Process Guide work Deviation Consequence Causes Recommendation

parameter action
Reactor Higher Higher Runaway Coolant  Provide
temperature reactor reaction in pump to temperature
temperature reactor reactor fails control
 Provide high
temperature
sensor/alarm
 Provide
pressure
relief valve
with
automatic
feed from
temperature
control
system

Coolant  Use heat
temperature exchanger
high temperature
control to
adjust inlet
cooler
temperature
Lower Lower Poor or no Coolant  Provide
reactor reaction; poor temperature temperature
temperature quality product low monitoring
in reactor
 Use heat
exchanger to
adjust inlet
coolant
temperature
Flow rate No No flow Level build up Melt pump  Provide level
in reactor fails control in
reactor with
automatic
flow through
a spare
pump
Less Less flow System upset; Make up or  Provide a
product quality recycle spare
affected; compressor compressor
system failure with
shutdown automatic
switch from
 the failed
compressor
More More flow More Initiator  Provide
(initiator) polymerization; pump adequate
possibility of malfunction flow control
runaway on both
conditions; initiator and
product quality monomer
off lines to
specifications maintain the
desired
initiator to
monomer
ratio
Less Less flow Less Make up and  Provide flow
(initiator) polymerization; recycle gas controllers
reaction compressor on ethylene
temperature failure and initiator
imbalance lines
affects
downstream
equipment
such as heat
exchanger