I-1 Causes and Auto Actions:
Causes:
1. I – 19
In case of no C.W or no instrument air it is
better to shut down the plant than to run it
under these dangerous conditions
2. Low Process Gas Flow (4655NMC/hr)
If feed gas flow to F-101 decreases to a very low
value and fuel is not reduced catalyst tubes may
burst due to over heating
3. Low Steam Flow To F-101 (18750kg/hr)
Steam flow is very important and critical for
reforming furnace. Low steam flow will cause
coking.
4. Low Fuel Pressure (0.6psi)
Low fuel pressure may cause the burner flame
to light off and unburnt fuel will accumulate in
the furnace that may cause explosion
5. Low Steam / Gas Ratio (1.45kg/NMC)
Back up security for low steam flow
6. Low Level In C-105 (33%on 1-LIT-709)
Loss of water in the boiler drum will lead to
overheating of the waste heat exchangers
tubes. Refilling of the boiler will result into
severe thermal quench and damage of tubes.
7. High Draft In F-101 (-25mmH2O)
High draft in furnace may cause refractory lining
to collapse due to very high negative pressure
in the furnace which will result in metal
overheating. Flame failure may also occur
8. Low Draught In F-101 (+5mmH2O)
If draught in the furnace is decreased then air
for combustion will decrease accordingly. So,
unburned fuel will accumulate in F-101 firebox,
which may result in drastic explosion.
9. ID Fan low Speed (300 rpm)
It is an additional security to safeguard low
draught.
10. Shutdown K-1003
This is back up security for low feed gas flow
security.
11. Manual trip CCR or field
Effects:
1. PV-6/7 will close to allow any fuel into
burner fuel header because it may lead to
overheating of tubes or accumulation of
fuel in fire box that may lead to explosion
2. FV-185/185A will close to prevent any fuel
into the furnace and FV-187 will open to
vent any fuel present
3. FV-3/7 will close so no feed gas is allowed
into catalyst tubes
4. Shutdown of K-1003 because no gas is
required after I-1 actuation as it will cause
coking of reformer tubes.
5. FV-4/8 will close to stop steam flow. Higher
flows will result in unnecessary overloading
of the boilers and rapid cooling of the
system. So, main steam flow valve is closed
on trip of reformer while steam flow
continues through the bypass valve.
6. HV-11 will open to provide steam for
process gas coil protection against thermal
shocks.
7. HV-116 will open for process air coil
protection.
8. HV-119 will close to stop Condensate to L-
106 so that in no excess condensate flow to
the shift converters.
9. 2-FV-1 will close to stop any steam from
entering HTSC to avoid condensation in
shift convertors
10. I-2/I-6/I-11/I-12/I-13/I-14 will be actuated
because no process gas would be present in
case of I-1 actuation
11. I-8/I-9 will actuate because there is no air
requirement after I-1 actuation.
12. CO2 compressor will trip because there will
be no CO2 generation after reforming
reaction has stopped
I-2 Causes and Auto Actions:
Causes:
1. I – 19
In case of no C.W or no instrument air or no
power it is better to shut down the plant than
to run it under these dangerous conditions.
2. Low air flow (6500NMC/hr)
At this air flow we assume that the burner in C-
102 may light off which will let the oxygen in
the air to pass on and it will oxidize the catalyst.
3. Low gas/air ratio (0.6)
Additional security against low air flue or low
gas flow.
4. Manual trip CCR or field
Effects:
1. CV-14/14A will open to vent the air present.
2. BV-704/705, CV-5 will close to stop the air
entry into C-102.
3. CV-61 will open to cool down the burner
tip.
4. HV-116 will open to avoid over heating of
process air coils in F-101.
5. I-11/I-12 will actuate because the molar wt.
of the gas will change due to N2 absence
and this will in turn damage the syn
compressors.
6. I-13/I-14 will actuate because there will be
no ammonia vapor generation due to
tripping of Syn compressors.
I-3 Causes and Auto Actions:
Causes: Effects:
1. I – 19 1. FV-6A/B and FV-7A/B will close to avoid loss
In case of no C.W or no instrument air or no of level in C-208 because loss of level will
power it is better to shut down the plant than result in absorber dry out and will damage
to run it under these dangerous conditions. the vanadation layer
2. Low level in C-208 (11% level) 2. I-6 will be actuated because in case of I-3
Low level tripping prevents the complete loss of actuation CO2 slippage may occur which will
level to avoid absorber dry run because in case increase methanator catalyst temperature
of level loss process gas may break through 3. I-11/I-12 will be actuated because after I-6
which will damage the vanadation layer and actuation there will be no gas after
move towards stripper operating at low methanator. CO2 presence will change gas
pressure molar wt. and CO2 gas is a poison for
3. Low level in C-203A/B bottom (30% level) convertor catalyst.
In case of strippers bottom low level, lean 4. I-13/I-14 will actuate because there will be
solution pump will trip and no lean solution will no ammonia vapor generation after syn
be present and CO2 slippage will occur which compressor tripping.
will increase methanator temperature and is
also a poison for convertor catalyst
4. Low level in flash vessel (6% level)
Low level in flash vessel will trip the semi lean
pumps and no semi lean solution will be
present for CO2 capture and CO2 slippage may
occur resulting in methanator temperature
increase or convertor catalyst damage
5. Low level in C-203A/B middle (23% level)
If semi lean solution pumps are selected with C-
203A/B middle, then low level in middle will
cause the pumps to trip.
6. Manual trip field or CCR
I-4/I-5 Causes and Auto
Actions:
Causes:
Low level in C-203A/B bottom (30% level)
1. I-4A actuates when G-206A trips on low
level of C-203A bottom or any other cause.
2. I-4B actuates when G-206B trips on low
level of C-203A bottom or any other cause.
3. I-4C actuates when G-206C trips on low
level of C-203A/B bottom i.e which one is
selected or any other cause.
Low level in C-2001 (6% level)
Effects:
1. In case of I-4 actuation i.e I-4A/B/C, I-3 will
be actuated because level loss will cause
the gas to pass onto strippers and no lean
solution will be available which will increase
CO2 slippage.
2. In case of I-5 actuation i.e I-5A/B/C, I-3 will
be actuated because level loss will cause
the gas to pass onto strippers no semi-lean
solution will be available which will increase
CO2 slippage.

1. I-5A actuates when G-201A trips on low

level of C-2001 or C-203A middle level
(which one is selected) or any other cause.
2. I-5B actuates when G-201B trips on low
level of C-2001 or C-203B middle level
(which one is selected) or any other cause.
3. I-5C actuates when G-201C trips on low
level of C-2001 or C-203A/B middle level
(which one is selected) or any other cause.
I-6 Causes and Auto Actions:
Causes:
1. High methanator temperature (398ᵒC)
High temperature will affect the life of
methanator catalyst. Also high temperature
means CO2 or CO presence which is poison for
convertor catalyst
2. Low I/A pressure to TV-32 (65psi)
Low instrument air pressure will not operate
methanator inlet I/V and it is better to trip the
methanator then to operate it under dangerous
conditions
Effects:
1. TV-32 will close to save methanator catalyst
from any upsets.
2. I-11/I-12 will be actuated because after I-6
actuation there will be no gas after
methanator. CO2 presence will change gas
molar wt. and CO2 gas is a poison for
convertor catalyst.
3. I-13/I-14 will actuate because there will be
no ammonia vapor generation after syn
compressor tripping

3. I-1/I-3 actuation
In case of I-1 actuation there will be no process
gas available. I-3 actuation means there is no
CO2 removal so to save methanator from high
temperature I-6 actuates

4. Manual trip CCR or field