Project:

Replacement of FB1903A sulphuric acid storage tank with h

Description: of 2500 MT
P&ID No:
Team Leader:
Design Intent: To increase the storage capacity of FB1903A from 2000 to 2
Node 1 IMC acid unloading tank transfering pump GA 511 to FB190
Parameter Flow
S.No
Deviation Possible Cause
1.01 Pump Inlet valves close

1.02 Pump suction line plug

1.03 Physical Low level in transfer tank.

1.04 Malfunction of level indication.

1.05 Pump outlet valves close

No flow
1.06 NRV fail

1.07 Pump discharge line plug

1.08 Pump failure

1.09 Pump stopped

1.10 Pump Inlet valves close

1.11 Pump suction line plug

1.12 Physical Low level in transfer tank.

Malfunction of level indication showing

1.13 more going less.

Low flow
 1.14 Pump outlet valves throttled.
Low flow
1.15 NRV malfunction

1.16 Pump discharge line plug

1.17 Pump low speed (VFD)

1.18 Low pump capacity

Instrumentation error showing more going

1.19 less.

1.20 Pump high speed (VFD)

More flow

1.21 High capacity pump

1.22 Reverse flow Wrong direction of drive

1.23 As well as flow NA

1.24 Part of flow NA

S.No Parameter Pressure

Deviation Possible Cause
1.25 No pressure NA

1.26 Low pressure Vent close / plug

1.27 More pressure NA

1.28 As well as pressure NA
1.29 Part of pressure NA
1.30 Reverse pressure Pump failure

Parameter Temperature
S.No
Deviation Possible Cause
1.31 No temperature NA
1.32 Low temperature NA
1.33 High temperature NA
1.34 As well as temperature NA
1.35 Part of temperature NA
1.36 Reverse temperature NA

Parameter Other than

S.No
Deviation Possible Cause

1.59 Accesability High at work on platform,

1.61 Vibration & Load Weak foudation / structure

ulphuric acid storage tank with higher storage volume

FB1903A tank
Session No: 1 Date :
acity of FB1903A from 2000 to 2500MT
ansfering pump GA 511 to FB1903A

Existing
Potential Consequences Recommendation/Action
System/Procedure
Pump failure due to SOP To be evident by Operation
cavitation
Pump failure due to DCS indication of Nil
cavitation pump current amp.
Pump failure due to Safety procedure To be evident by Operation
cavitation interlock provided
Schedule
Pump failure due to To be evident by
instrumentation PM
cavitation instrumentation
checkup.

Pump failure due to load SOP To be evident by Operation

Schedule maintence
Pump failure due to load To be evident by Maintence
PM checkup.
DCS indication of
Pump failure due to load Nil
pump current amp.
Flow backup to IMC acid NRV protection To be evident by Maintence
tank.
Flow backup to IMC acid
tank from common NRV protection To be evident by Maintence
header.
Pump failure due to SOP To be evident by Operation
cavitation
Pump failure due to DCS indication of Nil
cavitation pump current amp.
Pump failure due to Safety procedure To be evident by Operation
cavitation interlock provided
Schedule
Pump failure due to To be evident by
instrumentation PM
cavitation instrumentation
checkup.
Pump failure due to load SOP To be evident by Operation

Schedule maintence
Pump failure due to load To be evident by Maintence
PM checkup.
DCS indication of
Pump failure due to load Nil
pump current amp.
Excess time to fill tank
FB1903A leads to issue Only field indication DCS indication to be given
pump failure.

Excess time to fill tank Physical dip & level

FB1903A leads to issue Nil
indication in DCS
pump failure.
Storage estimation error Dry dip & Level
& over flow interlock Nil

Level indication &

IMC unloading tank Level interlock with VFD display in DCS
empty pump failure flow
LowLevel indication & SOP to be developed for the
IMC unloading tank Level interlock with new filter operation and
empty pump failure flow maintenance
Flow backup to IMC acid NRV protection To be evident by Maintence
tank.
NA NA Nil
NA NA Nil

Existing
Potential Consequences Recommendation/Action
System/Procedure
NA NA Nil
SOP must contain vent
SOP or check list to be checking ensure vent open or
Implosion of tank provided plug.If vent is plug to be clean
first.
NA NA Nil
NA NA Nil
NA NA Nil
Flow backup to IMC acid NRV protection To be evident by Maintence
tank.

Existing
Potential Consequences Recommendation/Action
System/Procedure
 NA NA Nil
NA NA Nil
NA NA Nil
NA NA Nil
NA NA Nil
NA NA Nil

Existing
Potential Consequences Recommendation/Action
System/Procedure
Proper working platforms with
Ergonomics - physical Nil approach ladders to be
strain/injury provided.

Foundations shall be tested for

designed capacity to
Equipment collapse Nil withstand the new load
conditions.