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This assignment "The Feed Line of a Propane-Butane Separation Column System" explains how the HAZOP technique can be used for the identification of causal events and hazards, and as an example, provides a fragment of the HAZOP table for the system. …
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Extract of sample "The Feed Line of a Propane-Butane Separation Column System"
Piping system
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06, 05, 2014
A. List 5 possible system hazards and carry out a hazard analysis based on a checklist.
Table 3: system hazard
Asset
Risk exposure
Evacuation
Property damage
Tank leaks
3
4
1
Over pressure
3
2
2
Faulty valve
4
2
Overheating
3
1
Blast
4
4
4
Likelihood table
Likelihood
1
Low
Not expected to occur
2
Medium
Possible
3
High
It will occur
4
Very
Must occur
The reason why this ranking system was used is that this is the standard practice for checklist and besides this classification indicates the level of occurrence
B. Explain how the HAZOP technique can be used for the identification of causal events and hazards, and as an example, provide a fragment of the HAZOP table for the system described above. (Include about 4 items). (Only for the flow parameter).
HAZOP stand for Hazard and Operability Study which is a detailed and structured technique for analyzing deviations from design in chemical process systems like the Butane-propane piping system. It detects procedural errors, failures, and other events. In the case at hand, the following is the HAZOP table
Process-
variable
No
Low
high
Part of
also
Other than
reverse
Flow
No flow
Low flow
High flow
one component
Im purities
Wrong pipe
Reverse flow
Level
nothing
Yes
Yes
Low interface
High interface
-
-
pressure
use atmosphere
Low
High
-
-
-
vacuum
temperature
freezing
Yes
Yes
-
-
-
Auto re frigeration
Use the FMECA approach to identify system hazards and produce a fragment of the FMECA table of the system described above (include about 5 items).
FMECA is a highly structured technique that is usually applied to a complex item of mechanical or electrical equipment. The overall system is described as a set of sub-systems and each of these as a set of smaller sub-systems down to component level. Individual system, sub-system and component failures are systematically analysed to identify their causes (which are failures at the next lower-level system), and to determine their possible outcomes, which are potential causes of failure in the next higher-level system. This technique is quite specialised and usually requires expert assistance.
In case at hand if a certain parameter goes above the maximum target value, changes would occur to ensure the set value is maintained. In so doing the values would be found within the range of maximum and minimum value. This can therefore be found in areas of specializations like agricultural, medicine and nursing, motor vehicle industry, real estate amongst other fields (Mondie 2005; Shah & macGregor 2005).
function
Potential failure mode
Potential effects (s) of failure
Potential cause (s) of failure
Current process controls
Recommended
Action(s)
Action taken
Tank leaks
leaks
Cause fire
Poor maintained tanks
Inspection
Repair
Overheating
Too much heat
Increase pressure
Unchecked power supply
verification
Automate power supply
Pressure
Overpressure
Blast
Unchecked pressure
None
None
Control pressure
valve
Faulty and leads
leakage
Old valves and unmaintained
Blast
Overheating and high pressure
Loss life and property
Several factors affecting the controller performance have been deduced together with their specific effects though in most cases these would be changed to ensure maximum results. The performance factor (bandwidth, voltage, time span, and channel diameter, power supply speed/velocity and flow rate at Best Efficiency Point is a good indicator of how regulate able parameters influences controller process’ performance (Richardson 2004). When such deviations are insignificant then their effect would not produce any noticeable effects on the controller function.
A good example would involve a more specialized system does the supervision as well as data acquisition, this is the supervisory and data acquisition abbreviated as SCADA (Zhang 2010). This system has been applied in areas like power plants, distribution of natural gas and supply of water pipelines. These areas would require a system that can ensure remote data are gathered within a low bandwidth that has an intermittent variation. The system uses an open loop control. Its remote terminal units would ensure that the supervisory data are send back to its control stations. Such systems must be integrated with a computer to rely the data that can be interpreted by the in build software. Such controlled processes have not only made some work easier to manage and get a real time results but has also saved a lot on several modalities that would have complicated the entire process and hence increasing the applicable cost of running very simple processes (Grimble 2006; Lewin et al. 2002; Zhang 2010).
Event tree for this process using overpressure as top event
Event
Detection
Shutdown /release
Evacuation
Outcome
From the event tree above it can be noted that when there is overpressure that is detected earlier and the pressure is released or pipe system shut down there is no evacuation or thus no risk associated with it. However when detected earlier but pressure release or shut down fails then evacuation takes place. When evacuation is on time, there is no risk but property is destroyed. Lastly, when there is late detection, only evacuation will take place since we may not have time for shutdown or release of pressure. In this case there will be risk to property but exposure to human will depend on the degree of evacuation as shown in the tree above.
d). The decision has been made to achieve adequate safely by ensuring that the equipment under control (EUC) is suitably safe
A risk graph method according to IEC 61508 to establishing the required safety integrity level (SIL) value of the EUC sub-system is where risk is assumed to occur when there is no safety systems and compared to frequency of the hazardous event for such area and its impact. The following formula is derived for it
Risk for unprotected area = F X C
Where F is hazardous event frequency for areas with no safety-related systems in place and C is the consequences of the hazardous event
Overheating of the mixture at the heat exchanger leads to rupture and subsequent fire, with the potential for a fatality, using the risk graph method, what is the SIL value for the temperature indicator controller, which is providing a continuous mode safety function.
CONCLUSION
The hazard analysis based on a checklist was used to do the risk assessment system. The methodology calculates the accurate probability for the frequency and magnitude of the occurrence of loss events. There are 4 stages in the methodology like Stage 1 – Identify scenario components, Stage 2 – Evaluate Loss Event Frequency (LEF), Stage 3 – Evaluate Probable Loss Magnitude (PLM), Stage 4 – Derive and articulate Risk. In Stage 1 the parameters that were at risk were classified and ranked based on their weights. In Stage 2, an evaluation of Loss Event Frequency (LEF) was made by estimating the Threat Event Frequency (TEF) and the capability of the threats were evaluated as Very High (VH), High (H)and Very Low (VL) respectively.
The most likely result of a threat event is known as a Probable Loss Magnitude (PLM) and in Stage 3, the PLM was evaluated besides determining the worst-case loss and the estimated probable loss. The worst case loss was evaluated as High (H) for all the 5 threat actions
The worst case loss was evaluated as Severe (SV) for all the 5 threat actions and 6 loss forms for the R & D database from the 3 threat communities because the loss would affect RWW severely to the point of going out of business. This is because most companies invest heavily in R & D and RWW is no exception and if hackers, viruses or malicious individual employees cause damage, then it would affect the ability of RWW to do business.
In stage 4, the risk assessment is done based on LEF, PLM and Worst-Case Loss Magnitudes (WCLM).
Reference List
Dale, RP & Fardo SW 2009, Industrial process control systems, Fairmont Press, Inc, Boca Raton USA.
Grimble, MJ 2006, Robust Industrial Control Systems; optimal design approach for polynomial systems, John Willey & Sons, Ltd, Chichester England.
Lewin, DR, Seider WD, Seade, JD 2002, ‘Integrated process design instruction’, Computers and Chemical Engineering, vol. 26, no.2, pp. 295-306.
Mondie, S (ed.) 2005, System, structure and control 2004, Elsevier-IFAC, Oxford-UK.
Richardson, P (ed.) 2004, Improving the thermal processing of foods, Woodhead publishing ltd, Cambridge- England.
Shah, LS & MacGregor, F. J. (ed.) 2005, Dynamics and control of process systems 2004, Elsevier-IFAC; Oxford UK.
Zhang, P 2010, Advanced Industrial Control Technology, Elsevier, Oxford UK.
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