Management Systems in Production Engineering

2012,No3(7),pp1820

RISKASSESSMENTANDACTIONSTOREDUCTIONOFRISKINEXPLOSIVEENVIRONMENT
TomPAULIEK,PeterIO,JurajZAUJEC,MarekBURDA SlovakAgriculturalUniversityinNitra

Abstract: This ar cle deals with assessment and risk reduc on measures in explosive atmospheres, respec vely of natural gas llingsta onCNGforcars,lorriesandbuses.Thellingsta onwasmonitoredfortwoyearsandFMEAhavebeenap pliedtodeneandevaluatedeciencies,suggestcorrec vemeasurestoreducethenumberoffailuresinthesystem. Applica onofthemethodFMEAhelpedbyiden fyingandminimizingthelikelihoodoffailuresinthesystem,whichisof greatimportancefromtheviewpointofpreven ngtheoccurrenceofadverseevents. Keywords:risk,disorder,FMEA,adverseevent

INTRODUCTION Possible dangers of origin re and explosion represent the parts of technological equipment, where during the produc onprocesspar cipatecombus blesubstancesand those parts of the process equipment in which ammable substances are manufactured, blended, stored, pumped, relled,exhaustedorareconsumed. Thegasllingsta onCNGarelocatedvarioustechnolo gical equipments, parts of equipment and components thatareexactlyspeciedunderthelegisla onasdedicated technical equipment involved in the func onal technologi calunit.TheCNGllingsta onsasthemainusedmedium isnaturalgasthatiscompressed,pumpedanddistributed, andnallylledintotanksofmotorvehicles. Safety is a key term in the issue with deals the risks, their examina on and minimizing. The safety of technical equipmentisstateofthetechnicalequipmentandmethod ofitsuse,inwhichisnotendangeredsafetyandthehealth oftheemployee[3,6]. Theaimofpaperistheexactspecica onofthemoni toredtechnologicalequipment,inwhichhavebeeniden ed the failures for two years. Realize them quan fy that wouldexpressesthetotalamountofhazardouseventswith thepossibilityof explosionand re.Of this amount of ha zardouseventsdeterminetheimportanceandtheassignto individual dangers the criterion of seriousness. To iden fy theoriginoftheriskofexplosionandreequipmentsthat are operated in an explosive environment. Eec vely ma nage the assessed risks and suggest remedies to minimize lossofproperty,livesandenvironment. The actual evalua on of failures will be assessed and evaluated by FMEA method Failure Modes and Eect AnalysisAnalysisoffailuremodesandeects.

MATERIALSANDMETHODS Characteris cs of equipment: gas lling sta on CNG forcars,lorriesandbuses. Itsfocusisforprocessing,treatment,transportandl ling of natural gas by designated technical equipments, electric,gasandpressure.

Fig.1.CNGdispensersGreeneldA.G.

Evalua on of failures: iden ca on of hazards and threatsthetracedequipmentsandintheperformedac vi ty, frequency and severity of failures, iden es the exact causesbymethodFMEA.

ManagementSystemsinProduc onEngineering3(7)/201219
T.PAULIEKetal.Riskassessmentandac onstoreduc onofriskinexplosiveenvironment

Proposeofremedies:Specica onofdesignandexact remedies to eradicate and prevent the poten al of origin risk of explosive environment in accordance with legal requirementsandcurrentlegisla on.(Laws,decrees,regu la onsandtechnicalstandards). MethodofFMEAapplica on: Deni onofthemonitoredsystem, Deningofthemonitoredsubsystem, Determina onofdamagedpart, Denethecauses,resp.displayoffailure, Determina onoffailureeect,

Determina onoffailurefrequency, Propose of correc ve ac ons leading to minimizing thelikelihoodofthefailureorigin. RESULTSANDDISCUSSION AppliedmethodFMEAincludesdenedsystemandsub sequentlysubsystem.Alsodenesthedamagedparts,their symptoms/causes of origin and the consequences a er possibleoriginoffailure.Liststhenumberoffailuresovera periodoftwoyearsanddenecorrec veac onsthatlead tominimizingthelikelihoodofadverseevents.
Table1 TheFMEAform

System:gasllingsta onCNG No. Subsystem Damagedpart rubbersealing Oringon sumpofcom pressor aluminium sealingring sealingpartsof quickcoupler MGUBN aluminium sealingring Cause/display offailure vibra onsofthecompressor Eectoffailure Num. of.f. 11 Trainingofwork safety,personal protec veequi pmentrespiratory lters,ven la on, space,reprocedu re,suitablere ex nguishersS5, PG6 Remedy (Correc veac on)

Compressorsta oncompressor

pressurerelief valveRAMSEYER Quickcoupler MGUBN opressurizing valveBhmer Kugelhhne llinghoseSWA GELOCKCCNG

vibra onsofthecompressor,the dierentthermalconstruc onchan ges Operatora en onforgo en,con necteddispenserguninamotor vehicle,movementofthevehicle vibra onsofthecompressor,the dierentthermalstructurechanges lowtemperaturecausingrigidityand bursthoses,violenthandlingbyope rators,breakageofissuancegun screwing Vibra onofissuancestand,dierent heatchangesofconstruc ons,pres surechangesinthesystem

8 escapeofgas,originof explosiveconcentra on 15

llinghose

Thro leBhmer Kugelhhne aluminium sealingring

escapeofgas,originof explosiveconcentra ons injuryoftheoperators

Controlofequi pment,operator training,personal protec ve,re gh ngequipment

Safetyvalve ANDERSON

dierentthermalchangesofcon struc ons,pressurechangesinthe system

Controlofstopper, equipmentopera tortraining,

8 9 10

Safetyvalve LESER Electricvalve LUCIFER Issuancestand CNGGreenField A.G Issuancegunof standGREEN FIELD

aluminium sealingring

dierentthermalchangesofcon struc ons,vibra oncompressor vibra onsofthecompressor escapeofgas,originof explosiveconcentra on

4 6 5 escapeofgas,originof explosiveconcentra on, injuryoftheoperators

sealingringCu failureofelectricmotorconversor bodyofquick couplertransfer ofhoseandgun

Trainingofhealth andsafety,perso nalprotec veequi pmentprotect gloves,ven la on ofspace,rstaid, suitablereex n guishersS5,PG6

11

unprofessionalmanipula onofope rators,badloadofquickcoupler

18 Operatortraining, personalprotec ve equipment,safety manualforcusto mers

12

Suc onequi pmentofairfor ven ngofinside spaceissuance standGreenField

intakevelves

createiceontheintakeairhole

cutoofequipment,equi pmentisnotundercontrol atescapeofgas,originof explosiveconcentra on, injuryoftheoperators

20ManagementSystemsinProduc onEngineering3(7)/2012 T.PAULIEKetal.Riskassessmentandac onstoreduc onofriskinexplosiveenvironment CONCLUSION Qualityofaproduc onprocesscanbeevaluatedonthe basis of product assessment of produc vity and non conformi es. Cri cal elements (risk, threat, and danger) whicharenecessarytoanalysecloserandtodenepreven on (reduc on) can enter to the manufacturing process. When assessing the process quality it is very important to placealsotheriskassessment[1,4,5]. Theprimaryaiminriskassessmentandriskreduc onremedies inanexplosiveenvironmentistheexactspecica onoftraced technologicalequipment.Gradually,wecometodeterminethe poten al of damaged parts and their expression and result a eroriginofadverseoccurrence.Wasdeterminedthenum berofarisenfailuresoveraperiodoftwoyearsandtoiden fy remedies leading to minimizing the likelihood of undesirable event. Failure the most numerous part (18 failures) is a body quick coupler,transferofhoseandgun,whichfallsunderthesubsys temissuancegunstandGREENFIELD.Thesecondmostfailure numerous part (15failures)are sealingpartsof quickcoupler MGUBNandthethirdpart(11)isarubbersealingOringon sumpofcompressor.IntheformofFMEAherearenineother damagedpartsthatweredamagedintwoyearslessthanten mes. A erapplica onofremediesitisexpectedtoreducethenum beroffailuresofindividualcomponentswhichwillbefurther examined. ACKNOWLEDGEMENTS
Thepaperhasbeenthesolvedwithintheframeofthegrantpro jectVEGA1/0576/09(20092011)"Improvingthequalityofagri culturalmachineryandproduc onfacili es."

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Ing.TomPauliek doc.Ing.PeterioCSc. Ing.JurajZaujec Ing.MarekBurda SlovakAgriculturalUniversityinNitra FacultyofEngineering DepartmentofQualityandEngineeringTechnologies Tr.A.Hlinka2,94976Nitra,SLOVAKIA email:t.paulicek@gmail.com