SENG 312/674IDL Final Exam May 4,2011

System Safefy Engineering

Final Exam
Open Book Exam. Show all your work to get credit.
Deadline: Pls tum the completed exam by May 6.

Name:

" On my honor, as an Aggie, I have neither given nor received unauthorized aid on this academic work."

Problems

1. List all the general causes of failures, in other words: reasons for general, typical failure modes- (6 pts)

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2. a.List all the failure modes for "switch: (5 pts)
tD 0p* Lfii; (-Wce; . U) Lhaffi)-
Li, P*A'ol\ A7e^ trv) P&Jtta.L! Unsed,

2. b. List all the failure modes for'aalve": (5 pts)

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Lii Prfi"\ A7.e'n
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3. List "all the contributing causes" of Bhopal incidents. (10 pts) j-
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 SENG 312/674/DL Final Exam N4ay 4,2017

4. Emergency shutdown systems are one example of the Safety lnstrumented Functions (SIF). List "four
recommendations" to minimize failure associated with the emergency shutdown systems. (6 pts)

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tiiD Wq4L^e,& 'Vt"{r^J
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5. Give 3 examples of "passive Independent Protection Layers (IPLs)" and their usages. (6 pts)

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-aft,
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-- da'
6. Compare the "monitdlring" and "auditing" process used in the safety management program. (6 pts)

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7. Prior to conduct aHAZOP,you will need some relevant information such as P&IDs (Piping and
Instrumentation Diagrams), Process Flow Diagrams (PFDs), chemical hazard information and plot plan.
Given a particular P&ID, identiff typical examples of HAZOP nodes (specific portions of the process
equipment) that will be used to perform HAZOP. (6 pts)

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SENG 31216741DL Final Exam May 4,2011

8. DAP Process:

@ Diammonium phosphate (DAP) is produced from continuous flow of phosphoric acid (PA) and
ammonia (A) solutions. PA+A ) DAP

E IfA and PA flow rates increase, rate of energy release will accelerate.

@ Too much PA fed to reactor: degraded product but no major reaction hazards.

Sl Too much A fed to the reactor: unreacted A may enter the DAP storage tank. Residual (toxic) A
will be released into the work area.

('LoAoFrG rJr{-o^orrG
aTAIK'XS sTATrOr$

AnuoilA
Sot.t Tf,)lil
STORAGE

ot TDooR$

Complete the following FMEA worksheet, focus on p_ressure relief valve" E and failure of level indicator
fi.T) on fhe ammonin sohrfion storage tank

FYI: Pressure relief valve, E, is considered a standard relief device installed in the reactor unit. Failure
modes for "E': failure to open, opens above set pressure, stuck open, fails to relieve required capacity,
opens spuriously, leakage.
 Final Exam May 4,2011
SENC 31216741DL

the FMEAworksheet:
Failure Safeguards
Identification Description
Modes

L-eveL lndrco$st Lt errr Anrrrsnla- Ietb toN h!)t-'e * Arnnontu bs\Avt te"ef
Foteryrtia-Q-
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Mvna* 'Cons'dlrt aAAiI

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SENG 312/674IDL Final Exam May 4,2011

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SENG 3121674/DL Final Exam May 4,2AIl

Identification Description Failure Effects Safeguards Actions

Modes

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SENG 3121674/DL Final Exam May 4,2011
SENG 31216741DL Final Exam May 4,2011

9. Complete the HAZOP worksheet for DAP system, focus only on the reactor unit and the ammonia solution storage tank. (30 pts)
ST
Parameter Deviation Causes Consequence Recommendations
s

Level. A,* t. Ulrrlnd;nn Arnrrtonia

lrom ?ota{h!- ln*To-llfron el tjreL
fu]- unWoAn'n g;h"&on Rdeetp 6l lntuon- o".8.
"'"- lwc!
h aL ,Wr'-n hwn"ni l lndeyztls'fr t^lAL
it. ^Wu* b &-otn. aluvy* talflr!
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Routa;^q q afu'elulu
2, Amnonio- S.1rrrayTomk &nz u V,"k h
lr{el tn&utpv W ls,,o. d,lre've +sL fl^z D.i
w+'il fi*. @ =,erru'bfun
to &'J?.*q
Ar/rnewlL.
oc€gs

Rgwero Ammonr'a-
U"itldA/;vy WCSA^ L0
R o"d-'aLq)ratt-
srtco. L1tr-r. eh
d;r wre,,,
SENG 3121674IDL Final Exam May 4,2011

IT:
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 }/ray 4,201I
Final Exam
SENG 31216741DL
Consequence Recommendations

Parameter s

Co^e,t.'raLon Hr'41^ Amnon)+ Sd,[tu''*' UnnsdtA. \, l,ttctat-L-

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endnyA vra*-onga-
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rE,.raTi6'd*.

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 May 4,2011
Final Exam
SENG 3T716'74IDL

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