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Guide Word Deviation Causes Consequences Safeguards Action Required

NONE NO FLOW (1) Blockage in line - Loss of flow to reactor, no reaction due - Line is electrically (a) Temperature
to control response. traced to maintain indicator and controller
- DEA solidifies in line. DEA as liquid. needed on line to control
- Possible line rupture due to pump - Pump is tripped by tracing.
overpressure. pressure in line. (b) Design pipes to take
- Pump motor burn out, possible fire. maximum pump
pressure.
(2) Solid DEA in tank As for (1) - (c) Heat tank using jacket
- Cavitation in pump and/or coil
(3) Pump fails As for (1) - Standby pump Covered by (a), (b), (c)
- DEA stays in storage tank
- Backflow through valve V-8
- Heat exchanger overheat, line expansion
(4) Pressure in line = pressure in As for (1) and (3) - Pressure controller Covered by (a), (b), (c)
reactor on reactor
- Pressure controller
on line

(5) Valve fails closed or blocks As for (1) and (3) - Bypass valve in (d) Regular inspection
- Overpressure in line before valve leading place and maintenance of
to rupture. valves.
(6) Leak or drain left open As for (1) to (5) - FRC on line (e) Put a blanking plate
- DEA released from pipework – - Trip on pump on drain flange plate.
hazardous. (f) Regular inspection of
- Potential damage to surrounding lines to look for leaks.
equipment. (g) Use flow controllers
on all lines with the
potential to leak.
(7) Empty tank/leak in tank/LSL As for (1) to (6) - Level alarm on (h) Ensure regular
fails tank. inspection of tank for
leakage.
(8) Heat exchanger blockage As for (1) to (7) - (g) Ensure good heat
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exchanger cleaning and

MORE OF MORE FLOW (9) Pump overpower or both
pumps operating
(10) FRC gives incorrect value
(too low)
(11) Valve failure
(12) Lower pressure in reactor
LESS OF LESS FLOW (13) FRC gives incorrect value
(too high)
(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
inspect after cleaning.
- Heat exchanger cannot heat stream - Electrically traced (h) Use a locking off
enough – DEA solidifies line for preventing procedure for pump not
- Reactor overflow/overpressure solidification in use.
- Excess DEA in reactor passing through - FRC on line (g) Surge meter to
process prevent pump
- Possible line rupture overpressure
Same as (9) - (i) Check FRC regularly
Same as (9) - Valves fail closed (j) Design valve for
maximum pressure
Same as (9) - Pressure controller Covered by (a) to (j)
on reactor
- Less reaction - Covered by (a) to (j)
- Higher DEA outlet temperature from heat
exchanger
- Insufficient reactor pressure
- Potential higher flow in other sections of
line possibly leading to pipe rupture
Same as (1), (6) and (13) Discussed previously Covered by (a) to (j)
Same as (13) - (k) Fit non return valve to
- Backflow of nitrogen into DEA line reactor inlet.
Same as (13) - Relief valve for Covered by (a) to (k)
- Reactor vessel rupture reactor
- Pressure controller
on reactor
Same as (13) - Valves should fail Covered by (a) to (k)
closed
Same as (13) - Covered by (a) to (k)
- Reduces heat transfer which could lead
to DEA solidifying
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(19) Insufficient DEA in tank Same as (13) - Level alarm on tank Covered by (a) to (k)
- Potential cavitation in pump
REVERSE REVERSE (20) High reactor pressure As previously discussed Reactor pressure Covered by (a) to (k)
FLOW control
(21) Reactor isolation valve fails - Backflow of reactor contents (including - (l) Add FIC to all reactor
open hydrogen) to DEA line inlet lines, shut down if
backflow into DEA line is
detected.
MORE OF MORE (22) Pump overpower Discussed previously - Covered by (a) to (l)
PRESSURE (23) PIC gives wrong value (too Discussed previously - Covered by (a) to (l)
low)
(24) Thermal expansion of DEA Discussed previously Discussed previously (m) Design pipes for
due to heat higher pressure and
expansion
(25) Steam rate fluctuation to Discussed previously - Temperature Covered by (a) to (m)
heat exchanger controller on steam (n) Consider cascading
flow flow and temperature
control for heat
exchanger steam
(26) Blockage/ closed valves Discussed previously Discussed previously Covered by (a) to (n)
LESS OF LESS (27) Pump failure Discussed previously Discussed previously Covered by (a) to (n)
PRESSURE (28) PIC gives wrong value (too Discussed previously Discussed previously Covered by (a) to (n)
high)
(29) Leakage Discussed previously Discussed previously Covered by (a) to (n)
(30) Valves more closed than Discussed previously Discussed previously Covered by (a) to (n)
expected
NONE OF NO PRESSURE (31) Solid DEA in tank with Discussed previously Discussed previously Covered by (a) to (n)
pump running Pipe buckles
MORE OF MORE (32) Excess steam in to heat Discussed previously Discussed previously Covered by (a) to (n)
TEMPERATUR exchanger - Reactant too hot, potential reaction
E problems
- Vaporisation in reactor
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- Thermal strain in pipes

(33) Electrical tracing too hot Discussed previously Discussed previously Covered by (a) to (n)
(34) Strong sunlight Discussed previously Discussed previously Covered by (a) to (n)
(35) Tank coil too hot Discussed previously Discussed previously (o) Add temperature
control to tank
LESS OF LESS (36) Insufficient steam in to Discussed previously Discussed previously Covered by (a) to (o)
TEMPERATUR heat exchanger - Insufficient reactor pressure
E (37) Tracing failure Discussed previously Discussed previously Covered by (a) to (o)
(38) Cold weather Discussed previously Discussed previously Covered by (a) to (o)
(39) Tank coil too cold Discussed previously Discussed previously Covered by (a) to (o)
START UP (40) Too fast - Heat exchanger too cold to heat DEA to Discussed previously Covered by (a) to (o)
required temperature
SHUT DOWN (41) Corrosion Discussed previously Discussed previously Covered by (a) to (o)
(42) Some DEA solidifies in line