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Item
1A
Study
Node
Process
Parameter
Deviation
N2 flow
Flow
No
1B
1C
1D
2A
Gas Stream
Possible Causes
Possible Consequences
Action Required
(Guide
Words)
1.Control valve fails closed
1. 2. Controller fails& closed valve
High
Temperature
Low
High
Flow
No
1.May be fatal
2. Flammable liquid
1. Clogging of gas in
pipeline cause
explosion occur in MIC
storage tank
2. As above
2. Place controller on
critical
instrumentation list
3. As above
High
1. possible runaway on
heating and lead to
explosion
2C
Low
1. Diminished cooling,
possible runaway and
can lead to explosion
due overheating
2. See 1A.2
2.
2D
As well
as
2E
Part of
1. Covered under 1C
2F
Reverse
2G
Other
than
2H
Sooner
than
1. See 1A.3
As above
1. Possible runaway
reaction with the MIC
component
1. Loss of cooling,
possible runaway of
heating
2. Contamination of MIC
component
1. None
1. Carry out
inspection
frequently.
2I
Later than
2J
Temperature
2K
2L
Pressure
2M
3A
Cooling
Stream
1. Operator error
1. Temperature rises,
possible runaway
Low
1. None
High
High
1.Cover under 1B
Low
1.Cover under 1C
Flow
No
1. Interlocking between
gas flow and reactor
feed (MIC)
1. None
1. Install high flow
alarm or MIC high
temperature alarm
High
Low
3C
3D
As well
as
4. Contamination of Freon
supply
4. Possible chemical
reaction with MIC
component
3E
Reverse
3. Loss of cooling,
possible runaway
3F
Other
than
3G
Part of
3H
Sooner
than
3I
Later than
3J
Where
else
3K
Temperature
3L
4A
Storage
Tank
Pressure
1. Operator error
1. Temperature may
increases
2. Route of water,
possible runaway
High
1. Cooling system
become limited,
temperature
increases
Low
1. None-controller
handle the situation
1. None
High
4B
4C
Temperature
Low
High
1. Overheated
2. Turn on the
refrigeration system
(Freon refrigeration
system was shutdown to
save money)
Low
5A
Agitation
No
sensor
1. Power Breakdown
Mixing
Eductor
No mixing, possible
accumulation of
unreacted product.
2. Motor malfunction
2
5B
More
5C
Less
5D
5E
Reverse
Faster
/slower
1. See 2A.2