1. Write a Hazop method and explain with one example.

HAZOP (Hazard and Operability Study) is a method used to identify potential risks in complex processes.
Here’s a simple summary of the process:
HAZOP Methodology
1. Define the Scope: Set clear goals and gather important documents like process diagrams.
2. Assemble the Team: Create a team of experts from different areas (engineering, operations, safety).
3. Break Down the Process: Divide the process into smaller sections (nodes) for easier analysis.
4. Identify Key Parameters: Find important factors (e.g., temperature, pressure) in each section.
5. Apply Guidewords: Use keywords like "more" or "no" to think about possible problems.
6. Analyze Deviations: Discuss the causes, consequences, and protections for each potential problem.
7. Document Findings: Record everything, including risks, causes, safeguards, and suggestions for
improvement.
Example: Chemical Reactor
Node: Chemical Reactor
Key Parameters: Temperature, Pressure, Flow Rate
Guideword Example:
"More": More reactant enters the reactor, potentially causing high pressure and an explosion. Safeguards
include relief valves and alarms. The recommendation is to maintain valves regularly.
"No": No cooling water, which could lead to overheating. Safeguards include backup power and temperature
monitors. The recommendation is to add extra cooling systems.
Using this method, the team can find and fix potential hazards to make the process safer.
2. Explain five steps of risk assessment methodology. ((Qualitative and Quantitative).
1. Hazard Identification: This is where you find out what could cause harm (hazards) and why they might
happen. This step is more about describing the problem.
2. Hazard Analysis: You look closely at how these hazards could happen and what the worst outcomes might
be, like injuries or damage. This step involves calculating the potential impact.
3. Risk Analysis: You figure out how likely it is that these hazards will actually happen, using data like failure
rates and other technical information. This helps estimate the overall risk.
4. Risk Assessment: Here, you compare the calculated risk to legal standards or safety limits to see if the risk
is acceptable or not.
5. Risk Management: Finally, you decide what actions to take to prevent or reduce the risk, using both
qualitative insights and quantitative data.

3. Write a note on Risk Counters (foot prints).

Risk Counters and the zones in case of toxic gas dispersion:
1. Zone 1 (Innermost Zone): This area has the highest concentration of
toxic gas, where the chances of fatality or serious injury are the greatest.
It’s too dangerous to enter or conduct rescue operations.
2. Zone 2 (Intermediate Zone): This is where immediate evacuation is
crucial to avoid fatalities and injuries. Emergency planning and rescue
efforts focus on this area, but safety precautions like protective gear are
essential.
3. Zone 3 (Outermost Zone): This is a safer area but could be at risk if the
gas spread worsens or lasts longer. People in this zone should be alerted
and possibly evacuated as a precaution.
Risk Counters are tools used in emergency planning to assess which areas might be affected and to prepare for
evacuations and other emergency responses.
4. Explain different Risk Control Measures or Elements of Risk Management.
(a) Mission Identification:
1. Set up risk management policies and procedures.
2. Communicate risks effectively.
3. Manage contracts to reduce risk.
4. Supervise claims.
5. Regularly review and evaluate the risk management program.
(b) Risk and Uncertainty Assessment:
1. Identify hazards.
2. Analyze risks.
3. Measure the level of risk.
4. Assess whether the risk is acceptable.
(c) Risk Control:
1. Avoid risks where possible.
2. Prevent losses or risks from occurring.
3. Reduce the impact of risks.
4. Manage information related to risks.
5. Transfer risks through contracts.
(d) Risk Financing:
1. Retain some level of risk.
2. Transfer risk through insurance.
(e) Program Administration:
1. Handle daily or shortterm planning.
2. Focus on longterm planning.
5. Differentiate Preliminary Hazard Analysis (PHA) and Hazard Analysis (HAZAN).

Preliminary Hazard Analysis (PHA): Hazard Analysis (HAZAN).

Purpose: PHA is used early in the design phase HAZAN is a more detailed and
of a project to identify potential quantitative analysis, usually done after
hazards before the final design is the preliminary design stage to evaluate
established. the safety of the design, operations, and
environmental controls.
Approach: It’s a quick, costeffective, and It involves a thorough analysis by
straightforward method that assumes experts using techniques like Failure
potential accidents or hazards, Mode and Effect Analysis (FMEA),
identifies the components or systems Fault Tree Analysis (FTA), and
that could cause them, and suggests consequence analysis to estimate the
safety measures. likelihood and impact of hazards.

Focus: It’s qualitative, focusing on It’s both qualitative and quantitative,

identifying hazards and suggesting identifying and classifying hazards,
design modifications to reduce or analyzing how they could occur, and
eliminate risks. assessing their potential consequences
like injuries, fatalities, and property
damage
When Used: Typically used at the start of a project Used after the preliminary hazard
to address hazards related to raw analysis and often revisited later in the
materials, operations, equipment, and project to refine risk levels and ensure
the operating environment. safety.

Application: Applied in various project stages like : It’s a comprehensive study to

R&D, predesign, design, understand the causes, effects, and
commissioning, and operation to controls of hazards, often requiring
identify hazards early on. specialized knowledge and tools.

6. What do you mean by Preliminary Hazard Analysis (PHA) elaborate with examples?
Preliminary Hazard Analysis (PHA) is an earlystage risk assessment tool used to identify potential hazards in
the design phase of a project, before final decisions are made. The goal of PHA is to spot hazards and assess
their risks so that design changes can be made to reduce or eliminate these hazards, or to mitigate the
consequences of potential accidents.
Steps Involved in PHA:
1. Identify Potential Hazards:
2. Identify Plant Components That Could Cause These Hazards:
3. Identify Events That Could Trigger These Hazards:
4. Propose Safety Measures:
5. Analyze the Importance of the System or Component:
Example of PHA:
Scenario: Design of a New Chemical Plant
Objective: The company plans to build a chemical plant for producing a certain industrial chemical. The PHA
is conducted to identify potential hazards in the design phase.
Step 1: Identifying Potential Hazards
1. Hazard 1: Toxic gas release during chemical reactions.
2. Hazard 2: Fire or explosion due to volatile chemicals.
3. Hazard 3: Chemical spill during storage or transfer.
Step 2: Identifying Components That Could Cause Hazards
1. Component 1: Reactor vessel where the chemical reaction takes place.
2. Component 2: Storage tanks containing volatile chemicals.
3. Component 3: Pipelines used for transferring chemicals between units.
Step 3: Identifying Events That Could Trigger Hazards
1. Event 1: Overheating of the reactor vessel leading to a pressure buildup and subsequent toxic gas release.
2. Event 2: A spark or static discharge near storage tanks leading to a fire or explosion.
3. Event 3: Pipeline corrosion or damage leading to a chemical spill.
Step 4: Proposing Safety Measures
1. Measure 1: Installing pressure relief valves and temperature monitoring systems on the reactor vessel to
prevent overheating.
2. Measure 2: Implementing explosionproof electrical systems and grounding procedures near storage tanks.
3. Measure 3: Regular inspections and corrosionresistant materials for pipelines, along with spill containment
systems.
Step 5: Analyzing the Importance of Systems or Components
1. Critical Focus: The reactor vessel is identified as critical because a failure here could lead to a large-
scale toxic release. Extra attention is given to its design, material selection, and monitoring systems.
7. Write a note on Failure Mode, Effect and criticality Analysis (FME&CA) with examples.
FMEA/FMECA
Failure Mode and Effects Analysis (FMEA) and Failure Mode, Effects, and Criticality Analysis (FMECA) are
systematic approaches used in reliability assessment to identify potential failure modes of components in a
system, understand their effects, and prioritize them based on their severity and frequency. These methods help
in improving the reliability and safety of systems by analyzing each component, predicting how it could fail,
and planning actions to mitigate those failures.
Key Points:
1. Flexible Approach: FMEA can be customized to different levels of detail and adapted to various industries,
making it a versatile tool for reliability professionals.
2. Component Analysis: Each component of a system is examined to determine how it might fail, how often it
might fail, and what impact that failure could have on the system.
3. Criticality Ranking: Failure modes are ranked based on their severity, helping prioritize which issues need the
most attention.
4. Application: It is widely used in hardware systems, process control systems, and is particularly useful for
manufacturers to improve product life and quality.
5. Limitations: FMEA relies on accurate failure rate data and does not account for problems caused by bad
design, adverse environments, or human errors.
Elaborated Example:
Scenario: Automotive Brake System Analysis
Let’s consider an FMEA analysis of a car's brake system to understand how this method works.
Step 1: Identify Components and Possible Failure Modes
Component 1: Brake Pad
Failure Mode: Worn out brake pads
Effect: Reduced braking efficiency, longer stopping distance
Criticality: Critical (high risk to safety)
Failure Rate: 1 failure every 50,000 miles (Reasonably Probable)
Component 2: Brake Fluid
Failure Mode: Leak in brake fluid line
Effect: Loss of braking power
Criticality: Catastrophic (immediate safety risk)
Failure Rate: 1 failure every 100,000 miles (Remote)
Component 3: Brake Pedal
Failure Mode: Stuck brake pedal
 Effect: Inability to brake or brakes staying engaged
Criticality: Critical (could lead to accidents)
Failure Rate: 1 failure every 1 million miles (Extremely Remote)
Step 2: Analyze Failure Effects and Rank Them
Brake Pad Worn Out:
Impact: Can lead to a crash if not replaced; highly critical for safety.
Ranking: High priority for regular checks and timely replacement.
Brake Fluid Leak:
Impact: Immediate loss of braking power; catastrophic if it happens suddenly.
Ranking: Requires frequent monitoring and maintenance to prevent leaks.
Brake Pedal Stuck:
Impact: Could lead to loss of control over the vehicle; though rare, it is critical.
Ranking: Regular inspections to ensure smooth operation.
Step 3: Determine Actions to Mitigate Failures
Brake Pad Worn Out: Regular inspections every 10,000 miles and timely replacement based on wear.
Brake Fluid Leak: Use highquality, durable materials for brake lines, and inspect fluid levels frequently.
Brake Pedal Stuck: Regular maintenance of the pedal mechanism, lubrication, and checking for obstructions.
Step 4: Evaluate the Effectiveness of Mitigations
After implementing these actions, the FMEA process would involve regular monitoring and reviews to ensure
that the risk of failures is minimized and the safety of the brake system is maintained.
8. Write a note on Faulty tree analysis (FTA) with examples.
Fault Tree Analysis (FTA) is a method used to figure out what might cause a system to fail by breaking down
the problem into smaller parts. It’s used in industries like aerospace, nuclear power, and chemical processing to
improve safety and reliability.
Key Components of FTA
Fault Tree Diagram: A visual chart that shows how different events can lead to a failure (the "top event"). It
uses:
Events: Specific failures or conditions.
AND Gate: All listed events must happen for the top event to occur.
OR Gate: Only one of the listed events needs to happen for the top event to occur.
FTA Methodology
1. Define the Top Event: Identify the failure you want to analyze.
2. Identify Causes: List the basic events that could cause the top event.
3. Build the Fault Tree: Connect the events using logical symbols to show their relationships.
4. Evaluate the Tree: Analyze the tree to find critical failure paths and assess the risk.
5. Implement Controls: Develop strategies to prevent the top event from happening.
Examples of FTA
Aircraft Crash: Causes might include navigation failure (due to incorrect route or equipment malfunction) or
low speed (due to engine failure or pilot error).
Employee Turnover: Causes might include poor recruitment practices or job dissatisfaction.
Construction Safety: Causes for a fall from scaffolding might include a slippery surface or a malfunctioning
safety belt.
Importance of FTA
Identifies Risks: Helps spot potential failure points in systems.
Allocates Resources: Focuses efforts on the most critical risks.
Ensures Compliance: Helps meet safety regulations.
Improves Understanding: The visual nature of FTA makes complex problems easier to understand and solve.
In summary, FTA is a useful tool for analyzing and preventing failures, leading to safer and more reliable
systems across various industries.
9. Write a note on Event tree analysis (ETA) with examples.
Event Tree Analysis (ETA) is a method used to assess what could happen after a specific event occurs. Unlike
Fault Tree Analysis (FTA), which looks for causes of a failure, ETA starts with an event and explores the
possible outcomes. This helps organizations understand and manage risks effectively.
Key Components of ETA
Event Tree Diagram: A visual chart that starts with an initiating event and branches out to show possible
outcomes.
Initiating Event: The starting point (e.g., a system failure).
Branches: Different possible events that could follow.
Intermediate Events: Key steps between the start and the final outcomes.
Outcomes: The end results of each possible path.
ETA Methodology
1. Define the System: Identify what system or process to analyze.
2. Identify the Initiating Event: Pick the event that triggers the analysis.
3. Develop the Event Tree: Create a diagram showing possible outcomes branching from the event.
4. Assign Probabilities: Estimate how likely each outcome is.
5. Analyze the Event Tree: Calculate the overall risk and prioritize areas for improvement.
6. Document Findings: Report the results and recommendations.
Examples of ETA
High Pressure in a Vessel: If a pressure vessel's safety system works, pressure is relieved. If it fails, it could
lead to an explosion.
Fire Incident: If a fire starts, a working sprinkler system can control it. If the system fails, manual efforts might
still stop it, or the fire could spread.
Engine Failure in Transportation: If an engine fails, a pilot might land safely, but if not, a crash could occur.
Importance of ETA
ETA is important because it helps:
Assess Risks: Understand what might happen after an event and prepare for it.
Improve Safety: Find and fix weaknesses in safety systems.
Ensure Compliance: Meet safety regulations by addressing potential hazards.

In summary, Event Tree Analysis helps organizations visualize and prepare for the consequences of specific
events, improving safety and reliability.
10. Types and Limitations of Hazop
HAZOP (Hazard and Operability Study) is a method used in engineering to spot potential problems in processes
before they happen. Here's a simpler breakdown:
Types of HAZOP
1. Process HAZOP: The most common type, focused on chemical processes. It looks at how things might go
wrong in the process.
2. Software HAZOP: Adapted for software, it checks for risks in how software operates.
3. System HAZOP: Looks at entire systems, considering how different parts interact and what risks might arise
from these interactions.
4. Project HAZOP: Used during the planning phase of a project to spot hazards before the project is built.
5. Management HAZOP: Focuses on how decisions and management practices could lead to risks.
Limitations of HAZOP
1. Subjectivity: The quality of the HAZOP depends a lot on the experience of the people doing it. Less
experienced teams might miss important hazards.
2. Qualitative Nature: HAZOP doesn’t provide numbers or precise measures of risk, which can be a drawback
when detailed risk assessments are needed.
3. Complexity Management: In very complex processes, traditional HAZOP might not catch all possible risks,
especially when multiple issues interact.
4. Guideword Overload: Too many guidewords (the terms used to explore potential issues) can sometimes
make the analysis confusing or repetitive.
5. Integration Challenges: It can be difficult to combine HAZOP results with other risk analysis methods,
which can limit the overall understanding of the risks.
6. Resource Intensive: HAZOP studies can be timeconsuming and expensive, which might be a challenge for
smaller organizations or projects with limited budgets.

In short, HAZOP is a useful way to identify risks, but it has its limitations, and sometimes it’s necessary to use
other methods alongside it for a more complete analysis.
11. Hazop Procedure with Diagram.
HAZOP procedure
1. Divide the system into sections (i.e., reactor, storage)
2. Choose a study node (i.e., line, vessel, pump, operating instruction)
3. Describe the design intent
4. Select a process parameter
5. Apply a guideword
6. Determine cause(s)
7. Evaluate consequences/problems
8. Recommend action: What? When? Who?
9. Record information
10. Repeat procedure (from step 2)
12. Explain 14 elements of PSM system and explain MOC.
The 14 elements of Process Safety Management (PSM) are guidelines set by OSHA to manage risks involving
hazardous chemicals and prevent serious incidents. Here’s a simplified overview:
14 Elements of PSM
1. Employee Participation: Involve employees in safety programs and decision-making.
2. Process Safety Information: Keep detailed records of chemicals, technology, and equipment.
3. Process Hazard Analysis (PHA): Regularly assess potential hazards in processes.
4. Operating Procedures: Write clear procedures for safe operations.
5. Employee Training: Train workers on chemical hazards and safety procedures.
6. Contractor Training: Ensure contractors are trained on relevant hazards and safety measures.
7. PreStartup Safety Review: Review safety measures before starting new or modified processes.
8. Mechanical Integrity: Regularly inspect and maintain process equipment.
9. Hot Work Permit: Use permits for tasks like welding to prevent fire hazards.
10. Management of Change (MOC): Manage any changes in processes, equipment, or personnel to maintain
safety.
11. Incident Investigation: Investigate all incidents to find root causes and prevent recurrence.
12. Emergency Planning and Response: Have plans in place for emergencies and train employees on them.
13. Compliance Audits: Conduct audits to ensure PSM standards are met.
14. Trade Secrets: Share necessary safety information with employees, even if it’s a trade secret.
Management of Change (MOC)
MOC is about safely managing changes to chemicals, technology, equipment, or procedures. It involves:
Evaluating the change: Assessing how the change affects safety.
Updating documentation: Adjusting procedures and safety info accordingly.
Training: Ensuring all affected workers are trained on the change.
Authorization: Getting approval before making the change.
MOC helps prevent new hazards and keeps the work environment safe by carefully managing changes in
operations.
13. Explain any three elements of PSM System.
Three key elements of Process Safety Management (PSM):
1. Process Hazard Analysis (PHA)
PHA is a systematic way to identify and control potential hazards in a process. It involves reviewing the
process, evaluating risks, developing safety controls, and getting management approval. The results guide the
overall safety program for the process.
2. Operating Procedures
These are clear, written instructions for safely conducting various tasks in a process, including startup, normal
operations, emergencies, and shutdowns. They ensure workers know how to safely perform their jobs and
handle different situations.
3. Management of Change (MOC)
MOC is a process for managing changes in processes, equipment, or personnel to maintain safety. It includes
evaluating the impact of changes, updating procedures, training employees, and getting approvals before
making changes. This helps prevent new hazards from being introduced.
14. How will you implement PSM in your organization? Explain.
How to implement a Process Safety Management (PSM) system in an oil storage terminal:
1. Leadership and Commitment
Management Support: Get top management to fully back the PSM program and provide the needed resources.
Safety Culture: Encourage a safetyfirst mindset among all employees.
2. Employee Participation
Involvement: Include employees in creating safety policies and procedures.
Feedback: Set up ways for employees to share safety concerns and suggestions.
3. Process Safety Information (PSI)
Documentation: Collect detailed information about hazardous chemicals and equipment.
Equipment Records: Keep track of specifications and maintenance history for all equipment.
4. Process Hazard Analysis (PHA)
Conduct PHAs: Identify potential hazards in the storage operations.
Mitigation Plans: Create and share action plans to reduce risks.
5. Operating Procedures
Written Procedures: Develop clear, detailed instructions for all operations, like filling and transferring.
Access: Make sure procedures are easy to access and regularly updated.
6. Training
Safety Training: Train employees on handling hazards and following procedures.
Refreshers: Regularly update training to keep safety practices top of mind.
7. Mechanical Integrity
Inspection and Maintenance: Regularly check and maintain storage tanks and equipment.
Records: Keep detailed records of all inspections and maintenance work.
8. Management of Change (MOC)
Change Procedures: Set up rules for safely managing changes in processes or equipment.
Documentation: Record and communicate all changes to affected employees.
9. Emergency Planning and Response
Emergency Plans: Develop plans for handling potential incidents like leaks or fires.
Drills: Regularly practice emergency drills to ensure readiness.
10. Compliance Audits
Regular Audits: Periodically review the PSM program to ensure it meets regulations.
Improvements: Use audit results to continuously improve safety practices.
11. Documentation and Record Keeping
Maintain Records: Keep detailed records of all PSM activities.
Access: Ensure records are accessible for review by authorities and stakeholders.
15. Explain PSSR:
A PreStartup Safety Review (PSSR) is a vital step in Process Safety Management (PSM) to ensure that a facility
or equipment is safe before it starts operating. The main goals of a PSSR are to:
1. Ensure Compliance: Confirm the facility or equipment is built according to design specifications.
2. Check Readiness: Make sure all necessary documents, procedures, and training are in place.
3. Resolve Issues: Verify that any safety concerns from the Process Hazard Analysis (PHA) have been
addressed.
Steps in the PSSR Process:
1. Identify Trigger Events: Determine when a PSSR is needed, such as for new installations or significant
modifications.
2. Determine PSSR Type: Choose the level of review (short, medium, or long) based on the complexity of the
situation.
3. Form a Team: Assemble a team of experts relevant to the process or equipment.
4. Conduct the PSSR:
Assign roles
Review documentation
Hold team meetings and conduct inspections
Track and resolve any safety issues
PSSR ensures that all safety measures are in place and that the facility or equipment is ready for safe operation,
preventing potential accidents.
16. Definition of HI, RA, HA, Risk Management etc...
Hazard: It is a physical situation or source with a potential for human injury, damage to property, damage to
environment or a combination of all.
Risk Analysis: The technical process of identifying, understanding and evaluating risk (analyzing cause and
effect wise)
Risk: An expression of the probability / impact of a mishap in terms of hazard severity and probability
Risk Management: A general management function that seeks to identify, assess, address, control and review
the causes and effect of uncertainty and risk on an organization.
Risk Assessment: It is a judgment of significance or activity that enables the risk manager to identify, evaluate
and measure risk and uncertainty and their potential impact on the organization.
Acceptable Risk Almost all human activities involve some risk and zero risk is not possible. Therefore the
concept of Acceptable risk is developed. It defines it as the level which is good enough where the advantages of
increased safety are not worth the extra costs of reducing risk. Thus it indicates the balancing condition of
accident costs Vs preventive costs
Individual Risk is the frequency at which an individual may be expected to sustain a given level of harm from
the realization of specific hazards
Reportable Accident An accident causing death or critical injury as defined by the OSH Act. Which has to be
reported to chief inspector within 48 hours in prescribed form.
Incident Rate are an indication of how many incidents have occurred, or how severe they were.
Maximum Credible Accident: an accident with a maximum reasonable damage distance possibility.
Societal Risk is the relationship between frequency of hazardous event and the number of people suffering a
specific level of harm in a given population from the realization of that event
Loss prevention is strategies and activities intended to reduce or eliminate the chance of loss

17. Full form of different short forms. i.e. FTA, ETA, PHA etc...

Safe operating procedures (SOP

Job safety analysis (JSA)
Fault tree analysis (FTA)
Even tree analysis(ETA)
Failure Mode and Effect Analysis (FMEA).
Failure Mode, Effect and Criticality Analysis (FMECA)
Maximum Credible Accident Analysis.(MCAA) –
Preliminary Hazard Analysis (PHA) &
Hazard Analysis (HAZAN).
Hazard and Operability study (HAZOP).
Management Oversight Review Technique (MORT).
Incident Recall TechniqueIRT .
Critical Incident Review Technique etc(CIRT).
Hazard Analysis.(HI)
Risk Assessment(RI):