No.

Element Intention Guide Word

1 Line 36 Charge leaching waste into R01 None

2 Less

3 Line 37 Supply sulphuric acid to T03 None

4 Line 38 Charge sulphuric acid into R01 None

5 Less

6 More

7 Sooner

8 Line 39 Vent T03 None

Less
9 T03 Hold 90% sulphuric acid More

10 More
11 Line 40 Supply cooling water to R01 jacket None

12 Less

13 Later
14 Line 42 Vent reactor gases None

15 Less
16 Line 43 Transfer neutralised material to holding tank T04 None

17 R01 Agitator Motor Mix reactor contents None

18 R01 House reaction More

19 More
20 More
21 Line 44 Discharge neutralised waste from T04 None

22 Less
23 Line 45 Recycle material into T04 None

24 Less
25 Line 46 Vent T04 None

26 Less
27 T04 House neutralised process material More

28 More
29 Line 47 Transfer process material to hydrocyclones None

30 Less

31 More

32 Line 48 Transfer neutralised liquid waste to sewage None

33 Less
34 Line 49 Transfer solid waste to collection area None

35 Less
Deviation Cause(s)
No flow - Blockage of line 36
- Failure of R01 feed pump
Less flow - Partial blockage of line 36
- R01 feed pump fault
No flow - Actuated valve in line 37 fails shut

No flow - Blockage of line 37

- Blockage of P02 compressed air line
- Failure of P02

Less flow - P02 fault

More flow - P02 fault

- R01 LI fault

Sooner flow - R01 LI fault

No flow - Blockage of T03 vent

Less flow See item 8

More level - Failure of T03 level indicator

More pressure See item 8

No flow - Blockage of cooling water supply line
- Failure of cooling water pump

Less flow - Partial blockage of cooling water

supply line
- Leak in cooling water supply line
- Malfunction of cooling water pump

Later flow - Fault in R01 temperature control loop

(TI fault)
No flow - Blockage of R01 vent

Less flow See item 14

No flow - Failure of P03
- Blockage in line 43

No rotation - Failure of R01 agitator motor

More level - Failure of R01 level sensor

More temperature See items 6, 7 , 11, 12, 13, 17

More pressure See items 14,15
No flow - Failure of P04

Less flow See item 21

No flow - Failure of P04
- Blockage of line 45
Less flow See item 22
No flow - Blockage of T04 vent line (line 46)

Less flow See item 25

More level Failure of T04 level indicator

More pressure See item 25

No flow - Failure of line 47 valve to closed
position
- Blockage of line 47

Less flow - P04 fault

- Line 47 actuated valve fails to open
fully

More flow - P04 fault

No flow - Blockage of line 48

Less flow - Partial blockage of line 48

No flow - Blockage of line 48

Less flow - Partial blockage of line 48

Consequence(s) Action
Stoppage of production Schedule regular checks of R01
feed pump
R01 filled slower leading to extended batch time Install flow meter in R01 feed line
36
- Stoppage of production Include rate of change of T03 level
check in control scheme (during
tanker unloading)

Stoppage of production Include rate of change of T03 level

check in control scheme (during
this batch phase)

R01 filled slower leading to extended batch time - Install flow meter in line 38
- Schedule regular checks of P02

- R01 temperature increases too high - Install hard-wired interlock that

- R01 contents could boil, over-pressurising shuts off P02 air supply on R01
reactor high high temperature
- Out-of-spec waste - Install flow control loop on P02

- Sulphuric acid added before full charge of - Install R01 level check before
alkaline waste enters R01, causing overheating of sulphuric acid addition occurs (in
reactor batch sequence)
- R01 contents could boil, over-pressurising - Install hard-wired interlock that
reactor shuts off P02 air supply on R01
- Out-of-spec waste high high temperature

- T03 overpressurises and fails, releasing - Schehule regular checks on T03

contents into immediate area (bunded) vent line (line 39)
- Install pressure/vacuum breathe
valve for vessel T03

See item 8 See item 8

Overflow of material into bund - Schedule regular checks of T03
level sensor

See item 8 See item 8

See item 6 See item 6

See item 6 See item 6

See item 6 - Schedule regular checks of R01

temperature sensors
 - R01 overpressurises and fails, releasing
contents into immediate area (bunded)
- Possible BLEVE (explosion) and generation of
airborn shrapnel
See item 14
Stoppage of production
- Stoppage of production
- Accumulation of unreacted sulphuric acid and
sodium hydroxide in R01 - if the agitator were to
restart, this would react rapidly causind
overheating of R01 and possible
overpressurisation causing catastrophic failure
- Egress of material out of R01 vent onto
unmade ground
See items 6, 7 , 11, 12, 13, 17
See items 14,15
- Stoppage of production
- Solid/liquid mixing (via jet mixer) in T04 stops,
allowing solids to settle. This will affect the
performance of the hydrocyclones downstream -
out-of-spec waste
See item 21
See item 21
See item 21
- T04 overpressurises and fails, releasing
contents into immediate area (bunded)
See item 25
Overflow of material into bund
See item 25
- Schedule regular checks on R01
vent line
- Install pressure protection
interlock using actuated valve on
P02 air supply line
See item 14
- Schedule regular checks of P03
- Include R01 and T04 level rate of
change checks in this stage of the
batch sequence control
- Schedule regular checks of R01
agitator and its motor
- Only allow addition of sulphuric
acid once R01 agitator has started
(control scheme)
- Install interlock that cuts off P02
air supply if R01 agitator stops
- Install hard-wired interlock
connected to a high level switch
on R01 - this must prevent
sulphuric acid addition
See items 6, 7 , 11, 12, 13, 17
See items 14,15
- Install flow meter at P04
discharge with audible alarm that
sounds at reduced/no flow
- Schedule regular checks of P04
See item 21
See item 21
See item 21
- Schehule regular checks on T04
vent line (line 39)
- Install pressure/vacuum breathe
valve for vessel T04
See item 25
Schedule regular checks of T04
level indicator
See item 25
T04 high level, leading to overflow of T04 into - Install flow meter in line 47
bund - Include line 47 flow check when
actuated valve in line 47 opens -
sound an audible alarm when no
flow is observed when valve is
open (stops production)

Reduced flow to hydrocyclones, causing poor - Install audible alarm that sounds
clarifaction performance leading to out-of-spec on P04 low flow (when line 47
waste actuated valve is open)
- Schedule regular checks for P04

Possibility of out-os-spec waste due to altered - Install P04 variable speed drive
performance of hydrocyclones connected to flow sensor in P04
discharge to control flow

Possibility of waste backing up pipe and - Schedule regular checks of line

interfering with hydrocyclone performance 48
- Install local flow indicators in line
48

See item 32 See item 32

Possibility of waste backing up pipe and - Schedule regular checks of line
interfering with hydrocyclone performance 49
- Install local flow indicators in line
49

See item 34 See item 34

Actionable Individual
Maintenance manager

Design engineer (Ollie Horton)

Design engineer (Ollie Horton)

Design engineer (Ollie Horton)

- Design engineer (Ollie Horton)

- Maintenance manager

Design engineer (Ollie Horton)

Design engineer (Ollie Horton)

Design engineer (Ollie Horton)

See item 8
Maintenance manager

See item 8
See item 6

See item 6

Maintenance manager
- Design engineer (Ollie Horton)
- Maintenance manager

See item 14
- Design engineer (Ollie Horton)
- Maintenance manager

- Design engineer (Ollie Horton)

- Maintenance manager

Design engineer (Ollie Horton)

See items 6, 7 , 11, 12, 13, 17

See items 14,15
- Design engineer (Ollie Horton)
- Maintenance manager

See item 21
See item 21

See item 21
Design engineer (Ollie Horton)

See item 25
Maintenance manager

See item 25
Design engineer (Ollie Horton)

- Design engineer (Ollie Horton)

- Maintenance manager

Design engineer (Ollie Horton)

- Design engineer (Ollie Horton)

- Maintenance manager

See item 32
- Design engineer (Ollie Horton)
- Maintenance manager

See item 34
 VENT 39

LI

SULFURIC ACID

T03 37 SUPPLY

COMPRESSED
AIR

FI
VENT 42

XI
P02 48
NEUTRALISED
LIQUID WASTE
VENT 46
FROM
38 FI
LEACHING SYSTEM 36
HTA HLA 45
PI
TI LI
LI 47

R01 FI

T04 FI

43
44
C01
P03 P04
COOLING
WATER SUPPLY 40 41
FI
COOLING
WATER RETURN SOLID WASTE
49 (TO LANDFILL)
 SULFURIC ACID
37 SUPPLY

NEUTRALISED
48 LIQUID WASTE
FI

47

FI

FI

4
C01
P04
FI

SOLID WASTE
49 (TO LANDFILL)