Assignment 1.

The following indicates the Cases Study for Failures And Accidents In Chemical Plant taken from Plant
And Machinery Failure Prevention By A.A. Hattangadi. Choose ONE ( 1 ) from EACH section only.

A. Chemical Plant Failures Due To Mechanical / Electrical Failures. ( Total Marks = 20 )

Case # 1.

A Mixing Vessel of 1 Cubic Metre capacity was fitted with a hinged and counter-weighted lid. The Vessel
was swiveled on trunnions for unloading. Residues sticking to the sides were manually shoveled out.
One day, the weld on the hinge between the Lid and the Vessel fractured, the Lid fell down and injured
the Worker. Investigation showed that the 10 year old Vessel had been subjected to some repairs on the
Hinge Welds and the quality of Welding was poor.

Case # 2.

A Reactor Vessel, which was one of a number of similar vessel connected in series, developed a crack
and was taken out for repairs. In order to keep the plant in operation, a Temporary Pipe was
manufactured locally and fitted to replace the Reactor Vessel. Due to deficiencies in the design of the
pipe and the flexible bellows, it broke under the effect of the high pressure of the gas within. The Highly
Inflammable Gas ( Cyclohexane ) poured out and produced a Vapour Cloud. It ignited when it reached an
Operating Furnace in the plant and 28 Workers were killed. A Major Part of the plant was destroyed.

Case # 3.

A pilot operated Relief Valve in the Cooling Circuit got stuck in the Open Position due to an Internal
Mechanical Defect. The Indicator Light on the Control Panel was operated by the Voltage at the Solenoid
of the Relief Valve and not by the actual position of the valve. Thus, the Control Panel Light indicated the
valve to be closed, whereas it was actually open. This caused confusion amongst the Operating Staff in
the Control Room and the steps they took to deal with a Minor Problem were incorrect. This led to a
number of malfunctions and eventually it led to the release of Radioactive Material into the
Atmosphere. This is the notorious Three Mile Island incident which did not result in any casualties but
caused a great deal of consternation amongst the Public.

B. Chemical Plant Failures Due To Chemical Reactions. ( Total Marks = 20 )

Case # 1.

A Pump handling an Inflammable Liquid was to be replaced. The fixing Bolts/Nuts had seized due to
rusting. It was decided by the Maintenance Staff to cut the Bolts using an Oxyacetylene Cutting Torch
after the Inflammable Liquids were drained out. The drain, which contained some Residues of the
Inflammable Liquid due to Level Defects, was merely covered by a Polyethylene Sheet ( instead of a
Steel Sheet ). The Hot Metal thrown out during the cutting operation burnt through the Polyethylene
Sheet and ignited the Inflammable Liquid Residues in the Drain. The fire was extinguished and there
were no casualties in this incident but it was a narrow escape from a Major Fire.

Case # 2.

An Organic Solvent, which was inflammable, was being manufactured in a plant. As the Electrical
Switchgear in its Control Panel was not Flameproof, its Cubicle was pressurized with Nitrogen which was
available in the plant. The idea was to prevent entry of Inflammable Vapours from entering the Cubicle.
There was no problem until one day the Nitrogen Pressure became too low due to Leakage and
Inflammable Vapour did accumulate in the Cubicle. An explosion occurred when the Switch was
operated. One Operator was injured. The Maintenance Staff had isolated a Low-Pressure Alarm Switch
provided by the original Designer of the system because it was operating frequently and this was
affecting production.

Case # 3.

A Crude Oil Distillation Plant had a Reflux Drum which often got filled with Water that remained below
the Oil. This was usually pumped out through a Drain at the bottom of the Vessel and sent to a Scrubber
Unit. During a Major Overhaul Schedule, when the plant was about to be re-started, it was discovered
that a Slip-Plate which had been inserted above the Drain Valve for isolating the Drum during overhaul
had been left in place inadvertently. The Foreman in charge thought he could remove the Slip-Plate and
re-tighten the Flange Bolts in less time than it took for the large quantity of Accumulated Water to leak
out while this was being done. He might have succeeded in doing so but the Gasket tore during the work
and a new one had to be brought from the Store and fitted in its place. Not only all the Water but also a
great deal of Oil sprayed out. Some of it reached the Oil Burners of a nearby Boiler and ignited. A Major
Fire ensued. Efforts to close the Burners failed because the Maintenance Staff had isolated the Remote
Control Devices provided for just such emergencies.

Tasks:

First and foremost, you need to take the position of being a Maintenance/Service Personnel. Treat this
exercise as training or exposure towards your job for the future. Here are the guides which might help
you in handling this assignment:

1.) Try to understand each Case Study by answering the question What Went Wrong?

2.) Try to find the possible causes, by asking the question How This Can Go Wrong?

3.) Try to find out ONE MAIN CAUSE, by asking the question What is the Trigger of Accident?

4.) Finally, in order to give suggestion of possible solution, ask the question What Can You Do To Ensure
This Does Not Happen Again?