Reactors Guide Word Deviation Causes Consequences Effect Action RECOMENDA TION NO No cooling Cooling water valve malfunction Temperature increase in reactor causes the reaction to slowdown Explosion in the reactor due to over flo w of hot water Installed high temperature alarm (TAH).and installed fail open v alve. To avoid over heating REVERSE Reverse cooling flow Failure of water source resulting in backward fl ow Less cooling, possible to less hot water to flow to the reactor No prope r cooling supply Install fail open check valve at the source of cooling w ater supply at tank. Reverse Reverse hot water flow Failure of water source resulting in backward fl ow Less heating, possible to less hot water to flow to the reactor No optim um temperature for reaction and reduces the storage of cooling water Install fail open check valve at the source of hot water supply. No No heating Hot water valve malfunction Temperature drops possi ble runaway reaction causes the reaction to slowdown No reaction happens Installed low temperature alarm (TAL).and installed fail open valve. To avoid wa stage of product MORE More cooling flow Control valve failure, operator fails to take ac tion on alarm Too much cooling, cause too much of hot water to flow Wastage of water supply Instruct operators on procedures on monitoring the flow alarm at cooling water supply. MORE More hot water flow Control valve failure, operator fails to take ac tion on alarm Too much heating, cause too much of cold water to flow Wastage of water supply Instruct operators on procedures on monitoring the flow alarm at cooling water supply. AS WELL AS Accumulation of product in the reactor or pipes. Long ter m reaction Pressure in the reactor and friction head in the pipe to increa se High pressure drop causes decreases pump efficiency Check maintenanc e procedures and schedules on reactor and pipes to reduce the accumulation OTHER THAN Foreign substance present in water Contamination of water s ource Reduce the efficiency of cooling and heating (Cp varying according to pr esence of foreign substances.) The wastage of water varying. Water supply is replaced with other sources.
5.1.2 Distillation Columns
Guide Word Deviation Causes Consequences Effects Action No No power No GEB supply Distillation will not achieve Process delayed Captive power plant provide Less Lower temperature Poor heating No distillation will take place Process delayed Temperature transmitter and controller are installed More More pressure Control valve failure High pressure in the distillati on column Explosion may occur due to overwhelming pressure. Pressure
relief valve installed
High High level Level controller failure collumn Destruct the recycling of methanol ed with the level controller. High High temperature Controller of temperature in column fails High inlet flow temperature to column High temperature in column is a fire hazard due to the presence of the flammable roller
Flooding in distillation High level alarm install
Install temperature cont
5.1.3 Pumps supply
Guide Word Deviation Causes Consequences Effects Action NO No flow Blocked pipe due to impurities No reactants for mixing Over heated to the pump motor and causes failure to transfer mixture Install filter at pipe to filter impurities. Arrow indicators to be provided on pipeline Less Less flow Control valve failure Valve jammed. Wrong setting of the valve Product will transfer at lower speed, process delayed Pumps causes blocking of mixture and causes pipe leakage Technici an must carry out testing for each of the valve with correct schedule if it spoi lt, replaced it with a new valve more More flow Pump Ampere more. Valve fully open than required set value. Finishing of reactants form the supply Too much reactant in the mixer, reactor Instruct operators on procedures and control valve changed Reverse Reverse Flow Blocked pipe/ Operator failure Insufficient amount of reactant Pump may be damaged Change or service the blocked pipe. Check maintenance procedures and sch edules Other than that Accumulation in the pipe Friction head drop Pump req uired more energy to sent the mixture Pump my heated up and causes the disturb ance in temperature Change or service the blocked pipe. Check maintenance pr ocedures and schedules
5.1.4. For mixer
Guide Word Deviation Causes Consequences Action Taken Reverse No flow Accumulation of other substance in the mixture Mixing cannot be done or built-up of mixture can cause leakage at the reactor Change or servic e the blocked pipe. Check maintenance procedures and schedules Less Less flow In consistence of signal transfer to controller from pne umatic valve Insufficient amount of reactant Sent professional process engine er to the control room to handle while changing the transmitters No No flow Blocked pipe due to impurities Mixing does not take place Install filter at pipe to filter and Check maintenance procedures and schedules regularly on filtering
5.1.5. For boilers
Guide word Deviation Causes Consequences Action Taken No No boiling Malfunction of control valve, steam cant flow into the b oiler The liquid does not achieve the required temperature Install low temp erature transmitter and controller. More More boiling of liquid Failure control valve to regulate the flow of st eam into the boiler The liquid temperature keeps rising and might become vap our Install high temperature transmitter and controller Less Not enough boiling of liquid malfunction of low temperature alarm The liquid temperature is lower than required temperature Check regularly the maintenance procedure on temperature transmitter. As well as Mixture in the boiler accumulates. Blockage at the componen t input valve. The liquid comes out with non-specified temperature and composit ion required. Refer to maintenance or housekeeping procedure to maintain the b oiler efficiency. For Condenser Guide word Deviation Causes Consequences Action Taken No No cooling flow Malfunction of control valve, cooling cant flow into the condenser. vapour will not condensed. pressure built-up in distillation col umn. Install low temperature transmitter and controlled valve. More More cooling liquid Failure control valve to regulate the flow of st eam into the boiler prresure built-up in the tubes of the condenser. Install high pressure transmitter and controller Less Not enough boiling of liquid malfunction of low temperature alarm The liquid temperature is lower than required temperature Check regularly the maintenance procedure on temperature transmitter. As well as Mixture in the condenser accumulates. Blockage at the componen t input valve. The liquid comes out with non-specified temperature and composit ion required. Refer to maintenance or housekeeping procedure to maintain the b oiler efficiency.