RELIABILITY

A chemical process control panel contains a digital temperature display that shows the
reaction temperature. If a critical temperature is reached, the operator must press an
emergency stop button, which results in the reaction being quenched and cooled. If this fails,
safety relies on an emergency venting system.

Concern has been expressed about the adequacy of relying on the operator to take the
necessary action when the temperature is too high. One proposal is to automate the reaction
quench sequence if a specified temperature is exceeded. One such simple system,
comprising three key components (A1, B1 and C1) connected in series, has been proposed.
A further suggestion is that an identical standby protective system (A2, B2 and C2) could be
placed in parallel to the first. This would be designed to cut in automatically by means of a
sensor and switch arrangement (D) in the event of failure of the first system.

The following reliability data are available:

i. If the manual system is retained, identify measures that could be taken to reduce the
probability of operator error resulting in the reaction not being quenched. (8)
ii. Using simple reliability theory, calculate the reliability of the proposed basic
protective system AND the improvement that the addition of the standby system
would provide. (8)
iii. Identify the factors that should be taken into account in deciding which of the two
automated systems to specify. (4)

Answer

There are several modifications that could be made to the system described without
automating the quench system. The digital readout could be replaced with a large,
obvious, centrally positioned analogue temperature display which could be marked
with danger bands to indicate the over-temperature levels. The number of other
displays on the control panel could be minimised to give emphasis to the temperature
readout. A distinct visual and audible warning could be fitted to the temperature
display such that over-temperature conditions are accompanied by a flashing light
 and an audible alarm. The stop button could be made prominent and positioned
adjacent to the temperature display. Access to the control panel could be restricting
so minimising distractions. Attention could be paid to the provision of lighting to the
control panel to ensure that the display is visible.

iv. Reliability of the proposed basic system:

R(1) = R(A1) × R(B1) × R(C1) = 0.94 × 0.95 × 0.91 = 0.8126

The improvement provided by the addition of a stand-by system:

Where the reliability for the combined system of two series circuits arranged in
parallel would be given by:

R(s) = 1 - [(1 - R(1)) × (1 - R(2))]

Where, R(1) is as already calculated above for the basic series circuit 1 (= 0.8126)
and, of course, the standby system arrangement alone (series circuit 2 in the
diagram) has a reliability given by:

R(2) = R(A2) × R(B2) × R(C2) × R(D) = R(1) × R(D) = 0.8126 × 0.98 = 0.7963

So, for the combined arrangement in parallel, we have the reliability:

R(s) = 1 - [(1 - 0.8126) × (1 - 0.7963)] = 0.9618

Relative Improvement = 100% × (0.9618 - 0.8126)/0.8126 = 18.36%

v. The factors that should be taken into account in deciding which of the two automated
systems to specify would include the cost of the two systems, the estimated
improvements in reliability created by applying the simple automated system and the
relative improvements in reliability associated with applying the more complex
system, and the magnitude of risk if the quench system were to fail.