Risk Assessment: FAULT TREE

Project Name: Cocoa Butter Alternatives Plant Design

Process: Dry Fractionating Process
Section: H 202 A-B; Oil Pre-heater
User:
SelectFailure
components
Rate µfrom Failure probability P
Item Component Reliability R = e-µt
drop down list
(faults/yr) = 1-R
1 Flow measurement (fluids) 1.14 0.320 0.680
2 Flow switch 1.12 0.326 0.674
3 Controller 0.29 0.748 0.252
4 Indicator lamp 0.044 0.957 0.043
5 Indicator lamp 0.044 0.957 0.043
6 Control valve 0.6 0.549 0.451
7Thermocouple temperature measurement 0.52 0.595 0.405
8
9
10

Formula for calculating the computations for various types of

component linkages, please refer to
Component Linkgages

Fault Tree for CP 205 of unit 200, please refer to

FAULT TREE FOR H 204
Mean Time Between Failures
MTBF = 1/µ
0.877
0.893
3.448
22.727
22.727
1.667
1.923
Risk Assessment: FAULT TREE

Project Name: Cocoa Butter Alternatives Plant Design

Process: Dry Fractionating Process
Section: CRZ 202 A,B; Crystallizer
User:
Select components
Failure Rate µ fromReliability R = e-µt Failure probability P
Item Component
drop down list
(faults/yr) = 1-R
1 Indicator lamp 0.044 0.957 0.043
2 Controller 0.29 0.748 0.252
3 Pressure measurement 1.41 0.244 0.756
4 Flow measurement (fluids) 1.14 0.320 0.680
5 Flow switch 1.12 0.326 0.674
6 Controller 0.29 0.748 0.252
7 Indicator lamp 0.044 0.957 0.043
8 Indicator lamp 0.044 0.957 0.043
9 Controller 0.29 0.748 0.252
10Thermocouple temperature measurement 0.52 0.595 0.405
11 Indicator lamp 0.044 0.957 0.043
12 Level measurement (liquids) 1.7 0.183 0.817
13 Controller 0.29 0.748 0.252
14 Control valve 0.6 0.549 0.451

Formula for calculating the computations for various types of

component linkages, please refer to
Component Linkgages

Fault Tree for CRZ 202 of unit 200, please refer to

Fault Tree--CRZ 204
Mean Time Between Failures
MTBF = 1/µ
22.727
3.448
0.709
0.877
0.893
3.448
22.727
22.727
3.448
1.923
22.727
0.588
3.448
1.667
Risk Assessment: FAULT TREE

Project Name: Cocoa Butter Alternatives Plant Design

Process: Dry Fractionating Process
Section: MFP 207 A,B ; Membrane Filter Press
User:
Select components
Failure Rate µ fromReliability R = e-µt Failure probability P
Item Component
drop down list
(faults/yr) = 1-R
1 Indicator lamp 0.044 0.957 0.043
2 Controller 0.29 0.748 0.252
3 Pressure measurement 1.41 0.244 0.756
4 Flow measurement (fluids) 1.14 0.320 0.680
5 Flow switch 1.12 0.326 0.674
6 Controller 0.29 0.748 0.252
7 Indicator lamp 0.044 0.957 0.043
8
9
10

Formula for calculating the computations for various types of

component linkages, please refer to
Component Linkgages

Fault Tree for M305 of unit 300, please refer to

FAULT TREE FOR MFP 207 A-B
Mean Time Between Failures
MTBF = 1/µ
22.727
3.448
0.709
0.877
0.893
3.448
22.727
Risk Assessment: FAULT TREE

Project Name: Cocoa Butter Alternatives Plant Design

Process: Hydrogenation Process User:
Select
Section: M304 A-B; Mixer drop d
Failure Rate µ Failure probability P Mean Time Between Failures
Item Component Reliability R = e-µt
(faults/yr) = 1-R MTBF = 1/µ
1 Indicator lamp 0.044 0.957 0.043 22.727
2 Controller 0.29 0.748 0.252 3.448
3 Level measurement (liquids) 1.7 0.183 0.817 0.588
4 Flow measurement (fluids) 1.14 0.320 0.680 0.877
5 Flow switch 1.12 0.326 0.674 0.893
6 Controller 0.29 0.748 0.252 3.448
7 Indicator lamp 0.044 0.957 0.043 22.727
8
9
10

Formula for calculating the computations for various types of

component linkages, please refer to
Component Linkgages

Fault Tree for M305 of unit 300, please refer to

FAULT TREE FOR M304 A-B
User:
Select components from
drop down list
Risk Assessment: FAULT TREE

Project Name: Cocoa Butter Alternatives Plant Design

Process: Hydrogenation Process User:
Section: R 306; Hydrogenation Reactor Select co
drop dow
Failure Rate µ Failure probability P Mean Time Between Failures
Item Component Reliability R = e-µt
(faults/yr) = 1-R MTBF = 1/µ
1 Pressure switch 0.14 0.869 0.131 7.143
2 Controller 0.29 0.748 0.252 3.448
3 Pressure measurement 1.41 0.244 0.756 0.709
4 Flow measurement (fluids) 1.14 0.320 0.680 0.877
5 Flow switch 1.12 0.326 0.674 0.893
6 Controller 0.29 0.748 0.252 3.448
7 Indicator lamp 0.044 0.957 0.043 22.727
8 Indicator lamp 0.044 0.957 0.043 22.727
9 Control valve 0.6 0.549 0.451 1.667
10 Thermocouple temperature measurement 0.52 0.595 0.405 1.923

Formula for calculating the computations for various types of

component linkages, please refer to
Component Linkgages

Fault Tree for R306 of unit 300, please refer to

FAULT TREE FOR R303 A-B
User:
Select components from
drop down list
 Failure of Heat
Exchanger

P = 0.174
R = 0.826
µ = 0.191
MTBF = 5.236

Failure
Indicator

Failure of
Temperature Indicator Failure of Flow Meter
Controller

P = 0.687 P = 0.896
R = 0.313 R = 0.104
µ = 1.164 µ = 2.26
MTBF = 2.994 MTBF = 0.44

Thermocouple
Flow
Indicator Control Valve Temperature Flow Switch
Measurement
Lamp Failure Failure Measurement Failure
Failure
Failure

P = 0.043 P = 0.451 P = 0.405 P = 0.68 P = 0.674

R = 0.957 R = 0.549 R = 0.595 R = 0.32 R = 0.326
µ = 0.044 µ = 0.6 µ = 0.52 µ = 1.14 µ = 1.12
MTBF = 22.727 MTBF = 1.667 MTBF = 1.923 MTBF = 0.877 MTBF = 0.893

1 2 3 4 5
R = 0.957 R = 0.549 R = 0.595 R = 0.32 R = 0.326
µ = 0.044 µ = 0.6 µ = 0.52 µ = 1.14 µ = 1.12
MTBF = 22.727 MTBF = 1.667 MTBF = 1.923 MTBF = 0.877 MTBF = 0.893

1 2 3 4 5
0.174
0.826
191
F = 5.236

Failure of Flow
Indicator Controller

P = 0.254
R = 0.746
µ = 0.293
MTBF = 3.413

Failure of Flow
ure of Flow Meter
Indicator

P = 0.896 P = 0.284
R = 0.104 R = 0.716
µ = 2.26 µ = 0.334
MTBF = 0.442 MTBF = 2.994

Flow Switch Controller Indicator

nt
Failure Failure Lamp Failure

P = 0.674 P = 0.252 P = 0.043

R = 0.326 R = 0.748 R = 0.957
µ = 1.12 µ = 0.29 µ = 0.044
77 MTBF = 0.893 MTBF = 3.448 MTBF = 22.727

5 6 7
 R = 0.326 R = 0.748 R = 0.957
µ = 1.12 µ = 0.29 µ = 0.044
77 MTBF = 0.893 MTBF = 3.448 MTBF = 22.727

5 6 7
 Failure of
Failure of Flow
Temperature Indicator
Indicator Controller
Controller

P = 0.254
R = 0.746
µ = 0.293
MTBF = 3.413

P = 0.574
Failure of Flow
Failure of Flow Meter
R = 0.426 Indicator
µ = 0.854
MTBF = 1.171

P = 0.896 P
R = 0.104 R
µ = 2.26 µ
MTBF = 0.442 M

Thermocouple
Flow
Indicator Controller Temperature Flow Switch Controller Indica
Measurement
Lamp Failure Failure Measurement Failure Failure Lamp Fa
Failure
Failure

P = 0.043 P = 0.252 P = 0.405 P = 0.68 P = 0.674 P = 0.252 P = 0.043

R = 0.957 R = 0.748 R = 0.595 R = 0.32 R = 0.326 R = 0.748 R = 0.957
µ = 0.044 µ = 0.29 µ = 0.52 µ = 1.14 µ = 1.12 µ = 0.29 µ = 0.044
MTBF = 22.727 MTBF = 3.448 MTBF = 1.923 MTBF = 0.877 MTBF = 0.893 MTBF = 3.448 MTBF = 22

1 2 3 4 5 6 7
 Indicator Controller Temperature Flow Switch Controller Indica
Measurement
Lamp Failure Failure Measurement Failure Failure Lamp Fa
Failure
Failure

P = 0.043 P = 0.252 P = 0.405 P = 0.68 P = 0.674 P = 0.252 P = 0.043

R = 0.957 R = 0.748 R = 0.595 R = 0.32 R = 0.326 R = 0.748 R = 0.957
µ = 0.044 µ = 0.29 µ = 0.52 µ = 1.14 µ = 1.12 µ = 0.29 µ = 0.044
MTBF = 22.727 MTBF = 3.448 MTBF = 1.923 MTBF = 0.877 MTBF = 0.893 MTBF = 3.448 MTBF = 22

1 2 3 4 5 6 7
 Failure of Crystallizer

P = 0.031
R = 0.969
µ = 0.031
MTBF = 31.755

e of Flow Failure of Pressure Failure

or Controller Indicator Controller Indicator C

P = 0.254
R = 0.746
µ = 0.293
MTBF = 3.413

Failure of Flow P = 0.825 Failure of Level

Indicator R = 0.175
I-6 Indicator
µ = 1.744
MTBF = 0.573

P = 0.284 P = 0.284
R = 0.716 R = 0.716
µ = 0.334 µ = 0.334
442 MTBF = 2.994 MTBF = 2.

Pressure
Controller Indicator Controller Indicator Indicator Controller
Measurement
Failure Lamp Failure Failure Lamp Failure Lamp Failure Failure
Failure

P = 0.252 P = 0.043 P = 0.252 P = 0.043 P = 0.756 P = 0.043 P = 0.252

R = 0.748 R = 0.957 R = 0.748 R = 0.957 R = 0.244 R = 0.957 R = 0.748
µ = 0.29 µ = 0.044 µ = 0.29 µ = 0.044 µ = 1.41 µ = 0.044 µ = 0.29
MTBF = 3.448 MTBF = 22.727 MTBF = 3.448 MTBF = 22.727 MTBF = 0.709 MTBF = 22.727 MTBF = 3.448

6 7 8 9 10 11 12
 Controller Indicator Controller Indicator Indicator Controller
Measurement
Failure Lamp Failure Failure Lamp Failure Lamp Failure Failure
Failure

P = 0.252 P = 0.043 P = 0.252 P = 0.043 P = 0.756 P = 0.043 P = 0.252

R = 0.748 R = 0.957 R = 0.748 R = 0.957 R = 0.244 R = 0.957 R = 0.748
µ = 0.29 µ = 0.044 µ = 0.29 µ = 0.044 µ = 1.41 µ = 0.044 µ = 0.29
MTBF = 3.448 MTBF = 22.727 MTBF = 3.448 MTBF = 22.727 MTBF = 0.709 MTBF = 22.727 MTBF = 3.448

6 7 8 9 10 11 12
 Failure of Level
Indicator Controller

P = 0.256
R = 0.744
µ = 0.296
MTBF = 3.378

Failure of Level
Failure of Level Meter
Indicator

P = 0.284
P = 0.900
R = 0.716
R = 0.100
µ = 0.334
µ = 2.3
MTBF = 2.994
MTBF = 0.435

Level
ndicator Controller Control Valve Measurement
mp Failure Failure Failure (Liquids)
Failure

.043 P = 0.252 P = 0.451 P = 0.817

.957 R = 0.748 R = 0.549 R = 0.183
044 µ = 0.29 µ = 0.6 µ = 1.7
F = 22.727 MTBF = 3.448 MTBF = 1.667 MTBF = 0.588

11 12 13 14
ndicator Controller Control Valve Measurement
mp Failure Failure Failure (Liquids)
Failure

.043 P = 0.252 P = 0.451 P = 0.817

.957 R = 0.748 R = 0.549 R = 0.183
044 µ = 0.29 µ = 0.6 µ = 1.7
F = 22.727 MTBF = 3.448 MTBF = 1.667 MTBF = 0.588

11 12 13 14
 Failure of Filter

P = 0.221
R = 0.779
µ = 0.250
MTBF = 4.004

Failure
Indicator

Failure of Level
Failure of Flow Meter
Indicator Controller

P = 0.869 P = 0.896
R = 0.131 R = 0.104
µ = 2.033 µ = 2.26
MTBF = 0.492 MTBF = 0.44

Level Flow
Indicator Controller Flow Switch
Measurement Measurement
Lamp Failure Failure Failure
Failure Failure

P = 0.043 P = 0.252 P = 0.817 P = 0.68 P = 0.674

R = 0.957 R = 0.748 R = 0.183 R = 0.32 R = 0.326
µ = 0.044 µ = 0.29 µ = 1.70 µ = 1.14 µ = 1.12
MTBF = 22.727 MTBF = 3.448 MTBF = 0.588 MTBF = 0.877 MTBF = 0.893
1 2 3 4 5
R = 0.957 R = 0.748 R = 0.183 R = 0.32 R = 0.326
µ = 0.044 µ = 0.29 µ = 1.70 µ = 1.14 µ = 1.12
MTBF = 22.727 MTBF = 3.448 MTBF = 0.588 MTBF = 0.877 MTBF = 0.893
1 2 3 4 5
0.221
0.779
250
F = 4.004

Failure of Flow
Indicator Controller

P = 0.254
R = 0.746
µ = 0.293
MTBF = 3.413

Failure of Flow
ure of Flow Meter
Indicator

P = 0.896 P = 0.284
R = 0.104 R = 0.716
µ = 2.26 µ = 0.334
MTBF = 0.442 MTBF = 2.994

Flow Switch Controller Indicator

nt
Failure Failure Lamp Failure

P = 0.674 P = 0.252 P = 0.043

R = 0.326 R = 0.748 R = 0.957
µ = 1.12 µ = 0.29 µ = 0.044
77 MTBF = 0.893 MTBF = 3.448 MTBF = 22.727
5 6 7
 R = 0.326 R = 0.748 R = 0.957
µ = 1.12 µ = 0.29 µ = 0.044
77 MTBF = 0.893 MTBF = 3.448 MTBF = 22.727
5 6 7
 Failure of Mixer

P = 0.221
R = 0.221
µ = 1.509
MTBF = 0.663

Failure
Indicato

Failure of Level
Failure of Flow Meter
Indicator Controller

P = 0.869 P = 0.896
R = 0.131 R = 0.104
µ = 0.504 µ = 2.26
MTBF = 1.984 MTBF = 0.44

Level Flow
Indicator Controller Flow Switch
Measurement Measurement
Lamp Failure SV4 Failure Failure
Failure Failure

P = 0.043 P = 0.252 P = 0.817 P = 0.68 P = 0.674

R = 0.957 R = 0.748 R = 0.183 R = 0.32 R = 0.326
µ = 0.044 µ = 0.29 µ = 0.17 µ = 1.14 µ = 1.12
MTBF = 22.727 MTBF = 3.448 MTBF = 0.588 MTBF = 0.877 MTBF = 0.893

1 2 3 4 5
R = 0.957 R = 0.748 R = 0.183 R = 0.32 R = 0.326
µ = 0.044 µ = 0.29 µ = 0.17 µ = 1.14 µ = 1.12
MTBF = 22.727 MTBF = 3.448 MTBF = 0.588 MTBF = 0.877 MTBF = 0.893

1 2 3 4 5
0.221
0.221
509
F = 0.663

Failure of Flow
Indicator Controller

P = 0.254
R = 0.746
µ = 0.293
MTBF = 3.413

Failure of Flow
ure of Flow Meter
Indicator

P = 0.896 P = 0.284
R = 0.104 R = 0.716
µ = 2.26 µ = 0.334
MTBF = 0.442 MTBF = 2.994

Flow Switch Controller Indicator

nt
Failure GV13 Failure Lamp Failure

P = 0.674 P = 0.252 P = 0.043

R = 0.326 R = 0.748 R = 0.957
µ = 1.12 µ = 0.29 µ = 0.044
77 MTBF = 0.893 MTBF = 3.448 MTBF = 22.727

5 6 7
 R = 0.326 R = 0.748 R = 0.957
µ = 1.12 µ = 0.29 µ = 0.044
77 MTBF = 0.893 MTBF = 3.448 MTBF = 22.727

5 6 7
 Failure

Failure
Indicator

Failure of Pressure
Failure of Flow Meter
Indicator Controller

P = 0.841 P = 0.896
R = 0.159 R = 0.104
µ = 1.84 µ = 2.26
MTBF = 0.543 MTBF = 0.4

Pressurel Flow
Pressure Controller Flow Switch
Measurement Measurement
Switch Failure Failure Failure
Failure Failure

P = 0.131 P = 0.252 P = 0.756 P = 0.68 P = 0.674

R = 0.869 R = 0.748 R = 0.244 R = 0.32 R = 0.326
µ = 0.14 µ = 0.29 µ = 1.41 µ = 1.14 µ = 1.12
MTBF = 7.143 MTBF = 3.448 MTBF = 0.709 MTBF = 0.877 MTBF = 0.893

1 2 3 4 5
R = 0.869 R = 0.748 R = 0.244 R = 0.32 R = 0.326
µ = 0.14 µ = 0.29 µ = 1.41 µ = 1.14 µ = 1.12
MTBF = 7.143 MTBF = 3.448 MTBF = 0.709 MTBF = 0.877 MTBF = 0.893

1 2 3 4 5
 Failure of Reactor

P = 0.147
R = 0.853
µ = 0.159
MTBF = 6.289

Failure of Flow
Indicator Controller

P = 0.254
R = 0.746
µ = 0.293
MTBF = 3.413

Failure of
Failure of Flow Temperature Indicator
ure of Flow Meter
Indicator Controller

P = 0.896 P = 0.284 P = 0.
R = 0.104 R = 0.716 R=0
µ = 2.26 µ = 0.334 µ = 1.1
MTBF = 0.442 MTBF = 2.994 MTBF

Flow Switch Controller Indicator Indicator Control valve

nt
Failure Failure Lamp Failure Lamp Failure GV14 Failure

P = 0.674 P = 0.252 P = 0.043 P = 0.043 P = 0.451

R = 0.326 R = 0.748 R = 0.957 R = 0.957 R = 0.549
µ = 1.12 µ = 0.29 µ = 0.044 µ = 0.044 µ = 0.6
77 MTBF = 0.893 MTBF = 3.448 MTBF = 22.727 MTBF = 22.727 MTBF = 1.667

5 6 7 8 9
 P = 0.043 P = 0.451
R = 0.326 R = 0.748 R = 0.957 R = 0.957 R = 0.549
µ = 1.12 µ = 0.29 µ = 0.044 µ = 0.044 µ = 0.6
77 MTBF = 0.893 MTBF = 3.448 MTBF = 22.727 MTBF = 22.727 MTBF = 1.667

5 6 7 8 9
 Failure of
Temperature Indicator
Controller

P = 0.687
R = 0.313
µ = 1.164
MTBF = 2.994

Thermocouple
Control valve Temperature
GV14 Failure measurement
Failure

P = 0.451 P = 0.405
R = 0.549 R = 0.595
µ = 0.6 µ = 0.52
7 MTBF = 1.667 MTBF = 1.923
9 10
 P = 0.451 P = 0.405
R = 0.549 R = 0.595
µ = 0.6 µ = 0.52
7 MTBF = 1.667 MTBF = 1.923
9 10
Table 1: Failure Rate Data for Various Selected Process Components (Crowl & Louvar, 2001)

Instrument Faults/year (µ)

Controller 0.29
Control valve 0.60
Flow measurement (fluids) 1.14
Flow measurement (solids) 3.75
Flow switch 1.12
Gas-liquid chromatograph 30.60
Hand valve 0.13
Indicator lamp 0.044
Level measurement (liquids) 1.70
Level measurement (solids) 6.86
Oxygen analyzer 5.65
pH meter 5.88
Pressure measurement 1.41
Pressure relief valve 0.022
Pressure switch 0.14
Solenoid valve 0.42
Stepper motor 0.044
Strip chart recorder 0.22
Thermocouple temperature measurement 0.52
Thermometer temperature measurement 0.027
Valve positioner 0.44
Table 1.1: Computations for various types of component linkages (Crowl & Louvar, 2001)
REFERENCE

No. Reference
1 Crowl, D.A., Louvar, J.F. 2001. Chemical Process Safety Fundamentals with Applications 2nd ed. Prentice Hall, Inc.
2 Flynn, A.M. 2002. Health, Safety and Accident Management in the Chemical Process Industries. Louis Theodore Ma
3 Mannan, S., Lees, F.P. 2005. Lee's Loss Prevention in the Process Industries: Hazard Identification, Assessment, and C
4 Palluzi, R.P. 1994. Pilot Plant and Laboratory Safety. McGraw-Hill,Inc.
5 Peter, M.S., Timmerhaus, K.D. 1991. Plant Design And Economics For Chemical Engineers 4th Edition. McGraw-Hill I
6 Sinnott, R.K. 2005. Chemical Engineering Design 4th Edition. Volume 6. Elsevier.
7 Steinbach, J. 1999. Safety Assessment for Chemical Processes. WILEY-VCH.
8 Taylor, J.R. 1994. Risk Analysis for Process Plant, Pipelines and Transport. E&FN SPON.
9 Thomas, C.E. 2007. Process Technology Safety, Health and Environment. 2nd ed. Thomson Delmar Learning.
10 U.S. Department of Labor Occupational Safety & Health Administration. http://www.osha.gov/
11 Wells, G. 2004. Hazard Identification and Risk Assessment. Institution of Chemical Engineers (IChemE).
12
13
ns 2nd ed. Prentice Hall, Inc.
ndustries. Louis Theodore Marcel Dekker, Inc.
entification, Assessment, and Control. Butterworth-Heinemann.

eers 4th Edition. McGraw-Hill International Editions.

mson Delmar Learning.

gineers (IChemE).