Hazard identification with failure mode & effect analysis and fault tree analysis in the chemical industry

Abstract

Introduction: The possibility of system failure is something that can happen and can cause harmful effects on workers and the community around the factory. This is shown from the component failure data for the last five years. Components of the sodium silicate production system often fail especially the production pump component. Thus, this study is aimed to analyze the forms of failure, conduct a risk assessment, and determine the basic cause (cut set) of component failure for risk mitigation. Methods: This was a cross-sectional study. This study was conducted in a company that has sodium silicate production (the company name is withheld). The data or sample that was collected was primary and secondary. FMEA was the next step after mapping the functional block diagram (FBD). Then from the results of the risk assessment on the FMEA, hazard identification was carried out using the FTA method to determine the basic cause (cut set) of component failure for mitigation. After that, the data was analyzed. Results: This study found that the highest risk values ​​were solvent tank leaks (with a risk value of 15) and production pumps that were not functioning (with a risk value of 20). The results of identification by using FTA to the peak incident of solvent tank leaks obtained 12 cut sets and a minimum of 2 cut sets, caused by the factor of poor maintenance and service life, in the pump production section received 7 cut sets and a minimum of 5 cut sets, caused by there was no supply factor of sodium silicate, bearing life, corrosion, irregular lubrication and short circuit. Conclusions: Regarding this study, the hazard identification was sodium silica from X company, mainly caused by the dissolver tank leakage and production pump.