Rocess safety report application of fmea study in chemical plant

Failure modes and effects analysis FMEA is a useful method for averting possibleissues and taking the necessary steps to eliminate the root of error in the oil sectors.. The purpose of t

HO CHI MINH UNIVERSITY OF TECHNOLOGY

FACULTY OF CHEMICAL ENGINEERING

-PROCESS SAFETY REPORT

APPLICATION OF FMEA STUDY IN

CHEMICAL PLANT

Instructor:

Class: CC03 Member of the group

Ho Chi Minh City, 27 December, 2022th

TABLE OF CONTENTS

ABSTRACT 3

Chapter I INTRODUCTION 4

Chapter II FAILURE MODES AND EFFECTS ANALYSIS 7

Chapter III METHODOLOGY 9

Chapter IV RESULTS 12

1 Identifying CTQs 12

2 Plate cutting 14

3 Welding 14

4 Improvement 15

DISCUSSION AND CONCLUSIONS 16

REFFERENCES 19

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Failure modes and effects analysis (FMEA) is a useful method for averting possibleissues and taking the necessary steps to eliminate the root of error in the oil sectors On the otherhand, being a developing nation, Iran's oil industry depends heavily on oil producing businesses,

of which Sepahan Oil Company is a major contributor The purpose of this study is todemonstrate how FMEA could be used to raise the product quality at Sepahan Oil Co Thecompany's four-litre production line has been chosen for enquiry for this reason The resultssuggested that the use of FMEA had decreased scraps from 50,000 to 5,000 parts per million andhad caused a 0.92 percent decrease in oil waste

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FMEA is a method for spotting possible issues "before the event" and figuring out whatsteps might be taken to prevent them (Shahin, 2004) It is an analytical technique whereby all

"potential failure" modes, the consequences that would follow if the failure really occurred, andall the factors that could result in the failure are all identified (Slinger, 1992; Healey, 1994; Slack

et al., 2001) Quantifying the effects of potential failures using a group-oriented, systematic, andstep-by-step approach enables a business to establish priorities for action (Vandenbrande, 1998).Improving the quality and dependability of the product or process and ensuring customersatisfaction are the key advantages of using the FMEA (Tang and Ho, 1996) Disruption risks of

a supply chain may be classified into two types: risks arising from within the supply chainand risks external to it (Miao et al., 2010) The issues with the internal supply chain areexamined in this research

As product design, development, and production are decentralised among outsourcedsuppliers, it is also necessary to build service reliability assessment tools to access productquality FMEA was used by Sinha et al (2004) to assess the importance of risk factors in thesupply chain for the manufacture of aeroplanes In order to evaluate the risk associated with eachstep in the pharmaceutical industry's reverse logistics activities, Kumar et al (2009) provided anFMEA evaluation Van Leeuwen et al (2009) used FMEA to rank the risk in analytical drugscreening, while Chiozza and Pozzenti (2009) identified the major lessons learned from usingFMEA in the pharmaceutical industry Chuang (2010) used Bayesian probability analysis toexamine the consequences of poor service and came to the conclusion that further study wasneeded to quantify the effects of intangible factors like customer complaints and market shareloss The four essential resources—people, equipment, materials, and schedules—needed tomaintain the lean systems were the basis for a modified FMEA created by Sonntag et al (2010).They discovered that there are no real-world approaches available to increase the lean systems'reliability To improve the decision-making process in new product development, Segismundoand Miguel (2008) developed a systematisation of technical risk management using FMEA(NPD) Better resource distribution among programme projects is evidence that the outcome had

a favourable impact on the decision-making process for product development FMEA was used

by Ookalkar et al (2009) in one of the top hospitals in Central India that offered dialysis and

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to pinpoint certain regions in the hemodialysate unit that required special attention Reducedprocess errors and overall risk mitigation were the outcomes, which ultimately led to efficientpatient care

Many top-tier businesses have benefited greatly from FMEA Iran, on the other hand, andits oil sector play a significant part in the Middle East and the world economy even if oil hasgrown to be a dominant factor within the power capability profile of every country (Ugoh andUkpere, 2010) Therefore, it is anticipated that using the technique alone will also offersignificant benefits to the nation and its stakeholders, even though FMEA may be used as acomponent of improvement toolkits, such as those of Six Sigma initiatives Iran is one of the topoil producers in the world, thus its significance in the global oil market is undeniable and vital.Iran is currently ranked second in the world for natural gas and fifth for proven oilreserves According to the most recent estimates made in 2008, it has 96.4 billion barrels of oil.According to early projections, Iran's GDP at basic costs increased by 5.2% at constant prices toreach $44.9 billion in 2008 Manufacturing, mining, services, oil, and agriculture all sawincreases in value-added of 8.5, 6.5, 3.0, and 4.7%, respectively, while their respective shares inGDP at current prices were 17.1, 48.8, 26.5, and 10.4% (OPEC, 2008)

In other words, managers need to figure out how to use resources efficiently by cuttingdown on waste, speeding up certain processes, or eliminating errors in the work that is done(Yaacob, 2010) Therefore, it is anticipated that minimising oil waste offers benefits includingcost reduction, quality improvement, increased productivity, and improved customer satisfaction.The oil and gas sector is rife with risk and uncertainty, according to Tiku (2005), practically atevery level of the company, from exploration through production to downstream marketing.When creating products for use in the correct completion and continuous monitoring operations,makers and suppliers of oil and gas as well as electronics were encouraged to employ FMEA as

an effective method for analysing the elements that cause risks It is significant to highlight that avariety of areas and applications use risk management strategies (Demir and Bostanci, 2010).Moghaddam (2010) conducted research on risk management at the National Iranian OilCompany (NIOC) and made a portfolio management suggestion to improve the allocation offinancial resources Environmental factors can also contribute to failures, in addition to those

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circumstances can result in employees being more productive, whereas poor working conditionscan cause employees to be less productive, which in turn can have an impact on the processesand machinery conditions In the meantime, oil producing firms are crucial to Iran's oil industry,and Sepahan Oil Co significantly contributes to this sector Therefore, the purpose of this study

is to demonstrate how FMEA could raise product quality at Sepahan Oil Co The four-litre oilproduction line of Sepahan Oil Co is the subject of the following FMEA demonstration andapplication

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According to the QS 9000 FMEA handbook, FMEA is a set of procedures for detectingand analysing a product's or process's possible failure and its impacts, choosing steps that mightprevent or lessen the possibility of a potential failure mode occurring, and recording the analysisprocess (Estorilio and Posso, 2010) FMEA is a methodical process that enables designers torecognize possible problems, assess them, look into them, and take preventative action Eachcause of failure is assigned a risk priority number (RPN) through the use of an easy gradingtechnique that was especially created to meet the needs of the firm

To lower the probability of failure, the corrective action is chosen for those possiblecauses with high RPN values The system components that might fail and result in a negativeconsumer reaction or a tarnished corporate reputation are also given attention

All conceivable ways it might fail to fulfil its intended purpose must be taken intoconsideration and explained in order to determine the probable failure modes An excellent place

to start is by reviewing earlier FMEAs, testing, and quality, warranty, durability, and reliabilityreports The team must consider how the component or process can fall short of engineeringspecifications For probable failure impacts, it is required to identify both the "local" and

"overall" consequences of failure and to define the failure's effects in terms of what the customerwould observe or feel Of course, a single failure mode might have several effects, and severalfailure modes could all have the same consequence Additionally, every potential reason forfailure must be documented The reasons for failure must then be rated in order to get the riskpriority number when the list is complete

The term "severity" refers to an evaluation of the significance of the probable failuremode's post-failure impact on the client Severity rating is the process of estimating anddocumenting the failure's severity on a scale from 1 to 10 The severity rating always stays thesame, regardless of the failure's potential causes, as it is based only on the result and not thereason for the failure

When thinking about "occurrence of failure," one must assess the risk, or the likelihoodthat the failure mode would happen as a result of a certain cause The only method to reduce therecurrence is by a change in design (Alam, 2009) The assessment of the chance of the failure

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failure mode and its potential causes, and the probability of occurrence would then be graded on

a scale of 1 to 10 On a scale from 1 to 10, determine the likelihood that a possible failure will bediscovered before it affects the consumer This is known as the "detection rate."

The risk priority number (RPN), which is computed as DSORPN=, is the sum of theratings for occurrence, severity, and detection For each reason of failure, the RPN needs to becalculated The higher the number, the more often the failure mode is to occur, and RPNillustrates this relationship A critical summary may be created from the RPN to emphasise theareas that require the most intervention Any cause of failure with a severity grade of "9" or "10"requires extra care, regardless of the RPN that results

Following RPN calculation, the business should make sure that the primary dangers areeliminated from the specification through re-engineering The three possible solutions are, inorder of desirability, to: (1) completely eliminate the issue through a design modification; (2)lessen the likelihood that the failure would occur; and (3) increase the likelihood of discoverythrough increased quality control The severity, occurrence, and detection must all be evaluatedagain once the improvement activities have been taken, and a new RPN must be computed Thelikelihood that the mode will fail increases with the RPN, hence this mode has higher priority forremedial action (Chang and Sun, 2009)

The study' findings assist managers and engineers in identifying failure modes, their rootcauses, and how to fix them throughout the design and manufacturing phases (Sharma andSharma, 2010) By detecting possible failures and avoiding them, establishing which risks will

be taken or must be taken, and coming up with strategies to reduce those risks, FMEA may beused to minimise costly adjustments to design features (Tanik, 2010)

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Case-based research is the method that was used to do this work The reason for this isbecause of different parts of the research, like how important the context is, how the variables areboth quantitative and qualitative, and how the data is collected and analyzed The company thatwas used in this study was chosen because it had a long history of managing waste and its datawas easy to find Even though the company has plans for reducing waste, it has never usedsystematic approaches like FMEA (Failure Modes and Effects Analysis and Improvement) to do

so Also, this project is part of the toolbox for a bigger Six Sigma project, and FMEA is one ofthe effective techniques in the toolbox The steps of the FMEA method are as follows:

1 Making a team with people from different fields and what they do

2 Figuring out what could go wrong with different process parts

3 Figuring out what this failure could mean and how bad it could be (S)

4 Figuring out the possible cause(s) of the possible failure and making sure it happened(O) (failures that occurred during the defined period)

5 Figuring out the current controls for prevention and detection and making sure that thecontrols put in place work (D)

6 How to figure out the risk priority number (RPN)

7 Making a plan of action and putting it into action

8 Recalculating RPN after doing what needs to be done

The study team is made up of an administrator, a consultant (the authors, through auniversity-industry research contract), a production planner, a quality control manager, a person

in charge of cleaning, and a maintenance supervisor The National Iranian Oil CompanyEmployees' Pension set up and funded Sepahan Oil Co in April 2002 The company trades in oiland petrochemical products all over the world Today, this company does business in most of thecountries in the world Brand names like Exxon, Esso, and Mobil are well-known Sepahan Oil

Co makes products that power modern transportation, power cities, lubricate industries, andprovide petrochemical building blocks that are important to thousands of consumers SepahanOil Co has been thought of as the largest supplier of engine oil in the country ever since it was

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The company can get more than 30% of the roughly 600 million litres of engine oil used in thecountry "Alvand" and "Arzhan" engine oils have taken up most of the market for years At themoment, "Speedy" and "Jey," which are trade names of Sepahan Oil Co., are ranked first amongboth domestic and foreign suppliers It makes almost all of the engine oils used in the UnitedStates, including those for gasoline, diesel, gas, dual fuel, two-stage and four-stage engines,tractors, locomotives, generators, gear boxes, and both manual and automatic differentials Oilcanning is when the flat parts of metal roofing and metal siding panels look like they are wavy.

In general, the width of the flat determines how long the wave lasts and how big it is Oilcanning is a natural part of the light gauge that could be used to make metal products, especiallythose with large flat areas Profiles are often called "architectural" roofing and sliding panelsbecause they have wide, flat surfaces These panels are different from corrugated shapes, whichare more complicated

Table 1 shows that the four-liter can line is the most important of the company's four production lines Most of the waste values are from the time period between August 2005 and August 2007 It's important to know that the four-litre production line has the highest rate of all the ones listed

So, it makes sense to target this line as the one with the most waste, since canning wastes 6% andfilling wastes 1%, which adds up to a huge loss of 7% of this line's total production The FMEA

is used to improve the quality of this line of production The project to make things better used information from internal complaint records and files in the historical documents Documents from the maintenance department were looked at to find out how much downtime there was Some information was also gathered from the Sepahan Oil Co website, such as annual reports and internal documents of the company, to describe the way the company works and its economic statistics Conversations with employees inside the company were also used to get

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