Plant Utilities and Maintenance Case Studies

UNIVERSITI KUALA LUMPUR

MALAYSIAN INSTITUTE OF CHEMICAL & BIOENGINEERING TECHNOLOGY

CASE STUDY COVER PAGE

Title of Case Study.

Assignment:
Name & ID
No: 1. Khairul Amin Bin Ahmad Shukri (55213218051)
(Individual)

Date of
Submission: Week 11 of Jan 2022 semester

*Penalty:
For any late submission, the mark will be reduced by 5% per day to a maximum of 3 days, after which it will NOT BE ACCEPTED.
Plagiarism will not be tolerated and will be given ZERO.

TOTAL MARK:
120 20% (CW mark)

Rubric Scheme
Poor Marginal Acceptable Good Outstanding
Criteria Wt. (1-4) (5-8) (9-12) (13-16) (17-20) Marks

Format, Language and

1
Organization
Case 1 1

Case 2 1

Case 3 1

Case 4 1

Case 5 1

TOTAL SCORE/120:
The following indicates the Cases Study for Failures and Accidents in Chemical Plant taken from Plant and
Machinery Failure Prevention by A.A. Hattangadi.

CPB 20403 Dr ASA

Plant Utilities and Maintenance Case Studies

CASE STUDY PUM CPB 20403

CASE STUDY 1
WHAT WENT WRONG?

POSSIBLE CAUSES
The hardened Material that obstructed the 3-inch Vent is the most likely reason for this case study. There
will be an explosion due to the difference compaction at vents 3-inch and 6-inch. Safety dictates that
equipment replacement be kept up to date to avoid accidents

WHAT TO DO TO ENSURE IT WON’T HAPPEN AGAIN?

1. Engineers must obtain safety officer approval before changing any equipment, including the vent
valve. Observe the original plant layout specifications.

2. According to the safety schedule, maintenance is required to ensure that every piece of equipment
is in excellent working order.

3. Should constantly be maintained to make sure it is in good shape and replaced if severe damage is
possible.

4. Make sure a second employee alerts the assembly point area if there is an explosion during the
procedure.

5. Ensure that everyone else on the team is safe and wearing PPE (Personal Protective Equipment).

CPB 20403 Dr ASA

Plant Utilities and Maintenance Case Studies

CASE STUDY 2
WHAT WENT WRONG?

POSSIBLE CAUSES
The operational personnel making a serious error during maintenance as a result of being perplexed by the
output of the Control panel light is the most likely explanation for this case study. With the extremely
harmful radioactive element having the ability to cause a great deal of concern, it creates a risky job
environment for the employee.

MOST POSSIBLE CAUSE

-The internal mechanical defect in the cooling circuit which causes the confusion leads to the malfunctions
to release radioactive materials to the enviroment

HOW CAN THIS GO WRONG?

- The mechanical defect in the cooling circuit causes all this to happen

WHAT TO DO TO ENSURE IT WON’T HAPPEN AGAIN?

1. Remove the old valve and install the new one. Avoiding uncontrolled pressure, which can be harmful, is
crucial.

2. Verify the equipment on the control panel to make sure it is in the right place and functioning properly.

3. Turn the control switch manually. If the lights don't turn on in the proper order, the switch is probably
broken and needs to be replaced.

4. Strong procedures must be in place to ensure that these individuals are competent and that they are
organised in their introduction to their specific professions, hence lowering the possibility of a human error
brought on by ignorance of the dangers.

5. Make sure the space is free of obstructions. The worker and everyone around should leave the area since
it is radioactive.

CPB 20403 Dr ASA

Plant Utilities and Maintenance Case Studies

CASE STUDY 3
WHAT WENT WRONG?

POSSIBLE CAUSES
The explosion in the manufacturing plant was most likely caused by the electrical switchgear in its control
panel not being flameproof, which was intended to protect the electrical appliances by cutting off the
overload and supplying the regular current.

MOST POSSIBLE CAUSE

- Because the control panel isn’t flameproof

WHAT TO DO TO ENSURE IT WON’T HAPPEN AGAIN?

1. Protective relays were included in the switchgear apparatus to identify faults and provide data to the
circuit breaker in the event of circuit corruption. By cutting off the overload and supplying the regular
current, create a flameproof switchgear to safeguard the electrical appliances.

2. Before starting the system, check all the equipment to make sure there are no leaks.

3. Nitrogen blanketing for greater product quality, process safety, and equipment longevity.

4. For all the machinery and equipment in your company, adhere to the recommended maintenance
methods from the manufacturer.

5. Make sure the area is free of any dust, liquids, or fumes that could catch fire. Make sure the employee is
wearing full personal protection.

CPB 20403 Dr ASA

Plant Utilities and Maintenance Case Studies

CASE STUDY 4
WHAT WENT WRONG?

POSSIBLE CAUSES
The foreman in charge's lack of experience is the most likely culprit in this case study. The high-risk
surroundings of the oil and gas industry may make for a hard workplace for new employees, with small
errors having the ability to compound into major, fatal consequences.

WHAT TO DO TO ENSURE IT WON’T HAPPEN AGAIN?

1. Make sure the person in charge is aware of their surroundings during the makeover.

2. Strong procedures must be in place to ensure that these individuals are competent and that they are
organized in their introduction to their various professions, hence lowering the possibility of human error
brought on by ignorance of the dangers.

3. Before beginning the system, test each piece of equipment to ensure there are no leaks.

4. Before utilizing or operating the distillation plant, inspect all of the equipment.

5. Maintenance in sealing the leaks while adhering to risk and safety evaluations

CPB 20403 Dr ASA

Plant Utilities and Maintenance Case Studies

CASE STUDY 5
WHAT WENT WRONG?

POSSIBLE CAUSES
The pressure inside the ladles builds up and explodes, which is the most likely explanation for this case
study's events. When gases are exposed to a heat source, such as a fire, sparks, or even static electricity, or
when the pressure of the gas rises because of the heat source, explosions frequently happen. Explosions
could happen. A reaction's cause could also be a chemical reaction.

WHAT TO DO TO ENSURE IT WON’T HAPPEN AGAIN?

1. While the process is going, verify that the equipment handling instructions have been followed.

2. To see if there have been any modifications inside the apparatus, test the pressure valves.

3. Before operating the ventilation equipment, check to make sure it is in good working order.

4. Verify that the ventilation system is in flawless operating order. Watch the air quality when handling
explosive items in confined spaces.

5. When handling melting metal, make sure the employees are wearing PPE.

CPB 20403 Dr ASA