Functions, Failures, Failure Modes, Failure Effects, Risks, Policy Decisions,

Caustic Soda Filling and Bagging System

Functional Analysis Failure and Failure Event Analysis

Failure
Function Functional Failure Failure Mode Mechanism Failure Effect

1 A 1

1 A 2

1 A 3

1 A 4

1 A 5

1 A 6

1 A 7

1 A 8

1 A 9

1 A 10

1 A 11

1 A 12

1 A 12

1 A 13

1 A 14

1 A 14

03/01/2023 1 of 19
 Functions, Failures, Failure Modes, Failure Effects, Risks, Policy Decisions,
Caustic Soda Filling and Bagging System

Functional Analysis Failure and Failure Event Analysis

Failure
Function Functional Failure Failure Mode Mechanism Failure Effect

1 A 15

1 A 16

1 A 17

1 A 18

1 A 19

1 A 20

1 A 21

1 A 22

1 A 23

1 A 24

1 A 25

1 A 26

1 A 27

1 A 28

1 A 29

1 A 30

03/01/2023 2 of 19
 Functions, Failures, Failure Modes, Failure Effects, Risks, Policy Decisions,
Caustic Soda Filling and Bagging System

Functional Analysis Failure and Failure Event Analysis

Failure
Function Functional Failure Failure Mode Mechanism Failure Effect

1 A 31

1 A 32

1 A 33

1 A 34

1 A 35

1 A 36

1 A 37

1 A 38

1 B 1

1 B 2

1 B 3

1 B 4

1 B 6

1 B 7

1 B 9

1 B 10

03/01/2023 3 of 19
 Functions, Failures, Failure Modes, Failure Effects, Risks, Policy Decisions,
Caustic Soda Filling and Bagging System

Functional Analysis Failure and Failure Event Analysis

Failure
Function Functional Failure Failure Mode Mechanism Failure Effect

1 B 11

1 C 1

1 C 2

1 C 3

1 D 1

1 E 1

1 E 2

1 E 3

2 A 1

3 A 1

3 A 2

4 A 1

5 A 1

6 A 1

7 A 1

8 A 1

03/01/2023 4 of 19
 Functions, Failures, Failure Modes, Failure Effects, Risks, Policy Decisions,
Caustic Soda Filling and Bagging System

Functional Analysis Failure and Failure Event Analysis

Failure
Function Functional Failure Failure Mode Mechanism Failure Effect

9 A 1

10 A 1

11 A 1

12 A 1

13 A 1

14 A 1

15 A 1

15 A 2

16 A 1

17 A 1

18 A 1

19 A 1

20 A 1

21 A 1

22 A 1

23 A 1

03/01/2023 5 of 19
 Functions, Failures, Failure Modes, Failure Effects, Risks, Policy Decisions,
Caustic Soda Filling and Bagging System

Functional Analysis Failure and Failure Event Analysis

Failure
Function Functional Failure Failure Mode Mechanism Failure Effect

24 A 1

25 A 1

26 A 1

27 A 1

28 A 1

29 A 1

03/01/2023 6 of 19
 Functions, Failures, Failure Modes, Failure Effects, Risks, Policy Decisions,
Caustic Soda Filling and Bagging System

Risk Analysis Policy Selection Residual Risk

1x Interval in
Analysis Risk CBM PM FT RTF Proposed Task Can be done Prob Severity
Change Years
Ref Type Prob Severity Risk by Risk

1 A 1 0 0

1 A 2 0 0

1 A 3 0 0

1 A 4 0 0

1 A 5 0 0

1 A 6 0 0

1 A 7 0 0

1 A 8 0 0

1 A 9 0 0

1 A 10 0 0

1 A 11 0 0

1 A 12 0 0

1 A 12 0 0

1 A 13 0 0

1 A 14 0 0

1 A 14 0 0

03/01/2023 7 of 19
 Functions, Failures, Failure Modes, Failure Effects, Risks, Policy Decisions,
Caustic Soda Filling and Bagging System

Risk Analysis Policy Selection Residual Risk

1x Interval in
Analysis Risk CBM PM FT RTF Proposed Task Can be done Prob Severity
Change Years
Ref Type Prob Severity Risk by Risk

1 A 15 0 0

1 A 16 0 0

1 A 17 0 0

1 A 18 0 0

1 A 19 0 0

1 A 20 0 0

1 A 21 0 0

1 A 22 0 0

1 A 23 0 0

1 A 24 0 0

1 A 25 0 0

1 A 26 0 0

1 A 27 0 0

1 A 28 0 0

1 A 29 0 0

1 A 30 0 0

03/01/2023 8 of 19
 Functions, Failures, Failure Modes, Failure Effects, Risks, Policy Decisions,
Caustic Soda Filling and Bagging System

Risk Analysis Policy Selection Residual Risk

1x Interval in
Analysis Risk CBM PM FT RTF Proposed Task Can be done Prob Severity
Change Years
Ref Type Prob Severity Risk by Risk

1 A 31 0 0

1 A 32 0 0

1 A 33 0 0

1 A 34 0 0

1 A 35 0 0

1 A 36 0 0

1 A 37 0 0

1 A 38 0 0

1 B 1 0 0

1 B 2 0 0

1 B 3 0 0

1 B 4 0 0

1 B 6 0 0

1 B 7 0 0

1 B 9 0 0

1 B 10 0 0

03/01/2023 9 of 19
 Functions, Failures, Failure Modes, Failure Effects, Risks, Policy Decisions,
Caustic Soda Filling and Bagging System

Risk Analysis Policy Selection Residual Risk

1x Interval in
Analysis Risk CBM PM FT RTF Proposed Task Can be done Prob Severity
Change Years
Ref Type Prob Severity Risk by Risk

1 B 11 0 0

1 C 1 0 0

1 C 2 0 0

1 C 3 0 0

1 D 1 0 0

1 E 1 0 0

1 E 2 0 0

1 E 3 0 0

2 A 1 0 0

3 A 1 0 0

3 A 2 0 0

4 A 1 0 0

5 A 1 0 0

6 A 1 0 0

7 A 1 0 0

8 A 1 0 0

03/01/2023 10 of 19
 Functions, Failures, Failure Modes, Failure Effects, Risks, Policy Decisions,
Caustic Soda Filling and Bagging System

Risk Analysis Policy Selection Residual Risk

1x Interval in
Analysis Risk CBM PM FT RTF Proposed Task Can be done Prob Severity
Change Years
Ref Type Prob Severity Risk by Risk

9 A 1 0 0

10 A 1 0 0

11 A 1 0 0

12 A 1 0 0

13 A 1 0 0

14 A 1 0 0

15 A 1 0 0

15 A 2 0 0

16 A 1 0 0

17 A 1 0 0

18 A 1 0 0

19 A 1 0 0

20 A 1 0 0

21 A 1 0 0

22 A 1 0 0

23 A 1 0 0

03/01/2023 11 of 19
 Functions, Failures, Failure Modes, Failure Effects, Risks, Policy Decisions,
Caustic Soda Filling and Bagging System

Risk Analysis Policy Selection Residual Risk

1x Interval in
Analysis Risk CBM PM FT RTF Proposed Task Can be done Prob Severity
Change Years
Ref Type Prob Severity Risk by Risk

24 A 1 0 0

25 A 1 0 0

26 A 1 0 0

27 A 1 0 0

28 A 1 0 0

29 A 1 0 0

03/01/2023 12 of 19
New Automatic Caustic Soda Flakes Bagging Machine
The caustic soda flakes exit from the flaker onto the flake collection conveyor. The conveyor discharges into the vibrating hopper. The vibrating hopper
discharges into a coarse and fine screw feeder which discharges into the weighing hopper which also incorporates a vibration function which discharges
into a formed bag.
The bags are formed from a flat roll of 200 microns polyethylene which in the first stage is rolled into a tube. The vertical seam and bottom horizontal
seams are created first. The bag is then filled with 25 kilograms of flakes. The bag is agitated to settle the caustic and the top is then sealed and cut. Two
seals are made, one becomes the bottom of the next back and the cut is made between the two seals. The full bag is ejected by means of a pneumatic
operated ejector and it falls onto a conveyor which takes it to palletizing.
Vibrating Hopper
The hopper is a square to conical shape constructed of welded 316 grade stainless steel construction. It is supported by steel structure which rests on
rubber pads bolted to the support beams. The bottom of the hopper is connected to the screw feeder by means of a flexible rubber bellows that encloses
it on all sides. The hopper is vibrated by means of a fixed speed vibrating 1.5 Kw 3phase 415volt 50 Hz motor which includes counterweights that can be
adjusted to change the vibrating amplitude. The vibrating motor is bolted directly to the hopper through a reinforced plate which is welded to the hopper.
The motor is controlled by the PLC. The vibrating motor can be start/stopped locally for maintenance purposes. The motor is protected against overload
by means of thermal overload relay.
 
Coarse Screw Feeder
The feeder is a screw of welded stainless steel construction and rotates in tube which incorporates an inspection door at the base of the inlet. The screw
is driven by means of a variable speed geared motor and a chain drive that includes a simplex roller chain and sprockets. The shaft is supported by two 4-
hole flanged sealed ball bearing units. The caustic soda is discharged through a pneumatic valve that is controlled by the PLC. The coarse screw feeder is
used to rapidly fill the bag up to 24.6kg where after the coarse feeder is stopped and the valve closed. The last 0.4 kg is filled by the fine feeder.
 
Fine Screw Feeder
The feeder is a screw of welded stainless steel construction and rotates in tube which incorporates an inspection door at the base of the inlet. The screw
is driven by means of a variable speed geared motor and a chain drive that includes a simplex roller chain and sprockets. The shaft is supported by two 4-
hole flanged sealed ball bearing units. The caustic soda is discharged through a pneumatic valve that is controlled by the PLC. The fine screw feeder is
operated together the coarse feeder. The fine feeder is stopped and the valve is closed when the weight in the bag filling hopper is 25 +- 0.05kg.
 
Weighing Hopper
The weighing is of stainless steel construction. It has a pneumatic operated valve in the bottom which opens and closes to fill a bag or become filled. The
hopper rests on 3 load cells together with the PLC control the weight that is filled into each bag. The hopper is vibrated by means of a fixed speed
vibrating 0.4 Kw 3phase 415volt 50 Hz motor which includes counterweights that can be adjusted to change the vibrating amplitude. The vibrating motor
is bolted directly to the hopper through a reinforced plate which is welded to the hopper. The motor is controlled by the PLC. The vibrating motor can be
start/stopped locally for maintenance purposes. The motor is protected against overload by means of thermal overload relay.
 
Bag Forming Chute
Polyethylene film is supplied on rolls with a hollow core. The rolls are loaded to the machine by inserting a stainless steel shaft through the core. The roll
is then placed on ball bearing rollers and the end of the film is fed through a series of rollers into the bag former. The polyethylene film is drawn off the
supply roller by pinch rollers over a series of rollers. The film is perforated with spiked rollers before the bags are formed. The film is drawn over the
forming tube by means of gear-motor driven feed rollers at the bag forming tube. A sensing roller indicates the need to add a new roll of film to the
machine. The end of the new roll is taped to the end of the finished roll to enable it to be drawn through the machine
 
Bag Sealer
The vertical seam of the bag is welded by means of Teflon covered heating elements as it is drawn over the forming tube. Two horizontal seams are
welded after the bag has been filled. One seam closes the top of the bag after filling and one seam closes the bottom of the next bag in preparation for
filling. The filled bag is cut off between the two seams and the bag.
Bag Agitator
The filled bag is briefly agitated by means of a pneumatic ram attached to the plate on which the filled bag rests prior to sealing.
supply roller by pinch rollers over a series of rollers. The film is perforated with spiked rollers before the bags are formed. The film is drawn over the
forming tube by means of gear-motor driven feed rollers at the bag forming tube. A sensing roller indicates the need to add a new roll of film to the
machine. The end of the new roll is taped to the end of the finished roll to enable it to be drawn through the machine
 
Bag Sealer
The vertical seam of the bag is welded by means of Teflon covered heating elements as it is drawn over the forming tube. Two horizontal seams are
welded after the bag has been filled. One seam closes the top of the bag after filling and one seam closes the bottom of the next bag in preparation for
filling. The filled bag is cut off between the two seams and the bag.
Bag Agitator
The filled bag is briefly agitated by means of a pneumatic ram attached to the plate on which the filled bag rests prior to sealing.
Ejector
The filled and sealed bag is discharged from the machine by means of an ejector plate to which a pneumatic ram is attached. The filled bags drop onto a
bag discharge conveyor which discharges the bags onto a roller table that feeds the pallatiser.
Dust Extraction and Scrubbing
Dust is extracted from the hoppers, screw feeders and bag filler by means of an extraction fan. The dust filled air extracted from the equipment
discharges into the scrubber which removes dust particles before the air is discharged outside the building. The scrubber consist is filled with packing
through which water is circulated by means of a centrifugal pump driven by means of an electric motor.
Air Supply
The system obtains air from the plant instrumentation air supply.
Air Conditioner
The equipment is enclosed and the air moisture content is controlled by means of air conditioning. The air temperature and moisture content is reduced
to less than ??%
 
 
 Risk Based Maintenance
Function and Failure Analysis
No Function
1 0

2 0
3 0
4 0
5 0
6 0
7 0
8 0
9 0
10 0
11 0
12 0
13 0
14 0
15 0
16 0
17 0
18 0
19 0
20 0
21 0
22 0
23 0
24 0
25 0
26 0
27 0
28 0
29 0
30 0
29 0

03/01/2023 15 of 19
 Functional Analysis
Function Functional Failure Failure Event Mechanism Failure Effect
 Functional Analysis

Function Functional Failure Failure Event Mechanism Failure Effect

 Functional Analysis

Function Functional Failure Failure Event Mechanism Failure Effect

Functional Analysis