Project name: T2 Laboratories, Inc.

Process: MCMT batch reactor

Section: Reactor
Item Study Node Process Parameters Deviations Possible Causes Possible Consequences Action Required
1A Cooling coil Flow No 1. Control valve fails closed 1. Loss of cooling, possible runaway and reactor overpressure 1. Select valve to fail open
2. Plugged cooling coils (possibly due to mineral scale) 2. Loss of cooling, possible runaway and reactor overpressure 2. Install filter with maintenance procedure.
Install cooling water flow meter and low flow alarm
Install high temperature alarm ti alert operator
3. Cooling water service failure 3. Loss of cooling, possible runaway and reactor overpressure 3. Check to monitor reliability of water service
4. Controller fails and closes valve 4. Loss of cooling, possible runaway and reactor overpressure 4. Place controller on critical instrumentation list
5. Air pressure fails, closing valve 5. Loss of cooling, possible runaway and reactor overpressure 5. See 1A.1
1B High 1. Control valve fails open 1. Reactor cools, reactant concentration builds, possible runaway on heating 1. Instruct operators and update procedures
2. Control fails and opens valve 2. Reactor cools, reactant concentration builds, possible runaway on heating 2. See 1A.4
1C Low 1. Partially plugged cooling line (possibly due to mineral scale) 1. Diminished cooling, possible runaway and reactor overpressure 1. See 1A.2
2. Partial water source failure 2. Diminished cooling, possible runaway and reactor overpressure 2. See 1A.2
3. Control valve fails to respond 3. Diminished cooling, possible runaway and reactor overpressure 3. Place valve on critical instrumentation list
1D As well as 1. Contamination of water supply 1. Not possible here 1. None/check maintenance procedures
1E Part of 1. Covered under 1C
1F Reverse 1. Failure of water source resulting in backflow 1. Loss of cooling, possible runaway and reactor overpressure 1. See 1A.2
2. Backflow due to high backpressure 2. Loss of cooling, possible runaway and reactor overpressure 2. Install check valve
1G Sooner than 1. Cooling normally started early 1. None
1H Later than 1. Operator error 1. Temperature rises, possible runaway and reactor overpressure 1. Interlock between cooling flow and reactor feed
1I Temperature Low 1. Low water supply temperature 1. None - controller handles 1. None
1J High 1. Higher water supply temperature 1. Cooling system capacity limited, temperature increases, pressure increases 1. Install high flow alarm and/or cooling water high temp. alarm

2A Stirrer Agitation No 1. Stirrer motor malfunction 1. No mixing, possible accumulation of unreacted materials 1. Interlock with feed line
2B More 1. Stirrer motor controller fails, resulting in high motor speed 1. None

3A Raw Materials Feed Flow No 1. Feed line is plugged 1. No reaction occurs 1. Operators should check/maintain feed line
*Feed line consists of all Reactant levels should constantly be checked
materials besides sodium 2. Feed line is cut 2. No reaction occurs 2. Operators should check/maintain feed line
Operators should check that rotameters are calibrated prior to startup
3B Low 1. Partially plugged feed line 1. Low reaction rate, low conversion 1. Operators should check feed lines, reactant levels, and update maint. procedures
2. Leaking feed line 2. Low reaction rate, low conversion. Possible hazardous spill of feed materials. 2. Operators should check feed lines, reactant levels, and update maint. procedures
Proper cleanup consistent with safety and hazard information
3C As well as 1. Contamination of feed, however very unlikely 1. Contaminated product, possible side reaction, low yield, unknown safety hazards 1. Quality control checks on feed materials and products
Operators should have general knowledge on hazardous side reactions of the reactant
3D Sooner than 1. Extra sodium added before adequate conversion is reached in the reactor 1. High reaction rate, higher temperatures. Possible overheating, runaway, overpressure 1. Operators should check feed lines and update maintenance procedures
3E Other than 1. Something else besides typical reactants added 1. Contaminated product, possible side reaction, unknown safety hazards 1. Quality control checks on feed materials and products
Operators should have general knowledge on hazardous side reactions of the reactant
3F Concentration High 1. Improper scaling of reactor vessel 1. High reaction rate, higher temperatures. Possible overheating, runaway, overpressure 1. Operators should maintain surface area to volume ratio during scale up

4A Reactor Temperature Low 1. Hot oil system or cooling coil malfunction, lower concentration of feed, faulty temp. indicator 1. Low reaction rate, low conversion 1. Install temp. indicator controller, check reactant levels, and update maint. procedures
4B High 1. Hot oil system or cooling coil malfunction, higher concentration of feed, faulty temp. indicator 1. High reaction rate, possible runaway and overpressure 1. Operators should check all process parameters and update maintenance procedures
4C Pressure High 1. Hot oil system or cooling coil malfunction, higher concentration of feed, faulty pressure indicator 1. Possible explosion 1. Operators should check all process parameters and update maintenance procedures
Adequate pressure relief valve system should be in place
4D Volume Low 1. Improper scaleup 1. High reaction rate, higher temperatures. Possible overheating, runaway, overpressure 1. Operators should maintain surface area to volume ratio during scale up

5A Drainage Valve Flow High 1. Drain valve malfunction/fails open 1. Water can not properly cool system, causing reactor to overheat. Possible runaway, overpressure 1. Operators should check drainage lines prior to startup.

6A Operating Instruction Rupture disk pressure limit Wrong action 1. Operators unaware of pressure safety hazards and set rupture disk pressure too high 1. Overpressure relieved too late, causing explosion 1. Operators should be aware of pressure specifications for each exothermic reaction
Thorough scale up analysis to determine the amount of pressure to relieve in each reaction
6B Training Low 1. Neither owners previously worked with reactive processes, insufficient experience 1. Insufficient knowledge on controlling runaway reactions or more exothermic side reactions 1. Owners should have sufficient training in reactive processes to safely operate
Increased severity in accidents Owners should discuss/update emergency instructions and management of change clearly to employees
Possible runaway and explosion Owners should be knowledgable on all safety hazards and minimize them
Owners should perform preventative maintenance on all process nodes
6C Process hazard information Unclear/none 1. Limited published information on MCMT 1. Hazards of product are not clearly identified. Employers can not adequately ensure safety 1. Owners should thoroughly investigate the reaction in the lab with as many scenarios as possible
Underestimation of full-scale batch temperatures Scaleup procedures should include reaction's behavior at higher temperatures
6D Emergency cooling Unclear/none 1. Insufficient experience, lacking sufficient safety training 1. Backup source of water was not immediately available 1. Owners should have sufficient training in reactive processes to safely operate
No emergency instructions to combat overheating of reactor when cooling line fails Owners should discuss/update emergency instructions and management of change clearly to employees
6E Venting hydrogen Wrong action 1. Insufficient experience, lacking sufficient safety training 1. Venting excess hydrogen to the atmosphere is extremely flammable and can cause severe damage 1. Hydrogen gas should have been burned out instead of vented since it is flammable