Case Stt1dy: Dust Extraction System

You are the head of Duse excraction syste111 of a

Blast
Furnace . Blast Furnace. You took round of your plant.
'J WOl~.J!M..
The DE c:;vc;1e111 consi<:1c; of 5 du•a collection
hood 10 suck dust fron1 outlet of MB= 1. and
outlet of 1IB=2 ac bell less top charging hopper.
Dust separation occurs in bag filler. The dW)t
storage silo shall be located beneath the bag filter.
The dust shall be discharged
- from the bag... filter to
c:; torage <:ilo through con,·cyor rornry air lock
\'ah·e. The dust accu1nulate<l in storage silo shall
be periodically discha rged to dtunper nucks
through retractable chute of DCL make \Yith built
DUST DUSI
COllECTJO~ STORAGE
DISCHARGE TO in bag filter.
DUMPER
HOOD .SlLO TRUO\ Apply :Nll-L\,'Th,I 10 the haLard-. you ha\'e seen in
your pla nt.
Dust Extraction System: System Breakdown
Dust extraction
syste1n

Dtist suction Dust handling Suction

& Transfer Bag Filter unit 1.;uit

Screw Dust
Com'e ·or Storaoe Silo
Sucriou Sensing
Duer Motor
Hood Indicator ID Fan
Drive
Compressed Bag Rotmy
Pulse Jet Air Svstem ,_,,_.,,....Rl!llIDent Vane Ti s

Pressw·e Temperature Bearing & Bevel

I Flange Gear

Control loop Relief Valve Piping

Hazard Tree 500 1~
450
400
'°"
80%
350 7°"
i;-
a
300 60% "I-
~ 250
Q"
SO%
9
t "00
i..- 4°" u

Illh■■-
150 3°"

100
SO
0 1112 13 1415 16 17 1819110 l'Jlll314 15
Hl -
Incide,na

Hnzard
Hl-Hn

' - -- H Eu
Hazard Matrix
Hazard HE l)II TIT

Suc1iou hood (HE! ) Suchon hood malfiu1ciiou People/Propeny/E11,·iro11ment

Duct (HE2) • Fan Malfunction People/Propeny1En,·i.ro11men1
• Blocked 011c1 (Low. :\tedium. Serious)
• Dusi accumulation
• Corrosion
• \Velding Failure
Dust sucrioo & Pre!>!tw·e inrucator (HE3) • Zero current flow due 10 open circuit People/Property/Environment
Transfer • Heating due to sho1t circuit
• Collllllwucarion Faillu·e
• Debonding. from the frame
• Diaphragm Failure
Temperamre indicator • Zero curreot flow due 10 open circuit People/Property/Em·ironmeu1
(HE4) • Heating due to short circuit
• Scale Build up over Sensor surface
• Conummica1iot1 Faihu-e
Pulse jet (HE5) • Abra~iou People/Propeny1En,·iroun1eni
• D11$1Acrumulation
Bag compamnent (HE6) Inappropriately Sized Dust People/Propeny/Em·iromnent
Bag Filter Bearing and Flange • Lubrication Failw·e People/Properry/Eu\'i.ronment
(HE7) • Corrosion
Bevel gear (HES) • Lubrication Failm·e People/Properry/Euvironmeu1
• Dust accuruulation
• Overloadin~
Hazard Pt-ot,ablU~· St'erit>' Delt'r tabllhy RP~

HJ 7 3 8 168
Hazard Prioritization
lC 2 9 8 144
ID §. -+ 5 120
1000 too
R4 9 6 3 162 900 90
fil 9 2 8 1-14 800 80
H6 7 2 4 56 ti
?00 10 J!
H" 6 9 5 270 600 60 9'1
HS 6 5 3 90 z 500 Sll
Cl.,
.,
~ .a."'

~
B9 l 4 6 24 400 40
-a
HIO 9 7 5 3 15 300

200
30
?O
a
HI I 3 7 9 189
100 to
HJ~ 4 8 9 288 0 0
,Rl3 4 2 3 24 ~~~~~~~~~~~~~~~~~
~ ~ ~ ~ ~

H14 9 3 2 54 Haza.rd
HI S -+ 3 9 108
Al6 7 I 5 35
HP 7 3 J 21
 Risks are iutolerable
Hazard Control Decisions excepl 1.11 extn\Ordiuary 0
Haznr d
IlHI

111:Z
RP~
3 15

Z88
circumstauces, and 1isk
.reduction
esseotiru.
rueasures ;ire
m Accountubility
Administnl tio.u

87 270
1n101erat>le Hnznrd RPN Risk reducriou measures are
Risk
lSIJ - - ·Jesil'able. but mny not be
implemented if their cost is
IT1 168
dispropo1tiooate ro lhe benefit
achieved
Exlenl of
H2 144
ALARP loe, I
Hazard RPN 0 Acco on tability

m
I\SSGS$ffi8nt R • HS JH
HO !W
lkJ1nrtme11tnl l1t!nJ
H3 120
ll6 56
Il15 108
1114 51
R lti 3~ 0
m
Accounhlbility
H9 :?4 Snfel)· officer
No furtherrisk reduction
1113 24
measmes nre nonuo IJy needed
HJ!7 and maiuraiu the level.