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Safety Valve V3
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Rsystem2: In system2, two pipes and their respective flow sensors are connected to
the furnace fir its successful operation. Each pipe and its flow sensor are connected
in series as they both are required for controlled flow of LPG in furnace. Since only
one set of pipe and flow sensor is required at a time for controlled and successful
working of furnace, they two sets of pipes with their respective flow sensors are
connected in parallel.
Rsystem3: In system3, safety valve V3, burner, motor, pump, alarm, coolant jacket and
power are connected in series as all these subunits need to be in working mode for
successful working of furnace.
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Category Effect
Frequent A A A B
Probable A B C
A
Occasional A B C C
Remote B C C D
Improbable C C D D
Incredible D D D D
Explosion hazard can cause catastrophic consequences like multiple loss of life of
personnel and harm to environment. Looking at the reliability of the process and
subsystem which could cause explosion, it can be seen that the frequency of
explosion is probable i.e. once in 3 years. This puts explosion hazard into ‘A’
category in ‘Risk class matrix’. As the table for ‘Risk defining categories’ shows, the
event of explosion is classified as ‘unacceptable in any circumstances’. Therefore,
risk reduction measures have to be employed to mitigate the risk of explosion hazard
to a reasonable level (or acceptable level, if possible).
5. The following risk reduction methods can be employed to reduce the risk of
explosion hazard (in order if significance):
6. The following summary throws light on the reasons of the above 3 risk reduction
measures and describes the order of their significance.
In current process, all the sensors and valves controls are operated by a single
controller ‘computer’. Failure of this computer would cause failure of temperature
sensor t1 which senses the temperature of furnace and signals any overheating to
the main computer. Failure of computer means, the system would still keep running
in an uncontrolled manner. Additional local controllers for different subsystems would
mean that even if the main computer fails, temperature sensor t 1 and t2 could signal
to the local controllers operating on valves v1 and v2, which in return could stop the
flow of LPG to the furnace. An isolated power backup system could be placed in
case the main power supply fails. This backup power supply would still keep the
main and local controller running. Guards and barriers around conveyor system
would work as a safeguard for personnel and could also prevent objects falling off
and on the conveyor belt. Extra temperature sensors could also be placed which
should be directly connected to alarm system and local controller controllers for
regulator valves. The temperature feed from these sensors could trigger these
valves to stop injecting fuel into furnace if it is above a threshold value. This
modification, as clearly indicates, responds to risk reduction in a very effective
manner.
Events like gas leakage, valves failure, sensors failure, alarm failure etc. are often
due to mechanical or electrical failure of these subsystems. This was concluded from
fault tree diagram. These subsystems require timely attention for their proper
working. For example, the fuel tanks need timely and preventive maintenance in
order to mitigate thermal and mechanical stresses, safety valve and regulator valves
need time-base lubrication, conveyor belt system would need timely oiling and
greasing in order for their proper running, etc. All the metallic parts of the systems
need to be guarded against rusting. In case of rusting in valves, it could clog them up
causing problems in fuel flow or leakage in some cases. A wise combination of
planned, preventive and conditional monitoring can look after all these parameters.
Maintenance comes at second place as it aims at reducing the overall risk of
subsystem failure. However, power and controller backup is of highest importance as
their failure would result in immediate disaster.
In case of fire or/and explosion, toxic fumes and gases are produced. These fumes
and gases are harmful to personnel and environment. This is a personal hazard
which could affect local areas and remote areas as well. A chimney with a purifier
could be placed above the furnace in a suitable manner to filter these fumes and
smoke to a reasonable level thus minimising the damage to people and environment.
However, this measure looks at minimising the effect of one of the many
consequences of fire and explosion. Consequently, it comes at 3rd place.