Hazan Spreadsheet

Risk Assessment: FAULT TREE

Project Name: Cocoa Butter Alternatives Plant DesignProcess: Dry Fractionating ProcessSection: H 202 A-B; Oil Pre-heater

Item Component

1 Flow measurement (fluids) 1.14 0.320 0.6802 Flow switch 1.12 0.326 0.6743 Controller 0.29 0.748 0.2524 Indicator lamp 0.044 0.957 0.0435 Indicator lamp 0.044 0.957 0.0436 Control valve 0.6 0.549 0.4517Thermocouple temperature measurement 0.52 0.595 0.40589

10

Fault Tree for CP 205 of unit 200, please refer to

Failure Rate µ (faults/yr)

Reliability R = e-µt Failure probability P = 1-R

Formula for calculating the computations for various types of component linkages, please refer to Component Linkgages

FAULT TREE FOR H 204

User:Select components from drop down list

B6

User: Select components from drop down list

0.8770.8933.448

22.72722.7271.6671.923

Mean Time Between Failures MTBF = 1/µ


Project Name: Cocoa Butter Alternatives Plant DesignProcess: Dry Fractionating ProcessSection: CRZ 202 A,B; Crystallizer

Item Component

1 Indicator lamp 0.044 0.957 0.0432 Controller 0.29 0.748 0.2523 Pressure measurement 1.41 0.244 0.7564 Flow measurement (fluids) 1.14 0.320 0.6805 Flow switch 1.12 0.326 0.6746 Controller 0.29 0.748 0.2527 Indicator lamp 0.044 0.957 0.0438 Indicator lamp 0.044 0.957 0.0439 Controller 0.29 0.748 0.252

10Thermocouple temperature measurement 0.52 0.595 0.40511 Indicator lamp 0.044 0.957 0.04312 Level measurement (liquids) 1.7 0.183 0.81713 Controller 0.29 0.748 0.25214 Control valve 0.6 0.549 0.451

Fault Tree for CRZ 202 of unit 200, please refer to




Fault Tree--CRZ 204


B6


22.7273.4480.7090.8770.8933.448

22.72722.7273.4481.923

22.7270.5883.4481.667



Project Name: Cocoa Butter Alternatives Plant DesignProcess: Dry Fractionating ProcessSection: MFP 207 A,B ; Membrane Filter Press

Item Component

1 Indicator lamp 0.044 0.957 0.0432 Controller 0.29 0.748 0.2523 Pressure measurement 1.41 0.244 0.7564 Flow measurement (fluids) 1.14 0.320 0.6805 Flow switch 1.12 0.326 0.6746 Controller 0.29 0.748 0.2527 Indicator lamp 0.044 0.957 0.04389

10

Fault Tree for M305 of unit 300, please refer to




FAULT TREE FOR MFP 207 A-B

User:Select components from drop down list

B6


22.7273.4480.7090.8770.8933.448

22.727



Project Name: Cocoa Butter Alternatives Plant DesignProcess: Hydrogenation ProcessSection: M304 A-B; Mixer

Item Component

1 Indicator lamp 0.044 0.957 0.043 22.7272 Controller 0.29 0.748 0.252 3.4483 Level measurement (liquids) 1.7 0.183 0.817 0.5884 Flow measurement (fluids) 1.14 0.320 0.680 0.8775 Flow switch 1.12 0.326 0.674 0.8936 Controller 0.29 0.748 0.252 3.4487 Indicator lamp 0.044 0.957 0.043 22.72789

10

Fault Tree for M305 of unit 300, please refer to





FAULT TREE FOR M304 A-B


B6




Project Name: Cocoa Butter Alternatives Plant DesignProcess: Hydrogenation ProcessSection: R 306; Hydrogenation Reactor

Item Component

1 Pressure switch 0.14 0.869 0.131 7.1432 Controller 0.29 0.748 0.252 3.4483 Pressure measurement 1.41 0.244 0.756 0.7094 Flow measurement (fluids) 1.14 0.320 0.680 0.8775 Flow switch 1.12 0.326 0.674 0.8936 Controller 0.29 0.748 0.252 3.4487 Indicator lamp 0.044 0.957 0.043 22.7278 Indicator lamp 0.044 0.957 0.043 22.7279 Control valve 0.6 0.549 0.451 1.667

10 Thermocouple temperature measurement 0.52 0.595 0.405 1.923

Fault Tree for R306 of unit 300, please refer to





FAULT TREE FOR R303 A-B


B6



Control Valve Failure

Thermocouple Temperature Measurement

Failure

Flow Measurement

Failure

Failure of Temperature Indicator

ControllerFailure of Flow Meter

Failure of Heat Exchanger

Indicator Lamp Failure

Flow Switch Failure

Controller Failure


Failure of Flow Indicator

Failure of Flow Indicator Controller

P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.451R = 0.549 µ = 0.6MTBF = 1.667

P = 0.405R = 0.595 µ = 0.52MTBF = 1.923

P = 0.68R = 0.32 µ = 1.14MTBF = 0.877

P = 0.674R = 0.326 µ = 1.12MTBF = 0.893

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.687R = 0.313 µ = 1.164MTBF = 2.994

P = 0.896R = 0.104 µ = 2.26MTBF = 0.442

P = 0.284R = 0.716 µ = 0.334MTBF = 2.994

P = 0.254R = 0.746 µ = 0.293MTBF = 3.413

P = 0.174R = 0.826µ = 0.191MTBF = 5.236

1 2 3 4 5 6 7



Failure

Flow Measurement

Failure


ControllerFailure of Flow Meter

Failure of Heat Exchanger


Flow Switch Failure

Controller Failure




P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.451R = 0.549 µ = 0.6MTBF = 1.667

P = 0.405R = 0.595 µ = 0.52MTBF = 1.923

P = 0.68R = 0.32 µ = 1.14MTBF = 0.877

P = 0.674R = 0.326 µ = 1.12MTBF = 0.893

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.687R = 0.313 µ = 1.164MTBF = 2.994

P = 0.896R = 0.104 µ = 2.26MTBF = 0.442

P = 0.284R = 0.716 µ = 0.334MTBF = 2.994

P = 0.254R = 0.746 µ = 0.293MTBF = 3.413

P = 0.174R = 0.826µ = 0.191MTBF = 5.236

1 2 3 4 5 6 7

Failure of Crystallizer

Failure of Flow MeterFailure of Flow

Indicator

Flow Measurement

Failure

Flow Switch Failure

Controller Failure



Controller Failure


Failure


Controller Failure


Level Measurement

(Liquids) Failure

Controller Failure


Pressure Measurement

Failure

P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.451R = 0.549 µ = 0.6MTBF = 1.667

P = 0.405R = 0.595 µ = 0.52MTBF = 1.923

P = 0.68R = 0.32 µ = 1.14MTBF = 0.877

P = 0.674R = 0.326 µ = 1.12MTBF = 0.893

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.756R = 0.244 µ = 1.41MTBF = 0.709

P = 0.817R = 0.183 µ = 1.7MTBF = 0.588

21 3 4 5 6 7 8 9 10 11 12 13

P = 0.574R = 0.426 µ = 0.854MTBF = 1.171

P = 0.896R = 0.104 µ = 2.26MTBF = 0.442

P = 0.284R = 0.716 µ = 0.334MTBF = 2.994

P = 0.254R = 0.746 µ = 0.293MTBF = 3.413

P = 0.031R = 0.969 µ = 0.031MTBF = 31.755

I-6

P = 0.825R = 0.175 µ = 1.744MTBF = 0.573

14


Failure of Pressure Indicator Controller


Controller

Failure of Level Indicator Controller

Failure of Level Indicator

Failure of Level Meter

P = 0.284R = 0.716 µ = 0.334MTBF = 2.994

P = 0.900R = 0.100µ = 2.3MTBF = 0.435

P = 0.256R = 0.744 µ = 0.296MTBF = 3.378



Indicator

Flow Measurement

Failure

Flow Switch Failure

Controller Failure



Controller Failure


Failure


Controller Failure


Level Measurement

(Liquids) Failure

Controller Failure



Failure

P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.451R = 0.549 µ = 0.6MTBF = 1.667

P = 0.405R = 0.595 µ = 0.52MTBF = 1.923

P = 0.68R = 0.32 µ = 1.14MTBF = 0.877

P = 0.674R = 0.326 µ = 1.12MTBF = 0.893

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.756R = 0.244 µ = 1.41MTBF = 0.709

P = 0.817R = 0.183 µ = 1.7MTBF = 0.588

21 3 4 5 6 7 8 9 10 11 12 13

P = 0.574R = 0.426 µ = 0.854MTBF = 1.171

P = 0.896R = 0.104 µ = 2.26MTBF = 0.442

P = 0.284R = 0.716 µ = 0.334MTBF = 2.994

P = 0.254R = 0.746 µ = 0.293MTBF = 3.413

P = 0.031R = 0.969 µ = 0.031MTBF = 31.755

I-6

P = 0.825R = 0.175 µ = 1.744MTBF = 0.573

14




Controller




P = 0.284R = 0.716 µ = 0.334MTBF = 2.994

P = 0.900R = 0.100µ = 2.3MTBF = 0.435

P = 0.256R = 0.744 µ = 0.296MTBF = 3.378



Indicator

Flow Measurement

Failure

Flow Switch Failure

Controller Failure



Controller Failure


Failure


Controller Failure


Level Measurement

(Liquids) Failure

Controller Failure



Failure

P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.451R = 0.549 µ = 0.6MTBF = 1.667

P = 0.405R = 0.595 µ = 0.52MTBF = 1.923

P = 0.68R = 0.32 µ = 1.14MTBF = 0.877

P = 0.674R = 0.326 µ = 1.12MTBF = 0.893

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.756R = 0.244 µ = 1.41MTBF = 0.709

P = 0.817R = 0.183 µ = 1.7MTBF = 0.588

21 3 4 5 6 7 8 9 10 11 12 13

P = 0.574R = 0.426 µ = 0.854MTBF = 1.171

P = 0.896R = 0.104 µ = 2.26MTBF = 0.442

P = 0.284R = 0.716 µ = 0.334MTBF = 2.994

P = 0.254R = 0.746 µ = 0.293MTBF = 3.413

P = 0.031R = 0.969 µ = 0.031MTBF = 31.755

I-6

P = 0.825R = 0.175 µ = 1.744MTBF = 0.573

14




Controller




P = 0.284R = 0.716 µ = 0.334MTBF = 2.994

P = 0.900R = 0.100µ = 2.3MTBF = 0.435

P = 0.256R = 0.744 µ = 0.296MTBF = 3.378



Indicator

Flow Measurement

Failure

Flow Switch Failure

Controller Failure



Controller Failure


Failure


Controller Failure


Level Measurement

(Liquids) Failure

Controller Failure



Failure

P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.451R = 0.549 µ = 0.6MTBF = 1.667

P = 0.405R = 0.595 µ = 0.52MTBF = 1.923

P = 0.68R = 0.32 µ = 1.14MTBF = 0.877

P = 0.674R = 0.326 µ = 1.12MTBF = 0.893

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.756R = 0.244 µ = 1.41MTBF = 0.709

P = 0.817R = 0.183 µ = 1.7MTBF = 0.588

21 3 4 5 6 7 8 9 10 11 12 13

P = 0.574R = 0.426 µ = 0.854MTBF = 1.171

P = 0.896R = 0.104 µ = 2.26MTBF = 0.442

P = 0.284R = 0.716 µ = 0.334MTBF = 2.994

P = 0.254R = 0.746 µ = 0.293MTBF = 3.413

P = 0.031R = 0.969 µ = 0.031MTBF = 31.755

I-6

P = 0.825R = 0.175 µ = 1.744MTBF = 0.573

14




Controller




P = 0.284R = 0.716 µ = 0.334MTBF = 2.994

P = 0.900R = 0.100µ = 2.3MTBF = 0.435

P = 0.256R = 0.744 µ = 0.296MTBF = 3.378



Indicator

Flow Measurement

Failure

Flow Switch Failure

Controller Failure



Controller Failure


Failure


Controller Failure


Level Measurement

(Liquids) Failure

Controller Failure



Failure

P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.451R = 0.549 µ = 0.6MTBF = 1.667

P = 0.405R = 0.595 µ = 0.52MTBF = 1.923

P = 0.68R = 0.32 µ = 1.14MTBF = 0.877

P = 0.674R = 0.326 µ = 1.12MTBF = 0.893

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.756R = 0.244 µ = 1.41MTBF = 0.709

P = 0.817R = 0.183 µ = 1.7MTBF = 0.588

21 3 4 5 6 7 8 9 10 11 12 13

P = 0.574R = 0.426 µ = 0.854MTBF = 1.171

P = 0.896R = 0.104 µ = 2.26MTBF = 0.442

P = 0.284R = 0.716 µ = 0.334MTBF = 2.994

P = 0.254R = 0.746 µ = 0.293MTBF = 3.413

P = 0.031R = 0.969 µ = 0.031MTBF = 31.755

I-6

P = 0.825R = 0.175 µ = 1.744MTBF = 0.573

14




Controller




P = 0.284R = 0.716 µ = 0.334MTBF = 2.994

P = 0.900R = 0.100µ = 2.3MTBF = 0.435

P = 0.256R = 0.744 µ = 0.296MTBF = 3.378



Indicator

Flow Measurement

Failure

Flow Switch Failure

Controller Failure



Controller Failure


Failure


Controller Failure


Level Measurement

(Liquids) Failure

Controller Failure



Failure

P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.451R = 0.549 µ = 0.6MTBF = 1.667

P = 0.405R = 0.595 µ = 0.52MTBF = 1.923

P = 0.68R = 0.32 µ = 1.14MTBF = 0.877

P = 0.674R = 0.326 µ = 1.12MTBF = 0.893

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.756R = 0.244 µ = 1.41MTBF = 0.709

P = 0.817R = 0.183 µ = 1.7MTBF = 0.588

21 3 4 5 6 7 8 9 10 11 12 13

P = 0.574R = 0.426 µ = 0.854MTBF = 1.171

P = 0.896R = 0.104 µ = 2.26MTBF = 0.442

P = 0.284R = 0.716 µ = 0.334MTBF = 2.994

P = 0.254R = 0.746 µ = 0.293MTBF = 3.413

P = 0.031R = 0.969 µ = 0.031MTBF = 31.755

I-6

P = 0.825R = 0.175 µ = 1.744MTBF = 0.573

14




Controller




P = 0.284R = 0.716 µ = 0.334MTBF = 2.994

P = 0.900R = 0.100µ = 2.3MTBF = 0.435

P = 0.256R = 0.744 µ = 0.296MTBF = 3.378

Controller Failure

Level Measurement

Failure

Flow Measurement

Failure


Failure of Flow Meter

Failure of Filter


Flow Switch Failure

Controller Failure




P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.817R = 0.183 µ = 1.70MTBF = 0.588

P = 0.68R = 0.32 µ = 1.14MTBF = 0.877

P = 0.674R = 0.326 µ = 1.12MTBF = 0.893

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.869R = 0.131 µ = 2.033MTBF = 0.492

P = 0.896R = 0.104 µ = 2.26MTBF = 0.442

P = 0.284R = 0.716 µ = 0.334MTBF = 2.994

P = 0.254R = 0.746 µ = 0.293MTBF = 3.413

P = 0.221R = 0.779µ = 0.250MTBF = 4.004

1 2 3 4 5 6 7

Controller Failure

Level Measurement

Failure

Flow Measurement

Failure



Failure of Filter


Flow Switch Failure

Controller Failure




P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.817R = 0.183 µ = 1.70MTBF = 0.588

P = 0.68R = 0.32 µ = 1.14MTBF = 0.877

P = 0.674R = 0.326 µ = 1.12MTBF = 0.893

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.869R = 0.131 µ = 2.033MTBF = 0.492

P = 0.896R = 0.104 µ = 2.26MTBF = 0.442

P = 0.284R = 0.716 µ = 0.334MTBF = 2.994

P = 0.254R = 0.746 µ = 0.293MTBF = 3.413

P = 0.221R = 0.779µ = 0.250MTBF = 4.004

1 2 3 4 5 6 7

Controller SV4 Failure

Level Measurement

Failure

Flow Measurement

Failure



Failure of Mixer


Flow Switch Failure

Controller GV13 Failure




P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.817R = 0.183 µ = 0.17MTBF = 0.588

P = 0.68R = 0.32 µ = 1.14MTBF = 0.877

P = 0.674R = 0.326 µ = 1.12MTBF = 0.893

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.869R = 0.131 µ = 0.504MTBF = 1.984

P = 0.896R = 0.104 µ = 2.26MTBF = 0.442

P = 0.284R = 0.716 µ = 0.334MTBF = 2.994

P = 0.254R = 0.746 µ = 0.293MTBF = 3.413

P = 0.221R = 0.221µ = 1.509MTBF = 0.663

1 2 3 4 5 6 7


Level Measurement

Failure

Flow Measurement

Failure



Failure of Mixer


Flow Switch Failure





P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.817R = 0.183 µ = 0.17MTBF = 0.588

P = 0.68R = 0.32 µ = 1.14MTBF = 0.877

P = 0.674R = 0.326 µ = 1.12MTBF = 0.893

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.869R = 0.131 µ = 0.504MTBF = 1.984

P = 0.896R = 0.104 µ = 2.26MTBF = 0.442

P = 0.284R = 0.716 µ = 0.334MTBF = 2.994

P = 0.254R = 0.746 µ = 0.293MTBF = 3.413

P = 0.221R = 0.221µ = 1.509MTBF = 0.663

1 2 3 4 5 6 7


Level Measurement

Failure

Flow Measurement

Failure



Failure of Mixer


Flow Switch Failure





P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.817R = 0.183 µ = 0.17MTBF = 0.588

P = 0.68R = 0.32 µ = 1.14MTBF = 0.877

P = 0.674R = 0.326 µ = 1.12MTBF = 0.893

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.869R = 0.131 µ = 0.504MTBF = 1.984

P = 0.896R = 0.104 µ = 2.26MTBF = 0.442

P = 0.284R = 0.716 µ = 0.334MTBF = 2.994

P = 0.254R = 0.746 µ = 0.293MTBF = 3.413

P = 0.221R = 0.221µ = 1.509MTBF = 0.663

1 2 3 4 5 6 7


Level Measurement

Failure

Flow Measurement

Failure



Failure of Mixer


Flow Switch Failure





P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.817R = 0.183 µ = 0.17MTBF = 0.588

P = 0.68R = 0.32 µ = 1.14MTBF = 0.877

P = 0.674R = 0.326 µ = 1.12MTBF = 0.893

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.869R = 0.131 µ = 0.504MTBF = 1.984

P = 0.896R = 0.104 µ = 2.26MTBF = 0.442

P = 0.284R = 0.716 µ = 0.334MTBF = 2.994

P = 0.254R = 0.746 µ = 0.293MTBF = 3.413

P = 0.221R = 0.221µ = 1.509MTBF = 0.663

1 2 3 4 5 6 7

Controller Failure

Pressurel Measurement

Failure

Flow Measurement

Failure



Failure of Reactor


Flow Switch Failure

Controller Failure

Pressure Switch Failure



P = 0.131R = 0.869 µ = 0.14MTBF = 7.143

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.756R = 0.244 µ = 1.41MTBF = 0.709

P = 0.68R = 0.32 µ = 1.14MTBF = 0.877

P = 0.674R = 0.326 µ = 1.12MTBF = 0.893

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.841R = 0.159 µ = 1.84MTBF = 0.543

P = 0.896R = 0.104 µ = 2.26MTBF = 0.442

P = 0.284R = 0.716 µ = 0.334MTBF = 2.994

P = 0.254R = 0.746 µ = 0.293MTBF = 3.413

P = 0.147R = 0.853µ = 0.159MTBF = 6.289

2 3 4 5 6 7


Control valve GV14 Failure

Thermocouple Temperature measurement

Failure

P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.451R = 0.549 µ = 0.6MTBF = 1.667

P = 0.405R = 0.595 µ = 0.52MTBF = 1.923

P = 0.687R = 0.313 µ = 1.164MTBF = 2.994


Controller

1 8 9 10

Controller Failure


Failure

Flow Measurement

Failure



Failure of Reactor


Flow Switch Failure

Controller Failure




P = 0.131R = 0.869 µ = 0.14MTBF = 7.143

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.756R = 0.244 µ = 1.41MTBF = 0.709

P = 0.68R = 0.32 µ = 1.14MTBF = 0.877

P = 0.674R = 0.326 µ = 1.12MTBF = 0.893

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.841R = 0.159 µ = 1.84MTBF = 0.543

P = 0.896R = 0.104 µ = 2.26MTBF = 0.442

P = 0.284R = 0.716 µ = 0.334MTBF = 2.994

P = 0.254R = 0.746 µ = 0.293MTBF = 3.413

P = 0.147R = 0.853µ = 0.159MTBF = 6.289

2 3 4 5 6 7




Failure

P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.451R = 0.549 µ = 0.6MTBF = 1.667

P = 0.405R = 0.595 µ = 0.52MTBF = 1.923

P = 0.687R = 0.313 µ = 1.164MTBF = 2.994


Controller

1 8 9 10

Controller Failure


Failure

Flow Measurement

Failure



Failure of Reactor


Flow Switch Failure

Controller Failure




P = 0.131R = 0.869 µ = 0.14MTBF = 7.143

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.756R = 0.244 µ = 1.41MTBF = 0.709

P = 0.68R = 0.32 µ = 1.14MTBF = 0.877

P = 0.674R = 0.326 µ = 1.12MTBF = 0.893

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.841R = 0.159 µ = 1.84MTBF = 0.543

P = 0.896R = 0.104 µ = 2.26MTBF = 0.442

P = 0.284R = 0.716 µ = 0.334MTBF = 2.994

P = 0.254R = 0.746 µ = 0.293MTBF = 3.413

P = 0.147R = 0.853µ = 0.159MTBF = 6.289

2 3 4 5 6 7




Failure

P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.451R = 0.549 µ = 0.6MTBF = 1.667

P = 0.405R = 0.595 µ = 0.52MTBF = 1.923

P = 0.687R = 0.313 µ = 1.164MTBF = 2.994


Controller

1 8 9 10

Controller Failure


Failure

Flow Measurement

Failure



Failure of Reactor


Flow Switch Failure

Controller Failure




P = 0.131R = 0.869 µ = 0.14MTBF = 7.143

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.756R = 0.244 µ = 1.41MTBF = 0.709

P = 0.68R = 0.32 µ = 1.14MTBF = 0.877

P = 0.674R = 0.326 µ = 1.12MTBF = 0.893

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.841R = 0.159 µ = 1.84MTBF = 0.543

P = 0.896R = 0.104 µ = 2.26MTBF = 0.442

P = 0.284R = 0.716 µ = 0.334MTBF = 2.994

P = 0.254R = 0.746 µ = 0.293MTBF = 3.413

P = 0.147R = 0.853µ = 0.159MTBF = 6.289

2 3 4 5 6 7




Failure

P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.451R = 0.549 µ = 0.6MTBF = 1.667

P = 0.405R = 0.595 µ = 0.52MTBF = 1.923

P = 0.687R = 0.313 µ = 1.164MTBF = 2.994


Controller

1 8 9 10

Controller Failure


Failure

Flow Measurement

Failure



Failure of Reactor


Flow Switch Failure

Controller Failure




P = 0.131R = 0.869 µ = 0.14MTBF = 7.143

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.756R = 0.244 µ = 1.41MTBF = 0.709

P = 0.68R = 0.32 µ = 1.14MTBF = 0.877

P = 0.674R = 0.326 µ = 1.12MTBF = 0.893

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.841R = 0.159 µ = 1.84MTBF = 0.543

P = 0.896R = 0.104 µ = 2.26MTBF = 0.442

P = 0.284R = 0.716 µ = 0.334MTBF = 2.994

P = 0.254R = 0.746 µ = 0.293MTBF = 3.413

P = 0.147R = 0.853µ = 0.159MTBF = 6.289

2 3 4 5 6 7




Failure

P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.451R = 0.549 µ = 0.6MTBF = 1.667

P = 0.405R = 0.595 µ = 0.52MTBF = 1.923

P = 0.687R = 0.313 µ = 1.164MTBF = 2.994


Controller

1 8 9 10

Controller Failure


Failure

Flow Measurement

Failure



Failure of Reactor


Flow Switch Failure

Controller Failure




P = 0.131R = 0.869 µ = 0.14MTBF = 7.143

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.756R = 0.244 µ = 1.41MTBF = 0.709

P = 0.68R = 0.32 µ = 1.14MTBF = 0.877

P = 0.674R = 0.326 µ = 1.12MTBF = 0.893

P = 0.252R = 0.748 µ = 0.29MTBF = 3.448

P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.841R = 0.159 µ = 1.84MTBF = 0.543

P = 0.896R = 0.104 µ = 2.26MTBF = 0.442

P = 0.284R = 0.716 µ = 0.334MTBF = 2.994

P = 0.254R = 0.746 µ = 0.293MTBF = 3.413

P = 0.147R = 0.853µ = 0.159MTBF = 6.289

2 3 4 5 6 7




Failure

P = 0.043R = 0.957 µ = 0.044MTBF = 22.727

P = 0.451R = 0.549 µ = 0.6MTBF = 1.667

P = 0.405R = 0.595 µ = 0.52MTBF = 1.923

P = 0.687R = 0.313 µ = 1.164MTBF = 2.994


Controller

1 8 9 10

Table 1: Failure Rate Data for Various Selected Process Components (Crowl & Louvar, 2001)

InstrumentController 0.29Control valve 0.60Flow measurement (fluids) 1.14Flow measurement (solids) 3.75Flow switch 1.12Gas-liquid chromatograph 30.60Hand valve 0.13Indicator lamp 0.044Level measurement (liquids) 1.70Level measurement (solids) 6.86Oxygen analyzer 5.65pH meter 5.88Pressure measurement 1.41Pressure relief valve 0.022Pressure switch 0.14Solenoid valve 0.42Stepper motor 0.044Strip chart recorder 0.22Thermocouple temperature measurement 0.52Thermometer temperature measurement 0.027Valve positioner 0.44

Faults/year (µ)

Table 1.1: Computations for various types of component linkages (Crowl & Louvar, 2001)

REFERENCE

No. Reference12345678910 U.S. Department of Labor Occupational Safety & Health Administration. http://www.osha.gov/111213

Crowl, D.A., Louvar, J.F. 2001. Chemical Process Safety Fundamentals with Applications 2nd ed. Prentice Hall, Inc.Flynn, A.M. 2002. Health, Safety and Accident Management in the Chemical Process Industries. Louis Theodore Marcel Dekker, Inc.Mannan, S., Lees, F.P. 2005. Lee's Loss Prevention in the Process Industries: Hazard Identification, Assessment, and Control. Butterworth-Heinemann.Palluzi, R.P. 1994. Pilot Plant and Laboratory Safety. McGraw-Hill,Inc.Peter, M.S., Timmerhaus, K.D. 1991. Plant Design And Economics For Chemical Engineers 4th Edition. McGraw-Hill International Editions.Sinnott, R.K. 2005. Chemical Engineering Design 4th Edition. Volume 6. Elsevier.Steinbach, J. 1999. Safety Assessment for Chemical Processes. WILEY-VCH.Taylor, J.R. 1994. Risk Analysis for Process Plant, Pipelines and Transport. E&FN SPON.Thomas, C.E. 2007. Process Technology Safety, Health and Environment. 2nd ed. Thomson Delmar Learning.

Wells, G. 2004. Hazard Identification and Risk Assessment. Institution of Chemical Engineers (IChemE).

Chemical Process Safety Fundamentals with Applications 2nd ed. Prentice Hall, Inc.Health, Safety and Accident Management in the Chemical Process Industries. Louis Theodore Marcel Dekker, Inc.

Lee's Loss Prevention in the Process Industries: Hazard Identification, Assessment, and Control. Butterworth-Heinemann.

Plant Design And Economics For Chemical Engineers 4th Edition. McGraw-Hill International Editions.

2nd ed. Thomson Delmar Learning.

. Institution of Chemical Engineers (IChemE).

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