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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

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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)

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(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

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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

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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)