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Risk Assessment: FAULT TREE Project Name: Cocoa Butter Alternatives Plant Design User: Select Process: Dry

Fractionating Process components Section: H 202 A-B; Oil Pre-heater drop down from Item
list Failure Rate µ (faults/yr) 1 Flow measurement (fluids) 1.14 2 Flow switch 1.12 3 Controller 0.29 4 Indicator lamp 0.04 5 Indicator lamp 0.04 6 Control valve 0.6 Thermocouple temperature measurement 0.52 7 8 9 10

Component

Reliability R = e-µt 0.320 0.326 0.748 0.957 0.957 0.549 0.595

Failure probability P = 1-R 0.680 0.674 0.252 0.043 0.043 0.451 0.405

Mean Time Between Failures MTBF = 1/µ 0.877 0.893 3.448 22.727 22.727 1.667 1.923

Formula for calculating the computations for various types of component linkages, please refer to Component Linkgages Fault Tree for CP 205 of unit 200, please refer to FAULT TREE FOR H 204

727 1.e Between Failures TBF = 1/µ 0.727 22.877 0.667 1.923 .893 3.448 22.

957 0.709 0.252 0.817 0.12 6 Controller 0.326 0.Risk Assessment: FAULT TREE Project Name: Cocoa Butter Alternatives Plant Design User: Select Process: Dry Fractionating Process components Section: CRZ 202 A.043 0.451 Mean Time Between Failures MTBF = 1/µ 22.B.748 0.244 0.893 3.595 0.29 10 Thermocouple temperature measurement 0.04 8 Indicator lamp 0.727 22.727 3. please refer to Component Linkgages Fault Tree for CRZ 202 of unit 200.448 22.877 0.7 13 Controller 0. Crystallizer drop down from Item list Failure Rate µ (faults/yr) 1 Indicator lamp 0.549 Failure probability P = 1-R 0.04 2 Controller 0.448 1.29 3 Pressure measurement 1.14 5 Flow switch 1.52 11 Indicator lamp 0.748 0.252 0.183 0.588 3.405 0.923 22.448 1.756 0.667 Formula for calculating the computations for various types of component linkages.6 Component Reliability R = e-µt 0.04 9 Controller 0.320 0.252 0.957 0.043 0.043 0.727 0.680 0.29 14 Control valve 0.04 12 Level measurement (liquids) 1.448 0.957 0.727 3.41 4 Flow measurement (fluids) 1.252 0.674 0.29 7 Indicator lamp 0. please refer to Fault Tree--CRZ 204 .043 0.748 0.957 0.748 0.

e Between Failures TBF = 1/µ 22.448 22.727 0.588 3.448 1.727 3.923 22.448 0.709 0.448 1.667 .893 3.727 22.877 0.727 3.

04 Reliability R = e-µt 0. please refer to Component Linkgages Fault Tree for M305 of unit 300.727 3.448 22.957 0.244 0.04 0.252 0.957 Failure probability P = 1-R 0. please refer to FAULT TREE FOR MFP 207 A-B .709 0.12 0.043 Mean Time Between Failures MTBF = 1/µ 22.748 0.748 0.320 0.043 0.727 Formula for calculating the computations for various types of component linkages.448 0.252 0.Risk Assessment: FAULT TREE Project Name: Cocoa Butter Alternatives Plant Design User: Select Process: Dry Fractionating Process components Section: MFP 207 A.326 0.756 0.893 3.29 1.41 1.B . Membrane Filter Press from drop down Item 1 2 3 4 5 6 7 8 9 10 Component Indicator lamp Controller Pressure measurement Flow measurement (fluids) Flow switch Controller Indicator lamp list Failure Rate µ (faults/yr) 0.680 0.674 0.14 1.29 0.877 0.

727 3.893 3.448 22.727 .448 0.709 0.877 0.e Between Failures TBF = 1/µ 22.

727 Formula for calculating the computations for various types of component linkages.326 0.893 3.448 #N/A #N/A 0.043 Mean Time Between Failures MTBF = 1/µ 22.957 0.04 0.727 3.748 0.252 0.748 0.29 0. please refer to FAULT TREE FOR M304 A-B .12 0. please refer to Component Linkgages Fault Tree for M305 of unit 300.448 22.29 0.957 0.674 0.04 0.043 0.252 #N/A #N/A #N/A #N/A #N/A #N/A 1. Mixer from drop down Item 1 2 3 4 5 6 7 8 9 10 Component Indicator lamp Controller Level measurement (liquids) Flow measurement (fluids) Flow switch Controller Indicator lamp list Failure probability Failure Rate µ Reliability R = e-µt P = 1-R (faults/yr) 0.Risk Assessment: FAULT TREE Project Name: Cocoa Butter Alternatives Plant Design User: Select Process: Hydrogenation Process components Section: M304 A-B.

893 3.448 22.727 .727 3.448 #N/A #N/A 0.e Between Failures TBF = 1/µ 22.

29 0.709 #N/A 0.748 0.549 0.043 Indicator lamp 0.29 0.674 Controller 0.6 0.893 3.869 0.595 0.131 Controller 0.448 0.923 Formula for calculating the computations for various types of component linkages.04 0.957 0.727 1.727 22.52 0.756 Flow measurement (fluids) #N/A #N/A #N/A Flow switch 1.244 0.448 22.667 1. please refer to Component Linkgages Fault Tree for R306 of unit 300.12 0.252 Pressure measurement 1. Hydrogenation Reactor from drop down Item 1 2 3 4 5 6 7 8 9 10 Component list Failure probability Failure Rate µ Reliability R = e-µt P = 1-R (faults/yr) Pressure switch 0.451 Thermocouple temperature measurement 0. please refer to FAULT TREE FOR R303 A-B .41 0.04 0.326 0.957 0.252 Indicator lamp 0.748 0.405 Mean Time Between Failures MTBF = 1/µ 7.043 Control valve 0.143 3.14 0.Risk Assessment: FAULT TREE Project Name: Cocoa Butter Alternatives Plant Design User: Select Process: Hydrogenation Process components Section: R 306.

667 1.e Between Failures TBF = 1/µ 7.923 .893 3.448 0.143 3.727 1.448 22.727 22.709 #N/A 0.

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13 0.70 6.86 5.Table 1: Failure Rate Data for Various Selected Process Components (Crowl & Louvar.022 0.65 5.42 0.044 0.14 0.52 0.027 0.60 0.60 1.12 30.22 0.41 0.29 0.75 1.044 1.88 1.44 .14 3. 2001) Instrument Controller Control valve Flow measurement (fluids) Flow measurement (solids) Flow switch Gas-liquid chromatograph Hand valve Indicator lamp Level measurement (liquids) Level measurement (solids) Oxygen analyzer pH meter Pressure measurement Pressure relief valve Pressure switch Solenoid valve Stepper motor Strip chart recorder Thermocouple temperature measurement Thermometer temperature measurement Valve positioner Faults/year (µ) 0.

2001) .1: Computations for various types of component linkages (Crowl & Louvar.Table 1.

Pilot Plant and Laboratory Safety. Health and Environment.Inc. E&FN SPON. 2004.gov/ Wells. R. 1991. G. Thomson Delmar Learning. . Process Technology Safety. 2005. Peter.S. http://www. C. U. 2nd ed. Louis Theodore Marcel Dekk Mannan. 2007. J. Steinbach..M. Hazard Identification and Risk Assessment. 1 2 3 4 5 6 7 8 9 10 11 12 13 Reference Crowl. Chemical Engineering Design 4th Edition. and Control.P. D.. Prentice Hall. S. 1994. McGraw-Hill. Safety Assessment for Chemical Processes. WILEY-VCH.osha. Chemical Process Safety Fundamentals with Applications 2nd ed. K. Lee's Loss Prevention in the Process Industries: Hazard Identification. Flynn. Volume 6. J. F. Pipelines and Transport. Palluzi. J. Department of Labor Occupational Safety & Health Administration. Health. Inc.S.E. Lees. Elsevier.. McGraw-Hill Internatio Sinnott. Timmerhaus. A. 1999. Taylor. Assessment. 2002. 1994. 2005. Louvar. Safety and Accident Management in the Chemical Process Industries. Risk Analysis for Process Plant. Institution of Chemical Engineers (IChemE). Thomas.F.D. 2001. Plant Design And Economics For Chemical Engineers 4th Edition. M.K. R.P.R.REFERENCE No.A.

Butterworth-Heinemann. Inc. sessment.ice Hall. McGraw-Hill International Editions. . and Control. . Inc. Theodore Marcel Dekker.