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Performance analysis as per safety compliances on pressure vessel at foundry and machine shop.


Vessels, tanks, and pipelines that carry, store, or receive fluids are called pressure vessels. A pressure vessel is defined as a container with a pressure differential between inside and outside. The inside pressure is usually higher than the outside, except for some isolated situations. The fluid inside the vessel may undergo a change in state as in the case of steam boilers, or may combine with other reagents as in the case of a chemical reactor. Pressure vessels often have a combination of high pressures together with high temperatures. Pressure vessels are air-tight containers used in foundry and machine shop, process industry, refinery and petrochemical plant to carry or hold liquid, gases or process fluids. They are typically subjected to pressure loading and internal or external operating pressure different from ambient pressure. Pressure vessel is the major component in many industries and as well critical equipment. Handling of this equipment will be complicated and higher amount of risk takes place in it.

2. Problem:

In machine shop and foundry the pressure vessel is identified as critical equipment. Pressure vessel was erected without any safety standard aspects. It is also an hazardous activity which may create major problem to man and machine. To rectify all the issues absorbed from the pressure vessel and compile to the standard provided in Tamilnadu Factory Rules 1950. For an improvement pressure vessel has to be absorbed daily as the shift basis along with the machine maintenance from that each individual pressure vessel has been marked, checklist has prepared and reported to the authorized person.


3. Observation:

GENBA observation to be made to all pressure vessel. From the visual inspection all the seen unsafe condition to be noted. Likewise day by day activity to be observed and noted. From the collected data unsafe conditions to be verified and corrective actions to be made. Plan for the future scope to avoid the repeated problems. Mark all the pressure vessel for the identification in time, date, duration and capacity of it. Observation helps us to develop the system step by step to overcome from the problem immediately and also to control the hazard in the earlier stage.

4. Analysis:


5. Action:

Eliminating the unsafe condition in the pressure vessel. Total number of pressure vessel: 359 Safety Feature required in machine:

~ Pressure relief valve

~ Pressure gauge

~ Automatic drain valve

~ Inlet and outlet valve

~ Safe operating procedure

Unsafe condition observed during GEMBA:
Safety Features          Air reservoir   Die coat tank   Oil cooler

Total no.of. Machines    194             69              40

Pressure relief valve    84              15              --

Pressure gauge           42              2               11

Automatic drain valve    23              --              --

Inlet and outlet valve   7               --              --

Safety Features          Nitrogen Cylinder   Total

Total no.of. Machines    56                  359

Pressure relief valve    --                  99

Pressure gauge           8                   63

Automatic drain valve    --                  23

Inlet and outlet valve   --                  7

6. Check:

Action taken for each pressure vessel has to be checked as per the schedule. Every vessel has to be marked and numbered for identification. Ultrasonic test be done for two year once. After testing the report will be generated and will be easy to compile with the safety standards. Continuous processed pressure vessel will be rusted soon for that vessel extra care will be taken and monitored to avoid problems in the future.

7. Standardization:

Implementing the system like safe operating procedure and scheduled monitoring to be made. Creating checklist and performance verification done weekly once. Safety training will be given to the employees. Pressure vessel to be added to the audit and checked two moths once.


In an industry even a small thing leads to major hazards. Concentrating on small issues will avoid the major hazards at the beginning stage. Developing a system for identifying the unsafe act and condition will improve the company standard and reputation


[1.] Tamilnadu Factory Rules 1950.

[2.] Static mobile pressure vessel rules.

[3.] Is 2825: Code for unfired pressure vessel.

[4.] Rupture Hazard Of Pressure Vessel--Environmental Protection Agency.

[5.] Emergency Prevention and Planning (Pressure Vessel)--News Letter.

[6.] Accidents in pressure vessel : Hazard awareness, 2010.

(1) J Pratheep, (2) A. Chandra kumar, (3) PSS. Srinivasan, (4) K. Visagavel, (5) D. Sakthivel, (6) K.S. Sathish kumar

(1) PG Scholar, Department of Mechanical Engineering, Knowledge Institute of Technology, Tamilnadu, India. (2,3,4,5) Faculty of Mechanical Engineering, Knowledge Institute of Technology, Salem, Tamilnadu, India.

(6) Senior Safety Manager, TVS- Sundharam Clayton Limited, Tamilnadu, India.

Received 25 April 2016; Accepted 28 May 2016; Available 5 June 2016

Address For Correspondence:

J. Pratheep, PG Scholar, Department of Mechanical Engineering, Knowledge Institute of Technology, Tamilnadu, India.

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Author:Pratheep, J.; kumar, A. Chandra; Srinivasan, PSS; Visagavel, K.; Sakthivel, D.; kumar, K.S. Sathish
Publication:Advances in Natural and Applied Sciences
Article Type:Report
Date:Jun 15, 2016
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