Process Safety & Risk Management
Semester 1, 2018
Cornell Notes
Questions:
What is an FMEA study?
Identify and list all hazards and
safety issues related to the
maintenance (inspection, testing,
cleaning, repair, modification etc.)
of a pump
Topic: Name: Sahil Hariramani
Group: 15
Workshop: Friday (Wednesday)
Date: 28/03/2018
MAIN IDEAS/FINDINGS:
Failure modes and effects analysis (FMEA) is a step-by-step approach to
identify all possible failures in a design, a manufacturing/assembly process
and also a product/service. Failures can be either errors or any defects,
especially the ones that will affect the consumer and can be potential
(Tague, 2004).
General Hazards:
Gould Pumps, a subsidiary of the ITT corporation (Goulds Pumps, 2008)
listed general hazards with operating a pump: They have been listed down
below.
 Operating a pump with coupling guard installed improperly
 Operating a pump with discharge valve closed
 Operating a pump with suction valve closed
 Operating a pump without safety devices installed
 Pump may handle hazardous and/or toxic materials. Precautions
must be taken to avoid injury.
 Driver power (Driver power must be locked out before operating
the pump to avoid accidental power up)
Pressure Testing:
When installing a new pump, pressure testing has to be done throughout
the following unit operations so that there is no pressure build-up that can
cause blow off a valve, or rupture a tank, etc.
Hazards and Safety Issues Related to Pressure Testing:
 Explosion of a tank due to hydrotesting (Goulds Pumps, 2008).
 Pressure buildup in a tank due to high pressure pumping causing
the blow off of a relief valve (Goulds Pumps, 2008).
 A leak of high pressure liquid can cut the skin and inject itself into
body tissues. This can cause adverse effects if the fluid is toxic. Use
safety equipment when maintaining pumps (EGIS HSEQC, 2003).
 A pump that is not securely attached or which fails due to pressure
buildup can spray the containing liquid and can hurt the operator. A
whip check should be performed before performing maintenance
checks on the pumps. A whip check is check that ensures that the
two ends of a pipe/hose are securely attached to an anchor point
(EGIS HSEQC, 2003).
Pump curve/performance testing :
This test is done so as to check whether the pump is made to the specified
requirements and will not fail once installed onto the system. Essentially,
the test is done to check the compatibility of the pump to the specified
system/plant. In this test a performance curve is plotted containing the
following curves:
1. The Head-Flow Curve. It is called the H-Q Curve.
2. The Efficiency Curve.
3. The Energy Curve. It records Brake Horsepower, BHP.
4. The Pump’s Minimum Requirement Curve. It’s called Net Positive
Suction Head required, NPSHr.
The pump is tested before its installation onto the system. The values are
then compared to the given data by the pump provider and then only
installed onto the system.
Hazards and Safety Implications Related to Performance Testing:
  When testing the pump, the pump may fail and cause a rupture in a
pipe/tank.
 A rupture is a pipe/tank can cause the leaking of a liquid which can
adversely affect the personnel’s health.
Trip Testing:
Systems running multiple pumps in parallel can undergo serious equipment
and piping damage during a pump trip caused by a power outage or a pump
mechanical failure. This test is performed so that the outcome can be
predicted if there is a power failure causing the failure of the pump so that
there is no back flow caused.
Hazards and Safety Implications Related to Performance Testing:
 Ensure that the lock power to the driver before performing
maintenance to the pumps as there is a risk of electrocution.
 If there is a rupture in the pump/pipe/tank, there will be a leakage
of liquid which will harm the operator unless protective equipment
is worn.
Leak testing in seals and joints:
This test is done to ensure that there are no leakages throughout the plant.
Hazards and Safety Implications:
 In case of high pressure in pumps or pipes connected to a pump, do
not operate without safety equipment as there can be a sudden
surge of liquid (may be hot) and can cause cuts to the body, or burn
the operator if the liquid contained is hot/toxic enough.
 Ensure that the lock power to the driver before performing
maintenance to the pumps as there is a risk of electrocution.
Draining surrounding lines
This is done so that maintenance checks can be performed on the pump.
Before maintaining the pump, all lines have to be cleared so as to uninstall
the pump and perform a check on it.
Hazards and Safety Implications:
 A vacuum can be formed in the tank/pipe when emptying it. This
can be avoided by checking the ventilation to the required unit
operation before emptying it.
 If a rupture is formed in the pipe/tank, it can cause a leakage of the
liquid which can cause burns and cuts to the operator.

Decontamination of the pump

When servicing or repairing the pump due to faults or failures, the pump
and the surrounding pipes/tanks have to be emptied.
Hazards and Safety Implications:
 When disconnecting a pump from the system, in case of high
pressures in pumps or pipes connected to the pump, do not
operate without safety equipment as there can be a sudden surge
of liquid (may be hot) and can cause cuts to the body, or burn the
operator if the liquid contained is hot/toxic enough.
 Ensure that the lock power to the driver before performing
maintenance to the pumps as there is a risk of electrocution.
 Use safety equipment to avoid risk of bodily harm or electrocution.
Summary:

References
EGIS HSEQC. (2003). SAFETY ALERT File Ref.: 03-04 Alert - Air lines & whip check Issued . EGIS HSEQC Dept.
Goulds Pumps. (2008). Industrial Process Pump Safety Manual . Goulds Pumps.
Tague, N. R. (2004). The Quality Toolbox, Second Edition. ASQ Quality Press.