DAP Process

FIC

FIC

Mahdi Gougol

Diammonium phosphate (DAP) is made by reacting ammonia and phosphoric acid. DAP is non-hazardous. Ammonia is the most hazardous chemical present. Reaction is exothermic.

FIC

FIC

Mahdi Gougol

Phosphoric Acid Feed Line to DAP Reactor

Deviation
No Flow

Cause
1. No feed material in storage tank.

Consequence
1-1. Unreacted Ammonia in storage tank that release to enclosed work area. 1-2. Loss of DAP production. 2-1. Same as1-1,1-2.

Safeguard
1-1-1. Ammonia detector and Alarm.

Recommendation
Consider using a closed tank for DAP storage or ventilation.

2. FIC fails high.

Consider adding an alarm/shutdown of the system for low flow to the reactor.

3. Leak or rupture of the line. 4. Control valve B fail closed. 5. Operator sets the flow controller too low. 6. Plugging of the line.

3-1. Same as1-1,1-2. 4-1. Same as1-1,1-2. 4-1-1. Periodic maintenance of valve B. Ensure that periodic maintenance and inspection for valve B are adequate.

5-1. Same as1-1,1-2.

6-1. Same as1-1,1-2. 3

Mahdi Gougol

Ammonia Solution Storage Tank

Deviation
High Level

Cause
7. Unloading ammonia from the unloading station without adequate space in the ammonia storage Tank. 8. Ammonia storage tank level indicator fails low.

Consequence
7-1. Potential release of ammonia to the Atmosphere.

Safeguard
7-1-1. Level indicator on the storage tank. 7-1-2. Ammonia storage tank relief valve to the atmosphere.

Recommendation
Review ammonia unloading procedures to ensure adequate space in the storage tank before unloading.

8-1. Same as7-1.

Consider sending the relief valve discharge to a scrubber. Consider adding independent high level alarm for the ammonia storage tank.

Mahdi Gougol

Ammonia Feed Line to the DAP Reactor

Deviation
High Flow

Cause
9. Ammonia feed line control valve A fails open.

Consequence
9-1. Unreacted ammonia carry over to the DAP storage tank and release to the work area. 10-1. Same as9-1.

Safeguard
9-1-1. Periodic maintenance of valve A.

Recommendation
Consider adding an alarm/shutdown of the system for high Ammonia flow to the reactor.

10. Flow indicator fails low. 11. Operator sets ammonia flow rate too high.

10-1-1.Ammonia detector and Alarm. Ensure periodic maintenance and inspection for valve A is adequate. Ensure adequate ventilation exist for enclosed work area and/or consider using an enclosed DAP storage tank. 12-1-1. Periodic maintenance of line. Ensure adequate ventilation exist for enclosed work area. 5

11-1. Same as9-1.

Other than (Leak)

12.Corrosion

12-1. Small continuous leak of ammonia to the enclosed work area.

Mahdi Gougol

Ammonia Feed Line to the DAP Reactor

Deviation Cause
13. Erosion. 14. External impact.

Consequence
13-1. Same as12-1. 14-1. Same as12-1.

Safeguard
13-1-1. Same as 12-1-1. 14-1-1. Periodic inspection tours by operator in the DAP process area.

Recommendation

15. Maintenance errors.

15-1. Same as12-1.

Mahdi Gougol

Phosphoric Acid Solution Storage Tank

Deviation
Low Concentration of Phosphoric Acid

Cause
16. Low Phosphoric Acid concentration supplied by the vendor.

Consequence
16-1. Unreacted ammonia in the reactor carried over to the DAP storage tank and release to the work area. 17-1. Same as16-1.

Safeguard
16-1-1.Ammonia detector and Alarm.

Recommendation
Ensure existence of adequate material handling and receiving procedures and labeling. Consider verifying the Phosphoric Acid concentration in the storage tank before operation. Ensure adequate ventilation exist for enclosed work area and/or consider using an enclosed DAP storage tank.

17. Error in charging Phosphoric Acid to the supply tank

Mahdi Gougol

DAP Reactor
Deviation
(Other Than) Loss of agitation

Cause
18. Agitator motor fails.

Consequence
18-1. Unreacted ammonia in the reactor carried over to the DAP storage tank and release to the work area.

Safeguard
18-1-1. Ammonia detector and Alarm.

Recommendation
Consider adding an alarm/shutdown of the system for loss of agitation in the reactor. Ensure adequate ventilation exist for enclosed work area and/or consider using an enclosed DAP storage tank.

19. Agitator Mechanical linkage fails. 20. Operator fails to activate the agitator.

19-1. Same as18-1.

19-1-1. Same as18-1-1. 19-1-1. Same as18-1-1.

19-1. Same as18-1.

Mahdi Gougol

DAP Reactor Outlet line to the DAP Storage tank.

Deviation
Reverse/misdi rected flow

Cause
21. No credible causes.

Consequence
No significant effects.

Safeguard

Recommendation

Mahdi Gougol

DAP Storage tank.

Deviation
High Level

Cause
22. Excess flow from the reactor.

Consequence
22-1. Operability problems caused by overfilling the DAP storage tank to the enclosed area(DAP dose not pose an acute hazard to personnel)

Safeguard
22-1-1. Operator observation of the DAP storage tank level.

Recommendation
.Consider adding a High level alarm for The DAP storage Tank.

23. No Flow to the loading station.(Plugging of the line.)

Consider providing a dike around the storage tank.

Mahdi Gougol

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