FAULT DETECTION AND FAILURE PREDICTION FOR AUTOMATED FLARE TOOLING

摘要

The implementation of automated tooling into the flare manufacturing processes has significantly improved the ergonomics, decreased the processing time of key flare components, and significantly increased the number of safeguards benefiting operators. Automated flare tooling sets the standard for improvement in operator performance, efficiency, and exceeding customer product expectations. This case study reports the results of several quantitative and qualitative risk analyses that were designed for fault detection and failure prediction. Hazards analyses for each automated tool have assessed the level of risk quantitatively and qualitatively for each potential failure mode in order to determine an appropriate hazard classification. The use of a Failure Modes and Effects Analysis (FMEA) for each of the automated tools in the design and qualification phases analyzes all component failure modes and the impact to the safety of personnel and equipment integrity. This report highlights critical failure modes from the hazards analysis' FMEA that assessed the most critical initiation hazards. Each potential failure mode was successful in predicting failures and ensuring that the designed process control systems adequately detected and safeguarded the tooling for all potential faults involved with the process. The primary purpose of the FMEA is to identify scenarios involved with each process that generates potential energy sources required for initiation of the flare. The development of recommendations and additional safeguards from unacceptable hazards identified in the FMEA lower the hazard severity and frequency of all potential failure modes. This report demonstrates the success of automated tooling in increasing flare production, decreasing the number of ergonomic challenges, reducing the amount of down-time for each tooling, and reducing the number of product quality escapements.