Table 6: FailureScenariosforHeatTransferEquipment Potential Design Solutions Active Heat Transfer Equipment (6) Procedural

No. 1 (T)

Operational Deviations Overpressure

Failure Scenarios Corrosion/erosion of exchanger internals resulting in a heat transfer surface leak or rupture and possible overpressure of the low pressure side

Inherently Safer/Passive

Double tube sheets Emergency relief device on low Corrosion detection device (e.g., Seal welding of tubes to pressure side coupons) tubesheets Periodic inspection/ analysis of Open low pressure side return low pressure fluid for high Design changes to reduce pressure fluid leakage erosion (e.g., lower velocities, inlet baffle) Secondary heat transfer fluid Design pressure of low pressure side equal to design pressure of high pressure side Use of more corrosion resistant alloys Use of less corrosive heat transfer media

2 (T)

Overpressure (Shell and Tube Exchanger)

Differential thermal expansion/contraction between tubes and shell resulting in tube leak/rupture (Fixed Tubesheet)

U-tube exchanger design Emergency relief device on low Procedural control of Shell expansion joint or internal pressure side introduction of process fluids floating head Automatic control of on start-up and shutdown Design pressure of low pressure introduction of process fluids Periodic inspection/ analysis of side equal to design pressure on start-up and shutdown low pressure fluid for high of high pressure side pressure fluid leakage Use of designs other than shell and tube (e.g., spiral, plate and frame)

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Table 6: FailureScenariosforHeatTransferEquipment Potential Design Solutions Active Heat Transfer Equipment (6) Procedural

No. 3 (T)

Operational Deviations Overpressure (Shell and Tube Exchanger)

Failure Scenarios Excessive tube vibration resulting in tube leak/rupture and possible overpressure of the low pressure side

Inherently Safer/Passive

Mechanical design (e.g., proper Emergency relief device on low Periodic inspection/ analysis of baffle spacing) pressure side low pressure fluid for high accommodating maximum pressure fluid leakage anticipated inlet feed pressure/velocity Design pressure of low pressure side equal to design pressure of high pressure side Use of designs other than shell and tube (e.g., spiral, plate and frame)

Overpressure

Excessive heat input resulting in vaporization of the cold-side fluid (e.g., control system failure, coldside blocked in)

Limit the temperature of the heating medium Design pressure of cold-side fluid equal to maximum expected pressure

Emergency relief device High temperature indication with alarm and interlock which isolates the heating medium

Manual control of heating medium based on temperature indication

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Table 6: FailureScenariosforHeatTransferEquipment Potential Design Solutions Active Emergency relief device Back-up cooling medium supply with automatic switch-over Automatic tempering of cooling medium temperature to avoid low tube wall temperature resulting in solids deposition Automatic venting of noncondensables Automatic isolation of input flow on detection of high vent temperature Heat Transfer Equipment (6) Procedural Manual adjustment of cooling medium tempering Periodic exchanger cleaning Manual venting on high pressure indication Manual activation of backup cooling Manual isolation of input flow on detection of high vent temperature

No. 5 (T)

Operational Deviations Overpressure (Condensing Side)

Failure Scenarios Loss of heat transfer due to fouling, accumulation of non-condensables, or loss of cooling medium

Inherently Safer/Passive Design exchanger for suitable velocity to minimize fouling Heat exchanger design less prone to fouling (e.g., direct contact) Provide additional surface area in air cooler to transfer heat via natural convection Continuous open venting of non-condensables Design for maximum expected pressure

Overpressure (air heated exchanger)

Ambient temperature Mechanical design increase resulting in higher accommodating maximum vaporization rate in air heated pressure/temperature exchanger Use heating medium other than air

Emergency relief device Automatic adjustment of vaporization pressure to control vaporization rate

Manual adjustment of vaporization pressure

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Table 6: FailureScenariosforHeatTransferEquipment Potential Design Solutions Active Heat Transfer Equipment (6) Procedural

No. 7

Operational Deviations Overpressure

Failure Scenarios Cold-side fluid blocked in while heating medium continues to flow

Inherently Safer/Passive Open cold side return

Thermal relief device Procedural controls on block Interlock to isolate heating valve closing medium upon detection of no Manual isolation of heating flow on cold-side medium on indication of no flow on cold side

Underpressure (air cooled exchanger)

Excessive heat transfer rate due to ambient temperature drop or rain

Mechanical design to accommodate minimum expected temperature and pressure Use of alternative heat exchanger designs

Automatic vacuum breaking system Automatic air inlet temperature control via air preheating with steam or air recirculation

Manual vacuum breaking Manual adjustment of air inlet temperature

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Table 6: FailureScenariosforHeatTransferEquipment Potential Design Solutions Active Heat Transfer Equipment (6) Procedural Emergency response plan Manual activation of fixed fire protection water spray (deluge) and/or foam systems

No. 9 (T)

Operational Deviations High Temperature

Failure Scenarios External fire

Inherently Safer/Passive

Use alternate heat exchanger Fixed fire protection water design to minimize impact of spray (deluge) and/or foam external fire systems activated by Fireproof insulation (limits heat flammable gas, flame, and/or input) smoke detection devices Slope-away drainage with Emergency relief device remote impounding of spills Locate outside fire affected zone Use cellular glass insulation to avoid insulation fires

10

High Loss of mechanical integrity Temperature of tube (on tube surface)

Mechanical design to Use of exchanger design less accommodate maximum sensitive to fouling (e.g., expected temperature and scraped surface exchanger) pressure Automatic control of heating Design exchanger for suitable medium temperature velocity to minimize fouling Use of heating medium with a maximum temperature that is limited to exchanger design temperature

High temperature indication with alarm Manual control of heating medium temperature Periodic inspection

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Table 6: FailureScenariosforHeatTransferEquipment Potential Design Solutions Active Provide air inlet temperature control via air preheating with steam or air recirculation Provide air flow control (e.g., variable pitch fans) Heat Transfer Equipment (6) Procedural Manual adjustment of air temperature or flow

No. 11

Operational Deviations Low Temperature (air cooled exchanger)

Failure Scenarios

Inherently Safer/Passive

Low ambient temperature Select different type of causes fluid freezing and tube exchanger to minimize or rupture eliminate consequences of freezing

22

Wrong Composition

Mixing of fluids resulting in exothermic reactions, phase changes, and/or fluid system contamination due to corrosion/erosion, vibration or differential thermal expansion

Select heat transfer media which are chemically compatible with process materials Mechanical design to accommodate maximum expected temperature and pressure of a possible exothermic reaction Intermediate heat transfer fluid system Double tubesheet design Seal weld tubes to tubesheets

Emergency relief device Downstream fluid analyzers with concentration alarms interlocked with automatic shutdown

Downstream fluid analyzers with concentration alarms Periodic sampling and analysis of fluids

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Table 6: FailureScenariosforHeatTransferEquipment Potential Design Solutions Active Vibration monitoring with automatic fan shutdown Heat Transfer Equipment (6) Procedural Manual fan shutdown on indication of excessive vibration

No. 1 3

Operational Deviations Loss of Containment (air cooled exchanger)

Failure Scenarios Vibration/fan failure and tube rupture due to impact with fan blade

Inherently Safer/Passive Use of alternative heat exchanger designs

34

Loss of Containment (Scraped Surface)

Scraper punctures heat transfer surface due to misalignment or entrance of foreign objects

Screens at entrance of heat exchanger to remove foreign objects Use of alternative exchanger designs

Automatic shutdown of motor on high amperage or power

Manual shutdown of motor on high amperage or power

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Table 6: FailureScenariosforHeatTransferEquipment Potential Design Solutions Active Automatic fire extinguishing system Heat Transfer Equipment (6) Procedural Emergency response procedures Manual activation of fire extinguishing system

No. 1 5

Operational Deviations Loss of Containment (Plate and Frame)

Failure Scenarios Fire exposure causes gasket failure

Inherently Safer/Passive Use of alternative exchanger design Locate exchanger outside fire affected zone Use fire resistant (metal jacketed) gaskets Use of welded plate design Provide splash shields around exchanger

46

Loss of Containment (Carbon Block)

Fire exposure causes combustion and failure of exchanger

Use of alternative exchanger design Locate exchanger outside fire affected zone

Automatic fire extinguishing system

Emergency response procedures Manual activation of fire extinguishing system

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