RISK ASSESSMENT Item
Guide Word
Deviation
Possible Ca Causes
Possible Consequences
Action Re Required
Recommendation
Belt Dryer
NO
No fow
)ess temperat ure
1. "#$ cannot process practicall% 1. )ow dr%in! rate
1. &'ould be install sensors t'at detects an% c'an!es 1. &'ould be install sensors
1. (nstall sensors
)"&&
1. Pipe bloca!e or pipe leaa!es 1. *eat *eatin in! ! steam steam inlet valve mal+unction
OR"
ore pressure
1. Dr%er can broen
1. (nstall (nstall sa+et sa+et% % valve valve
Grinder
)"&&
)ess fo fow
1. Accumulation o+ "#$ in t'e !rinder
1. (nstall an% sensor w'ic' can detect an% bloca!e in t'e !rinder
Hammer Mill
NO
No fow
1. $uil $uild/ d/up up o+ o+ !ases durin! t'e dr%in! process 1. ec'anical +ailure o+ t'e !rinder or bloca!e in t'e s%stem 1. 0alve mal+unction
1. )oss o+ unit or !eneration
Biomass feedstock inlet
NO
No #low
1. )oss o+ +eed suppl%
1. No +eedstoc into t'e reactor . Release o+ to,ic material
1. Carr%in! out preventive maintenance o+ 'ammer mill 1. &'ould be provide wit' fow indicator . Carr% out re!ular sc'edule inspection
1. (nstall temperature sensors +or e,ample t'ermocouplest'ermometers w'ic' can detect c'an!es in temperatures 1. (nstal (nstalll pressu pressure re relie relie++ valve w'ic' can control t'e e,cess !ases inside t'e dr%er 1. (nstall fow indicator
1. (nstall fow indicator
1. (nstall !lass in t'e pipeline to see t'e fow . (nstall alarm
(Flidised Bed! "yrolysis reactor
)"&&
)ess #low
1. #lowrate valve not +unctionin! . Partiall% plu! line 2. )ine be+ore reactor leaa!e
1. 3oo )ess +eedstoc fowrate cause ine4cienc% in t'e reactor
1. (nspection 'ave to be carried out re!ularl%
1. (nstall !as detection s%stem . (nstall alarm
OR"
ore #low
1.#lowrate valve not +unctionin!
1. (nspection 'ave to be carried out re!ularl%
1. (nstall alarm
)OW
)ow Pressure
1. 5ndetected leaa!e
1. Overfow . a% cause leaa!e in t'e reactor 1. 5ndesired product %ield . a% cause reverse fow
1. (nstall low pressure alarm
*(G*
*i!' Pressure
1. 3'ermal overpressure . Pressure controller not +unctionin!
1. Pressure inside t'e reactor build up .Can cause t'e reactor e,plode
)OW
)ow temperat ure
3emperature controller not +unctionin!
*(G*
*i!' 3emperat ure
3emperature controller not +unctionin!
1. Di6erence in percenta!e o+ product t'at are produced 1. Can cause e,plosion
1. Pressure indicator is provided to noti+% t'e operator . (nspection done re!ularl% 1. Pressure indicator is provided to noti+% t'e operator . (nspection +or pressure done re!ularl% 1. (nspection +or temperature done re!ularl% 1. (nspection +or temperature done re!ularl%
1. Decrease 'eat source
1. (nstall 'i!' pressure alarm
1. (ncrease 'eat source
NO
Heater (frnace!
1. No +eed suppl% into t'e reactor. . al+unction o+ +urnace- 'eat e,c'an!erfuidised bed
1. No product produce
1. Pressure indicator is provided to noti+% t'e operator . 3emperature indicator is provided to noti+% t'e operator 2. &'ould be provided wit' fow indicator
1. Repair t'e mal+unctioned components
)ow 3emperat ure *i!' temperat ure
1. *i!'er fow in t'e burner
1. 3emperature indicator is provided to noti+% t'e operator 1. 3emperature indicator is provided
1. &low down fowrate . (ncrease +uel source in t'e burner 1. (ncrease t'e fowrate in burner
)OW
)ow pressure
1. )eaa!e in t'e coil
1. P%rol%sis process would not be e4cient 1. 3oo muc' o+ 'eat suppl% to t'e p%rol%sis reactor. &o Di6erence in percenta!e o+ product t'at are produced 1. Drop in t'e temperature
1. Pressure indicator is provided
1. (nstall low pressure alarm
*(G*
*i!' Pressure
1. $loca!e in t'e coil
1. Pressure indicator is provided
1. (nstall 'i!' pressure alarm
NON"
None 3emperat ure
1. *eat source not +unctionin!
1. &udden increase in temperature 1. No conversion occurs
1.Carr% out re!ular sc'edule inspection
1. C'ec 'eat source
)OW
*(G*
Heat e#c$an%er &
No reaction
1. )ower fow in t'e burner
Inside %asi'cation reactor
)OW
)ow 3emperat ure
1. 3oo little 'eat is supplied +rom t'e 'eat source
1. Desired reaction +ail to ac'ieve
*(G*
*i!' 3emperat ure
1. 3oo muc' o+ 'eat suppl% +rom 'eat source
1. Can cause e,plosion
)"&&
)ess #low
1. )ess +eed suppl% into t'e reactor . 3emperature and pressure are not at desired condition
1. )ess product produce. . 5ndesired product qualit%.
OR"
ore +eed
1. ore +eed suppl% into t'e reactor.
1. #eed in reactor increases and causes undesired product purit%. . *eats build up t'at ma% lead to reactor e,plosion.
1. 3emperature indicator is provided to noti+% t'e operator . Carr% out re!ular sc'edule inspection 1. 3emperature indicator is provided to noti+% t'e operator . Carr% out re!ular sc'edule inspection 1. Pressure indicator is provided to noti+% t'e operator . 3emperature indicator is provided to noti+% t'e operator 2. &'ould be provide wit' fow indicator 1. Pressure indicator is provided to noti+% t'e operator . 3emperature indicator is provided to noti+% t'e operator 2. &'ould be provide wit' fow indicator
1.(ncrease 'eat source
1.Reduce 'eat source
1. (ncrease t'e pressure o+ t'e +eed inlet . (ncrease t'e amount o+ +eed
1. Decrease t'e pressure o+ t'e +eed inlet . Decrease t'e amount o+ +eed
NO
No #low
*(G*
*i!' #low
)OW
)ow Pressure
1. 5ndetected leaa!e
*(G*
*i!' Pressure
1. 3'ermal overpressure . Pressure controller not +unctionin!
1. Pressure inside t'e reactor build up .Can cause t'e reactor e,plode
)OW
)ow 3emperat ure
1.3emperature controller not +unctionin!
1. Di6erence in percenta!e o+ product t'at are produced 1. Can cause e,plosion
*(G*
Heat E#c$an%er
NO
1. $loca!e in pipes . Controller +ails 1. Control valve 7fowrate valve8 +ails to open
*i!' 1. 3emperature temperat controller not ure +unctionin! No fow o+ 1. #ailure o+ valve 'ot water to open . Pipe bloca!e 2. Pipe leaa!e
1. Product %ield decreases. 1. Di6erence in percenta!e o+ product t'at are produced 1. 5ndesired product %ield . a% cause reverse fow
1. Cause e,plosion . "nvironmental pollution
1. Place controller on critical instrumentation list Place controller on critical instrumentation list
1. (nstall !as detection s%stem . (nstall alarm 1. (nstall !as detection s%stem . (nstall alarm
1. Pressure indicator is provided to noti+% t'e operator . (nspection done re!ularl% 1. Pressure indicator is provided to noti+% t'e operator . (nspection +or pressure done re!ularl% 1. (nspection +or temperature done re!ularl%
1. (nstall low pressure alarm
1. (nspection +or temperature done re!ularl% 1. Open valve to re9ner% +uel !as +rom !asi9cation process . (mmediatel% s'ut down t'e !asi9cation process
1. Decrease 'eat source
1. (nstall 'i!' pressure alarm
1. (ncrease 'eat source
NO
OR"
No fow o+ 1. Pipe bloca!e coolin! . Pipe leaa!e water ore 1. #ailure o+ coolin! outlet valve to water open
)"&&
)ess coolin! water
1. Pipe leaa!e . )ow pressure 2. #ailure o+ outlet valve to close 1. #ailure o+ outlet valve to open
R"0"R&"
Reverse fow o+ coolin! water
CORRO&( ON
Corrosion o+ tube
1. *ardness o+ coolin! water
)OW
)ow temperat ure o+ outlet s%nt'etic !as
1. al+unction o+ 'eat e,c'an!er . #ailure o+ outlet valve o+ coolin! water to close
)OW
)ow pressure
1. Pipe leaa!e . al+uction o+ pressure relie+
1. 3emperature o+ s%nt'etic !as remain same 1. $urstin! o+ tube . 3emperature o+ 'ot stream decrease 1. 3emperature o+ s%nt'etic !as still 'i!' wit' small reduction in temperature 1. 3emperature o+ s%nt'etic !as still 'i!' wit' small reduction in temperature 1. )ess coolin! and crac o+ tube 1. Need to 'eat up t'e s%nt'etic !as to ac'ieve tar!eted temperature
1. (nstall low fow alarm
1. Reduce fuid fow rate
1. onitor 'eat e,c'an!er pressure
1. onitor t'e coolin! water fow rate in fow indicator
1. onitor t'e coolin! water fow rate in fow indicator . (nstall low fow alarm 1. (nstall c'ec valve
1. aintenance must tae place +requentl% 1. onitor outlet temperature o+ s%nt'etic !as +rom 'eat e,c'an!er
valve
"ressre S)in% Adsor*er
*(G*
*i!' temperat ure o+ outlet s%nt'etic !as
1. al+unction o+ 'eat e,c'an!er . Coolin! water pipe bloca!e 2. *i!' fow o+ s%nt'etic !as
*(G*
*i!' pressure
1. Pipe bloca!e . al+unction o+ pressure relie+ valve
NO
No fow o+ 1. Pipe bloca!e s%nt'etic . Pipe leaa!e !as into 2. #ailure o+ P&A control valve to open *i!' fow 1. #ailure o+ o+ control valve s%nt'etic . *i!' pump !ases capacit%
*(G*
*(G*
*i!' temperat ure
1. al+unction o+ 'eat e,c'an!er
1. Cause e,plosion . Dama!e t'e ne,t unit7 adsorbent8 2. "nvironmental pollution 1. $urstin! o+ tube or s'ell
1. Open valve to re9ner% +uel !as . (nstall 'i!' temperature alarm
1. Cause e,plosion . "nvironmental pollution 1. Purit% o+ '%dro!en will be low . Dama!e t'e adsorbent in vessel 1. Cause e,plosion . "nvironmental
1. Close all valves and s'ut down P&A unit
1. onitor t'e pump pressure . (nstall bac up pressure relie+ valve
1. (nstall b%pass valve . (nstall 'i!' pressure alarm
1. Open valve to re9ner% +uel !as . (nstall 'i!' temperature alarm
pollution *(G*
*i!' pressure
)"&&
)ow fow o+ s%nt'etic !ases
)"&&
Ha*er "rocess Reactor
)ow pressure
NO
No #low
)"&&
)"&& #low
1. #ailure o+ pressure relie+ valve to open . *i!' pump capacit% 1. #ailure o+ control valve . )ow pump capacit% 2. Pipe bloca!e :. Pipe leaa!e
1. Cause e,plosion . "nvironmental pollution 1. )ess production . Dama!e t'e adsorbent in vessel due to dr%in!
1. onitor t'e pump pressure . (nstall bac up pressure relie+ valve
1. Pipe bloca!e . Pipe leaa!e 2. #ailure o+ pressure relie+ valve to close 1. )oss o+ +eed suppl% . )ine rupture 2. )ine be+ore t'e reactor leaa!e 1. Control valve +ailure . Partiall% plu! line 2. )ine be+ore reactor leaa!e
1. Reaction +ail to occur
1. Close t'e outlet valve until t'e pressure reac'ed its tar!eted pressure
1. No process !as into t'e reactor . Release o+ to,ic material 1. )ess process !as supplied in t'e reactor . Release o+ to,ic material 2. Drop o+
1. &'ould be provide wit' fow indicator . Carr% out re!ular sc'edule inspection
1. (nstall !as detection s%stem . (nstall alarm
1. &'ould be provide wit' fow indicator . Carr% out re!ular sc'edule inspection
1. (nstall !as detection s%stem . (nstall alarm
1. (nstall rec%clin! stream in P&A unit . (nstall low fow alarm
OR"
OR" #low
1. Control valve trim c'an!ed
R"0"R&"
R"0"R&" #low
1. #ailure o+ pressure controller . Compressor trips 1. )eain! 'eat e,c'an!er tubes
)OW
)OW 3emperat ure
*(G*
*(G* 3emperat ure
*(G*
*(G* Pressure
1. #ailure o+ coolin! water s%stem
1. 3'ermal overpressure . #ailed open pressure control
pressure inside t'e reactor 1. Over pressure inside t'e reactor. . a% cause e,plosion o+ t'e reactor 2. Worsen product qualit% 1. #low reversed +rom reactor. . Product %ield decreases. 1. Desired reaction +ail to ac'ieve
1. 3emperature inside t'e reactor increase. . Can cause to reactor e,plosion 1. Pressure inside t'e reactor build up .Can cause t'e
1. &'ould be provide wit' fow indicator . Carr% out re!ular sc'edule inspection
1. (nstall alarm
. Carr% out re!ular sc'edule inspection
1. (nstall c'ec valve
1. 3emperature indicator is provided to noti+% t'e operator . Carr% out re!ular sc'edule inspection 1. 3emperature indicator is provided to noti+% t'e operator . Carr% out re!ular sc'edule inspection
1. (nstall low temperature alarm
1. Pressure indicator is provided to noti+% t'e operator . Carr% out re!ular
1. (nstall 'i!' pressure alarm
1. (nstall 'i!' temperature alarm
valve
reactor e,plode
sc'edule inspection 1. Pressure indicator is provided to noti+% t'e operator . Carr% out re!ular sc'edule inspection 1. Pressure indicator is provided to noti+% t'e operator . 3emperature indicator is provided to noti+% t'e operator 2. &'ould be provide wit' fow indicator
)OW
)OW Pressure
1. 5ndetected leaa!e . al+unction o+ compressor
1. 5ndesired product %ield . a% cause reverse fow
NO
NO Reaction
1. No +eed suppl% into t'e reactor. . al+unction o+ compressor and 'eat e,c'an!er
1. No product produce
)"&&
)"&& Reaction
1. )ess +eed suppl% into t'e reactor . 3emperature and pressure are not at desired condition
1. )ess product produce. . 5ndesired product qualit%.
OR"
OR" Reaction
2. ore +eed suppl% into t'e reactor.
1. #eed in reactor increases and causes undesired product purit%.
1. Pressure indicator is provided to noti+% t'e operator . 3emperature indicator is provided to noti+% t'e operator 2. &'ould be provide wit' fow indicator 1. Pressure indicator is provided to noti+% t'e operator . 3emperature indicator is provided to noti+% t'e operator
1. (nstall low pressure alarm
Stream after Ha*er "rocess Reactor
NO
1. $loca!e in pipes . Controller +ails
1. Product %ield decreases.
. *eats build up t'at ma% lead to reactor e,plosion. 1. Place controller on critical instrumentation list
2. &'ould be provide wit' fow indicator
1. (nstall !as detection s%stem . (nstall alarm
