Use of Boolean Algebra in Fault Tree Analysis

Manoj Mishra, Associate Vice President,

Chemicals Business, SRF Limited, New Delhi, India
[email protected]

21-10-2010

1
The SRF Problem Solving Process

1. Select the theme

2. Understand current circumstances

3. Analyse causes

4. Find solutions

5. Implement the solutions

6. Verify results

7. Standardise and institutionalise

8. Reflect

2
1. Select the theme

Theme

Increase HF plant stream

capacity from an average
of 25 TPD to 32 TPD and
maintaining the
breakdown hours at the
current level of 78 hours
per month

3
1. Select the theme

Stream capacity (TPD) April-07 to May-08

Stream capacity (TPD)

30.0
28.6 28.6 29.0 28.7
26.3 26.7 26.6
25.0 24.4
23.9 23.6 23.2
21.9
20.0 19.9
18.4
15.0
Jun-07

Oct-07

Feb-08

Mar-08
May-07

Jul-07

Nov-07

Dec-07

Jan-08

May-08
Sep-07
Apr-07

Aug-07

Apr-08
Month

Inference:Average steam capacity is 25 TPD.

Stream Capacity = Total production /running hours x 24

4
 Breakdow n hours April-07 to May-08
Breakdown hours (Hrs)

350.0
300.0 316.2
250.0
200.0
150.0 168.1
Average:77.7hrs 112.6
100.0 90.2 101.3
50.0 42.3 57.3 45.4 39.0 29.3
28.6 23.1 11.7 22.5
0.0
Jul-07
Jun-07

Oct-07

Nov-07

Dec-07

Jan-08

Feb-08

Mar-08
May-07

May-08
Sep-07
Apr-07

Apr-08
Aug-07
Month

Inference:Average breakdown hours is 78 hours/month.

5
 Background

Anhydrous Hydrofluoric Acid is manufactured by reacting Fluoro Spar(CaF2) with Sulfuric Acid (H2SO4) in rotary
Kiln. Gas, which is generated, is purified by passing through pre scrubbing tower and sulfur separator and then it is
condensed and stored in crude tank. Crude HF is pumped into distillation column to further purify it from SO2,
moisture and Sulfuric Acid.
 
Installed capacity of this plant was 16 TPD. Over the time demand for AHF has increased due to increase of R-22
production, AHF requirement in FSP and new generation refrigerant plant(R-134a). With the increase in demand for
AHF it is imperative to increase capacity of HF plant .Debottlenecking exercise was carried out to increase capacity
to 35 TPD in two phases. Phase-I debottlenecking exercise was carried out in Feb-05 and Phase-ll in Oct-06. After
debottlenecking exercise average stream capacity that could be achieved in the past one year was 25 TPD. AHF
requirement per day is around 30 TPD and there is a gap. AHF is purchased from outside to meet the requirement.
The quality of AHF, which is procured, is not upto the specification and it impacts the performance of RG plant.
Purchase AHF cannot be used for FSP and R-134a plants as SO2 and moisture contents are high.
Indigenous AHF cost is very high ,procurement and transportation is a great challenge. Handling AHF in ISO,
transporting and unloading into our storage tank call for expertise and it involves great safety risk. Procurement of
AHF from China and handling AHF in port and subsequent handling and unloading at our storage tank involves even
greater challenge and safety risk. It is very critical to stabilize AHF production at 32 TPD so as to meet the
requirement of all the plants. It is even bigger challenge to sustain the quality of AHF at higher capacity.
PSP silver project was taken to address this challenge and to stabilized HF plant at 32 TPD keeping the breakdown
at the same level.

6
7
Breakdowns phenomenon analysis
• FTA – Gemba

FMEA

Quality aspects

8
 Analysis of breakdown through Phenomenon
• Master list of all the breakdowns made from April-08 to October-08.
• Phenomenon of each breakdown identified and stratified.
• Phenomenon is stratified based on breakdown hours and number of
breakdowns
• Each phenomenon is further stratified based on equipments.
• Identified of major phenomenon and carried out a FTA on specific
equipment.
• Identify minimum cut set of events for a failure to happen and took
counter measures to prevent the event to happen.
• Develop a excel sheet module of FTA for simulation.
• FTA is done after carrying out the FMEA. Most of the potential causes
identified in FMEA are are getting captured in FTA.

9
Phenomenon based Phenomenon based
breakdown hours breakdown numbers
Details (All)
Details (All) Date (All)
Date (All) time (All)
time (All) Date 2 (All)
Date 2 (All) time2 (All)
time2 (All) TOTAL BD HR (All)
TOTAL BD HR (All) Remarks (All)
Remarks (All) Tag No (All)
Tag No (All)
Count of Phenomenon
Sum of TOTAL BD HR Phenomenon Total
Phenomenon Total choking 89.0
choking 124.1 High load 15.0
Broken 62.3 Slippage 15.0
High load 31.5 Leakage 12.0
Leakage 29.1 Broken 11.0
Slippage 28.3 Power failure 9.0
Accumulation 23.3 Accumulation 8.0
Knowledge gap 23.0 Knowledge gap 8.0
Restriction 13.5 Restriction 2.0
Power failure 7.8 Back up 1.0
Back up 2.2 Delay 1.0
Delay 1.4 Cavitation 1.0
Cavitation 1.3 Short circuit 1.0
Short circuit 1.3 Steam failure 1.0
Steam failure 0.9 Loose 1.0
Loose 0.8 Closed 1.0
Closed 0.6 Grand Total 176.0
Grand Total 351.2

10
 Apr-08 to Oct-08
Pareto Diagram
Phenomenon wise (breakdown hours)
Breakdow n hours: 351.17
Breakd o w n h o u rs (Hrs)

Cu m u lative p ercen tag e

350.0 100.0
300.0 90.0
80.0
250.0 70.0
200.0 60.0
124.1 50.0
150.0 40.0
100.0 62.3 30.0
31.5 29.1 28.3 23.3 23.0 20.0
50.0 13.5 7.8 2.2 1.4 1.3 1.3 0.9 0.8 0.6 10.0
0.0 0.0

Ac c um ulation

Steam failure
Short c irc uit
R es tric tion

Pow er failure

C av itation
C hok ing

H igh load

Leak age

Bac k up
Know ledge
Slippage
Brok en

C los ed
D elay

Loos e
gap
Pre pared by : Manoj Kum ar Mis hra

Apr-08 to OCT-08 Apr-08 to Oct-08

Pareto Diagram Pareto Diagram
Choking Phenomenon in equipments (Breakdown hours) High load - phenomenon in equipments (Breakdown hours)
Breakdow n hours: 124.1
Breakdow n hours: 31.5
120.00 100.0

Cumulative percentage
30.00 100.0
Breakdown hours

80.0 23.4

Breakdown Hours
24.00 80.0
80.00

Cumulative
percentage
60.0 60.0
43.4 18.00
35.2 40.0
40.00 12.00 40.0
18.9 5.8
9.0 7.3 5.5 3.2 20.0
1.5 0.2 6.00 2.0 20.0
0.3
0.00 0.0 0.00 0.0
P-223B

HAG
BE-304

SC-300

SC-150
SC-152

SC-200

SC-151

SC-153

Oleum
BE-304
SC-300

SC-204

Pump
Prepared by : Manoj Mishra

Apr-08 to Oct-08 Apr-08 to Oct-08

Pareto Diagram Pareto Diagram
Leakage- Phenomenon (Breakdown hours)
Broken -Phenomenon in equipments (Breakdown hours) Breakdow n hours: 28.58
Breakdow n hours: 62.28
100.0

Cumulative percentage
100.0
Breakdown hours

60.0 80.0
Breakdown hours

50.0 38.7 80.0 20.0

60.0
Cumulative
percentage

40.0 60.0 9.2 40.0

30.0 10.0 7.5
15.1 40.0 4.0 2.5 20.0
20.0 2.0 1.8 1.6
10.0 4.6 2.2 1.8 20.0 0.0 0.0

H2SO4
SC-200

SC-153

SC-300
FCV-
Reactor

1409

acid line

Heater
Oleum

0.0 0.0

Feed
BE-

SC-

SC-

SC-
SC-
304

204

300

151

152

11
 Apr-08 to Oct-08
Pareto Diagram
Phenomenon wise (Breakdown numbers)
Breakdow n Nos: 176

100.0

Cumulative percentage
Breakdown numbers

150 90.0
80.0
70.0
100 89 60.0
50.0
40.0
50 30.0
15 15 12 11 9 20.0
8 8 2 1 1 1 1 1 1 1 10.0
0 0.0
Choking

High load

Leakage

Broken

Restriction

Back up

Cavitation

Closed
Delay
Slippage

Steam failure
Short circuit
Accumulation
Power failure

Knowledge

Loose
gap
Prepared by : Manoj Kum ar Mishra

Apr-08 to OCT- Apr-08 to Oct-08

Pareto Diagram 08 Pareto Diagram
Choking Phenomenon in equipments (Frequency) High load -Phenomenon in equipments (Frequency)
Breakdow n nos: 89 Breakdow n nos: 15

100.0 Cumulative percentage 15 100.0

Breakdown numbers

12
80
80.0 80.0

Cumulative
Breakdown

percentage
numbers
10 60.0
60.0
35 5 40.0
40 30 40.0 1 1 1 20.0
9 7 20.0 0 0.0
3 2 1 1 1

Oleum
SC-

BE-
304

SC-
300

204

Pump
0 0.0
P-223B
SC-152

SC-200

BE-304

SC-150
SC-151

SC-153

SC-300

HAG

Prepared by : Manoj Kum ar Mishra

Apr-08 to Oct-08 Apr-08 to Oct-08

Pareto Diagram Pareto Diagram
Slippage - phenomenon in equipments (Frequency) Leakage- Phenomenon (Frequency)
Breakdow n nos: 11
Bre akdow n nos: 15
15.0 100.0

Cumulative percentage
Breakdown numbers

15.00 100.0
Breakdown numbers

80.0 80.0
8.0
Cumulative
percentage

10.00 60.0
60.0 5.0
40.0 4.0 40.0
5.00 2.0 2.0
20.0 1.0 1.0 20.0
0.00 0.0 0.0 0.0
BE-304

BE-304

SC-300

SC-204

SC-151

SC-152
12
Major breakdown phenomenon

BREAKDOWN
PHENOMENON NUMBERS BREAKDOWN HOURS

Choking 1 1

High load 2 3

Slippage 3 5

Leakage 4 4

Break 5 2

Power failure 6 9

Accumulation 7 6

Knowledge gap 8 7

Restriction 9 8

Back up 10 10

Delay 11 11

Cavitation 12 12

Short circuit 13 13

Steam failure 14 14

Loose 15 15

Closed 16 16

13
 BREAKDOWN PHENOMENON EQUIPMENT WISE
   
PHEMENON EQUIPMENT NO. BREAKDOWN HOURS FREQUENCY REMARKS
SC-151 3 1 Choking is a common
phenomenon which takes
SC-152 1 2 place in spar feeding
Choking
SC-153 6 3 system from SC-151 to
pre-reactor.
SC-200 2 4
High load phenomenon is
observed in gypsum
handling system only in
High load SC-300 1 1 SC-300.
Slippage phenomenon is
exclusively seen in BE-
304. Bucket elevator chain
slippage is a chronicle
Slippage BE-304 1 1 problem.
SC-200 1 1 Leakage phenomenon is
observed in gland sealing
Leakage SC-153 2 5 and they happen when the
system get pressurized
SC-300 3 7 due to accumulation.
BE-304 1 1
Break SC-300 2 3 Break phenomenon is observed
in Gypsum handling
SC-204 3 2 system.

14
 FTA
• SC-152 CHOKING PHENOMENON
• SC-151 CHOKING PHENOMENON
• SC-200 CHOKING PHENOMENON

15
 What is a Fault Tree?

• Fault Tree Analysis (FTA) is a method for

discovering the root causes of failures or potential
failures. FTA is a top-down approach that helps
you understands how to fix or prevent a failure.
FTA starts with a top-level event like a service
outage. Then one goes down to detailing all the
contributing faults and the causes of faults for that
failure. You use the resulting FTA diagram to
establish countermeasures to eliminate the causes
of the outage.

16
 Fault Tree Gates
A gate is used to describe the relationship between the input and output events in a fault tree.
Fault trees can have several different kinds of gates. Two kinds of gates are described and
shown below:

Description Picture Truth Table

AND Gate. The AND gate indicates Input A Input B Output

that the output occurs if and only if
all of the input events occur.
T T T
T F F
F T F
F F F

OR Gate. The OR gate indicates that Input A Input B Output

the output occurs if and only if at
least one of the input events occur. T T T
T F T
F T T
F F F

17
 Boolean algebra:

• Boolean algebra can be used in FTA to simplify the complex logical

expression to simple expression. The simpler expression can be used
to understand the events and the relationship which can cause the top
event to happen. It is easy to find solution and implement.
• The English mathematician George Boole (1815-1864) sought to give
symbolic form to Aristotle's system of logic. Boole wrote a treatise on
the subject in 1854, titled An Investigation of the Laws of Thought, on
Which Are Founded the Mathematical Theories of Logic and
Probabilities, which codified several rules of relationship between
mathematical quantities limited to one of two possible values: true or
false, 1 or 0. His mathematical system became known as Boolean
algebra.

18
 Boolean arithmetic
• If we add numbers together:

• The first three sums is elementary addition. The last sum,

contradicts principles of addition for real numbers, but not
for Boolean numbers. In Boolean algebra, there are only
two possible values for any quantity and for any arithmetic
operation: 1 or 0. Since the sum "1 + 1" certainly isn't 0, it
must be 1 by process of elimination.

19
 Addition
It is the same pattern of 1's and 0's as seen in the truth table for an OR gate. In other words,
Boolean addition corresponds to the logical function of an "OR" gate, as well as to parallel
switch contacts:

20
 Multiplication
Multiplication is valid in Boolean algebra, and is the same as in real-
number algebra: anything multiplied by 0 is 0, and anything multiplied
by 1 remains unchanged:

21
Boolean multiplication corresponds to the logical function of an "AND" gate, as
well as to series switch contacts:

22
23
• Based on Boolean Algebra models were
developed in excel to test these simplified
logical expression for all the three screws in
the plant E.g. SC-151, SC-152 and SC-200

24
FTA OF SC-152 CHOKING

25
Solving equation using Boolean

26
Solution implemented in SC-152 to prevent events to happen

27
Design change- SC-153 plug length provide and SC-152 outlet size increased
BEFORE AFTER

From SC-152 From SC-152

SC-153 SC-153

To Pre-reactor To Pre-reactor

SC-153 fleight iscontinuous. On kiln pressurisation gas will Plug length provide in SC-153. On kiln pressurisation gas will
find its way back to SC-152 through Sc-153. HF gets not find its way back to SC-152 through Sc-153. Spar will not
condensed and spar gets wet and gets deposited at Sc-152 get wet and there by choking at Sc-152 outlet will not take
outlet. This leads to choking phenomenon. place.

SC-152 breakdown trend (Choking phenomenon)

BEFORE AFTER
10
9
SC-153 plug length provided.VGP
8
No of breakdowns

Avg: 6.5 sleeve removed. Inspection of SC-

7 152 started.PVC sheet bellow
6 provided in SC-151 outlet.
5
4
3
Avg: 1.2
2
1
0
Apr-08 May-08 Jun-08 Jul-08 Aug-08 Sep-08 Oct-08 Nov-08 Dec-08
28
 Design change- SC-300 flight redesigned
BEFORE AFTER

Gypsum was first getting accumulated

to 60% and then it was getting pushed.
In normal design the loading should not
exceed 40% capacity.

Normal current: 21 amps Normal current: 10 amps

Screw profile is such that it has less angle at the perifery then Screw profile changed and made smoother. Angle is uniform.
closer to the shaft and there by it does not push the material
forward as much as it does at the centre of the shaft and there
by gypsum gets accumulated.

SC-300 breakdown trend(High load phenomenon)

BEFORE AFTER
8
VGP sleeve removed.
7
No of breakdowns

6 New modif ied screw installed.

5 Screw profile modified. Current
came dow n from 20 amps to 9 amps
4 Avg: 2.8
3
2
1 Avg: 0.2
0
Apr-08 May-08 Jun-08 Jul-08 Aug-08 Sep-08 Oct-08 Nov-08 Dec-08

29
 FMEA details
Before After
• FMEA was carried out on 31-July-08. • FMEA was carried out on 1-Dec-08.
– Whole HF plant was covered. – Whole HF plant was covered.
– Total failure mode identified: 56 nos – Total failure mode identified: 56 nos
– Total potential causes identified: 140 – Total potential caused identified: 140
nos. nos.
– Total number of points whose RPN – Total number of points whose RPN
number is more then 100 is 43 nos. number is more then 100 is zero.
– Total number of points whose severity – Total number of points whose severity
is 8 - 25 nos. is 8 - 13 nos.
– Total number of points whose severity
– Total number of points whose severity
is 9 - 6 nos.
is 9 - 6 nos
– All points with RPN number more
than 100 is addressed to bring it below – Total design change: 6 nos
100. – Total SOP revised: 8 nos
– All points with severity more than 8 – QCPC revised
and RPN more than 100 is addressed – Troubleshooting chart revised
(14 nos).
– Three month (April-08 to Jun-08) – Inspection schedule revised.
breakdowns was studied to find out the
actual occurrences. Actual occurrence
was use in RPN calculation.
– Existing system for control and
detection was taken for evaluation of
RPN.

30
 PLAN VS ACTUAL
Date of
SRF LIMITED, FCB,Bhiwadi preparation 07-Jul-08
Activity schedule for PSP and Execution themes Year 2008-09
Responsibility : Manoj Mishra Members : Manoj Mishra,Yogesh Mittal
Execution / PSP : Increase HF plant stream capacity from an average of 25 TPD to 32 TPD Target item: Oleum ratio f rom :25 to : 32
and maintaining the breakdown hours at a level of 37.9 hours per month Target date start: 23/06/08 f inish : 23/12/08

June-08 Jul-08 Aug-08 Sep-08 Oct-08 Nov08 Dec-08

S.
Activity Resp P/A
No.
W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4

1 Select the theme AKC

P
- Charter preparation, team formation
A

Understand current circumstances DS / P

2 - Data collection, observation, past data
RKG
reorganisation & stratification A

Analyse causes AKC / P

3 - Special causes, hypothesise on probable
DS
causes, test them A

Find solutions P
4 - Generate solutions, screen them, AKC
experimentation, implementation schedule A

Implement the solutions DS / P

5 - Implement obvious solutions, training on
RKG
planned solutions & implement them A

6 Verify results RKG / P

- Check results, evaluate effects DS
A

7 Standardise and institutionalise AKC

P
- Issue standards, incorporate in DM
A

Reflect P
8 - Horizontal deployment, problems carried AKC
forward, report preparation A
Name Signature
Legend:
P:planned Prepared by Manoj Mishra

A: actual Approved by

31
 Stream capacity monthly basis
Stream capacity on m onthly basis (TPD) April-07 to Dec-08
Stream capacity (TPD)

35.0 Target:32TPD
33.7
30.0 28.6 28.6 29.0 28.7 28.9
Averaget:25TP 27.2 26.1 27.9 27.1 26.6
26.3 26.7 26.6
25.0 23.9 24.4 23.6 23.2
21.9 All solutions
20.0 19.9
18.4 implemented
15.0

Month

•Average stream capacity after implementation of all solutions (26 th Nov. 09)
is 33.7 TPD in the month of Dec. 09 which exceeds the target of 32 TPD.
•Average stream capacity has increased from 25 TPD to 28.2 TPD.

32
 Stream capacity on daily basis
Stream capacity of HF plant after Implementation
Data: 26-Nov-08 to 31-Dec-08 (36 nos)
40 215/4 L/R line UC L=39.76
BE-304 chain
blockage
slipped
Indiv idual Value

35 _
X=33.15

30

LC L=26.54
25
1 1

26-Nov -08 30-Nov-08 4-Dec-08 8-Dec-08 12-Dec -08 16-Dec-08 20-Dec-08 24-Dec-08 28-Dec-08
Da te

1
UC L=8.118
7.5
Mov ing Range

5.0

__
2.5 MR=2.485

0.0 LC L=0

26-Nov -08 30-Nov-08 4-Dec-08 8-Dec-08 12-Dec -08 16-Dec-08 20-Dec-08 24-Dec-08 28-Dec-08
Da te

Prepared by: Manoj Mishra

•Plant capacity was increased to 35 TPD after correcting the VGP. Average
stream capacity is 33.15 TPD. Plant was operated at 36 TPD without any problem
33
 Breakdown hours
Breakdow n hours April-07 to Dec-08

350.0
300.0 316.2
Breakdown hours (Hrs)

250.0 Average:50.3hrs
200.0
Average:77.7hrs 168.1
150.0
100.0 101.3 112.6 59.6 66.2
90.2 74.8 40.5
50.0
28.6 42.3 57.3 23.1 11.7
22.5
39.029.3 30.9 52.6 27.7
45.4
0.0
Jul-07

Jul-08
Jun-07

Oct-07

Jan-08

Jun-08

Oct-08
Feb-08
Mar-08
Nov-07

Nov-08
Dec-07

Dec-08
May-08
May-07

Sep-07

Sep-08
Apr-08
Apr-07

Aug-07

Aug-08
Month

•Average breakdown has come down from 77.7 hours to 50.3 hours.
Breakdown in the last three months is in decreasing trend.

34
 Breakdown hours/stream capacity
Breakdow n hours/stream capacity April-07 to Dec-08

20.000
17.18
Breakdown hours (Hrs)

15.000

10.000 Average:3.386 Average:1.819

5.000 5.09 5.88

3.43 3.94 2.192.86 2.291.94
0.980.50 1.71 1.34
1.20 1.93 2.35 0.84 1.02 1.11
1.52
0.000 0.82
Jul-07

Jul-08
Jun-07

Jun-08
Oct-07

Jan-08

Oct-08
Mar-08
Feb-08
Dec-07

Dec-08
Nov-07

Nov-08
May-07

May-08
Sep-07

Sep-08
Apr-08
Apr-07

Aug-07

Aug-08
Month

•Breakdown hours per stream capacity has come down from 3.386 to 1.819
and it is at 0.82 for the month of December .

35
 Breakdown hours 3 months moving average
Breakdow n hours 3 months moving average April-07 to Dec-08

200
145.0 153.3
Breakdown hours (Hrs)

150
148.7 Target:< 77.7hrs
100 89.2 82.8
67.6
67.0 65.7 42.6 54.6 57.3 53.1 40.2
50 48.9 60.2 55.1 49.9
19.1 37.9
0
Jul-07

Jul-08
Jun-07

Jun-08

Oct-08
Oct-07

Jan-08

Feb-08

Mar-08
Nov-07
Dec-07

Nov-08
Dec-08
May-07

May-08

Sep-08
Sep-07
Apr-07

Apr-08
Aug-07

Aug-08
Month

•3 months moving average of breakdown hours is less than 77.7 hours.

After PSP , HF plant capacity increased from 25 TPD to 33.7 TPD without
increase in breakdown hours.
36
 Feed acid moisture (Quality)

Histogram of FA moisture-Before
Before Data: 01/04/08 to 28/07/08
Mean: 8.66
St. Dev: 2.739
N : 303

70
USL
After installation of dip pipe
60
in oleum reactor and mass
50

flow meter in PSA system to

Frequency

40

30

20
measure density , feed acid
10 moisture came down from an
0
0.0 3.6 7.2 10.8
FA moisture
14.4 18.0 21.6 average of 8.7% to 7.3%.
Prepared by : Manoj Mishra

Histogram of FA moisture-After
Feed acid moisture variation
After Data: 28/07/08 to 19/01/09
Mean: 7.25 N: 451 also came down significantly
St. Dev: 1.364
USL
90
80
from a St. dev of 2.739 to
70
60
1.364.
Frequency

50
40
30
1% reduction in feed acid
20 moisture will reduce 7%
10
0
0 3 6 9 12 15 18 21
energy consumption.
Prepared by: Manoj Mishra
FA moisture
37
6. Verify results
PSA moisture (Quality)
Before Histogram of PSA moisture before
Data: 1/4/08 to 28/7/08
Mean:19.6 N:317

80
UCL St. Dev:7.35 After installation of dip
70

60
pipe in oleum reactor and
50 mass flow meter in PSA
Frequency

40

30
system to measure density ,
20 PSA moisture came down
10

0
from an average of 19.6%
0 9
Prepared by : Manoj Mishra
18 27 36
PSA moisture before
45 54 63
to 16.4%. Feed acid
After Histogram of PSA moisture after
Data: 29/7/08 to 19/1/09
moisture variation also
came down significantly
Mean: 16.4 N:455
UCL St. Dev: 2.71
80

70

60
from a St. dev of 7.35 to
50 2.71.
Frequency

40

30

20

10

0
-0.0 8.8 17.6 26.4 35.2 44.0 52.8 61.6
PSA moisture after
Prepared by : Manoj Mishra

38
6. Verify results
SO2 in Crude tank (Quality)

Before Histogram of SO2 in crude HF-Before

Data: 06/04/08 to 07/06/08
Mean: 1.01 N: 8
USL St. Dev: 0.333
3.0
After installation of dip pipe
2.5

2.0
in oleum reactor SO2 in crude
Frequency

1.5 tank came down from a level

1.0

0.5
of 1% to 0.76%. As per
0.0
0.0 0.5 1.0 1.5 2.0
specification SO2 should be
Prepared by : Manoj Mishra
SO2 in crude HF
less than 1%. Reduction in
After Histogram of SO2 in crude HF-After
SO2 in crude tank will have
USL
Data: 19/06/08 to 18/01/09
0.76
Mean: 7.25
St. Dev: 0.091
N: 24 less load on distillation
9
8
column and it is easier to get
7
6
a quality product with SO2
Frequency

5
4
less than 10 ppm.
3
2
1
0
0.00 0.32 0.64 0.96 1.28 1.60 1.92
SO2 in crude HF_1
Prepared by : Manoj Mishra

39
7. Standardise and institutionalise

STANDARDISATION

S.NO STANDARDISATION DOCUMENT NO.

1 SC-151 out bellow inspection added in check list HF-CL-02

2 SC-152 outlet cleaning to be done during any plant stoppage HF-CL-02

3 SOP for stopping feed to pre-reactor to avoid choking. HF-WI-01

4 Pre-reactor feed acid blockage incorporated in troubleshooting chart. HF-WI-01

5 Mix acid flow calculation formula changed. SCADA

6 Density reading incorporated in control room log sheet. HF-F-04

7 Oleum addition procedure changed to control feed acid moisture around 7%. HF/QCPC/01

8 Inspection schedule changed. HF-T-03

9 Feed acid and PSA moisture troubleshooting. HF-WI-01

10 QCPC revised to control PSA moisture. HF/QCPC/01

40
7. Standardise and institutionalise

FIELD CHECK LIST

41
7. Standardise and institutionalise

CONTROL ROOM LOG SHEET

42
7. Standardise and institutionalise

INSPECTION SCHEDULE

43
8. Reflect
REFLECTION

• FTA tool was used for the first time in CB and it was found to be very
useful in bring significant improvement in the system. It makes the system
robust.
• From FMEA many points immersed out having high severity but low RPN
numbers. They can be studied further to improve the system.
• Study to be made to find out the limitation of HF plant beyond 36 TPD.
• Installation of Pre-heater in feed line to distillation column to be carried
out.
• FTA & FMEA can be implemented in other plants to bring significant
improvement.
• Simulation module of FTA in Excel can be used as training tool.
• PSP silver can bring dramatic change in the System and can improve Q C
D S M by many folds.
• Boolean Algebra can be used effectively in solving complex equation in
FTA.

44
 BENEFITS
• HF plant is stabilized at 36 TPD. This has helped to meet the HF requirements of RG,
HFC and FSP plat at the same time at full capacity.
• HF Stock has increased to a maximum level i.e. 190 MT. This excess stock will help to
carry out maintenance jobs if required without affecting RG,HFC&FSP capacity.
• AHF quality has improved significantly. S02 has come down below 10 ppm which
helped to remove Smell problem in R-134 a.
• Feed acid moisture has comedown from a level of 9% to 7%. This has improved the
process stability. This has reduced the corrosion of kiln. Lot of energy saving. 1%
moisture reduction will reduce 7% energy consumption.
• Breakdown has comedown significantly. This will improve yields, steam and power
norms.
• HF purchase from outside has stopped completely. This has saved about 860 lakhs. He
ISO unloading was stopped completely. This has improved the safely significantly.
• People capability has improved.
• Morale his gone up.
• Environment his improved. No kiln pressurization.
• Choking phenomenon in spar feed section reduced significantly.
• Leaned the importance of FTA. It’s a tool to bring improvement in system.
Productively has improved by 30%.
• It has changed the mind set of people. They have become more positive.
• Team wonk can brings a see charge.
45
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