Reduce in suction power