Vous êtes sur la page 1sur 13

VCM-2 Emergency Shutdown

2003-2004

Root Cause Analysis

Ethylene High Pressure Shutdown

Presented by : Sudjaritchat Sudjarit


History Plant Shutdown

Case Date Plant Shutdown Events


1 20 Mar 2003 M-PAHH1225, Ethylene pressure ‘High’

2 27 Mar 2003 M-PAH1426, Fuel pressure ‘High’

3 5 Nov 2003 M-TAHH1412B, Furnace temperature ‘High’


4 25 Jan 2004 M-FALL1215, suction flow of recycle gas compressor
‘Low’
5 11 Feb 2004 M-FALL1215, suction flow of recycle gas compressor
‘Low’
6 12 Feb 2004 M-XAHH1274, HS gear of recycle gas compressor,
vibration ‘High’
7 29 Oct 2004 M-PAHH1226 Ethylene pressure ‘High’
8 7 Nov 2004 M-PAHH1226 Ethylene pressure ‘High’
Ethylene Process & Instrument Diagram

M-PAHH1225 M-PAHH1226
Root Cause Analysis (Possible
Cause)

Main Cause Possible Cause Corrective and Preventive Action

1.Process 1.Pressure real high when Study and improvement loop control
Condition pressure main line upset. pressure between M-PAHH1225,1226.(WK)

2. Instrument 1.Electrical and electronics 1.Change fuse and relay all.(CP)


Equipment parts end life time. 2.Change transmitter.(CP)
2.Equipment high response not 3.Improvement grounding system.(CP)
match with process. 4.Install redundant card I/O TRICON
3.Surge/Transient affect from system.(CP)
field or electronics board. 5.Install Redundant power distributor
switch box.(CP)
6.Install surge and transient protection in
line main power supply.(CP)
7.Install surge and transient protection in
line analog input.(CP)
8.Add delay timer 1 sec.(CP)
Corrective
Preventive Change new Fuses and Relay
Action

Cause of
Instrument Change new fuses on electronics board and power
distributor switch box.Change new 24v relay digital output of
TRICON
Corrective
Preventive Change Transmitter from Rosemount to Yokogawa
Action

Cause of
Instrument Rosemount transmitter has high response to
dynamic pressure more than other brand.This performance
may be not match with process condition.Because if
process have a little pressure surge transmitter will get
data and sent signal to control system due to interlock
shutdown.

Yokog
awa
Rosemou
nt
Corrective
Preventive
Action
Improvement Grounding System

Cause of Improve ground connection in field junction


Instrument block(JB) and cabinet room. Bonding ground at ground bar
and isolate ground signal and power supply.

Junction Box Mar. Rack DCS/ESD

Bonding ground
Field Instrument E1 SB
Terminal

Terminal
I/P

Ground rod Ground rod


Signal cable
(1-pair)
Ground bar

Shield Multi-pair cable

Structure ground
E1 SB
Ground bar

Grounding rod E ZB
≤5Ω
E ZB

E ZB

Ground rod Ground rod


Corrective
Preventive
Action Install redundant I/O card of TRICON
system
Cause of Install redundant input/output cards such as
Instrument -Analog input (3),
-Thermo couple (2),
-Digital input(5),
-Digital output(3).
Redundant
Corrective
Preventive
Action Install redundant Power Distributor Switch Box.

Cause of
Instrument Install redundant power distributor switch
box for supply field terminal cards (FTA/RTA) and
solenoids valve of emergency valve(XV valve).

Redundant SW.

FTA/RTA

Old

New
Corrective
Preventive Install surge protection line main power supply
Action

Cause of
Instrument Install 2 unit of surge protection & transient over
voltage (MA100) parallel at Busbar line main power supply
instrument.
Corrective
Preventive
Action
Install Signal Surge and Transient
Protection

Cause of
Install signal surge
Instrument
and transient protection in
line analog input between
field instruments and TRICON
amount 30 tag from 62 tag
selected by logic diagram.
Corrective
Preventive
Action
Add timer delay 1000 ms

Cause of Add timer delay 1000 ms (1 sec)


Instrument
1.OC Reactor
2.Recycle Compressor
3.Furnace A
4.Furnace B

Section 200
OC Reactor
Corrective
Preventive
Action
Improvement cost

Cause of
Instrument Item Improvement description Cost (Baht)
1 Change fuse and relay 134,500.00
2 Change transmitter 113,400.00
3 Improve grounding system 276,300.00
4 Install redundant card I/O TRICON system. 2,574,000.00

5 Install Redundant power distributor switch 449,000.00


box.
6 Install surge and transient protection line 53,000.00
main power
7 Install surge and transient protection 152,000.00
analog input
TOTAL 3,752,200.00