Trouble Shooting

Trouble Shooting
7 Trouble Shooting
7 Trouble Shooting ....................................................... 7-1

7.1 General information ..................................................... 7-2
7.2 List of faults ................................................................. 7-4
7.2.1 Burner faults ................................................................ 7-4
7.2.2 Reformer pipe faults .................................................... 7-4
7.2.3 Stack Faults................................................................. 7-5
7.2.4 Trouble Shooting ......................................................... 7-5
7.3 Index of faults ............................................................ 7-53
H2- Production Plant Habas II Turkey 123100722/00, 722E007_uk, 28.03.2013 7-1/57

Trouble Shooting
7.1 General information
Should any irregularities in comparison

with the normal operation of the plant be
discovered, shut down the plant and con-
tact Mahler AGS!
If the plant is switched to Step 0 as a re-

sult of a fault, immediate measures are to
be taken to restore the cooling water sup-
ply, the feed water supply of the heat re-
covery unit, the instrument air supply and
the N2-supply for purging the plant. Pro-
vide temporary supply connections in case
of emergency. This is necessary to pre-
vent possible danger and damages.
The current alarm is displayed in header of the
SCADA system
⇒ see 5.6.1 „Errors, Alarms and Warnings in the
Group Display“ in Operating description SCADA-
System File 3
see also the manufacturers’ instructions regarding

faults.
If it is possible for an operator to detect the cause
of a fault directly after its occurrence and to elimi-
nate it, the plant can be restarted.
If it is not immediately to detect and eliminate, or
some repair work is needed, the plant must be put
out of operation in any case.
⇒ see 5.5 „Shutdown in the manual mode of opera-
tion“ or 5.6 „Shutdown in the automatic mode of
operation“
If faults occur, prove the operating parameters
registered in the acceptance record. Correct them
if necessary!

Trouble Shooting
Repairs can be fulfilled only by authorized skilled

personnel in the presence of the company’s safety
inspector.
For the attention of repair personnel!
Observe safety instructions for handling hy-
drogen!
Danger of fire!
No smoking or open flame while fulfilling
the following work. Keep potential ignition
sources away!
Basically, the instructions of manufacturers of
particular instruments and devices concerning
faults are to be observed.
⇒ see: separate manufacturer’s instructions
With all faults it is basically to prove if the measur-
ing is completed correctly. Prove measuring in-
struments and signal lines.
If there are faults in the operation of motors, check
the driving devices and pumps or fans.
With faults caused by a mechanical failure of a
valve, check the corresponding valve.
• Prove the adjustment of valves.
• Prove the pneumatic and electrical connec-
tions.
• Prove if the instrument air is polluted.
• Prove the seals of the valve.
• Prove if the drive runs correctly.
• Prove if the positioner functions correctly.

Trouble Shooting
7.2 List of faults
7.2.1 Burner faults

Fault Possible cause Remedy
Burner cannot achieve Burner gas system is clogged up − Clean the burner gas system
its full performance
Excess air is too much − Reduce the supply of combustion
air
Too little combustion air − Increase the supply of combustion
air
Inappropriate mixture of fuel gas and − Change the ratio between the igni-
combustion air tion and the combustion air
Flame form changes Inappropriate mixture of fuel gas and − Change the ratio between the igni-
Burner gas nozzle is clogged up − Clean the burner gas nozzle
Combustion air supply is clogged − Remove clogging matters
CO-excess in flue gas Too little combustion air − Increase the supply of combustion
air
Formation of carbon Too little combustion air − Increase the supply of combustion
air
7.2.2 Reformer pipe faults

Unequally hot zones Catalyst contamination − Replace the catalyst
Catalyst activity is diminished because − Replace the catalyst
of its age
The pipe is cooled only in the areas of − Knock on the pipe to remove the
the steam reformation reaction. This is hollows. This can be done only
caused by duct formation in the cata- when the plant is in standstill.
lyst bed.
Hot spots and stripes There is an overheating in the hollows − Knock on the pipe to remove the
of the catalyst bed. hollows. This can be done only
when the plant is in standstill.
Temperature increase Catalyst activity is too low. − A additional reduction should be
in all reformer pipes is carried out.
higher than expected
Under firing; reformer The filling material is carbonised − Carbon deposition can be eliminat-
outlet temperature is (deposition of carbon) ed by a new reduction process.
higher than usually − Exchange the catalyst if necessary.

Trouble Shooting
7.2.3 Stack Faults

Flame appearance at the Bad weather circumstances. − Reduce plant capacity to minimum
top of the stack. (35%).
− Feed nitrogen by using a hose at the
bottom of the stack.
If these actions will not be successful then trip the
plant after 10 hours of flame appearance.
7.2.4 Trouble Shooting
Fault messages Meaning Remedy

EOSAL1601 Motor M1601 of the − Check if the motor protection
RUN M1601 combustion air blower is not is on.
Medium:
***
running. − Check the cabling.
− Check the motor.
− Switch off the motor and
check motor and blower on
mechanical blockage.
ESAL1601 Motor protecting switch of − Check the bimetal.
OVERLOAD M1601 motor M1601 of the − Check the thermistor protec-
Medium: combustion air blower was tive relay.
***
activated. − Switch off the motor and
check motor and compressor
on mechanical blockage and
repair it if necessary.
FAL1601; FSL1601 Combustion air flow after − Check the settings of the
F-COMBUSTION AIR combustion air blower valves for orifice measuring
Medium: V01601 is too low. and correct it if necessary.
COMBUSTION AIR
− Check filter F1601 on impuri-
ties and clean it if necessary.
− Check the blower and motor.
− Check the lines on the pres-
sure sides for leakages.
− Check the settings of the but-
terfly valves K1602, K1603
and correct it if necessary.
− Open butterfly valve K1601 for
a short time and check air
preheater W11002 on obsta-
cles and remove them if nec-
essary.

Trouble Shooting

FZALL1601 Combustion air flow after − Check the settings of the
F-COMBUSTION AIR combustion air blower valves for orifice measuring
Medium: V01601 is much too low. and correct it if necessary.
COMBUSTION AIR
− Check the blower and motor.
− Check the lines on the pres-
sure sides for leakages.
− Check the settings of the but-
terfly valves K1602, K1603
a short time and check air
preheater W11002 on obsta-
cles and remove them if nec-
essary.
FJSAL1601 Connection or transmitter of − Check the transmitter and re-
FAULT TRANSMITTER the flow measuring place or repair it if necessary.
Medium:
***
(combustion air) is defective. − Check lines and connection
and repair them if necessary.
TJAL1601 Connection or transmitter − Check the transmitter and re-
FAULT TRANSMITTER TT1601 of temperature pair and replace if necessary.
Medium: measuring is defective. Check lines and connections
***
and repair it if necessary.
TSAH1601 Coil temperature in the − Check the motor if venting
T-FAULT WINDING M1601 motor of the combustion air openings are covered and re-
Medium: blower is too high. move obstacles if necessary.
MOTOR WINDING
− The room temperature is pos-
sibly too high.
− Check blower V1601 on me-
chanical blockage and repair it
if necessary.
EOSAL1602 Motor M1602 of the − Check if the motor protection
RUN M1602 combustion air blower for is on.
Medium:
***
the ignition burner is not − Check the cabling.
running. − Check the motor.
OVERLOAD M1602 motor M1602 of the ignition − Check the thermistor protec-
Medium: air blower V01602 was tive relay.
***
activated. − Switch off the motor and
mechanical blockage and re-
pair it if necessary.

Trouble Shooting

PAHH1602 Outlet pressure of − Check settings of shut off
P-COMBUSTION AIR combustion air blower valves to pressure transmitter
Medium: V01601 is much too high. V1602 and correct them if
COMBUSTION AIR
necessary.
− Check the set values of pres-
sure measuring and correct
them if necessary.
− Check butterfly valves K1602,
K1603 and open them if nec-
essary.
a short time to prove air pre-
heater W11002 on any obsta-
cles which cut off the flow of
combustion air.
PAL1602; PSL1602 Outlet pressure of − Check settings of shut off
Medium: V01601 is too low. V1602 and correct them if
COMBUSTION AIR
necessary.
them if necessary.
− Check combustion air line on
pressure side of the blower
V01601 on leakages and seal
line if necessary.
− Check combustion air inlet on
any obstacles which cover the
inlet and remove them if nec-
essary.
− Check function of combustion
air blower V01601 and repair it
if necessary.
PZALL1602 Outlet pressure of − Check settings of shut off
Medium: V01601 is much too low. V01602 and correct them if
COMBUSTION AIR
necessary.
them if necessary.
pressure side of the blower
V01601 on leakages and seal
line if necessary.
− Check combustion air inlet on
any obstacles which cover the
inlet and remove them if nec-
essary.
− Check function of combustion
air blower V01601 and repair it
if necessary.

Trouble Shooting

PJSAL1602 Connection or transmitter of − Check the transmitter and re-
FAULT TRANSMITTER pressure measuring PT1602 pair or replace it if necessary.
Medium: (combustion air) is defective. Check lines and connections
***
***
***
FAL8002 Cooling water flow is too − Check the Cooling water-
F-COOLING WATER low. supply.
Medium:
COOLING WATER
− Check if K8001, K8002, K8005
and K8006 are opened and
open them if necessary.
− Check the filters F8001 and
F8002 for impurities and clean
them if necessary.
PSAL8201 Pressure of the instrument − Check instrument air supply at
P-INSTRUMENT AIR air supply is too low. battery limit.
Medium:
INSTRUMENT AIR
− Check inlet ball valve H8201
and open it if necessary.
− Check the setting of pressure
reducer PC8201 and correct
setting if necessary.
− Check filter F8201 for impuri-
− Check instrument air line on
leakages and seal line if nec-
essary.
FAULT TRANSMITTER flow measuring FT8301 (fuel place or repair it if necessary.
Medium:
***
gas) is defective. − Check lines and connection
FAH8301 Flow of fuel gas at orifice − Check the setting of pressure
F-FUEL GAS measuring FX8301 is too reducer PC8302 (350 mbar ü)
Medium: high. and correct it if necessary.
FUEL GAS
− Check control parameters and
correct them if necessary.
− Check the settings of the shut
off valves at orifice measuring
V8301 and correct the settings
if necessary.
− Check function of pneumatic
valves FV8301, UV8300 and
repair them if necessary.

Trouble Shooting

FAL8301 Flow of fuel gas at orifice − Check fuel gas line on leak-
F-FUEL GAS measuring FX8301 is too ages and seal line if neces-
Medium: low. sary.
FUEL GAS
− Check the setting of pressure
reducer PC8302 (350 mbar ü)
if necessary.
− Check, if ball valves H8301,
H8302 are open and open
them if necessary.
ties and clean them if neces-
sary.
− Check non return valve R8302
FSAHH8301 Flow of fuel gas at orifice − Check the setting of pressure
F-FUEL GAS measuring FX8301 is much reducer PC8302 (350 mbar ü)
Medium: too high. and correct it if necessary.
FUEL GAS
if necessary.
PZAL8301 Fuel gas pressure (NG) at − Check, if ball valve H8302,
P-FUEL GAS PS8301 is too low. H8301 is open and open it if
Medium: necessary.
FUEL GAS
− Check the settings of pressure
reducer PC8302, PZH8302
and correct settings if neces-
sary.
− Check fuel gas line on leak-
ages and seal line if neces-
sary.
RZAL8311 Fault on Flame monitoring at − Check Flame monitoring sys-
FLAME FAULT BURNER 1 burner 1. tem.
Medium:
***
− Check lines and connection

Trouble Shooting

RJAL8311 Connection, electr. lines or − Check the transmitter and re-
FAULT TRANSMITTER transmitter RT8311 is pair or replace it if necessary.
Medium: defective. Check the lines and connec-
***
tions and repair them if neces-
sary.
RZAL8321 Fault on Flame monitoring at − Check Flame monitoring sys-
FLAME FAULT BURNER 2 burner 2. tem.
Medium:
***
− Check lines and connection
RJAL8321 Connection, electr. lines or − Check the transmitter and re-
FAULT TRANSMITTER transmitter RT8321 is pair or replace it if necessary.
***
sary.
EOSAL8302 Leakage test failed. − Check valves UV8300,
FAULT LEAKAGE TEST A shut down in step 4 takes UV14203, UV8311/21,
BURNER place. UV8312/22.
Medium:
*** − Check burn gas supply for
leakages.
PZAL8302 Leakage test failed. − Check valves UV8300,
P-FUEL GAS LEAKAGE A shut down in step 4 takes UV14203, UV8311/21,
TEST place. UV8312/22.
Medium:
FUEL GAS − Check burn gas supply for
leakages.
PZAH8303 Fuel gas pressure (NG) is − Check the settings of pressure
P-FUEL GAS too high. reducer PC8302, PZH8302
Medium: and correct settings if neces-
FUEL GAS
sary.
PZAH8304 Failure on pressure switch − Check fuel gas supply.
P-FUEL GAS LEAKAGE PS(Z)8304 or leakages on − Check connections at pres-
TEST pneumatic valves UV8300, sure switches of leakage test
Medium: UV14203.
FUEL GAS and repair them if necessary.
valves UV8300, UV14203 and
PSAH8305 Fuel gas pressure (NG) of − Check the settings of pressure
P-FUEL GAS inlet E8301 is too high. reducer and correct settings if
Medium: necessary.
FUEL GAS
EOSAL8316 Failure on burner AA8311. − Check the burner and repair it

CHECK-BACK SIGNAL if necessary.
BURNER 1 − See also manual of manufac-
Medium:
*** turer of the burner.
EZAL8316 Fault on burner AA8311 − Check the firing devices.
FAULT BURNER 1: LIGHT firing device. − Check the UV-cell.
FROM EXTERNAL SOURCE
Medium:
***
EOSAL8326 Failure on burner AA8321. − Check the burner and repair it
CHECK-BACK SIGNAL if necessary.
BURNER 2 − See also manual of manufac-
Medium:
*** turer of the burner.

Trouble Shooting

EZAL8326 Fault on burner AA8321 − Check the firing devices.
FAULT BURNER 2: LIGHT firing device. − Check the UV-cell.
FROM EXTERNAL SOURCE
Medium:
***
ESAL8801 Fault on level probe − Check the probes of the ampli-
L-KNOCK OUT DRUM (LS(Z)8801) of knockout fier.
DEVICE FAULT VEGA drum F14001. − Check if vessel F14001 is
Medium:
CONDENSATE filled.
− Check the evaluating device.
(G)AL8801 Valve LV8801 is too far − Check level situation in
G-KONDENSATE F14001 TO closed. F14001
DRAIN − Contact Mahler AGS.
Medium:
***
LAH8801 The filling level of knockout − Check the settings of the shut
L-KNOCK OUT DRUM drum F14001 is too high. off valves at level measuring
F14001 V8802, V8803 and open them
Medium:
CONDENSATE
if necessary.
− Check the function of the level
switches and repair them or
correct settings if necessary.
valve LV8801 (pressure re-
ducer, electr. pneum. posi-
tioner and solenoid valve) and
LAL8801 The filling level of knockout − Check lines and knock out
L-KNOCK OUT DRUM drum F14001 is too low. drum F14001 on leakages and
F14001 There is a hazard of process seal lines or knock our drum if
Medium: gas escaping into the
CONDENSATE
necessary.
atmosphere. − Check discharge valves
H8804, H8806, V8805 and
close them if necessary.
off valves at level measuring
V8802, V8803 and open them
if necessary.
switches and repair or correct
settings if necessary.

Trouble Shooting

LSAHH8801 The filling level of knockout − Check the settings of the shut
L-KNOCK OUT DRUM drum F14001 is much too off valves at level measuring
F14001 high. V8802, V8803 and open them
Medium:
CONDENSATE
if necessary.
LSALL8801 The filling level of knockout − Check lines and knock out
L-KNOCK OUT DRUM drum F14001 is much too drum F14001 on leakages and
F14001 low. There is a hazard of seal lines or knock our drum if
Medium: process gas escaping into
CONDENSATE
necessary.
the atmosphere. − Check discharge valves
H8804, H8806, V8805 and
off valves at level measuring
V8802, V8803 and open them
if necessary.
LJSAL8801 Connection or transmitter − Check the transmitter and re-
FAULT TRANSMITTER LT8801 at level measuring is pair or replace it if necessary.
***
tion and repair them if neces-
sary.
LZAL8801 The filling level of knockout − Check the probes of the ampli-
L-KNOCK OUT DRUM drum F14001 is too low. fier.
F14001 TRIPPED There is a hazard of process − Check if the vessel is filled.
Medium:
CONDENSATE
gas escaping into the − Check the actuator.
atmosphere. − Check the pilot valve.
− Check the setting of PC8801.
LSAH8802 Filling level in knock out − Check pneumatic valve
L-KNOCK OUT DRUM drum F14001 is too high. LV8801.
F14001 TRIPPED PV14001will be closed, so − Check if V8806 and V8801 are
Medium: that no liquid enters the
CONDENSATE open and open them if neces-
PSA. sary.
EAL9001 Failure of sequence − Check the sequence and cor-
FAULT SFC PSS 1 NOT IN rect the settings if necessary.
AUTOMATIC Change the mode of the se-
Medium:
***
quence from manual to auto-
matic.
− Contact Mahler AGS.

Trouble Shooting

Medium:
***
matic.
Medium:
***
matic.
Medium:
***
matic.
Medium:
***
matic.
Medium:
***
matic
Medium:
***
matic.
Medium:
***
matic.
Medium:
***
matic.
Medium:
***
matic.

Trouble Shooting

Medium:
***
matic.
Medium:
***
matic.
FAULT SFC MSS 1 NOT IN rect the settings if necessary
AUTOMATIC − Contact Mahler AGS.
Medium:
***
Medium:
***
Medium:
***
EZAL9031 A software fault is present in − Please contact Mahler AGS.
FAULT LIFEBIT DB-PUT the PLC.
Medium:
***
EAL9032 A software fault is present in − Please contact Mahler AGS.

FAULT LIFEBIT DB-GET- the PLC.
ANA
Medium:
***
FAULT LIFEBIT DB-GET-BIN the PLC.
Medium:
***

FAULT LIFEBIT DB-GET- the PLC.
TIME
Medium:
***
S7-417F_OB80_CYCLE the PLC.
TIME FAULT
Medium:
***
EAL9041 Low power of PLC buffer − Change PLC buffer battery.
S7-417F_OB81_BATTERY battery.
FAULT
Medium:
***

Trouble Shooting

S7- the PLC.
417F_OB82_DIAGNOSTIC
ALARM
Medium:
***
S7-417F_OB85_OB NOT the PLC.
LOADED FAULT
Medium:
***
S7-417F_OB86_LOSS OF the PLC.
RACK FAULT
Medium:
***
S7-417F_OB121_PROGRAM the PLC.
ERROR FAULT
Medium:
***
S7-417F_OB122_MODULE the PLC.
ACCESS ERROR
Medium:
***
EAL9048 The message appears in − The message disappears after
S7-417F NOT IN SAFETY programm edit mode. quitting the program edit
OPERATION MODE mode.
Medium:
***
ESAL9051 This message appears, if − Eliminate present malfunctions
SWITCH OFF PSS02 AFTER the plant must be switched and start up the plant.
PSS04 RC FAULT due to a malfunction into the
Medium: step 4. If the temperature of
***
the reformer > 750 C the
combustion air blowers will
be switched off (step 2) to
avoid a cooling down of the
reformer.
EZAL9052 EMERGENCY STOP push − Detect the reason to activate
EMERGENCY STOP button to deactivate the the EMERGENCY STOP push
BURNER OFF burner was pushed. button and eliminate the mal-
Medium:
***
function.
− Unlock EMERGENCY STOP
push button electrically and
mechanically.
− Start up the plant again.
ESAH9054 A software fault is present in − Please contact Mahler AGS.
DIFFERENT LOAD POINTER the PLC.
>2
Medium:
***
ESAL9055 The actuell burner in PSS04 − Please contact Mahler AGS.
TOO MANY BURNER cannot start correctly − Check the firing devices.
FAULTS PSS04 − Check the UV-cell.
Medium:
***

Trouble Shooting

Medium:
***
Medium:
***
COMMON FAULT the PLC.
FB00008_DI_24
Medium:
***
FB00024_DI_24
Medium:
***
FB00040_AI_6
Medium:
***
FB00056_AI_6
Medium:
***
FB00072_DO_10
Medium:
***
FB00080_DO_10
Medium:
***
FB00088_DO_10
Medium:
***
FB00056_DI_8
Medium:
***
EMERGENCY STOP +CP button at the control cabinet the EMERGENCY STOP push
Medium: was pushed. button and eliminate the mal-
***
function.
mechanically.

Trouble Shooting

EZAH9204 Key switch for enable − Switch back the key switch
ENABLE MANUAL Operation manual Operation of Z-
OF Z-EQUIPMENT Equipment is on.
Medium:
***
ESAH9204 Key switch for enable − Switch back the key switch
ENABLE MANUAL Operation manual Operation of
OF EQUIPMENT Equipment is on.
Medium:
***
EAL9208 Outlet socket fuse tripped. − Check the outlet sockets and
FUSE TRIPPED SOCKET- repair or replace them if nec-
OUTLETS LOCAL essary.
Medium:
*** − Check the cables of the outlet
sockets and repair them if
necessary.
EAL9209 Control cabinet lighting fuse − Check the Control cabinet
FUSE TRIPPED FAN AND tripped. lighting.
SOCKET-OUTLETS Control cabinet fan fuse − Check the Control cabinet fan.
Medium: tripped.
***
EAL9211 Supply voltage 230V AC − Check supply voltage 230V
FUSE TRIPPED SUPPLY fuse tripped. AC, detect the reason of over-
230V AC load and repair it if necessary.
Medium:
***
EAL9213 Supply voltage 24V DC fuse − Check supply voltage 24V DC
FUSE TRIPPED SUPPLY tripped. and repair it if necessary.
24V DC
Medium:
***
EAL9217 Supply voltage 24V DC fuse − Check supply voltage 24V DC
FUSE TRIPPED SUPPLY tripped. and repair it if necessary..
ENERGY METER
Medium:
***
ESAL9220 The plant was tripped − Check the reason for shut
EXTERNAL TRIP H2-PLANT external. down.
Medium:
***
− Eliminate malfunctions if nec-
essary.
− Put the plant in operation.
FAL9401 Flow of nitrogen at flow − Check nitrogen line on leak-
F-NITROGEN transmitter FIT9401 is too ages at seal line if necessary.
Medium:
NITROGEN
low. − Check, if ball valve H9401 is
open and open it if necessary.
− Check the settings of the ball
valves to atmosphere and
− Check the settings of the throt-
tle valves V9406, V9407 and
open a little more if necessary.
− Check the function of pneu-
matik valves UV902, UV9403,
UV9404, UV9405 and repair
them if necessary.
− Check the non return valves
R9401, R9402 on mechanical
blockage and repair them if
necessary.

Trouble Shooting

FJAL9401 Connection or transmitter of − Check the transmitter and re-
FAULT TRANSMITTER flow measuring FIT9401 place or repair it if necessary.
Medium:
***
(N2) is defective. − Check lines and connection
PAL9402 Pressure of the N2-supply at − Check nitrogen supply at bat-
P-NITROGEN pressure transmitter PT9402 tery limit.
Medium:
NITROGEN
is too low. − Check setting of shut off
valves to pressure transmitter
V9402 and correct it if neces-
sary.
− Check nitrogen inlet ball valve
H9401 and open it if neces-
sary.
− Check shut off valves to at-
mosphere H9402, H9403 and
− Check nitrogen line on leak-
sary.
PJAL9402 Connection or transmitter of − Check the transmitter and re-
FAULT TRANSMITTER pressure measuring PT9402 pair or replace it if necessary.
Medium: is defective. Check lines and connections
***
EMERGENCY STOP FENCE button at fence door 1-3 was the EMERGENCY STOP push
DOOR 1-3 activated. button and eliminate the mal-
Medium:
***
function.
mechanically.
TAH9703 Temperature in the EEC − Check the air conditioning sys-
TEMPERATURE EEC ROOM room is too high. tem of the EEC room.
Medium:
AIR

***
***
***
***

Trouble Shooting

EAL9706 Fault on electrical electrical − Check the fuse.
COMMON FAULT PIPE trace heating. − Check the electrical trace
HEATING +1UVRBH heating.
Medium:
*** − See also the manual of the
manufacturer
EOSAL9706 Failure at electrical trace − Check electrical trace heating
CHECK-BACK SIGNAL PIPE heating +1UVRBH. and lines and repair it if nec-
HEATING +1UVRBH ON essary.
Medium:
*** − See also manual of the manu-
facturer of the electrical trace
heating.
FJAL10001 Connection or transmitter − Check the transmitter and re-
FAULT TRANSMITTER FT10001 of pressure pair or replace it if necessary.
***
PAH10001 Incomming pressure of NG − Check the settings of the shut
P-NG is too high. off valves to pressure trans-
Medium: mitter V10001 and correct set-
NG
tings if necessary.
valve UV10001 and repair it
necessary.
− Check ball valve H10003/04
and open it if necessary.
PJAL10001 Connection or transmitter − Check the transmitter and re-
FAULT TRANSMITTER PT10001 of pressure pair or replace it if necessary.
***
EMERGENCY STOP HEAT button at heat exchanger the EMERGENCY STOP push
EXCHANGER skid was activated. button and eliminate the mal-
Medium:
***
function.
mechanically.
− Start-up the plant again.

Trouble Shooting

FAL10201 NG flow after desuphurizer − Check NG line on leakages
F-NG CONTENT FEED C10201 at orifice measuring and seal line if necessary.
Medium:
NG
FX10201 to mixing point − Check control parameters and
(steam / feed gas) is much correct them if necessary.
low. − Check ratio value and correct
it if necessary.
− Check setting of shut off
valves at orifice measuring
V10201 and correct settings if
necessary.
− Check, if shut off valve
V10206 is closed and close it
if necessary.
valves UV10204, FV10201,
UV10205 and repair them if
necessary.
blockage and correct it if nec-
essary.
FSALL10201 NG flow after desuphurizer − Check NG line on leakages
F-NG CONTENT FEED C10201 at orifice measuring and seal line if necessary.
Medium:
NG
FX10201 to mixing point − Check control parameters and
(steam / feed gas) is much correct them if necessary.
too low. − Check ratio value and correct
it if necessary.
− Check setting of shut off
valves at orifice measuring
V10201 and correct settings if
necessary.
if necessary.
valves UV10204, FV10201,
UV10205 and repair them if
necessary.
blockage and correct it if nec-
essary.
FAULT TRANSMITTER flow measuring (NG) place or repair it if necessary.
Medium:
***
FT10201 is defective. − Check lines and connection
FAULT TRANSMITTER pressure measuring pair or replace it if necessary.
Medium: PT10201 is defective. Check lines and connections
***
***

Trouble Shooting

***
***
***
***
TAH10205 NG temperature at outlet of − Check HT-CO-Shift C14001
T-NG PREHEATER OUTLET Preheater W14001 is too on impurities and clean them if
Medium: high. necessary.
NG
− Check preheater W14001 on
impurities and clean them if
necessary
TAL10205 NG temperature at outlet of − Check HT-CO-Shift C14001
Medium: low. necessary.
NG
necessary
***
TAH10206 NG temperature at outlet of − Check HT-CO-Shift C14001
NG
necessary
TAL10206 NG temperature at outlet of − Check HT-CO-Shift C14001
Medium: low. necessary.
NG
necessary
***

Trouble Shooting

EOSAL11001 Motor M11001 of waste gas − Check if the motor protection
RUN M11001 blower V11001 is not is on.
Medium:
WASTE GAS
running. − Check the cabling.
ESAL11001 Motor protecting switch of − Check if the motor protection
OVERLOAD M11001 motor M11001 of the waste is on.
Medium:
***
gas blower was activated. − Check the cabling.
***
LZAL11001 Water level in the heat − Check function of level trans-
L-HEAT-RECOVERY D11001 recovery D11001 is too low. mitter, level switches and re-
Medium: pair them or correct settings if
BOILER FEED WATER
necessary.
− Check, if shut off valves
V11006, V11018, V11017,
V8807, H12003 are closed
and close them if necessary.
− Check heat recovery system
D11001 and BFW-lines on
leakages and seal lines or
heat recovery system if nec-
essary.
− Check settings of throttle valve
V12010 and open it if neces-
sary.
− Check non return valve
R12003 on mechanical block-
age and repair them if neces-
sary.
− Check the set values for the
steam amount and correct the
values if necessary.
− Check the steam pressure and
correct the steam pressure if
necessary.
− Check the parameters of feed
water supply and correct them
if necessary.
− Check the feed water supply.

Trouble Shooting

PAH11001 Pressure in heat recovery − Check the reformer tempera-
P-HEAT RECOVERY D11001 D11001 is too high. ture control and correct set-
Medium: tings if necessary.
STEAM
− Check the steam amount and
− Check the air amount and cor-
rect settings if necessary.
− Check throttle valve V13201
and open it a little more if nec-
essary V13201.
valve TV13201 and repair it if
necessary.
− Check position of main steam
valve V11202 and open it if
necessary.
PZAHH11001 Pressure in heat recovery − Check the reformer tempera-
P-HEAT RECOVERY D11001 D11001 is much too high. ture control and correct set-
Medium: tings if necessary.
STEAM
− Check the air amount and cor-
essary V13201.
necessary.
− Check position of main steam
valve V11202 and open it if
necessary.

Trouble Shooting

PZAH11010 Pressure in heat recovery − Check the reformer tempera-
P-HEAT RECOVERY D11001 D11001 is too high. ture control and correct pa-
Medium: rameters if necessary.
STEAM
− Check waste gas temperature
after reformer and correct
temperature if necessary.
correct it if necessary.
− Check the air and fuel gas
amount and correct it if neces-
sary.
(BFW-supply) and correct set-
ting if necessary.
(bypass process gas of
W11003) and open it more if
necessary.
− Check control butterfly valve of
feed super heater W11001
and throttle it more if neces-
sary.
necessary.
T-FAULT WINDING M11001 motor M11001 of the waste openings are covered and re-
Medium: gas blower V11001 is too move obstacles if necessary.
MOTOR WINDING
high. − Check the thermistor protec-
tive relay.
sibly too high.
− Check waste gas blower on
***
LSAH11002 Water level in the heat − Check the parameters of the
P-BOILER W11001 recovery is too high. feed water control.
Medium:
WATER
steam amount.
− Check the steam pressure.
− Check PC12001.
− Check FV12001.

Trouble Shooting

TAH11002 Temperature before waste − Check set and actual value of
T-WASTE GAS SUCTION gas blower V11001 is too temperature measuring and
BLOWER INLET high. correct setting if necessary.
Medium:
WASTE GAS − Check setting of control butter-
fly valve at feed super heater
and throttle a little if neces-
sary.
− Check butterfly valve K1601
sary.
TSAHH11002 Temperature before waste − Check set and actual value of
T-WASTE GAS SUCTION gas blower V11001 is much temperature measuring and
BLOWER INLET too high. correct setting if necessary.
Medium:
WASTE GAS − Check setting of control butter-
fly valve at feed super heater
sary.
− Check butterfly valve K1601
sary.
***
***
***

Trouble Shooting

PSAL11003 Pressure in heat recovery − Check shut off valves to pres-
P-HEAT RECOVERY D11001 D11001 is too low. sure transmitter V11007 and
Medium: correct settings if necessary.
STEAM
steam amount and correct
amount if necessary.
− Check waste gas after re-
former temperature and cor-
rect temperature if necessary.
− Check, shut off valves
V11002, V11003, V11006,
V11018, V11017 are closed
(BFW-supply) and open it
more if necessary.
− Check Parameters of BFW-
control and correct settings if
necessary.
W11003) and close it more if
necessary.
and open it more if necessary.
necessary.
− Check steam line, BFW-line
and heat recovery D11001 on
leakages and seal lines and
essary.

Trouble Shooting

LAL11004 Water level in the heat − Check function of level trans-
L-HEAT-RECOVERY D11001 recovery D11001 is too low. mitter, level switches and re-
Medium: pair them or correct settings if
STEAM
necessary.
V11006, V11018, V11017,
essary.
sary.
sary.
necessary.
if necessary.

Trouble Shooting

LALL11004 Water level in the heat − Check function of level trans-
L-HEAT RECOVERY D11001 recovery D11001 is much mitter, level switches and re-
Medium: too low. pair them or correct settings if
BOILER FEED WATER
necessary.
V11006, V11018, V11017,
essary.
sary.
sary.
necessary.
if necessary.
LAHH11004 Water level in the heat − Check function of level trans-
L-HEAT RECOVERY D11001 recovery D11001 is much mitter, level switches and re-
Medium: too high. pair them or correct settings if
BOILER FEED WATER
necessary.
V12010 and throttle it if nec-
essary.
necessary.
if necessary.
LJAL11004 Connection or transmitter − Check the transmitter and re-
FAULT TRANSMITTER LT11004 at level measuring pair or replace it if necessary.
Medium: is defective. Check the lines and connec-
***
sary.

Trouble Shooting

PAL11005 Pressure in heat recovery − Check shut off valves to pres-
P-HEAT RECOVERY D11001 D11001 is much too low. sure transmitter V11007 and
STEAM
V11002, V11003, V11006,
more if necessary.
necessary.
necessary.
necessary.
essary.

Trouble Shooting

PSALL11005 Pressure in heat recovery − Check shut off valves to pres-
P-HEAT RECOVERY D11001 D11001 is much too low. sure transmitter V11007 and
STEAM
V11002, V11003, V11006,
more if necessary.
necessary.
necessary.
necessary.
essary.
QAH11020 Dosing of hydrazin is to high. − Check Dosing Station.
CONDUCTIVITY HEAT
RECOVERY D11001
Medium:
BOILER FEED WATER
QJAL11020 Connection, electr. lines or − Check the transmitter and re-
FAULT TRANSMITTER transmitter QT11020 is pair or replace it if necessary.
***
sary.
***

Trouble Shooting

FAL11201 Flow of process steam to − Check the set values for the
F-PROCESS STEAM mixing point (steam / steam amount and correct
Medium: feedgas) is too low. amount if necessary.
STEAM
− Check ratio value and correct
it if necessary.
− Check the inlet temperature of
the reformer and correct it if
necessary.
and correct the settings if nec-
essary.
− Check process steam line on
essary.
valves FV11201, UV11201
FSALL11201 Flow of process steam to − Check the set values for the
F-PROCESS STEAM mixing point (steam / steam amount and correct
Medium: feedgas) is much too low. amount if necessary.
STEAM
− Check ratio value and correct
it if necessary.
− Check the inlet temperature of
the reformer and correct it if
necessary.
essary.
− Check process steam line on
essary.
valves FV11201, UV11201
FAULT TRANSMITTER pressure measuring place or repair it if necessary.
Medium:
***
FT11201 (process steam) is − Check lines and connection
defective. and repair them if necessary.
FAULT TRANSMITTER PT11201of the pressure pair or replace it if necessary.
***
***

Trouble Shooting

EAL11202 Ratio process steam / NG is − Check the set values for the
RATIO PROCESS STEAM / too low. steam amount and increase if
NG necessary.
Medium:
STEAM / NG − Check the steam pressure and
− Check the NG amount and
correct the amount if neces-
sary.
− Check the shut off valves of
orifice measuring V10201
(NG), V11201 (process steam)
essary.
− Ckeck the NG and process
steam lines for leakages and
if necessary.
− Check pneumatic valves
UV10204, FV10201, UV10205
in the NG line on mechanical
necessary.
FV11201, UV11202 in the
process steam line on me-
chanical blockage and repair
them if necessary.
− Check, if condensate dis-
charge valve V11205 is closed
and close it if necessary.

Trouble Shooting

ESALL11202 Ratio process steam / NG is − Check the set values for the
RATIO PROCESS STEAM / much too low. steam amount and increase if
NG necessary.
Medium:
STEAM / NG − Check the steam pressure and
correct the amount if neces-
sary.
− Check the shut off valves of
orifice measuring V10201
(NG), V11201 (process steam)
essary.
− Ckeck the NG and process
steam lines for leakages and
if necessary.
UV10204, FV10201, UV10205
in the NG line on mechanical
necessary.
FV11201, UV11202 in the
process steam line on me-
chanical blockage and repair
them if necessary.
− Check, if condensate dis-
charge valve V11205 is closed
and close it if necessary.
GOSAL11202 Main steam valve V11202 at − Check the setting of the main
CHECK-BACK VALVE heat recovery is closed or steam valve V11202 and open
V11202 PROCESS STEAM proximity initiator GS11202 it if necessary.
OUTLET HEAT RECOVERY is defective. − Check proximity initiator and
Medium:
STEAM repair or adjust it if necessary.
UYAL11203 Pressure in the process − Check the pressure in heat re-
PD-STEAM / FEED (P11201 - steam line is too low in covery.
P13001) comparison with the feed − Check the steam valve
Medium: line.
STEAM / FEED V11202.
There is a hazard of the NG
return flow in the steam line.
UYSALL11203 Pressure in the process − Check the pressure in heat re-
PD-STEAM / FEED (P11201 - steam line is too low in covery.
P13001) comparison with the feed − Check the steam valve
Medium: line.
STEAM / FEED V11202.
There is a hazard of the NG
return flow in the steam line.
The plant will be switched
down to step 5.
FAULT TRANSMITTER pressure measuring place or repair it if necessary.
Medium:
***
PT11204 is defective. − Check lines and connection

Trouble Shooting

UYALL11204 Pressure in the process − Check the pressure in heat re-
PD-STEAM / steam line is too low in covery.
EXPORTSTEAM (P11001 - comparison with the export − Check the steam valve
P11204) steam line. V11204.
Medium:
STEAM / EXPORTSTEAM
FAULT TRANSMITTER flow measuring FT11210 is place or repair it if necessary.
Medium:
***
defective. − Check lines and connection
TJAL11210 Connection or transmitter of − Check the transmitter and re-
FAULT TRANSMITTER temperature measuring place or repair it if necessary.
Medium:
***
TT11210 is defective. − Check lines and connection
EOSAL12001 Motor M12001 of the BFW- − Check if the motor protection
RUN M12001 supply is not running. is on.
Medium:
***
− Check the cabling.
OVERLOAD M12001 motor M12001 of the BFW- − Check the thermistor protec-
Medium: pump P12001 was activated. tive relay.
***
check motor and pump on
FAULT TRANSMITTER flow measuring FT12001 place or repair it if necessary.
Medium:
***
(BFW-supply) is defective. − Check lines and connection
TAH12001 Temperature at the outlet of − Check pre-switched process-
T-BOILER FEED WATER the boiler feed water- es.
BFW-PREHEATER Preheater W14002 is too − Check the process parameter.
Medium:
BOILER FEED WATER
high. − Check the W14001.
TJAL12001 Connection or transmitter of − Check the transmitter and re-

FAULT TRANSMITTER temperature measuring place or repair it if necessary.
Medium:
***
TT12001 is defective. − Check lines and connection
T-FAULT WINDING M12001 motor M12001 of the boiler openings are covered and re-
Medium: feed water pump P12001 is move obstacles if necessary.
MOTOR WINDING
too high. − Check the thermistor protec-
tive relay.
sibly too high.
− Check boiler feed water pump

Trouble Shooting

Medium:
***
check the motor and the pump
***
FSAL12002 Flow of boiler feed water at − Check boiler feed water line
F-BOILER FEED WATER flow switch FIS12002 is too on leakages at seal line if nec-
Medium: low. essary.
BOIEL FEED WATER
− Check, if ball valve H12001/05
is open and open it if neces-
sary.
− Check the pumps P12001/02
MOTOR WINDING
tive relay.
sibly too high.
Medium:
***
***

Trouble Shooting

MOTOR WINDING
tive relay.
sibly too high.
Medium:
***
check the motor and the pump
***
FSAL12004 Flow of boiler feed water at − Check boiler feed water line
F-BOILER FEED WATER flow switch FIS12004 is too on leakages at seal line if nec-
Medium: low. essary.
BOIEL FEED WATER
− Check, if ball valve H12002/06
is open and open it if neces-
sary.
− Check the pumps P12003/04
MOTOR WINDING
tive relay.
sibly too high.
EOSAL12110 Dosing unit is not running. − Check if the motor protection
RUN DOSING UNIT is on.
Medium:
***
− Check the dosing unit..
ESAL12110 Motor protecting switch the − Check if the motor protection
OVERLOAD DOSING UNIT dosing unit was activated. is on.
Medium:
***
− Check the dosing unit..

Trouble Shooting

LAH12101 Filling level of feed water − Check the settings of the shut
L-DEGASIFIER B12101 degaser B12101 is too high. off valves on level measuring
Medium: V12116, V12117 and open
DEMINERALISED WATER
them if necessary.
− Check function and settings of
level switches and transmitters
and repair them or correct set-
tings.
− Check function of BFW-
pumps and correct function if
necessary.
− Check the settings of butterfly
valves K12001, K12002 and
open them if necessary.
− Check strainers F12001,
F12002 on impurities and
clean them if necessary.
− Check non return valves on
pair them if necessary.
− Check shut off valves V12005,
V12007 and open them if nec-
essary.
LAL12101 Filling level of feed water − Check the settings of the shut
L-DEGASIFIER B12101 degaser B12101 is too low. off valves on level measuring
Medium: V12116, V12117 and open
DEMINERALISED WATER
them if necessary.
− Check discharge valves
V12127, H12118, V12115,
V12123 and close them if
necessary.
− Check lines and feed water
degaser B12101 on leakages
and seal lines and vessel if
necessary.
tings.
LSALL12101 Filling level of feed water − Check the settings of the shut
L-DEGASIFIER B12101 degaser B12101 is much too off valves on level measuring
Medium: low. V12116, V12117 and open
DEMINERALISED WATER
them if necessary.
− Check discharge valves
V12127, H12118, V12115,
V12123 and close them if
necessary.
− Check lines and feed water
degaser B12101 on leakages
and seal lines and vessel if
necessary.
tings.

Trouble Shooting

LJAL12101 Connection or transmitter − Check the transmitter and re-
FAULT TRANSMITTER LT12101 at level measuring pair or replace it if necessary.
Medium: is defective. Check the lines and connec-
***
sary.
EAL12101 No check back signal from − Check level measurement.
LEVEL TRANSMITTER level measurement − Check the cabling.
Medium: LE12101.
***
TAH12102 Temperature of feed water − Check set and actual value of

T-DEGASIFIER B12101 degasifying is too high. temperature measuring and
DEMINERALISED WATER
− Check demin. water supply.
− Check amount of steam sup-
ply and correct amount if nec-
essary.
***
FAULT TRANSMITTER flow measuring FT12102 is place or repair it if necessary.
Medium:
***
defective. − Check lines and connection
TAH12103 Temperature of deminwater − Check set and actual value of
T-DEGASIFIER B12101 outlet W14003 is too high. temperature measuring and
DEMINERALISED WATER
− Check demin. water supply.

***
EAL12111 Common fault at dosing − Detect the reason for the
COMMON FAULT DOSING station. common fault.
UNIT − See also manual of the manu-
Medium:
DOSING AGENT facturer of the dosing station.
LAL12110 Buffer filling at dosing − Buffer filling, see also manual
BUFFER FILL DOSING UNIT station. of the manufacturer of the
Medium: dosing station.
DOSING AGENT
LSAL12111 Level at Buffer tanks at − Detect the reason for the

BUFFER LOW LEVEL dosing station. common fault.
DOSING UNIT − See also manual of the manu-
Medium:
DOSING AGENT facturer of the dosing station..
***

Trouble Shooting

PSAH13001 Feed gas pressure before − Check the air preheater and
P-REFORMER INLET reformer is much too high. the setting of the control but-
Medium: terfly valve at the preheater
FEED
and correct its setting if nec-
essary.
− Check function of the pneu-
matic valve TV13201 and re-
PSAHH13001 Feed gas pressure before − Check the air preheater and
P-REFORMER INLET reformer is much too high. the setting of the control but-
Medium: terfly valve at the preheater
FEED
and correct its setting if nec-
essary.
− Check function of the pneu-
matic valve TV13201 and re-
TAH13001 Temperature of the feed gas − Check parameters of tempera-
T-REFORMER INLET before the reformer is too ture control and correct them if
PROCESS GAS
− Check steam amount and cor-
rect amount if necessary.
− Check ratio and correct it if
necessary.
TSAHH13001 Temperature of the feed gas − Check parameters of tempera-
T-REFORMER INLET before the reformer is much ture control and correct them if
Medium: too high. necessary.
PROCESS GAS
− Check steam amount and cor-
rect amount if necessary.
− Check ratio and correct it if
necessary.
***
TJSAL13001 Connection or transmitter − Check the transmitter and re-
***
EAL13100 Calibration switch for oxygen − Check the oxygen analyser
CALIBRATE O2-ANALYSIS analyser is too long active. and correct the settings if nec-
Medium: essary. See also the manual
***
of the manufacturer of the ox-
ygen analyser.
EKSALL13100 Calibration switch for oxygen − Check the oxygen analyser
CALIBRATE O2-ANALYSIS analyser is too long active. and correct the settings if nec-
Medium: essary. See also the manual
***
of the manufacturer of the ox-
ygen analyser.
EAL13101 Common fault at O2 − Detect the reason for the
STATUS O2-ANALYSIS analyzer. common.
Medium:
***

Trouble Shooting

EMERGENCY STOP button at Reformer was the EMERGENCY STOP push
REFORMER activated. button and eliminate the mal-
Medium:
***
function.
mechanically.
QAH13101 O2-concentration in the − Prove the composition of the
O2-ANALYSIS WASTE GAS reformer furnace is too high. air, and fuel gas and correct it
Medium: if necessary.
OXYGEN IN WASTE GAS
− Check the butterfly valves
K1602, K1603 and throttle
them a little if necessary.
QAL13101 O2-concentration in the − Prove the composition of the
O2-ANALYSIS WASTE GAS reformer furnace is too low. air, and fuel gas and correct it
Medium: if necessary.
OXYGEN IN WASTE GAS
− Check air blower V01601.
− Check combustion air supply.
K1602, K1603 and open them
if necessary.
essary.
QSALL13101 O2-concentration in the − Prove the composition of the
O2-ANALYSIS WASTE GAS reformer furnace is much air, and fuel gas and correct it
Medium: too low. if necessary.
OXYGEN IN WASTE GAS
− Check air blower V01601.
− Check combustion air supply.
K1602, K1603 and open them
if necessary.
essary.
TDAL13101 Difference between actual − Check the parameter of the re-
TD-REFORMER TC13101_W and set value of temperature former furnace temperature
- TC13101_X measuring TE13101 is control and correct them if
Medium: deviates too much.
***
necessary.
− Check the setting of the but-
terfly valve K1601 and correct
it if necessary.
− Check the setting of the con-
trol butterfly valve of feed su-
per heater W11001.

Trouble Shooting

TDSALL13101 Difference between actual − Check the parameter of the re-
TD-REFORMER TC13101_W and set value of temperature former furnace temperature
- TC13101_X measuring TE13101 is control and correct them if
Medium: deviates too much.
***
necessary.
− Check the setting of the but-
terfly valve K1601 and correct
it if necessary.
− Check the setting of the con-
trol butterfly valve of feed su-
per heater W11001.
UYAH13101 Error at average value- − Check if there is a fault at one
MEASUREMENT forming temperature of the probes.
SELECTION TT13101/12 measurement. − Replace the probes or repair
Medium: The difference of the two
*** them if necessary.
measurements is too large.
A probe error is probably
present.
UYAL13101 Error at average value- − Check the transmitters. Re-
MEASUREMENT forming temperature place if necessary. Check the
SELECTION TT13101/12 measurement. lines.
Medium:
***
One of the temperature − Check the connections.
transmitters has an error.
(TT13101/11).
UYZALL13101 Error at average value- − Check the transmitters. Re-
Medium:
***
Both temperature − Check the connections.
transmitters have errors.
(TT13101/11).
PDJAL13101 Connection or transmitter is − Check the transmitter and re-
FAULT TRANSMITTER PDT(Z)13101 is defective. pair or replace it if necessary.
Medium: Check lines and connections
***
QJAL13101 Connection, electr. lines or − Check the transmitter and re-
FAULT TRANSMITTER transmitter QT13101 is pair or replace it if necessary.
***
sary.
***
TZAHH13101 Temperature of the waste − Check the steam amount.
T-REFORMER gas in the reformer furnace − Check the ratio.
Medium:
WASTE GAS
is much too high. − Check the fuel gas amount.
− Check temperature control
T13101 and correct settings if
necessary.
MEASUREMENT forming differential pressure of the probes.
SELECTION PDT13101/02 measurement. − Replace the probes or repair
present.

Trouble Shooting

MEASUREMENT forming differential pressure place if necessary. Check the
SELECTION PDT13101/02 measurement. lines.
Medium:
***
One of the differential − Check the connections.
pressure transmitters has an
error.
(PDT(Z)13101/PDT(Z)13102
).
MEASUREMENT forming differential pressure place if necessary. Check the
SELECTION PDT13101/02 measurement. lines.
Medium:
***
Both differential pressure − Check the connections.
(PDT(Z)13101/PDT(Z)13102
).
PDJAL13102 Connection or transmitter is − Check the transmitter and re-
FAULT TRANSMITTER PDT(Z)13102 is defective. pair or replace it if necessary.
Medium: Check lines and connections
***
TJAL13102 Connection or transmitter is − Check the transmitter. Re-
FAULT TRANSMITTER defective. place if necessary. Check the
Medium: lines. Check the connections.
***
PDAH13103 Differential pressure at − Check the set value for the

PD-REFORMER D13101 transmitter PDT(Z)13101/02 furnace pressure and correct
Medium: in the reformer furnace is too them if necessary.
WASTE GAS
high. − Check the combustion air
sary.
− Check the function of waste
gas blower V11001 and cor-
rect function if necessary.
− Check the measuring and im-
pulse line on leakages and
choking and repair lines if
necessary.
PDAL13103 Differential pressure at − Check the set value for the
Medium: in the reformer furnace is too them if necessary.
WASTE GAS
low. − Check the combustion air
sary.
− Check the function of waste
gas blower V11001 and cor-
rect function if necessary.
necessary.

Trouble Shooting

PDZAHH13103 Differential pressure at − Check the set value for the
Medium: in the reformer furnace is them if necessary.
WASTE GAS
much too high. − Check the combustion air
sary. Check the function of
waste gas blower V11001 and
correct function if necessary.
necessary.
PDSALL13103 Differential pressure at − Check the set value for the
Medium: in the reformer furnace is them if necessary.
WASTE GAS
much too low. − Check the combustion air
sary. Check the function of
waste gas blower V11001 and
correct function if necessary.
necessary.
TJAL13103 Connection or transmitter is − Check the transmitter. Re-
FAULT TRANSMITTER defective. place if necessary. Check the
Medium: lines. Check the connections.
***

MEASUREMENT forming temperature of the probes.
SELECTION TT13102/03 measurement. − Replace the probes or repair
present.
Medium:
***
One of the temperature − Check the connections.
transmitters has an error.
(TT13102/03).
Medium:
***
Both temperature − Check the connections.
(TT13102/03).

Trouble Shooting

TAH13104 Temperature of the process − Check ratio and correct rela-
T-PROCESS GAS gas on the outlet of the tion if necessary.
REFORMER OUTLET reformer is too high. − Check the steam amount and
Medium:
PROCESS GAS correct it if necessary.
− Check parameters of tempera-
ture TC13101 and correct
them if necessary.
TZAHH13104 Temperature of the process − Check ratio and correct rela-
T-PROCESS GAS gas on the outlet of the tion if necessary.
REFORMER OUTLET reformer is much too high. − Check the steam amount and
Medium:
PROCESS GAS correct it if necessary.
− Check parameters of tempera-
ture TC13101 and correct
them if necessary.
TAL13105 Temperature of the process − Check if the heating ramp is
T-PROCESS GAS gas on the reformer outlet is expired.
REFORMER OUTLET too low. − Check the fuel gas.
Medium:
PROCESS GAS
TSALL13105 Temperature of the process − Check if the heating ramp is
Medium:
PROCESS GAS
TAL13106 Temperature of the process − Check if the heating ramp is
Medium:
PROCESS GAS
TSALL13106 Temperature of the process − Check if the heating ramp is
Medium:
PROCESS GAS
***
TAH13112 Temperature of the waste − Check the steam amount.
T-FEED PRE-HEATER gas at the heat recovery is − Check the ratio.
Medium:
WASTE GAS
too high. − Check the fuel gas amount.
necessary.
T-FEED PRE-HEATER gas at the heat recovery is − Check the ratio.
Medium:
WASTE GAS
much too high. − Check the fuel gas amount.
necessary.

Trouble Shooting

TAH13113 Temperature of the waste − Check the steam amount.
T-FEED PRE-HEATER gas between the reformer − Check the ratio.
Medium:
WASTE GAS
furnace and the heat − Check the fuel gas amount.
recovery is too high. − Check temperature control
necessary.
T-FEED PRE-HEATER gas between the reformer − Check the ratio.
Medium:
WASTE GAS
furnace and the heat − Check the fuel gas amount.
recovery is much too high. − Check temperature control
necessary.
FAULT TRANSMITTER PT13201 of temperature pair and replace if necessary.
***
***
TAH13201 Process gas temperature − Check steam amount and cor-
T-COOLER W11003 after the heat recovery is too rect it if necessary.
OUTLET high. − Check ratio and correct it if
Medium:
PROCESS GAS necessary.
essary.
necessary.
− Check set and actual value of
temperature control TC13201
and correct them if necessary.
TAL13201 Process gas temperature − Check steam amount and cor-
T-COOLER W11003 after the heat recovery is too rect it if necessary.
OUTLET low. − Check ratio and correct it if
Medium:
and throttle it a little more if
necessary.
necessary.

Trouble Shooting

TZAHH13201 Process gas temperature − Check steam amount and cor-
T-COOLER W11003 after the heat recovery is rect it if necessary.
OUTLET much too high. − Check ratio and correct it if
Medium:
essary.
necessary.
(G)AH14001 Valve PV14001 is too far − Check pressure situation in
G-PROCESS GAS TO opened. PSA.
ATMOSPHERE BEFORE − Contact Mahler AGS.
PSA
Medium:
***
T-PROCESS GAS HT-CO- the HT-CO converter es.
CONVERTER C14001 is too high. − Check the ratio.
Medium:
PROCESS GAS
CO content in the process − Check the process parameter.
gas is too high. − Check the reformer.
***
***
T-PROCESS GAS NG- the NG-Preheater W14001 es.
PREHEATER is too high. − Check the process parameter.
Medium:
PROCESS GAS − Check the HT-CO-Shift.
***
T-PROCESS GAS BFW- the BFW-Preheater W14002 es.
PREHEATER is too high. − Check the process parameter.
Medium:
PROCESS GAS − Check the W14001.
***
T-PROCESS GAS DEMIN- the Demin-Water-Preheater es.
WATER-PREHEATER W14003 is too high. − Check the process parameter.
Medium:
PROCESS GAS − Check the W14002.

Trouble Shooting

***
TAH14005 Process gas temperature at − Check cooling water supply
T-KNOCK OUT DRUM outlet of knockout drum out of the battery limit.
OUTLET F14001 is too high. − Check heat exchanger
Medium:
PROCESS GAS W14001...W14004 on impuri-
sary.
− Check strainer F8001, F8002
on impurities and clean them if
necessary.
valves K8001...K8006 and cor-
on mechanical blockage.
− Check cooling water line on
essary.
TSAHH14005 Process gas temperature at − Check cooling water supply
T-KNOCK OUT DRUM outlet of knockout drum out of the battery limit.
OUTLET F14001 is much too high. − Check heat exchanger
Medium:
PROCESS GAS W14001...W14004 on impuri-
sary.
− Check strainer F8001, F8002
on impurities and clean them if
necessary.
valves K8001...K8006 and cor-
on mechanical blockage.
− Check cooling water line on
essary.
***
T-DEMIN-WATER the Demin-Water-Preheater es.
PREHEATER W14003 is too high. − Check the process parameter.
Medium:
DEMIN-WATER − Check the W14002.
***

Trouble Shooting

EMERGENCY STOP PSA button at PSA-Skid was the EMERGENCY STOP push
SKID activated. button and eliminate the mal-
Medium:
***
function.
mechanically.
Medium:
***
(H2-Product) is defective. − Check lines and connection
***
***
PAH14110 Pressure on the outlet of − Check settings of shut valves
P-ADSORBER A14101 adsorber A14110 is too high. to pressure transmitter
Medium: V14110 and correct settings if
HYDROGEN
necessary.
− Check the cycle time of PSA
and correct the time parame-
ters if necessary.
− Check the set value of the fill-
ing amount and correct filling
valves PV14110 and repair it if
necessary.
PSAL14110 Pressure on the outlet of − Check settings of shut valves
P-ADSORBER A14101 adsorber A14110 is too low. to pressure transmitter
HYDROGEN
necessary.
ters if necessary.
− Check function of solenoid
valve MV14131 and repair or
replace it necessary.
necessary.
FAULT TRANSMITTER PT14110 of the pressure pair or replace it if necessary.
***

Trouble Shooting

FAULT TRANSMITTER flow measuring (purge place or repair it if necessary.
Medium:
***
gas)FT14170 is defective. − Check lines and connection
HYDROGEN
necessary.
ters if necessary.
necessary.
P-ADSORBER A14102 adsorber A141202 is too to pressure transmitter
Medium: low. V14120 and correct settings if
HYDROGEN
necessary.
ters if necessary.
necessary.
***
HYDROGEN
necessary.
ters if necessary.
necessary.

Trouble Shooting

P-ADSORBER A14103 adsorber A14130 is too low. to pressure transmitter
HYDROGEN
necessary.
ters if necessary.
necessary.
***
HYDROGEN
necessary.
ters if necessary.
necessary.
P-ADSORBER A14104 adsorber A14140 is too low to pressure transmitter
HYDROGEN
necessary.
ters if necessary.
necessary.
***

Trouble Shooting

(G)AH14192 Pressure in the customer − Check pressure situation in
G-BLOWING TO product piping is too high. product piping.
ATMOPHERE AFTER PSA
Medium:
***
UYSAL14124 Difference between − Check the parameter of the
PD-PRDUCT GAS P14101 - PT14101 AND PT14124 is pressure transmitter and con-
P14124 deviates too much. trol and correct them if neces-
Medium:
HYDROGEN
sary.
− Check the pressure settings t
costumer
PAL14201 Purge gas pressure to − Check settings of shut off
P-PURGE GAS mixing point (NG / purge valves to pressure transmitter
Medium: gas) is much low. V14202 and correct settings if
PURGE GAS
necessary.
− Check purge gas line on leak-
sary.
− Check ball valve H14202
(sample point) and close it if
necessary.
valves UV14203, FV14201
PSALL14201 Purge gas pressure to − Check settings of shut off
P-PURGE GAS mixing point (NG / purge valves to pressure transmitter
Medium: gas) is much too low. V14202 and correct settings if
PURGE GAS
necessary.
− Check purge gas line on leak-
sary.
− Check ball valve H14202
(sample point) and close it if
necessary.
valves UV14203, FV14201
LAH14201 Condensat level in the purge − Check the level switch
L-PURGE GAS BUFFER gas buffer is too high. − Open ball valve H14201 and
Medium:
CONDENSATE
empty the purge gas buffer

FAULT TRANSMITTER flow measuring (purge gas) place or repair it if necessary.
Medium:
***
FT14102 is defective. − Check lines and connection
***

Trouble Shooting

FAH15201 Flow of H2-recycle at orifice − Check the control parameters
F-CIRCULATION measuring FT15201 is too of FIRQAHL15201 and correct
HYDROGEN high. them if necessary.
Medium:
HYDROGEN − Check the settings of shut
valves V15201 at orifice
measuring and correct them if
necessary.
matic valve FV15201 and re-
reducer PC15215 (4bar g) and
correct the setting if neces-
sary.
FAL15201 Flow of H2-recycle at orifice − Check the control parameters
F-CIRCULATION measuring FT15201 is too of FIRQAHL15201 and correct
HYDROGEN low. them if necessary.
Medium:
HYDROGEN − Check hydrogen-recycle line
on leakages and seal the line
if necessary.
− Check the settings of shut
valves V15201 at orifice
measuring and correct them if
necessary.
− Check, if the ball valves
H15210, H15208, H15209,
H15215 are open and open
them if necessary.
reducer PC15215 (4bar g) and
correct the setting if neces-
sary.
− Check the function of solenoid
valves MV15201, MV15202,
MV15203 and repair them if
necessary.
matic valve FV15201 and re-
− Check non return valves
R15202, R15203, R15201 on
Medium:
***
(H2-Recycle) is defective. − Check lines and connection

Trouble Shooting
7.3 Index of faults
(G)AH14001 7-47 EAL9044 7-15

(G)AH14192 7-53 EAL9045 7-15
(G)AL8801 7-11 EAL9046 7-15
EAL11202 7-33 EAL9048 7-15
EAL12101 7-39 EAL9060 7-16
EAL12111 7-40 EAL9061 7-16
EAL13100 7-41 EAL9062 7-16
EAL13101 7-41 EAL9063 7-16
EAL9001 7-12 EAL9064 7-17
EAL9002 7-13 EAL9065 7-17
EAL9003 7-13 EAL9066 7-17
EAL9004 7-13 EAL9067 7-17
EAL9005 7-13 EAL9208 7-17
EAL9006 7-13 EAL9209 7-17
EAL9007 7-13 EAL9211 7-18
EAL9008 7-13 EAL9213 7-18
EAL9009 7-13 EAL9217 7-18
EAL9010 7-13 EAL9706 7-20
EAL9011 7-14 EKSALL13100 7-41
EAL9012 7-14 EOSAL11001 7-23
EAL9021 7-14 EOSAL12001 7-35
EAL9022 7-14 EOSAL12002 7-36
EAL9023 7-14 EOSAL12003 7-36
EAL9032 7-14 EOSAL12004 7-37
EAL9033 7-14 EOSAL12110 7-38
EAL9034 7-14 EOSAL1601 7-5
EAL9040 7-14 EOSAL1602 7-6
EAL9041 7-15 EOSAL8302 7-10
EAL9042 7-15 EOSAL8316 7-10
EAL9043 7-15 EOSAL8326 7-11

Trouble Shooting
EOSAL9706 7-20 FAL8002 7-8

ESAH9054 7-16 FAL8301 7-9
ESAH9204 7-17 FAL9401 7-18
ESAL11001 7-23 FJAL10001 7-20
ESAL12001 7-35 FJAL11210 7-35
ESAL12002 7-36 FJAL12001 7-35
ESAL12003 7-37 FJAL12102 7-39
ESAL12004 7-37 FJAL14170 7-51
ESAL12110 7-38 FJAL14190 7-50
ESAL1601 7-5 FJAL14201 7-54
ESAL1602 7-6 FJAL15201 7-55
ESAL8801 7-11 FJAL9401 7-18
ESAL9051 7-15 FJSAL10201 7-21
ESAL9055 7-16 FJSAL11201 7-32
ESAL9056 7-16 FJSAL1601 7-6
ESAL9057 7-16 FJSAL8301 7-8
ESAL9220 7-18 FSAHH8301 7-9
ESALL11202 7-34 FSAL12002 7-36
EZAH9204 7-17 FSAL12004 7-37
EZAL10201 7-20 FSALL10201 7-21
EZAL13109 7-41 FSALL11201 7-32
EZAL14101 7-50 FAL1601 7-5
EZAL8316 7-10 FZALL1601 7-6
EZAL8326 7-11 GOSAL11202 7-34
EZAL9031 7-14 LAH12101 7-38
EZAL9052 7-16 LAH14201 7-54
EZAL9201 7-17 LAH8801 7-11
EZAL9601 7-19 LAHH11004 7-29
FAH15201 7-54 LAL11004 7-28
FAH8301 7-8 LAL12101 7-38
FAL10201 7-21 LAL12110 7-40
FAL11201 7-32 LAL8801 7-11
FAL15201 7-55 LALL11004 7-29

Trouble Shooting
LJAL11004 7-29 PJAL13001 7-40

LJAL12101 7-39 PJAL13201 7-46
LJSAL8801 7-12 PJAL14001 7-48
LSAH11002 7-25 PJAL14110 7-51
LSAH8802 7-12 PJAL14120 7-51
LSAHH8801 7-12 PJAL14130 7-52
LSAL12111 7-40 PJAL14140 7-53
LSALL12101 7-39 PJAL14190 7-50
LSALL8801 7-12 PJAL14201 7-54
LZAL11001 7-23 PJAL9402 7-19
LZAL8801 7-12 PJSAL1602 7-8
PAH10001 7-20 PSAH13001 7-40
PAH11001 7-24 PSAH8305 7-10
PAH14110 7-50 PSAHH13001 7-40
PAH14120 7-51 PSAL11003 7-27
PAH14130 7-52 PSAL14110 7-50
PAH14140 7-52 PSAL14120 7-51
PAHH1602 7-7 PSAL14130 7-52
PAL11005 7-30 PSAL14140 7-53
PAL14201 7-53 PSAL8201 7-8
PAL9402 7-19 PSALL11005 7-31
PDAH13103 7-44 PSALL14201 7-54
PDAL13103 7-44 PAL1602 7-7
PDJAL13101 7-42 PZAH11010 7-25
PDJAL13102 7-43 PZAH8303 7-10
PDSALL13103 7-44 PZAH8304 7-10
PDZAHH13103 7-44 PZAHH11001 7-24
PJAL10001 7-20 PZAL8301 7-9
PJAL10201 7-21 PZAL8302 7-10
PJAL11001 7-25 PZALL1602 7-7
PJAL11201 7-32 QAH11020 7-31
PJAL11204 7-35 QAH13101 7-41
PJAL12119 7-40 QAL13101 7-41

Trouble Shooting
QJAL11020 7-31 TJAL10202 7-22

QJAL13101 7-43 TJAL10203 7-22
QSALL13101 7-42 TJAL10204 7-22
RJAL8311 7-10 TJAL10205 7-22
RJAL8321 7-10 TJAL10206 7-22
RZAL8311 7-9 TJAL10221 7-22
RZAL8321 7-10 TJAL11001 7-23
TAH10205 7-22 TJAL11002 7-26
TAH10206 7-22 TJAL11003 7-26
TAH11002 7-26 TJAL11004 7-26
TAH12001 7-35 TJAL11022 7-31
TAH12102 7-39 TJAL11201 7-32
TAH12103 7-39 TJAL11210 7-35
TAH13001 7-40 TJAL12001 7-35
TAH13104 7-45 TJAL12102 7-39
TAH13112 7-46 TJAL12103 7-39
TAH13113 7-46 TJAL13101 7-43
TAH13201 7-47 TJAL13102 7-43
TAH14001 7-47 TJAL13103 7-44
TAH14002 7-48 TJAL13112 7-46
TAH14003 7-48 TJAL13201 7-46
TAH14004 7-48 TJAL14001 7-48
TAH14005 7-49 TJAL14002 7-48
TAH14011 7-49 TJAL14003 7-48
TAH9703 7-19 TJAL14004 7-48
TAL10205 7-22 TJAL14005 7-49
TAL10206 7-22 TJAL14011 7-49
TAL13105 7-45 TJAL14190 7-50
TAL13106 7-45 TJAL1601 7-6
TAL13201 7-47 TJAL1691 7-8
TDAL13101 7-42 TJAL1692 7-8
TDSALL13101 7-42 TJAL9700 7-19
TJAL10201 7-21 TJAL9701 7-19

Trouble Shooting
TJAL9702 7-19 TZAHH13112 7-46

TJAL9703 7-19 TZAHH13113 7-46
TJSAL13001 7-41 TZAHH13201 7-47
TSAH11001 7-25 UYAH13101 7-42
TSAH12001 7-36 UYAH13102 7-43
TSAH12002 7-36 UYAH13103 7-45
TSAH12003 7-37 UYAL11203 7-34
TSAH12004 7-37 UYAL13101 7-42
TSAH1601 7-6 UYAL13102 7-43
TSAHH11002 7-26 UYAL13103 7-45
TSAHH13001 7-40 UYALL11204 7-35
TSAHH14005 7-49 UYSAL14124 7-53
TSALL13105 7-45 UYSALL11203 7-34
TSALL13106 7-46 UYZALL13101 7-42
TZAHH13101 7-43 UYZALL13102 7-43
TZAHH13104 7-45 UYZALL13103 7-45

Trouble Shooting

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Trouble Shooting

7 Trouble Shooting ....................................................... 7-1

H2- Production Plant Habas II Turkey 123100722/00, 722E007_uk, 28.03.2013 7-1/57

7.1 General information

Should any irregularities in comparison

If the plant is switched to Step 0 as a re-

see also the manufacturers’ instructions regarding

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Repairs can be fulfilled only by authorized skilled

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7.2 List of faults

7.2.1 Burner faults

7.2.2 Reformer pipe faults

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7.2.3 Stack Faults

7.2.4 Trouble Shooting

Fault messages Meaning Remedy

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Fault messages Meaning Remedy

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Fault messages Meaning Remedy

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Fault messages Meaning Remedy

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Fault messages Meaning Remedy

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Fault messages Meaning Remedy

EOSAL8316 Failure on burner AA8311. − Check the burner and repair it

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Fault messages Meaning Remedy

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Fault messages Meaning Remedy

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Fault messages Meaning Remedy

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Fault messages Meaning Remedy

EAL9032 A software fault is present in − Please contact Mahler AGS.

EAL9034 A software fault is present in − Please contact Mahler AGS.

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Fault messages Meaning Remedy

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Fault messages Meaning Remedy

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Fault messages Meaning Remedy

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Fault messages Meaning Remedy

TJAL9700 Connection or transmitter − Check the transmitter and re-

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Fault messages Meaning Remedy

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Fault messages Meaning Remedy

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Fault messages Meaning Remedy

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Fault messages Meaning Remedy

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Fault messages Meaning Remedy

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Fault messages Meaning Remedy

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Fault messages Meaning Remedy

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