ERT 461 - Week 9 SEM 1 2016/2017 1
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
Biosystems Engineering Design
(ERT 461/3)
Safety and Health in Engineering
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
Introduction
Safety is define as a freedom from harm or danger.
Health is define as the condition of being free from illness or disease.
Danger expresses the relative exposure to hazard (source of danger; a possibility of loss). A hazard may presence, but there may be little danger because of the precautiontaken.
ERT 461 - Week 9 SEM 1 2016/2017 2
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
Works or processes must meet acceptable safety and environmental performance standards because:
• It is required by law
• The costs (human, social, economic) of non-compliance can be catastrophic.
• Negligent attitudes are reflected in insurance premiums, stock prices.
• Moral and ethical obligations
Safety & Environment
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
• Factory and Machinery Act (FMA) 1967
• 11 regulations of FMA 1967:
1. STEAM BOILER AND UPV 1970
2. ELECTRIC PASSENGER AND GOODS LIFT 1970
3. FENCING OF MACHINERY AND SAFETY 1970
4. SAFETY, HEALTH AND WELFARE 1970
5. CERTIFICATES OF COMPETENCY—EXAMINATIONS 1970
6. NOTIFICATION, CERTIFICATE OF FITNESS AND INSPECTION 1970
7. LEAD 1984
8. ASBESTOS PROCESS 1986
9. BUILDING OPERATIONS AND WORKS OF ENGINEERING CONSTRUCTION (SAFETY) 1986
10. NOISE EXPOSURE 1989
11. MINERAL DUST 1989
Safety Legislation
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
• The Occupational Safety and Health Act (OSHA) 1994• Employers must provide a place of employment free from recognized hazards to safety and
health, such as exposure to toxic chemicals, excessive noise levels, mechanical dangers, heat or cold stress, or unsanitary conditions.
• Seven regulations of OSHA 1994:
1. EMPLOYERS SAFETY AND HEALTH GENERAL POLICY STATEMENT (EXCEPTION) REGULATION 1995
2. CONTROL OF INDUSTRY MAJOR HAZARDS (CIMAH) REGULATIONS 1996
3. SAFETY AND HEALTH COMMITTEE REGULATIONS 1996
4. CLASSIFICATION, PACKAGING AND LABELING OF HAZARDOUS CHEMICALS (CPL) REGULATIONS 1997
5. SAFETY AND HEALTH OFFICER REGULATIONS 1997
6. USE AND STANDARDS OF EXPOSURE OF CHEMICALS HAZARDOUS TO HEALTH (USECHH) REGULATIONS 2000
7. NOTIFICATION OF ACCIDENT, DANGEROUS OCCURRENCE, OCCUPATIONAL POISONING AND OCCUPATIONAL DISEASE (NADOPOD) REGULATION 2004
Safety Legislation
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
The Occupational Safety and Health Act (OSHA) 1994• For all industries
• If >5 Employees-Safety & Health Policy
• ≥40 Employees (S30) -Safety & Health Policy + Safety & Health Committee
• For high risk industries (i.e. construction, ship building, gas etc.)
• >100 Employees (Order 1997) -Safety & Health Policy + Safety & Health Committee + a Certified Safety & Health Officer
• For low risk industries (other than the above mentioned industries)
• >500 Employees (Order 1997) -Safety & Health Policy + Safety & Health Committee + a Certified Safety & Health Officer
Safety Legislation
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
Types of HAZARDS
1. Physical Hazards
2. Chemical Hazards
3. Biological Hazards
4. Electrical Hazards
5. Radiation Hazards
6. Psychological Hazards
ERT 461 - Week 9 SEM 1 2016/2017 7
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
Types of HAZARDS
1. Physical Hazards
2. Chemical Hazards
3. Biological Hazards
4. Electrical Hazards
5. Radiation Hazards
6. Psychological Hazards
ERT 461 - Week 9 SEM 1 2016/2017 8
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
Physical Hazards
Physical Hazards
Example: height, force, noise, vibration, lighting, etc
Can cause tissue damage, hearing loss, lifting, manual handling, ergonomic, traffic hazards, collapse, falling objects
ERT 461 - Week 9 SEM 1 2016/2017 9
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
Physical Hazards
Manual Handling
• The lifting and carrying of loads is a big problem in everyindustry.
• Manual handling injuries contributed about 25% of all work-related injuries
ERT 461 - Week 9 SEM 1 2016/2017 10
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
Physical Hazards
How to reduce the effects• Bagged materials must be less than 25 kg.• Apart of the weight factor, other factors also affect this
manual handling related accident such as:1. Individual
-Age
-Gender
-Training
-Experience
-Previous injury
2. The overall operation
ERT 461 - Week 9 SEM 1 2016/2017 11
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
Physical Hazards
Works Related Upper Limb Disorder (WRULD)
• WRULD is caused by repetitive movements diseases
associated such as:
• Neck, shoulder and elbow disorder
• Wrists and hand lesions
• Thoracic outlet syndrome
ERT 461 - Week 9 SEM 1 2016/2017 12
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
Physical Hazards
Factors associated with the development of WRULD
• Resisting Excessive Force• Frequency and duration of movement• Posture – ergonomic• Works ogranization
Length of work period without rest break, lack of training and
inadequate supervision.• Psychosomatic factors (illness due to the interaction of
the mind and the body)• Poor awareness by managers and empoyess
• Lack of management to detect problems.
• Poor ergonomic job design
• Lack of training to control WRULD
ERT 461 - Week 9 SEM 1 2016/2017 13
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
Physical Hazard
Noise
• It can cause hearing loss
• Factors influencing hearing loss• Intensity of the noise
• Frequency
• Length of exposure
• Individual tolerance. This factor is also affected by other factors such as age and effect of drugs.
ERT 461 - Week 9 SEM 1 2016/2017 14
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
Physical Hazard
Noise
ERT 461 - Week 9 SEM 1 2016/2017 15
Sound Level in dB (A) Sources
Harmfull140 Jet Engine
130 Riveting Hammer
Critical
120 Propeller Aircraft
110 Rock Drill
100 Typical outdoor construction, plate fabrication noise
90 Heavy Vehicle
Safe
80 Pile drivers, power lawn mower, very busy traffic
70 Private car
60 Air compressor and concrete mixers
50 Conversation (at 1 m)
40 Average business office
30 Quite Whisper
Levels
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
How to control noise hazard ?
• Review the design and change if possible
• Change with other processes or equipment
• PPE (Personal Protective Equipment) : Earmuff
ERT 461 - Week 9 SEM 1 2016/2017 16
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
Physical Hazard
Vibration
• Result in tissue damage
• Two kind of vibration • Whole body vibration:vehicles
• Segmental vibration:pneumatic handheld tools
• How to control this hazard ?• Use of vibrational isolator
• Select equipment that produces less vibration.
ERT 461 - Week 9 SEM 1 2016/2017 17
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
Types of HAZARDS
1. Physical Hazards
2. Chemical Hazards
3. Biological Hazards
4. Electrical Hazards
5. Radiation Hazards
6. Psychological Hazards
ERT 461 - Week 9 SEM 1 2016/2017 18
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
Chemical Hazards
Example: Gas, Liquid, Vapor, Fumes, Mist, Dust, Asbestos, Lead
Can cause inhalation, skin contact with chemical, ingestion of chemical.
ERT 461 - Week 9 SEM 1 2016/2017 19
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
Chemical Hazards
Routes of Entry of Toxic Agents
• Respiratory
• Skin and eye contact
• Mouth (Ingestion)
• Injection
ERT 461 - Week 9 SEM 1 2016/2017 20
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
Chemical Hazards
Type of effects
• Acute• A lot of exposure
• The reaction happen in short period of time
• Chronic• Repeated small exposure
• Long period of time
ERT 461 - Week 9 SEM 1 2016/2017 21
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
Chemical Hazards
ERT 461 - Week 9 SEM 1 2016/2017 22
Common Types of Toxic Effect
• Irritations- Lung
• By inhaling some chemicals, e.g. ozone,sulfur dioxide and nitrogen dioxide
- Skin: chemical, physical, mechanical and biological
• Central Nervous System (CNS) Depression
- Headache, Drowsiness, Unconsciousness - Organ affected: brain
- Many solvents (toluene, xylene, ether, acetone)produce this effect if the vapor concentration ishigh
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
Chemical Hazards
ERT 461 - Week 9 SEM 1 2016/2017 23
• Cancer
- The effect is about 20-30 years
Sources
• Benzene Leukemia• Chromium and Arsenic Trioxide Lung Cancer • Asbestos Larynx, Lung and Abdomen cancer • Vynil Chloride Liver Cancer • Coal Tar Pitch Skin Cancer• Benzidine Bladder Cancer
Common Types of Toxic Effect
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
Chemical Hazards
ERT 461 - Week 9 SEM 1 2016/2017 24
Factors Affecting Toxic Effect• Factors related to the agent
- Chemical Composition- Physical properties
- Solubility in body fluids
• Factors related to the Exposure Situation- Dose: how much and how long?
- Co-factors: Presence of other materials
• Factors related to the individuals- Individual differences: genetic status and allergic status -
Age
- Presence of predisposing disease:
• Angina (Heart Disease) cannot tolerate carbon monoxide• Emphysema (lung ailment)
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
Chemical Hazards
ERT 461 - Week 9 SEM 1 2016/2017 25
Asbestos
• It can cause lung cancer
• The disease develops 20-40 years after exposure
• Problems with asbestos in construction
- Many construction contracts are being awarded without the
contractors being informed of the presence of asbestos materials
Construction Materials Causing
Occupational Diseases
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
Chemical Hazards
ERT 461 - Week 9 SEM 1 2016/2017 26
Hazards related materials
- Workplace Hazardous MaterialInformation System (WHMIS) (Canada’s National Workplace Hazard Communication
Std)
The key elements of the system are cautionary labelling of
containers of WHMIS "controlled products", the provision of
Material Safety Data Sheets (MSDSs) and worker
education and training programs
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
Chemical Hazards
Hazards related materials usually has
• Workplace Hazardous Material Information System (WHMIS) symbols
• Material Safety Data Sheets (MSDSs)
ERT 461 - Week 9 SEM 1 2016/2017 27
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
Chemical Hazards
ERT 461 - Week 9 SEM 1 2016/2017 28
Class B: FlammableClass A: Compressed Gas& Combustible
WHMIS Symbol
Class C: Oxidizing Material Class D: Poisonous andInfectious Material
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
Chemical Hazards
ERT 461 - Week 9 SEM 1 2016/2017 29
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
Chemical Hazards
Material Safety Data Sheets - MSDS
ERT 461 - Week 9 SEM 1 2016/2017 30
A form with data regarding the detailed properties of aparticular hazardous material
An important component of product stewardship andworkplace safety, it is intended to provide workers andemergency personnel with procedures for handling orworking with that substance in a safe manner
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
Chemical Hazards
What is MSDS ?
ERT 461 - Week 9 SEM 1 2016/2017 31
• A Material Safety Data Sheet (MSDS) providesdetailed information about a specific hazardousmaterial. An MSDS contains the followinginformation:
- Identity (name of substance)
- Physical Hazards (target organ)
- Health Hazards
- Routes of Body Entry
- Permissible Exposure Limits (PEL)
- Carcinogenic Factors (cancer causing)
- Safe-Handling Procedures
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
Chemical Hazards
What is MSDS ?
ERT 461 - Week 9 SEM 1 2016/2017 32
• A Material Safety Data Sheet (MSDS) providesdetailed information about a specific hazardousmaterial. An MSDS contains the followinginformation:
- Data of Sheet Preparation
- Control Measures (personal protective equipment)
- Emergency First Aid Procedures
- Contact Information (for the preparer of the sheet)
- Special Instructions
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
Chemical Hazards
ERT 461 - Week 9 SEM 1 2016/2017 33
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
Chemical Hazards
Why do you use a MSDS ?
ERT 461 - Week 9 SEM 1 2016/2017 34
• You should use an MSDS whenever you need additionalinformation about a hazardousmaterial that is not includedon the product label.
• For example, you have spillednitric acid on the floor, and youneed to know how to clean itup safely. You need only refer to the "Safe-Handling Procedures" section of the nitric acid MSDS.
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
Chemical Hazards
ERT 461 - Week 9 SEM 1 2016/2017 35
Why do you use a MSDS ?
• Some chemicals, such as sodium hydroxide, are very
dangerous. If you have an accident, you may not have
time to look up the information you need in an MSDS.
• You should read the MSDSs for the hazardous materials
present in your work area before you work with them.
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
Types of HAZARDS
1. Physical Hazards
2. Chemical Hazards
3. Biological Hazards
4. Electrical Hazards
5. Radiation Hazards
6. Psychological Hazards
ERT 461 - Week 9 SEM 1 2016/2017 36
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
Biological Hazards
• Microorganism -Fungi, Bacteria, Viruses
route –in contact with bacteria thro’ improper treated cooling towers
• Arthropods – mosquitoes, spiders
route – bitten by infected mosquitoes
• Animals – crocodiles, snakes
• Plant allergens and toxins – pollen
• Protein allergens – food, urine, feces, hair
route – rodent dropping/urine
ERT 461 - Week 9 SEM 1 2016/2017 37
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
Types of HAZARDS
1. Physical Hazards
2. Chemical Hazards
3. Biological Hazards
4. Electrical Hazards
5. Radiation Hazards
6. Psychological Hazards
ERT 461 - Week 9 SEM 1 2016/2017 38
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
Electrical Hazards
Example: current, voltage, sparks
Can cause direct electrocution, contact with overhead or underground cables
ERT 461 - Week 9 SEM 1 2016/2017 39
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
Types of HAZARDS
1. Physical Hazards
2. Chemical Hazards
3. Biological Hazards
4. Electrical Hazards
5. Radiation Hazards
6. Psychological Hazards
ERT 461 - Week 9 SEM 1 2016/2017 40
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
Radiation Hazards
Example: UV light, lasers etc
Can cause skin contact, eye contact
ERT 461 - Week 9 SEM 1 2016/2017 41
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
Radiation Hazards
ERT 461 - Week 9 SEM 1 2016/2017 42
• UV can damage eyes and skin
- Skin cancer
- Skin burn
- Eye discomfort
• Where is the exposure of this hazard?
- Outdoor job
- Welding
- Work using high intensity lamp
• How to reduce the hazard?
- Sun block
- UV Protection Sunglasses - Blue color costume
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
Types of HAZARDS
1. Physical Hazards
2. Chemical Hazards
3. Biological Hazards
4. Electrical Hazards
5. Radiation Hazards
6. Psychological Hazards
ERT 461 - Week 9 SEM 1 2016/2017 43
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
Psychological Hazards
Example: workplace, space, organizational culture, stress
ERT 461 - Week 9 SEM 1 2016/2017 44
Occupational Stress
• Three types of occupational stress
- Physical
- Mental
- Emotional
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
Psychological Hazards
Causes of occupational stress
ERT 461 - Week 9 SEM 1 2016/2017 45
• Uncertainty and lack of control (low jobdiscretion)
• Lack of support from others, including co-workers
• Conflicts
• High demands of working environment, e.g. long hours, high responsibility, commitment
• Very low demands: boredom, lack of meaning in work
• Work station: noise, poor lighting, lack of space, extremetemperatures, poor ergonomics
• Chemical hazards, fumes, passive smoking
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
Psychological Hazards
Causes of occupational stress
ERT 461 - Week 9 SEM 1 2016/2017 46
• Organizational culture
• Repetitive Tasks
• Low pay leading to overtime and piecework
• Change
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
Psychological Hazards
ERT 461 - Week 9 SEM 1 2016/2017 47
How do humans react? 3 stages
• Alarm Stage
-Immediate reaction
- Fight or Flight?
- Human body coordinates the readiness of
action, influencing mood, causing heart
palpitation, shallow fast breathing, muscle
tension, dryness of throat, dizziness and light-
headedness, numbness of the limbs, nausea,
anxiety and sweating
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
Psychological Hazards
ERT 461 - Week 9 SEM 1 2016/2017 48
Alarm stage cannot be maintained indefinitelyAt one point, resistance stage occurs in which humansdevelop survival strategies and a way of fighting the stress
Typically, short-term relief is preferable
• Exhaustion Stage-Stress response is healthy and a motivator- When expectations are not realistic, humans becomesuffer
How do humans react?
• Resistance Stage
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
RISK MANAGEMENT
ERT 461 - Week 9 SEM 1 2016/2017 49
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
Risk Management
ERT 461 - Week 9 SEM 1 2016/2017 50
Checking and Reviewing the risk control
Controlling the risk• Eliminating the hazard, if possible
• Minimizing, if possible
• Controlling the hazard
Risk management involves the:
identification,
assessment, and prioritization of risks followed
by coordinated and economical application of resources to
minimize, monitor, and control the probability
and/or impact of unfortunate events or to
maximize the realization of opportunities.
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016 ERT 461 - Week 9 SEM 1 2016/2017 51
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016 ERT 461 - Week 9 SEM 1 2016/2017 52
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016 ERT 461 - Week 9 SEM 1 2016/2017 53
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016 ERT 461 - Week 9 SEM 1 2016/2017 54
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016 ERT 461 - Week 9 SEM 1 2016/2017 55
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
Failure Mode Effect Analysis
• An early stage approach to identifying problems with a technology
• Scope encompasses safety, environment, operational feasibility
• Slightly different versions can be used for process design and product design
• Goal is to identify the critical technical risks using a semi-quantitative procedure
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
FMEA Procedure
1. Brainstorm for failure modes
2. For each FM, rate severity of impact (SEV, 1 - 10)
3. For each FM, brainstorm for possible causes (there may be multiple)
4. For each cause, rate likelihood of occurring (OCC, 1-10)
5. Rate the probability that the systems currently in placewill detect & prevent the problem before it has an impact (DET, 10 - 1). Do not assume that something that will be added to the design later will take care of the problem.
6. Overall Risk Probability Number RPN = SEV x OCC x DET
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016 ERT 461 - Week 9 SEM 1 2016/2017 58
FMEA Notes
• Most practitioners use a 1,4,7,10 scale to increase granularity
• DET scale is inverse to SEV and OCC
• FMEA is always associated with a particular design revision and should be updated whenever a new revision is released
Rating Likelihood of Occurrence Severity Detection
1 Failure is very unlikely Effect is insignificant Current safeguard will almost
certainly prevent the failure mode
4 Occasional failure likely Minor disruption, Customer
dissatisfied
High chance that safeguard will
detect
7 Moderate likelihood of failure Major components must be
replaced
Low chance that safeguard will detect
10 Failure is very likely Fails without warning may
endanger customer
No known method of detection
Suggested Rating Scale
FMEA Notes
• Most practitioners use a 1,4,7,10 scale to increase granularity
• DET scale is inverse to SEV and OCC
• FMEA is always associated with a particular design revision and should be updated whenever a new revision is released
Rating Likelihood of Occurrence Severity Detection
1 Failure is very unlikely Effect is insignificant Current safeguard will almost
certainly prevent the failure mode
4 Occasional failure likely Minor disruption, Customer
dissatisfied
High chance that safeguard will
detect
7 Moderate likelihood of failure Major components must be
replaced
Low chance that safeguard will detect
10 Failure is very likely Fails without warning may
endanger customer
No known method of detection
Suggested Rating Scale
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016 ERT 461 - Week 9 SEM 1 2016/2017 60
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
FMEA Tool
Project Name
Project Number Sheet 1REV DATE BY REV DATE BY APVD
Owner's Name
Plant Location
Case Description
Process Step or Key
InputFailure Mode Consequence
Impact
SE
V
Cause
Fre
quencey O
CC
Dete
ction D
ET
Priority
RP
N
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Current Control Action
APVDAddress
Company Name
Form XXXXX-YY-ZZ
FAILURE MODE EFFECT ANALYSIS
FMEA is easily implemented in a spreadsheet:
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
Example: Dryer FMEA
• In the manufacture of chocolate, cocoa butter is extracted from the cocoa solids using butane as solvent
• The solids are dried in a rotary dryer. The off gas from the dryer is sent to cyclones to recover solids fines, cooled to recover solvent and then recycled to the dryer
• Part of the cocoa solids is sold as product and part is used in downstream processing to make different grades of chocolate
ERT 461 - Week 9 SEM 1 2016/2017 62
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
Example: Dryer FMEA
Solids out
Make-up gas
Solids in
Cooler
HeaterDryer
Fan
Solids fines
Solvent out
Loss of heat source to heater
Loss of coolant to cooler
Blockage of solids flow
Blockage of solids flow
Solids carryover
and fouling of cooler
Loss of power
Fan failure
Level
control
failure
Loss of feed
Erosion
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016
FMEA Example
• Failure mode
• Interruption of solids flow from second stage cyclone
• Consequence
• 2nd stage cyclone does not operate effectively, solids carry over into cooler, cooler becomes fouled and eventually pressure drop becomes high and gas flow is reduced limiting dryer capacity
• Cause
• 2nd stage cyclone dip leg plugged with solids
• Frequency of occurrence: occasional, OCC = 4
• Severity
• Minor disruption. Takes long time to have serious effect as long as first stage cyclone is still working. Nuisance to clean out though. SEV = 4
• Detection
• Hard to detect solids flow, fouling or build up of powder in cooler. Might show up as sediment in the recovered solvent, but it is probably always pretty dusty and may not even be sampled (difficult to sample butane as it will flash). DET = 10
• Risk Probability Number
• RPN = OCC x SEV x DET = 4 x 4 x 10 = 160
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016 ERT 461 - Week 9 SEM 1 2016/2017 65
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016 ERT 461 - Week 9 SEM 1 2016/2017 66
Firdaus Muttalib
School of Bioprocess
Engineering
8/11/2016 ERT 461 - Week 9 SEM 1 2016/2017 67