Академический Документы
Профессиональный Документы
Культура Документы
10892 HARLINGEN
TABLE OF CONTENTS
1. METHODOLOGY IMPLEMENTED 5
1.1. GRAVITY IMPACT ON HEALTH AND SAFETY 6
1.2. TYPE OF CONTROL REQUIRED 7
1.3. SIL CLASSIFICATION 8
1.3.1. ESP 9
1.3.2. Fabric Filter 10
1.3.3. SCR 11
1.3.4. ID FAN 12
1.3.5. Ammonia 13
1.3.6. BICAR 14
1.3.7. Activated Carbon 15
1.3.8. Spent sorbent 16
1.3.9. Heat Exchanger 17
6. ID FAN HSC10 46
6.1. GAS EXTRACTION 46
6.1.1. ID Fan 46
7. ANALYSERS HNE10 48
7.1. GAS ANALYSING 48
APPENDIX 1 111
1. METHODOLOGY IMPLEMENTED
Risk analysis aims to assess qualitatively if a hazard or an operational problem may arise
when deviations from the normal process design occur. It permits to know in detail
measures taken to control risks (preventive and protective measures) expected by the
designer.
The principle of the method implemented is based on impact on health and safety studies,
similarly to HAZOP (Hazard and Operability Studies).
This method examines and determines all the undesirable events defined during the
functional blocs division. As each undesirable event or deviation is considered its potential
causes and consequences are assessed. Consequences are quantified with a gravity
impact on health and safety, associated with a level control.
Risk analysis document is divided into clearly sections that follow the P&IDs on a line-by-
line basis.
The tables achieved are formed with the following columns:
Undesirable events or deviations: they represent the different situations able to cause
some risks. Product risks, process risks and operating errors risks identification allow to
list them.
Causes: conditions, errors, breakdown or failures that are the cause of the undesirable
event.
Consequences: this column lists every consequence that the undesirable event can lead
to (actions implemented being considered ineffectual or insufficient).
Gravity (G): it is a matter of the gravity of the consequence without considering actions
implemented. The gravity impacts classification is mentioned hereinafter.
Actions: this column lists every preventive and protective measures in order to avoid or
reduce causes and/or limit consequences, thus reducing the gravity of the situation.
Control (C): it is a matter of the control of the event by considering actions implemented.
The control levels classification is mentioned hereinafter.
For the major risks, a SIL classification has been established, following the project calibration (see
Appendix 1)
E = 1 0 1 1 1 1
A vo id a n c e o f
e x p o s u re
e n viro n m e n t
A =
S IL e n v iro n m e n t = 0 0 0 0 0 0
F in a n c ia l lo s s e s R e p a ir o f d a m a ge d E S P R e p a ir o f d a m a g e d E S P R e p a ir o f d a m a g e d E S P R e p a ir o f d a m a g e d E S P R e s o lvin g s h o rt c irc u it c a u s e R e s o lvin g s h o r t c ir c u it
in t e rn a ls is e x p e c te d to c o s t in t e rn a ls is e x p e c t e d t o in t e rn a ls is e x p e c t e d t o in t e rn a ls is e x p e c t e d t o ( t o o h i g h fl y a s h in E S P c a us e w ill c o s t s b e
100 k D ow n t im e c o s t s a re c o s t 1 0 0 k a n d re p a ir o f c os t 10 0k c os t 10 0k h o p p e r) w ill c o s ts b e 1 0 k - 1 0 k - 1 0 0 k . D o w n t im e
5 d a y s w h ic h e q u a ls 7 00 k . o ve rs t re s s e d d u c t in g 5 k . 1 0 0 k .D o w n t im e c o s t s a re 2 c o s t s a re lo w .
T o t a l fi n a n c i a l d a m a g e is D o w n t im e c o s t s a re 5 d a y s d a y s w h ic h e q u a ls 2 7 0 k .
th u s 8 0 0 k w h ic h e q u a ls 7 0 0 k . T o t a l T o t a l fi n a n c ia l d a m a g e is t h u s
fi n a n c ia l d a m a g e i s t h u s le s s t h a n 10 00 k
80 0k
L= 3 3 3 3 3 2
A vo id a n c e o f G ive n t h a t t h e in c re a s e o f It i s e x p e c t e d t h a t o p e r a t o r
fi n a n c i a l l o s s e s fl u e g a s t e m p e r a t u r e i s a c t io n c a n a vo id t h e d a m a g e
s lo w , it is e x p e c t e d t h a t
o p e ra t o r a c t io n c a n a vo id
th e d a m a g e
A = 1 1 1 1 1 1
S IL fin a n c ia l = a a a a 1 a
S IL to ta l = a a a a 1 a
S c e n a rio D e s t r u c t i o n o f f a b r i c fi l t e r D e s t r u c t i o n o f fa b r i c f i l t e r U n d e r p r e s s u r e i n fl u e g a s D e s t r u c t i o n o f fa b r i c f i l t e r D e s t r u c t i o n o f fa b r i c f i l t e r
d e s c rip t io n o f bags bags s y s t e m e x c e e d in g d e s ig n bags bags
FO D p re s s u re . C ra c k a t w e a k e s t
p o in t (p ro b a b ly a d u c t ) le a d in g
t o in g re s s o f a ir
F = 2 3 2 2 2 1
S a fe t y N one N one N one M in o r N one N one
cons equenc es
p e o p le
S = 0 0 0 1 0 0
T im e ly p re s e n c e
o f p e o p le
T= 1
A vo id a n c e o f
e x p o s u re
A =
S IL s a fe ty= 0 0 0 0 0 0
C onsequenc es N one N one M in o r M in o r N one N one
e n vir o n m e n t
E = 0 0 1 1 0 0
A vo id a n c e o f
e x p o s u re
e n vir o n m e n t
A =
S IL en viro n m en t = 0 0 a a 0 1
F in a n c ia l lo s s e s R e p a ir o f d a m a g e d b a g s is C o s t fo r r e m p l a c e m e n t o f R e p a ir o f d a m a g e d b a g s is R e p a ir o f lo c a l e q u ip m e n t / d u c t R e s o lvin g s h o r t c irc u it c a u s e R e p a ir o f d a m a g e d b a g s is
e x p e c te d to c o s t 100k s o m e b a g s w ill b e le s s t h a n e x p e c te d to c o s t 100k d a m a g e le a d t o m in im a l d o w n ( t o o h i g h fl y a s h i n E S P e x p e c te d to c o s t 100k
D o w n t im e c o s t s a re 5 d a y s 10 k D o w n tim e c o s t s a re 5 d a y s t im e (b e c a u s e p ro d u c t io n m a y h o p p e r) w ill c o s t s b e 1 0 k - D o w n t im e c o s t s a re 5 d a y s
w h ic h e q u a ls 7 0 0 k . To ta l w h ic h e q u a ls 7 0 0 k . To ta l c o n t in u e t ill n e x t p la n n e d s t o p 1 0 0 k . D o w n t im e c o s t s a re w h ic h e q u a ls 7 0 0 k . To ta l
fi n a n c ia l d a m a g e is t h u s fin a n c i a l d a m a g e is t h u s w it h s o m e t e m p o ra ry re p a irs ). 2 d a y s w h ic h e q u a ls 2 7 0 k . fi n a n c i a l d a m a g e is t h u s
800k 800k T h u s e x p e c t e d d o w n t im e c o s t T o t a l fi n a n c i a l d a m a g e i s 800k
is le s s t h a n 1 0 0 0 k (5 d a y s ) t h u s le s s t h a n 1 0 0 0 k
L= 3 1 3 3 2 3
A vo id a n c e o f It is e x p e c t e d t h a t o p e r a t o r It i s e x p e c t e d t h a t o p e r a t o r It i s e x p e c t e d t h a t o p e r a t o r It i s e x pe c te d th a t o p e ra t o r It i s e x p e c t e d t h a t o p e r a t o r It i s e x p e c t e d t h a t o p e r a t o r
fi n a n c i a l l o s s e s a c t io n c a n a vo id t h e d a m a g e a c t io n c a n a vo id t h e d a m a g e a c t io n c a n a vo id t h e d a m a g e a c t io n ca n a vo id t h e dam age a c t io n c a n a vo id t h e d a m a g e a c t io n c a n a vo id t h e d a m a g e
by bas ed o n va r io u s o th e r P ro d u c t io n c a n n c o n t in u e
p re s s u re m e a s u re m e n ts w it h 7 c e lls o n 8
A = 1 1 1 1 1 1
S IL fi n a n c ia l= 1 a 1 1 a a
S IL to ta l = 1 a 1 1 a a
A = 1 0 1 1 1
S IL =
fi n a n c i a l
1 a 1 0 a 1 a 0
S I L to ta l = 1 1 1 0 a 1 a a
F = 2 2 2 1 1
S a fe t y M in o r R o t o r d is e n g a g e m e n t m a y le a d to R o to r d is e n g a g e m e n t m a y le a d t o N o n e N o n e
c o n s e q u e n c e s s e rio u s in ju ry s e rio u s in ju ry
p e o p le
S = 1 2 2
T im e ly p r e s e n c e A re a is a tte n d e d r a re ly (< 1 0 - 2 0 % ) A re a is a tt e n d e d ra re ly (< 1 0 - 2 0 % )
o f p e o p le p e r s h ift p e r s h i ft
T = 1 1 1
A vo id a n c e o f In c a s e o f h ig h v ib r a t io n , it is e x p e c te d In c a s e o f h i g h t e m p e r a t u r e i t is
e x p o s u re t h a t o p e ra t o r s w ill b e a b le t o a vo id e x p e c t e d t h a t o p e ra t o rs w ill b e a b le t o
e x p o s u re a vo id e x p o s u re
A = 1 1
S IL s a f e ty = 0 a a 0 0
C o n s e q u e n c e s M in o r N o n e N o n e N o n e N o n e
e n viro n m e n t
E = 1 0 0 0 0
A vo id a n c e o f
e x p o s u re
e n viro n m e n t
A =
S IL e n v iro n m e n t = a 0 0 0 0
F in a n c ia l lo s s e s R e p a ir o f lo c a l e q u ip m e n t / d u c t E x c e s s iv e d a m a g e t o ID fa n b e a r in g s E x c e s s iv e d a m a g e t o ID fa n b e a r i n g s R e p a ir o f m o t o r b e a rin g m a y R e p a ir o f m o t o r w in d in g s
d a m a g e le a d t o m in im a l d o w n a n d p o s s ib le ro t o r d a m a g e (p o s s ib le a n d p o s s ib le ro t o r d a m a g e (p o s s ib le ta k e m o re th a n a w e e k a n d m a y ta k e m o n th s a n d
t im e (b e c a u s e p ro d u c t io n m a y r o t o r d is e n g a g e m e n t ) re p a ir c a n b e ro to r d is e n g a g e m e n t) re p a ir c a n b e a s s o c ia t e d d o w n t im e c o s t s a s s o c ia t e d d o w n tim e c o s ts
c o n t in u e t ill n e x t p la n n e d s t o p r e a lis e d w it h in 3 d a y s (b e c a u s e s p a r e re a lis e d w it h in 3 d a y s (b e c a u s e s p a re w ill b e lim it e d t o 1 0 0 k m a x w ill e x c e e d 1 0 0 0 k
w it h s o m e t e m p o ra r y r e p a irs ) . p a rt s a re a va ila b le o n s t o c k ) . H o w e ve r p a rt s a re a va ila b le o n s t o c k ). H o w e ve r (d u e to o n s to c k s p a re m o to r C o n s id e r t o m a in t a in a n
T h u s e x p e c t e d d o w n t im e c o s t in c a s e o f th e e x tre m e e ve n t (ro to r in c a s e o f t h e e x t re m e e ve n t (ro t o r b e a rin g ) s p a re (o n s to c k ) m o to r
is le s s t h a n 1 0 0 0 k (5 d a y s ) d is e n g a g e m e n t ) t h e d a m a g e a n d d o w n d is e n g a g e m e n t) t h e d a m a g e a n d
t im e w ill b e s ig n ifi c a n t ly m o r e d o w n t im e w ill b e s ig n ific a n t ly m o r e
L = 3 3 3 2 4
A vo id a n c e o f It i s e x p e c te d th a t o p e ra t o r It is e x p e c t e d t h a t o p e r a t o r a c t io n c a n It is e x p e c t e d t h a t o p e r a t o r a c t io n c a n It is e x p e c t e d t h a t o p e r a t o r O ve rh e a tin g is p ro b a b ly
fin a n c ia l lo s s e s a c t io n c a n a vo id t h e d a m a g e b y a vo id t h e d a m a g e b y b a s e d o n b e a rin g a vo id t h e d a m a g e b y b a s e d o n b e a rin g a c t io n c a n a vo id t h e d a m a g e a vo id e d b y o ve r d im e n s io n in g
b a s e d o n va rio u s o t h e r p re s s u re t e m p e ra tu re vib ra t io n b y b a s e d o n b e a r in g vib ra t io n th e m o to r
m e a s u re m e n ts
A = 1 1 1 1 1
S IL fi n a n c i a l = 1 1 1 0 1
S IL t o t a l = 1 1 1 0 1
F u n c t io n P re ve n t c o n t in u o u s re le a s e P re ve n t A m m o n ia c a l w a t e r P re ve n t a m m o n ia le a k a g e P re ve n t c o n t in u o u s re le a s e
o f A m m o n ia d is p e rs io n d u e t o t o o h ig h p re s s u re o f A m m o n ia
S c e n a r io P o t e n t ia l e x p o s u re o f P o t e n t ia l p o llu t io n P o t e n t ia l e x p o s u re o f P o t e n t ia l p o llu t io n
d e s c rip t io n o f s t a ff/ w o r k e r s t o A m m o n ia s t a ff/ w o r k e r s t o A m m o n ia
F O D
F = 2 2 2 2
S a fe t y E x p o s u r e c o u ld le a d t o a E x p o s u re c o u ld le a d t o a E x p o s u re c o u ld le a d t o a E x p o s u re c o u ld le a d t o a
c o n s e q u e n c e s s e r io u s in ju ry s e rio u s in ju ry s e r io u s in ju ry s e rio u s in ju ry
p e o p le
S = 2 2 2 2
T im e ly p re s e n c e A re a is a t t e n d e d ra re ly (< 1 0 A re a is a t t e n d e d ra re ly (< 1 0 A re a is a t t e n d e d ra re ly (< 1 0 A re a is a t t e n d e d ra re ly (< 1 0
o f p e o p le - 2 0 % ) p e r s h ift - 2 0 % ) p e r s h i ft - 2 0 % ) p e r s h ift - 2 0 % ) p e r s h i ft
T = 1 1 1 1
A v o id a n c e o f A m m o n ia s m e ll w ill a la rm A m m o n ia s m e ll w ill a la rm
e x p o s u re s t a ff/ w o r k e r s a n d s u ffi c ie n t ( 2 s t a ff/ w o r k e r s a n d s u ffic i e n t ( 2
o r m o r e ) n u m b e r o f e s c a p e o r m o r e ) n u m b e r o f e s c a p e
A = ro u t e s a re p ro vid e d 1 1 1 ro u t e s a re p ro vid e d 1
S I L s a f e ty = a a a a
C o n s e q u e n c e s M in o r e n viro n m e n t a l im p a c t t e m p o ra ry e n v ir o n m e n t a l M in o r e n viro n m e n t a l im p a c t M in o r e n viro n m e n t a l im p a c t
e n v ir o n m e n t im p a c t
E = 1 3 1 1
A v o id a n c e o f ra in w a t e r n e t p o llu t io n
e x p o s u re
e n v ir o n m e n t
A =
S I L e n v ir o n m e n t = a 2 a a
F in a n c ia l lo s s e s M in o r fin a n c ia l im p a c t M i n o r fi n a n c ia l i m p a c t M in o r fin a n c ia l im p a c t M i n o r fi n a n c i a l i m p a c t
e x p e c t e d e x p e c t e d e x p e c t e d e x p e c t e d
L = 1 1 1 1
A v o id a n c e o f
fi n a n c ia l l o s s e s
A =
S I L f i n a n c i a l = 0 0 0 0
S I L t o t a l= a 2 a a
F u n c t io n P r e v e n t o v e r fillin g o f t h e P re v e n t re le a s e o f B ic a r t o p re ve n t m o t o r d a m a g e
B ic a r S ilo e n v ir o n m e n t in c a s e o f filt e r
c lo g g in g o r o v e r fillin g
C a u s e O p e ra t o r e rro r O p e ra t o r e rro r
S c e n a rio R e le a s e o f B ic a r t o R e le a s e o f B ic a r t o
d e s c rip t io n o f e n viro n m e n t e n viro n m e n t
F O D
A =
S I L s a f e t y = 0 0 0
C o n s e q u e n c e s T h e re le a s e h a s m in o r T h e re le a s e h a s m in o r N o n e
e n viro n m e n t e n v iro n m e n t a l im p a c t e n viro n m e n t a l im p a c t
E = 1 1 1
A vo id a n c e o f
e x p o s u re
e n viro n m e n t
A =
S I L e n v ir o n m e n t = 0 0 0
F in a n c ia l lo s s e s R e le a s e o f B ic a r w ill re q u ir e R e le a s e o f B ic a r w ill re q u ire E s t im a t e d c o s t s 1 0 - 1 0 0 k
s ig n ific a n t c le a n in g a c t iv it ie s . s ig n ific a n t c le a n in g a c t iv it ie s .
E s t im a t e d c o s t s 1 0 - 1 0 0 k E s t im a t e d c o s t s 1 0 - 1 0 0 k
L = 2 2 2
A vo id a n c e o f D u e t o t h e s t a n d b y lin e , t h e
fin a n c ia l lo s s e s p ro d u c t io n c a n c o n t in u e in
n o m in a l c o n d it io n s
A = 1 1 1
S I L f i n a n c i a l = 0 0 a
S I L t o t a l = 0 0 a
F in a l E le m e n t C lo s in g fi l l i n g va lve C lo s in g fi l l i n g va lve R e le a s e o f n it ro g e n
D e m a n d ra t e G i v e n t h a t t h e s i l o i s fi l l e d o n l y a G i v e n t h a t t h e s i l o i s fi l l e d o n l y a V e ry ve ry lo w
c o u p le o f t im e s p e r y e a r, t h e c o u p le o f t im e s p e r y e a r, t h e
e x p e c t e d d e m a n d ra t e is ve ry lo w e x p e c t e d d e m a n d ra t e is ve ry lo w
F = 1 1 1
S a fe t y E x p o s u re o f o p e ra to r to a c t iva t e d E x p o s u re o f o p e ra to r to A c t iva t e d P o s s ib le s e rio u s in ju ry
c o n s e q u e n c e s c a rb o n C a rb o n
p e o p le
S = 1 1 2
T im e ly p re s e n c e O p e r a t o r is a lw a y s p r e s e n t a t fillin g O p e ra t o r is a lw a y s p re s e n t a t fillin g S ilo a re a is ra re ly a tt e n d e d
o f p e o p le w h ic h is o u t s id e t h e b u ild in g . T h e w h ic h is o u t s id e t h e b u ild in g .
a c t u a l re le a s e p o in t in c a s e o f
o v e r fillin g is in t h e b u ild in g w h ic h is
r a re ly o c c u p ie d
T = 1 1 1
A vo id a n c e o f P e rs o n s c a n a v o id t h e e x p o s u r e
e x p o s u re b e c a u s e t h e t im e b e tw e e n t h e
in it ia l fir e a n d lo s s o f in t e g rit y o f
t h e s ilo is s u ffic ie n t t o a vo id
e x p o s u re
A = 1
S I L s a fe ty = 0 0 0
C o n s e q u e n c e s T h e r e le a s e h a s m in o r e n viro n m e n t a l T h e r e le a s e h a s m in o r T h e re le a s e h a s m in o r
e n viro n m e n t im p a c t e n viro n m e n t a l im p a c t e n viro n m e n t a l im p a c t
E = 1 1 1
A vo id a n c e o f
e x p o s u re
e n viro n m e n t
A =
S I L e n v ir o n m e n t = 0 0 0
F in a n c ia l lo s s e s R e le a s e o f a c t iv a t e d c a r b o n w ill R e le a s e o f A c t iva t e d C a rb o n w ill R e le a s e o f a c t iva t e d c a rb o n w ill
r e q u ir e s ig n ific a n t c le a n in g a c t iv it ie s . r e q u ir e s ig n ific a n t c le a n in g r e q u ir e s ig n ific a n t c le a n in g
E s t im a t e d c o s t s 1 0 - 1 0 0 k a c t ivit ie s . E s t im a t e d c o s t s 1 0 - a c t ivit ie s a n d s ilo m a y h a ve to
1 0 0 k b e re p la c e d . E s t im a t e d c o s ts
1 0 - 1 0 0 k
L = 2 2 2
A vo id a n c e o f G ive n t h a t t h e t ru c k u n lo a d in g p o in t is G ive n t h a t t h e t ru c k u n lo a d in g p o in t It is e x p e c t e d t h a t if t h e fir e
fin a n c ia l lo s s e s lo c a t e d o u t s id e t h e b u ild in g a n d t h e is lo c a t e d o u t s id e t h e b u ild in g a n d w o u ld o c c u r, t h e o p e ra t o r c a n
s ilo is in s id e t h e b u ild in g , it is t h e s ilo is in s id e t h e b u ild in g , it is n o t a vo id t h e d a m a g e (n o o t h e r
e x p e c te d t h a t t h e fin a n c ia l lo s s e s c a n e x p e c t e d t h a t t h e fin a n c ia l lo s s e s m e a n s fo r d e t e c t io n o f a n
p ro b a b ly n o t b e a vo id e d c a n p ro b a b ly n o t b e a vo id e d i n t e r n a l fi r e a v a i l a b l e )
A = 2 2 2
S I L fi n a n c i a l = 0 0 0
S I L to ta l = 0 0 0
F in a l E le m e n t R e le a s e o f n it ro g e n
F u n c tio n E x t i n g u i s h a n s p e n t s io r b e n t fi r e i n
t h e s ilo
Cause H o t s p o t in s ilo
S c e n a rio F i r e i n s i l o w h i c h m a y a ff e c t t h e s i l o
d e s c rip t io n o f in t e g rit y
FO D
D e m a n d ra te V e r y ve r y lo w
F= 1
S a fe t y P o s s ib le s e rio u s in ju ry
consequences
p e o p le
S = 2
T im e ly p re s e n c e S ilo a re a is ra re ly a t t e n d e d
o f p e o p le
T= 1
A vo id a n c e o f P e r s o n s c a n a vo id t h e e x p o s u r e
e x p o s u re b e c a u s e t h e t im e b e t w e e n t h e in it ia l
fi r e a n d l o s s o f i n t e g r i t y o f t h e s i l o i s
s u f fi c i e n t t o a v o i d e x p o s u r e
A = 1
S IL =
s a fe ty 0
Consequences T h e r e le a s e h a s m in o r e n vir o n m e n t a l
e n vir o n m e n t im p a c t
E = 1
A vo id a n c e o f
e x p o s u re
e n vir o n m e n t
A =
S IL en viro n m en t = 0
F in a n c ia l lo s s e s R e le a s e o f s p e n t s o rb e n t w ill re q u ire
s ig n ific a n t c le a n i n g a c t ivi t ie s a n d s il o
m a y h a ve t o b e r e p la c e d . E s t im a t e d
c o s ts 1 0 - 1 0 0 k
L= 2
A vo id a n c e o f It i s e x p e c t e d t h a t i f t h e f i r e w o u l d
fi n a n c i a l l o s s e s o c c u r , t h e o p e r a t o r c a n n o t a vo id t h e
d a m a g e ( n o o t h e r m e a n s fo r d e t e c t i o n
o f a n i n t e r n a l fir e a va i l a b l e )
A = 2
S I L fin a n c ia l 0
S I L to ta l = 0
F in a l E le m e n t S t o p p in g c irc u la t io n p u m p s S t o p p in g c irc u la t io n p u m p s R 1
N D A 1 1 / N D A 1 2 A P 0 0 1 if 3 w a y s
va l ve n o t i n b y - p a s s ( R 1
N D B 1 0 A A 3 5 1 p o s it io n s w it c h )
F u n c t io n p ro t e c t t h e d o w n s t re a m p ro t e c t t h e H E a n d t h e
e q u ip m e n t s a g a in s t t h e d o w n s t re a m e q u ip m e n t s a g a i n s t
c o rro s io n ris k t h e c o rro s io n ris k
C ause H i g h h e a t r e c o ve r y w i t h l o w w a t e r c o n t r o l l o o p fa i l u r e o r
lo a d a n d n o S C R b y -p a s s fu r n a c e t r o u b l e s o r l i n e s t a r t - u p
S c e n a rio
d e s c ri p t io n o f
FOD
D e m a n d ra t e B a s e d o n e x p e rie n c e : o n c e E x p e c t e d d e m a n d ra t e le s s t h a n
p e r y e a r - o n c e p e r 1 0 y e a rs once per 1 year
F= 2 1
S a fe t y N one None
cons equences
p e o p le
S =
T im e ly p re s e n c e
o f p e o p le
T=
A vo i d a n c e o f
e x p o s u re
A =
S IL s a fe ty = 0 0
C onsequenc es N one None
e n vi r o n m e n t
E =
A vo i d a n c e o f
e x p o s u re
e n vi r o n m e n t
A =
S IL e n v ir o n m e n t = 0 0
F in a n c ia l lo s s e s L i fe t i m e w i l l b e s h o r t e n e d L i fe t i m e w i l l b e s h o r t e n e d d u e t o
d u e t o c o rro s io n . E x p e c t e d c o rro s io n . E x p e c t e d d a m a g e is
d a m a g e is le s s t h a n 1 0 0 k le s s t h a n 1 0 0 k
L= 2 2
A vo i d a n c e o f It i s e x p e c t e d t h a t o p e r a t o r It i s e x p e c t e d t h a t o p e r a t o r
fi n a n c i a l l o s s e s a c t i o n c a n a vo i d t h e d a m a g e a c t i o n c a n a vo i d t h e d a m a g e b y
b y m a n u a l a c t io n m a n u a l a c t io n
A =
S IL fi n a n c i a l= a 1
S IL to ta l = a 1
WHAT IF
2.1.1.8.Air intake The manholes are not Corrosion 1 Technology choice : double flap 1
correctly closed
Check there is no leak at doors
Air intake through ashes
Operating manual instructions
circuit: evacuation
system
2.1.1.9.Low temperature hopper heating Hopper heating fault Ash plugging risk in the 2 Low temperature switch in the 2
hopper hopper with alarm
Operator checking
2.1.1.10.Electrical troubles with HV (high Operation at too low Disruptive breakdown 2 ID Fan running signal is a 2
voltage system) temperature or at too low of insulator necessary condition to run the HV
gases flowrate
Correct temperature at the ESP
inlet and at the ESP outlet is a
necessary condition to run the HV
WHAT IF
WHAT IF
WHAT IF
WHAT IF
PID 004.2 4.2. SPENT SORBENT EXTRACTION 4.2.1. Fabric filter hoppers
4.2.1.3.Low temperature heating hopper Hopper heating fault Spent sorbent plugging 2 Heating Temperature sensor 2
risk in the hopper
Operator checking
WHAT IF
4.3.1.4.Flue gas is cooled around the Cold air in pre-heating duct Duct corrosion around 2 Hot sealing air injected in the pre- 2
pre-heating dampers during normal the pre-heating heating duct
operation dampers
Air temperature sensor at the air
Battery corrosion heating battery outlet with low and
Pre heating fan very low alarm
corrosion
Operator checking.
4.3.1.5. Flue gas flow through pre- Pre-heating dampers not Pollutants level 2 Limit switch on the pre-heating 2
heating duct during normal operation tight increasing at the stack dampers with discrepancy control
Overpressure in the pre-heating
duct with sealing air injection
1 local overpressure sensor to be
checked every shift by the
operator
WHAT IF
PID 005 5.1. DIOXINS REMOVAL AND NOX 5.1.1. Reactor SCR
REDUCTION
5.1.1.2.Catalytic reactor pressure drop Catalytic reactor plugging ID fan electrical 2 1 pressure drop sensor with high 2
increases with dust and/or salts consumption increases alarm and very high alarm
Reduction of NOx 1 local pressure drop sensor on
removal efficiency the catalytic reactor layer.
Operator checking
NOx measurement at the stack
5.1.1.8.Very High dust concentration in Fabric filter by-passed SCR catalyst clogging 3 Dust concentration analyser at the 3
the flue gas risk fabric filter outlet with high and
very high alarm.
Dust concentration analyser at the
stack inlet with high and very high
alarm
SCR is by-passed in case of very
high dust concentration during a
time period or in case of fabric
filter by-pass
WHAT IF
PID 005 5.1 DIOXINS REMOVAL AND NOX 5.1.2. Gas-Gas Heat exchangers
REDUCTION
WHAT IF
PID 005 5.1 DIOXINS REMOVAL AND NOX 5.1.3. Gas-Steam Heat exchangers
REDUCTION
WHAT IF
PID 005 5.1 DIOXINS REMOVAL AND NOX 5.1.4. Fresh air damper
REDUCTION
WHAT IF
PID 005 5.1 DIOXINS REMOVAL AND NOX 5.1.5. Preheating system
REDUCTION
WHAT IF
6.1.1.2.ID Fan bearing : Very High ID Fan balance fault ID Fan bearing damage 3 Vibrations sensor with high and 3a
vibrations very high alarm
Operator checking
ID fan motor is stopped in case of
very high alarm
WHAT IF
PID 007 7.1. GAS ANALYSING 7.1.1. Analyser at the stack inlet
WHAT IF
WHAT IF
WHAT IF
PID 010 & 011 8.3. AMMONIA INJECTION 8.3.1. NH4OH Pumps
WHAT IF
PID 010 & 011 8.3 AMMONIA INJECTION 8.3.2. NH4OH injection circuit
WHAT IF
WHAT IF
WHAT IF
WHAT IF
WHAT IF
PID 008 9.4. BICAR EXTRACTION AND 9.4.1. Bicar buffer-tank extraction
INJECTION
WHAT IF
PID 008 9.4 BICAR EXTRACTION AND INJECTION 9.4.2. Bicar injection
WHAT IF
10.1.1.2.Activated carbon leakage during Activated carbon Activated carbon in the 2 1 high pressure sensor in the silo 2
the unloading overflowing from the top atmosphere and/or on with alarm
of the silo the floor
1 very high level sensor and 1
High pressure : safety analogical weight sensor with high
valve opens and very high alarm,
Activated carbon silo filter with
fault alarm
Unloading general fault alarm
obtained in case of 1 on 2 very
high alarm or silo filter fault alarm
is reached or high pressure alarm
in the silo
Unloading stopped (unloading
valve closes) if unloading general
fault is obtained
Klaxon horns if unloading general
fault is reached
High level silo indication (lamp) on
the unloading box
1 Safety valve connected on the
silo
Protection clothes and eye-
washers
Operator checking
WHAT IF
PID 009
WHAT IF
10.3.1.2.Activated carbon not available Fluidisation air injection Activated carbon 2 Alarm if low level in buffer tank 2
for extraction fault extraction stopping risk abnormally maintained
Checking by the operator of the
good operation of the silo
extraction equipment
WHAT IF
WHAT IF
10.4.1.3.No Activated carbon available Fan fault Dioxins removal 2 Low pressure sensor on transport 2
efficiency decreases air pipe
Reagent injection pipe
broken or open Activated carbon extraction
system stops in case of low
pressure
Operator checking
Automatic switch on the stand-by
injection system in case of fault
WHAT IF
WHAT IF
WHAT IF
WHAT IF
11.2.1.2.Ash silo filter clogged Ash silo filter cleaning fault Ash extraction troubles 1 Check the ash silo filter 1
11.2.1.3.Ash clogging in the silo Moisture in ashes Ash silo extraction fault 2 Heat tracing with fault alarm 2
risk
Instrument air injection in the
bottom of the silo to dry ashes
Operator checking
11.2.1.4.Very high ash temperature Electrical heating too strong Unloading design 2 1 Temperature sensor in the silo 2
temperature for truck with high and very high alarm
ESP ash too hot
exceeded
The truck loading sequence stops
in case of high temperature
Operator checking
WHAT IF
WHAT IF
WHAT IF
WHAT IF
WHAT IF
WHAT IF
WHAT IF
PID 012 13.1. GAS/WATER HEAT EXCHANGER 13.1.1. Gas/water heat exchanger (gas side)
WHAT IF
PID 012 13.1 GAS/WATER HEAT EXCHANGER 13.1.2. Gas/water heat exchanger (water side)
13.1.2.2.Very high water temperature at Very high gas Increase of the water 2 Heat exchanger is designed for 2
the gas-water heat exchanger temperature alarm at the temperature to maximal all the water temperature
gas-water heat gas temperature and conditions , according to the
exchanger inlet possible exceeding the contract
design temperature of
Failure of water 1 safety valve on the water pipe
the Heat exchanger
temperature control loop set below the heat exchanger
pressure design
water pump not in
operation
WHAT IF
PID 012 13.2. CONDENSATE WATER/WATER 13.2.1. Condensate water-water heat exchanger
HEAT EXCHANGER HE4 HE4 (water side)
WHAT IF
PID 012 13.2 CONDENSATE WATER/WATER 13.2.2. Condensate water-water heat exchanger
HEAT EXCHANGER HE4 HE4 (condensate water side)
WHAT IF
PID 012 13.3. CIRCULATION WATER PUMPS 13.3.1. Circulation Water pumps
APPENDIX 1
SIL Project Calibration