RISK ASSESSMENT

Item

Guide
Word

Deviation

Possible Causes

Possible
Consequences

Action Required

Recommendation

Belt Dryer

NO

No flow

Less
temperat
ure

1. EFB cannot
process
practically
1. Low drying
rate

1. Should be install
sensors that detects
any changes
1. Should be install
sensors

1. Install sensors

LESS

1. Pipe blockage
or pipe
leakages
1. Heating steam
inlet valve
malfunction

MORE

More
pressure

1. Dryer can
broken

1. Install safety valve

Grinder

LESS

Less flow

1. Accumulation
of EFB in the
grinder

1. Install any sensor

which can detect any
blockage in the
grinder

Hammer Mill

NO

No flow

1. Build-up of
gases during
the drying
process
1. Mechanical
failure of the
grinder or
blockage in
the system
1. Valve
malfunction

1. Loss of unit
or
generation

Biomass
feedstock
inlet

NO

No Flow

1. Loss of feed
supply

1. No feedstock
into the reactor
2. Release of
toxic material

1. Carrying out
preventive
maintenance of
hammer mill
1. Should be provide
with flow indicator
2. Carry out regular
schedule inspection

1. Install temperature
sensors for example
thermocouples,
thermometers which
can detect changes in
temperatures
1. Install pressure relief
valve which can control
the excess gases inside
the dryer
1. Install flow indicator

1. Install flow indicator

1. Install glass in the

pipeline to see the flow
2. Install alarm

(Fluidised
Bed)
Pyrolysis
reactor

LESS

Less Flow

1. Flowrate
valve not
functioning
2. Partially plug
line
3. Line before
reactor
leakage

1. Too Less
feedstock
flowrate cause
inefficiency in
the reactor

1. Inspection have to
be carried out
regularly

1. Install gas detection

system
2. Install alarm

MORE

More Flow

1.Flowrate valve
not functioning

1. Inspection have to
be carried out
regularly

1. Install alarm

LOW

Low
Pressure

1. Undetected
leakage

1. Overflow
2. May cause
leakage in the
reactor
1. Undesired
product yield
2. May cause
reverse flow

1. Install low pressure

alarm

HIGH

High
Pressure

1. Thermal
overpressure
2. Pressure
controller not
functioning

1. Pressure
inside the
reactor build up
2.Can cause the
reactor explode

LOW

Low
temperat
ure

Temperature
controller not
functioning

HIGH

High
Temperat
ure

Temperature
controller not
functioning

1. Difference in
percentage of
product that are
produced
1. Can cause
explosion

1. Pressure indicator
is provided to notify
the operator
2. Inspection done
regularly
1. Pressure indicator
is provided to notify
the operator
2. Inspection for
pressure done
regularly
1. Inspection for
temperature done
regularly
1. Inspection for
temperature done
regularly

1. Decrease heat
source

1. Install high pressure

alarm

1. Increase heat source

Heater
(furnace)

NO

No
reaction

1. No feed supply
into the reactor.
2. Malfunction of
furnace, heat
exchanger,
fluidised bed

1. No product
produce

1. Pressure indicator
is provided to notify
the operator
2. Temperature
indicator is provided
to notify the operator
3. Should be
provided with flow
indicator

1. Repair the
malfunctioned
components

LOW

Low
Temperat
ure
High
temperat
ure

1. Higher flow in
the burner

1. Temperature
indicator is provided
to notify the operator
1. Temperature
indicator is provided

1. Slow down flowrate

2. Increase fuel source
in the burner
1. Increase the flowrate
in burner

LOW

Low
pressure

1. Leakage in the
coil

1. Pyrolysis
process would
not be efficient
1. Too much of
heat supply to
the pyrolysis
reactor. So
Difference in
percentage of
product that are
produced
1. Drop in the
temperature

1. Pressure indicator
is provided

1. Install low pressure

alarm

HIGH

High
Pressure

1. Blockage in
the coil

1. Pressure indicator
is provided

1. Install high pressure

alarm

NONE

None
Temperat
ure

1. Heat source
not functioning

1. Sudden
increase in
temperature
1. No
conversion
occurs

1.Carry out regular

schedule inspection

1. Check heat source

HIGH

Heat
exchanger 1

1. Lower flow in
the burner

Inside
gasification
reactor

LOW

Low
Temperat
ure

1. Too little heat

is supplied from
the heat source

1. Desired
reaction fail to
achieve

HIGH

High
Temperat
ure

1. Too much of
heat supply from
heat source

1. Can cause
explosion

LESS

Less Flow

1. Less feed
supply into the
reactor
2. Temperature
and pressure are
not at desired
condition

1. Less product
produce.
2. Undesired
product quality.

MORE

More feed

1. More feed
supply into the
reactor.

1. Feed in
reactor
increases and
causes
undesired
product purity.
2. Heats build
up that may
lead to reactor
explosion.

1. Temperature
indicator is provided
to notify the operator
2. Carry out regular
schedule inspection
1. Temperature
indicator is provided
to notify the operator
2. Carry out regular
schedule inspection
1. Pressure indicator
is provided to notify
the operator
2. Temperature
indicator is provided
to notify the operator
3. Should be provide
with
flow indicator
1. Pressure indicator
is provided to notify
the operator
2. Temperature
indicator is provided
to notify the operator
3. Should be provide
with flow indicator

1.Increase heat source

1.Reduce heat source

1. Increase the
pressure of the feed
inlet
2. Increase the amount
of feed

1. Decrease the
pressure of the feed
inlet
2. Decrease the
amount of feed

Heat
Exchanger 2

NO

No Flow

HIGH

High Flow

1. Blockage in
pipes
2. Controller fails
1. Control valve
(flowrate valve)
fails to open

1. Product yield
decreases.
1. Difference in
percentage of
product that are
produced
1. Undesired
product yield
2. May cause
reverse flow

LOW

Low
Pressure

1. Undetected
leakage

HIGH

High
Pressure

1. Thermal
overpressure
2. Pressure
controller not
functioning

1. Pressure
inside the
reactor build up
2.Can cause the
reactor explode

LOW

Low
Temperat
ure

1.Temperature
controller not
functioning

HIGH

High
temperat
ure
No flow of
hot water

1. Temperature
controller not
functioning
1. Failure of valve
to open
2. Pipe blockage
3. Pipe leakage

1. Difference in
percentage of
product that are
produced
1. Can cause
explosion

NO

1. Cause
explosion
2.
Environmental
pollution

1. Place controller on
critical
instrumentation list
Place controller on
critical
instrumentation list

1. Install
system
2. Install
1. Install
system
2. Install

gas detection

1. Pressure indicator
is provided to notify
the operator
2. Inspection done
regularly
1. Pressure indicator
is provided to notify
the operator
2. Inspection for
pressure done
regularly
1. Inspection for
temperature done
regularly

1. Install low pressure

alarm

1. Inspection for
temperature done
regularly
1. Open valve to
refinery fuel gas from
gasification process
2. Immediately shut
down the gasification
process

1. Decrease heat
source

alarm
gas detection
alarm

1. Install high pressure

alarm

1. Increase heat source

NO

No flow of
cooling
water
More
cooling
water

1. Pipe blockage
2. Pipe leakage

LESS

Less
cooling
water

REVERSE

Reverse
flow of
cooling
water

1. Pipe leakage
2. Low pressure
3. Failure of
outlet valve to
close
1. Failure of
outlet valve to
open

CORROSI
ON

Corrosion
of tube

1. Hardness of
cooling water

LOW

Low
temperat
ure of
outlet
synthetic
gas

1. Malfunction of
heat exchanger
2. Failure of
outlet valve of
cooling water to
close

LOW

Low
pressure

1. Pipe leakage
2. Malfuction of
pressure relief

MORE

1. Failure of
outlet valve to
open

1. Temperature
of synthetic gas
remain same
1. Bursting of
tube
2. Temperature
of hot stream
decrease
1. Temperature
of synthetic gas
still high with
small reduction
in temperature
1. Temperature
of synthetic gas
still high with
small reduction
in temperature
1. Less cooling
and crack of
tube
1. Need to heat
up the synthetic
gas to achieve
targeted
temperature

1. Install low flow

alarm

1. Reduce fluid
flow rate

1. Monitor heat
exchanger pressure

1. Monitor the
cooling water flow
rate in flow indicator

1. Monitor the
cooling water flow
rate in flow indicator
2. Install low flow
alarm
1. Install check valve

1. Maintenance must
take place frequently
1. Monitor outlet
temperature of
synthetic gas from
heat exchanger

valve

Pressure
Swing
Adsorber

HIGH

High
temperat
ure of
outlet
synthetic
gas

1. Malfunction of
heat exchanger
2. Cooling water
pipe blockage
3. High flow of
synthetic gas

HIGH

High
pressure

1. Pipe blockage
2. Malfunction of
pressure relief
valve

NO

No flow of
synthetic
gas into
PSA

HIGH

High flow
of
synthetic
gases

1. Pipe blockage
2. Pipe leakage
3. Failure of
control valve to
open
1. Failure of
control valve
2. High pump
capacity

HIGH

High
temperat
ure

1. Malfunction of
heat exchanger

1. Cause
explosion
2. Damage the
next
unit( adsorbent)
3.
Environmental
pollution
1. Bursting of
tube or shell

1. Open valve to
refinery fuel gas
2. Install high
temperature alarm

1. Cause
explosion
2.
Environmental
pollution
1. Purity of
hydrogen will be
low
2. Damage the
adsorbent in
vessel
1. Cause
explosion
2.
Environmental

1. Close all valves

and shut down PSA
unit

1. Monitor the pump

pressure
2. Install back up
pressure relief valve

1. Install bypass
valve
2. Install high
pressure alarm

1. Open valve to
refinery fuel gas
2. Install high
temperature alarm

pollution
HIGH

High
pressure

LESS

Low flow
of
synthetic
gases

LESS

Haber
Process
Reactor

Low
pressure

NO

No Flow

LESS

LESS Flow

1. Failure of
pressure relief
valve to open
2. High pump
capacity
1. Failure of
control valve
2. Low pump
capacity
3. Pipe blockage
4. Pipe leakage

1. Cause
explosion
2.
Environmental
pollution
1. Less
production
2. Damage the
adsorbent in
vessel due to
drying

1. Monitor the pump

pressure
2. Install back up
pressure relief valve

1. Pipe blockage
2. Pipe leakage
3. Failure of
pressure relief
valve to close
1. Loss of feed
supply
2. Line rupture
3. Line before the
reactor leakage
1. Control valve
failure
2. Partially plug
line
3. Line before
reactor leakage

1. Reaction fail
to occur

1. Close the outlet

valve until the
pressure reached its
targeted pressure

1. No process
gas into the
reactor
2. Release of
toxic material
1. Less process
gas supplied in
the reactor
2. Release of
toxic material
3. Drop of

1. Should be provide
with flow indicator
2. Carry out regular
schedule inspection

1. Install gas detection

system
2. Install alarm

1. Should be provide
with flow indicator
2. Carry out regular
schedule inspection

1. Install gas detection

system
2. Install alarm

1. Install recycling
stream in PSA unit
2. Install low flow
alarm

MORE

MORE
Flow

1. Control valve
trim changed

REVERSE

REVERSE
Flow

LOW

LOW
Temperat
ure

1. Failure of
pressure
controller
2. Compressor
trips
1. Leaking heat
exchanger tubes

HIGH

HIGH
Temperat
ure

1. Failure of
cooling water
system

HIGH

HIGH
Pressure

1. Thermal
overpressure
2. Failed open
pressure control

pressure inside
the reactor
1. Over pressure
inside the
reactor.
2. May cause
explosion of the
reactor
3. Worsen
product quality
1. Flow reversed
from reactor.
2. Product yield
decreases.
1. Desired
reaction fail to
achieve

1. Temperature
inside the
reactor
increase.
2. Can cause to
reactor
explosion
1. Pressure
inside the
reactor build up
2.Can cause the

1. Should be provide
with flow indicator
2. Carry out regular
schedule inspection

1. Install alarm

2. Carry out regular

schedule inspection

1. Install check valve

1. Temperature
indicator is provided
to notify the operator
2. Carry out regular
schedule inspection
1. Temperature
indicator is provided
to notify the operator
2. Carry out regular
schedule inspection

1. Install low
temperature alarm

1. Pressure indicator
is provided to notify
the operator
2. Carry out regular

1. Install high pressure

alarm

1. Install high
temperature alarm

valve

reactor explode

schedule inspection
1. Pressure indicator
is provided to notify
the operator
2. Carry out regular
schedule inspection
1. Pressure indicator
is provided to notify
the operator
2. Temperature
indicator is provided
to notify the operator
3. Should be provide
with flow indicator

LOW

LOW
Pressure

1. Undetected
leakage
2. Malfunction of
compressor

1. Undesired
product yield
2. May cause
reverse flow

NO

NO
Reaction

1. No feed supply
into the reactor.
2. Malfunction of
compressor and
heat exchanger

1. No product
produce

LESS

LESS
Reaction

1. Less feed
supply into the
reactor
2. Temperature
and pressure are
not at desired
condition

1. Less product
produce.
2. Undesired
product quality.

MORE

MORE
Reaction

3. More feed
supply into the
reactor.

1. Feed in
reactor
increases and
causes
undesired
product purity.

1. Pressure indicator
is provided to notify
the operator
2. Temperature
indicator is provided
to notify the operator
3. Should be provide
with flow indicator
1. Pressure indicator
is provided to notify
the operator
2. Temperature
indicator is provided
to notify the operator

1. Install low pressure

alarm

Stream after
Haber
Process
Reactor

NO

1.
Blockage
in pipes
2.
Controller
fails

1. Product yield
decreases.

2. Heats build
up that may
lead to reactor
explosion.
1. Place
controller on
critical
instrumentation
list

3. Should be provide
with flow indicator

1. Install gas
detection system
2. Install alarm