[Type text]
Guide
Word
Deviation
NONE
NO FLOW
Causes
(1) Blockage in line
(2) Solid DEA in tank
(3) Pump fails
(4) Pressure in line =
pressure in reactor
Consequences
Safeguards
Action Required
- Loss of flow to reactor, no
reaction due to control response.
- DEA solidifies in line.
- Possible line rupture due to
pump overpressure.
- Pump motor burn out, possible
fire.
- Line is
electrically
traced to
maintain DEA as
liquid.
- Pump is tripped
by pressure in
line.
-
(a) Temperature
indicator and
controller needed on
line to control
tracing.
(b) Design pipes to
take maximum
pump pressure.
(c) Heat tank using
jacket and/or coil
Covered by (a), (b),
(c)
As for (1)
- Cavitation in pump
As for (1)
- DEA stays in storage tank
- Backflow through valve V-8
- Heat exchanger overheat, line
expansion
As for (1) and (3)
- Standby pump
- Pressure
controller on
reactor
- Pressure
controller on line
Covered by (a), (b),
(c)
(d) Regular
inspection and
maintenance of
valves.
(e) Put a blanking
plate on drain flange
plate.
(f) Regular
(5) Valve fails closed or
blocks
As for (1) and (3)
- Overpressure in line before valve
leading to rupture.
- Bypass valve in
place
(6) Leak or drain left
open
As for (1) to (5)
- DEA released from pipework
hazardous.
- Potential damage to surrounding
- FRC on line
- Trip on pump
[Type text]
equipment.
MORE OF
MORE
FLOW
(7) Empty tank/leak in
tank/LSL fails
As for (1) to (6)
- Level alarm on
tank.
(8) Heat exchanger
blockage
As for (1) to (7)
(9) Pump overpower or
both pumps operating
- Heat exchanger cannot heat
stream enough DEA solidifies
- Reactor overflow/overpressure
- Excess DEA in reactor passing
through process
- Possible line rupture
Same as (9)
- Electrically
traced line for
preventing
solidification
- FRC on line
Same as (9)
- Valves fail
closed
- Pressure
controller on
reactor
-
(10) FRC gives incorrect
value (too low)
(11) Valve failure
LESS OF
LESS FLOW
(12) Lower pressure in
reactor
Same as (9)
(13) FRC gives incorrect
value (too high)
- Less reaction
- Higher DEA outlet temperature
from heat exchanger
- Insufficient reactor pressure
- Potential higher flow in other
inspection of lines to
look for leaks.
(g) Use flow
controllers on all
lines with the
potential to leak.
(h) Ensure regular
inspection of tank
for leakage.
(g) Ensure good
heat exchanger
cleaning and inspect
after cleaning.
(h) Use a locking off
procedure for pump
not in use.
(g) Surge meter to
prevent pump
overpressure
(i) Check FRC
regularly
(j) Design valve for
maximum pressure
Covered by (a) to (j)
Covered by (a) to (j)
[Type text]
(14) Partial blockage/leak
in pipe
(15) Pump underpowered
(16) High reactor
pressure
(17) Valve stuck partially
closed
(18) Fouling in pipes and
heat exchanger
REVERSE
MORE OF
REVERSE
FLOW
MORE
PRESSURE
(19) Insufficient DEA in
tank
(20) High reactor
pressure
(21) Reactor isolation
valve fails open
(22) Pump overpower
(23) PIC gives wrong
value (too low)
(24) Thermal expansion
of DEA due to heat
sections of line possibly leading to
pipe rupture
Same as (1), (6) and (13)
Same as (13)
- Backflow of nitrogen into DEA
line
Same as (13)
- Reactor vessel rupture
Same as (13)
Same as (13)
- Reduces heat transfer which
could lead to DEA solidifying
Same as (13)
- Potential cavitation in pump
As previously discussed
- Backflow of reactor contents
(including hydrogen) to DEA line
Discussed
previously
-
- Relief valve for
reactor
- Pressure
controller on
reactor
- Valves should
fail closed
-
- Level alarm on
tank
Reactor pressure
control
-
Covered by (a) to (j)
(k) Fit non return
valve to reactor
inlet.
Covered by (a) to (k)
Covered by (a) to (k)
Covered by (a) to (k)
Covered by (a) to (k)
Covered by (a) to (k)
Discussed previously
Discussed previously
(l) Add FIC to all
reactor inlet lines,
shut down if
backflow into DEA
line is detected.
Covered by (a) to (l)
Covered by (a) to (l)
Discussed previously
Discussed
previously
(m) Design pipes for
higher pressure and
[Type text]
LESS OF
NONE OF
MORE OF
LESS
PRESSURE
NO
PRESSURE
MORE
TEMPERATU
RE
(25) Steam rate
fluctuation to heat
exchanger
Discussed previously
- Temperature
controller on
steam flow
(26) Blockage/ closed
valves
(27) Pump failure
Discussed previously
(28) PIC gives wrong
value (too high)
(29) Leakage
Discussed previously
(30) Valves more closed
than expected
(31) Solid DEA in tank
with pump running
(32) Excess steam in to
heat exchanger
Discussed previously
Discussed
previously
Discussed
previously
Discussed
previously
Discussed
previously
Discussed
previously
Discussed
previously
Discussed
previously
(33) Electrical tracing too
hot
(34) Strong sunlight
(35) Tank coil too hot
Discussed previously
Discussed previously
Discussed previously
Pipe buckles
Discussed previously
- Reactant too hot, potential
reaction problems
- Vaporisation in reactor
- Thermal strain in pipes
Discussed previously
Discussed previously
Discussed previously
Discussed
previously
Discussed
previously
Discussed
previously
expansion
Covered by (a) to
(m)
(n) Consider
cascading flow and
temperature control
for heat exchanger
steam
Covered by (a) to (n)
Covered by (a) to (n)
Covered by (a) to (n)
Covered by (a) to (n)
Covered by (a) to (n)
Covered by (a) to (n)
Covered by (a) to (n)
Covered by (a) to (n)
Covered by (a) to (n)
(o) Add temperature
control to tank
[Type text]
LESS OF
LESS
TEMPERATU
RE
(36) Insufficient steam in
to heat exchanger
(37) Tracing failure
Discussed previously
- Insufficient reactor pressure
Discussed previously
(38) Cold weather
Discussed previously
(39) Tank coil too cold
Discussed previously
START UP
(40) Too fast
SHUT
DOWN
(41) Corrosion
(42) Some DEA solidifies
in line
- Heat exchanger too cold to heat
DEA to required temperature
Discussed previously
Discussed
previously
Discussed
previously
Discussed
previously
Discussed
previously
Discussed
previously
Discussed
previously
Covered by (a) to (o)
Covered by (a) to (o)
Covered by (a) to (o)
Covered by (a) to (o)
Covered by (a) to (o)
Covered by (a) to (o)
