CPB 20004- Plant Utilities and Maintenances

Assignment 1(updated): Group ALKANDROS Page |0

UNIVERSITI KUALA LUMPUR INSTITUTE OF CHEMICAL AND

BIOENGINEERING TECHNOLOGY

Subject Code and Name : CPB 20004- Plant Utilities And Maintenances

Lecturer : Sir Syahidi Fadzli bin Alfan

Task Title : Assignment 1 (updated)

Semester : 4 (Jan 2016)

Section : L01-T02

Date Submitted : 12 April 2016

Group Name : Alkandros

No. Student Name ID Number

1 Muhammad Naquib bin Muzamir 55213114300

2 Muhammad Fauzan bin Ariffin 55213114023

3 Muhammad Khalish bin Mohammad Ilias 55213114324

4 Muhammad Amir bin Mat Aris 55213114396

5 Muhammad Anas bin Mohamad Azmi 55213114385

6 Siti Hajar Mohamed 55213114225

7 Nabilah binti Nordin 55213114016

CPB 20004- Plant Utilities and Maintenances
Assignment 1(updated): Group ALKANDROS Page |1

ASSIGNMENT 1

Section 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.

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

Vessel fractured, the lid fell down and injured the worker.

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

i. The 10 year old vessel had been subjected to some repairs on the hinge welds.

ii. The quality of welding was poor.

iii. The maintenance job was done poorly.

iv. The vessel should be checked monthly to avoid undesired events like this to
happen.

v. The residues sticking to the side were manually shoved out.

vi. Safety officers of the company does not undergo HIRARC on this machine.

vii. The mixing vessel is not repair by engineers.

CPB 20004- Plant Utilities and Maintenances
Assignment 1(updated): Group ALKANDROS Page |2

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

The weld on the hinge between the lid and the vessel fractured.

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

i. The inspection should be done often in order to maintain the performance and
manage to keep its condition at the best.

ii. The company should hire an experts welder in order to provided more quality
work so that there are no injury for the worker.

iii. The company should place the signboard in the area which in danger condition
and the job of repairing is on going so the other workers will know the condition
of the machine and the environment of the place.

iv. The company should sent their worker to welding courses in order to provide
them with special skill of welding and able to perform a quality welding and also
the company can reduce cost from hiring outside expert welder.

v. Safety and health officer must undergo HIRARCH to all section of the plant, so
damages of equipment can be detected and the maintenance worker can repair
the problem equipment.
CPB 20004- Plant Utilities and Maintenances
Assignment 1(updated): Group ALKANDROS Page |3

Section B. Chemical Plant Failures Due To Chemical Reactions

(Total Marks= 20)

CASE # 1 :

In an Ethylene Plant, a ID pipe carrying fluids at very high pressures was provided with
joints of a very special and precise design. These called for special skills and the Staff had to be
given special training. As a result of Staff re-shuffles included in Cost Reduction Schemes, the
work got re-assigned to Staff without adequate training and experience. One badly fitted joint
developed heavy leaks, leaked Inflammable Gases and these eventually ignited causing an
explosion, 4 Workers were killed and several more injured. There were no devices for detecting
Inflammable Gases that they may have leaked although the Plant was dealing with Highly
Inflammable Gases.

1. Try to understand each Case Study by answering the question What Went Wrong?
i. One badly fitted joint developed heavy leaks.
ii. Leakage of inflammable gases until eventually ignited cause explosion.
iii. Staff re-shuffles to the worker without adequate and experience.

2. Try to find the most possible cause, by asking the question How This Can Go Wrong?
i. One badly fitted joint that developed heavy leaks.
ii. There also no devices for detecting leaked inflammable gases in the plant even
though this plant is dealing with highly inflammable gases.
iii. The work also been re-assigned to staff without adequate training and experience.
iv. The cost reduction scheme is not prepared really well.
v. Leaked inflammable gases and causing an explosion.

3. Try to find out ONE MAIN CAUSE, by asking the question What is the Trigger of
Accident?
CPB 20004- Plant Utilities and Maintenances
Assignment 1(updated): Group ALKANDROS Page |4

Staff re-shuffles which make the work got re-assigned to staff without adequate and
experience.

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

i. The inspection should be done to maintain the performance and manage to keep
its condition at the best.
ii. The company should assign staff with the qualified skills and experience to do
the work and sent staff to training, the staff can be specialize in that work and
insured the safety of the work.
iii. The company should equip the plant with devices to detect leaked gases so it can
give early warning if there are leaks in the plant and the contagious plan can be
take place to avoid the incident from occurs.
iv. Company should sent their staff to cost reduction courses so that they can prepare
very well cost reduction scheme without effecting the production and the plant.
v. The engineer should apply scheduled preventive maintenance (TBM) on the
joints of a very special and precise design that is used in this plant so that
catastrophic failures of the plant can be avoid and the production can be
unaffected.

Table of Content

No. Content Page Number

1 Section A: Case #1 1
CPB 20004- Plant Utilities and Maintenances
Assignment 1(updated): Group ALKANDROS Page |5

2 Section B: Case #1 3