Deviation Causes Consequenc Detection Suggeste

es and d/
safeguard required
s actions,
comment
1. High temperature after 1.1 Tail gas No harmful EVA1 Add
s EM-
EVA1 flow to AFB2 consequences in temperature SD
too high fuel side indicators (8 triggered
downstream. + 1 in outlet by high
line) temperat
ure after
EVA1.

1. High temperature after 1.1 Tail gas Failures of Add EM-

EVA2 flow to AFB2 AFB2/EVA1 are SD
too high possible (to be triggered
covered in by high
connection with temperat
tail gas/heating ure after
system). EVA1.

1. High temperature after 1.2 EtOH-1 No harmful EVA1 Change

EVA3 flow to AFB2 consequences in temperature control of
too high fuel side indicators (8 DP1 from
downstream. + 1 in outlet TI-FP5 to
line) EVA1
outlet
temperat
1. High temperature after 1.2 EtOH-1 Failures of
EVA4 flow to AFB2 AFB2/EVA1 are
too high possible (to be
covered in
connection with
tail gas/heating
system).

1. High temperature after 1.3 Fuel flow No harmful EVA1

EVA5 to EVA1 too consequences in temperature
low fuel side indicators (8
downstream. + 1 in outlet
line).
AFB2 outlet
temperature
indicator (TI-
FP5).
2. Low temperature after 2.1 Tail gas No complete EVA1 Add EM-
EVA1 flow to AFB2 vaporization in temperature SD
too low (to be EVA1 → problems indicators (8 triggered
covered in in SRR, no + 1 in outlet by low
connection reforming because line) temperat
with tail of low ure after
gas/heating temperature. EVA1.
system). Serious problems
downstream.

2. Low temperature after 2.2 No EtOH-1 No complete EVA1

EVA2 to AFB2 when vaporization in temperature
needed or EVA1 → problems indicators (8
amount of in SRR, no + 1 in outlet
EtOH-1 too reforming because line)
low (to be of low
covered in temperature.
connection Serious problems
with tail downstream.
gas/heating
sys-
tem).
 2.3 Fuel flow No complete EVA1
2. Low temperature after to EVA1 too vaporization in temperature
EVA1 high EVA1 → problems indicators (8
in SRR, no + 1 in outlet
reforming because line)
of low
temperature.
Serious problems
downstream.

2.4 Fouling of No complete EVA1 Use of

2. Low temperature after EVA1 heat vaporization in EVA1 temperature deionized
EVA2 exchange → problems in SRR, indicators (8 water.
surfaces, no reforming + 1 in outlet EtOH
because of because of low line) must not
impurities in temperature. contain
water or in Serious problems sediment.
EtOH.
downstream.
Doesn´t happen
immediately, slow
process.

3. High temperature after 3.1 Tail gas No harmful EVA2 Add EM-
EVA2 flow to AFB1 consequences in temperature SD
too high (to fuel side indicators (6 triggered
be covered in downstream. + 1 in outlet by high
connection line) temperat
with tail ure after
gas/heating EVA2.
system).
3. High temperature after 3.1 Tail gas No serious
EVA3 flow to AFB1 consequences to
too high (to HX3/EVA2.
be covered in
connection
with tail
gas/heating
3. High temperature after 3.2 SU-EtOH-3 No harmful EVA2 Commen
EVA4 flow to AFB1 consequences in temperature t: SU-
too high (to fuel side indicators (6 EtOH-3
be covered in downstream. + 1 in outlet designed
connection line) not to be
with tail used in
gas/heating steady
system). state.
3. High temperature after 3.2 SU-EtOH-3 No serious
EVA5 flow to AFB1 consequences to
too high (to HX3/EVA2.
be covered in
connection
with tail
gas/heating
3. High temperature after 3.3 Fuel flow No harmful EVA2
EVA6 to EVA2 too consequences in temperature
low fuel side indicators (6
downstream. + 1 in outlet
line)
HX3 outlet
temperature
indicator.

4. Low temperature after 4.1 Tail gas No complete EVA2 Add EM-
EVA2 flow to AFB1 vaporization in temperature SD
too low (to be EVA2 → problems indicators (6 triggered
covered in in SRR, no + 1 in outlet by low
connection reforming because line) temperat
with tail of low ure after
gas/heating temperature. EVA2.
system). Serious problems
downstream.
4. Low temperature after 4.2 No SU- No complete EVA2
EVA3 EtOH-3 to AFB1 vaporization in temperature
when needed or EVA2 → problems indicators (6
amount of SU- in SRR, no + 1 in outlet
EtOH-3 too low reforming because line)
(to be covered of low
in con- temperature.
nection with tail Serious problems
gas/heating
downstream.
system).

4. Low temperature after 4.3 Fuel flow No complete EVA2

EVA4 to EVA2 too vaporization in temperature
high EVA2 → problems indicators (6
in SRR, no + 1 in outlet
reforming because line)
of low
temperature.
Serious problems
downstream.
4. Low temperature after 4.4 Fouling of No complete EVA2 Use of
EVA5 EVA2 heat vaporization in EVA2 temperature deionized
exchange → problems in SRR, indicators (6 water.
surfaces, no reforming + 1 in outlet EtOH
because of because of low line) must not
impurities in temperature. contain
water or in Serious problems sediment.
EtOH
downstream.
Doesn´t happen
immediately, slow
process.

5. High fuel flow to SRR Comme

(correct composition) nt: Not
very
probable
because
dosing of
both H2O
6. Low fuel flow to SRR 6.1 Small No serious Container Carry
(correct composition) leakage after consequences. ventilation. out
the mixer Contact of fuel with pressure
electronic equipment tests with
can cause harm. nitrogen
Consequences and at least
related detection and after any
safeguards of ethanol modificati
leakage to be covered on to the
later more detail in system.
section Leaks from Add
system inside EtOH
container. detector
inside the
container,
because
small
leakage
can be
difficult to
detect.
6. Low fuel flow to SRR 6.2 Leakage Fuel flows to AFB2 PI-01 Verify if
(correct composition) in EVA1 or (leakage in EVA1) or EVA1 the fuel
EVA2 to HX3 (leakage in temperature can burn
EVA2) and possibly indicators (8 in AFB2.
burns in AFB2. + 1 in outlet
Possible “extra flue line)
gas” generated by EVA2
fuel burning in AFB2 temperature
or non-burned fuel indicators (6
flows with other flue + 1 in outlet
gases to exhaust gas line)
vent line. Possibly SRR
explosive gas temperature
mixture at the top of indicators (7
vent line. separate
indicators).
6. Low fuel flow to SRR 6.3 Blockage Pressure before Pressure
(correct composition) in filter F1 or the filter indicator PI-
F2 because of increases. Product 01.
impurities in gas output EVA1
H2O or in decreases. temperature
EtOH. If only one of the indicators (8
filters is blocked, + 1 in outlet
the fuel flow goes
line)
EVA2
through the other
temperature
one causing indicators (6
changes in EVA1 + 1 in outlet
and EVA 2 line)
temperatures.

7. No fuel flow to SRR 7.1 Broken Both fuel and Pressure Add EM-
pipeline or product gas start to indicator PI- SD
fitting escape from the 01 triggered
system. SRR by PI-01
Temperature temperature low
increase in SRR. indicators (7 pressure
separate (6 bar(g))
indicators). Add
after the
tail gas
tank a
shut-off
valve that
closes if
7. No fuel flow to SRR 7.2 Both feed System stops. Pressure the
Comme
pumps FFP1 indicator PI- nt: Not
and FFP2 01 very likely
inoperable that both
feed
pumps
fail
simultane
ously.
8. High pressure of SRR 8.1 Blockage Equipment design Pressure Add
fuel flow in SRR or pressure can be indicator PI- emergenc
equipment exceeded. Pumps 01 y shut
after it due to are able to down
catalyst generate 16 triggered
flaking. bar(g). by PI-01
Design pressure high
for components
pressure
(9 bar(g)).
(in FP) is 10
bar(g).

9. Low pressure of SRR 9.1 Big Both fuel and Pressure Add
fuel flow leakage product gas start to indicators PI- emergenc
escape from the 01, PI-04 y shut
system. down
Temperature triggered
increase in SRR. by PI-01
low
pressure
(< 6
bar(g)),
Add
after the
tail gas
tank a
10. H2O/C -ratio too low 10.1 Water Coking in SRR. Water tank shut-off
Locate
(below 4) tank empty WGS reaction level the low
conditions not indicator LI- level
optimal, too high CO 03 triggers indicator
concentration for AUTO-SD in water
PSA. FI-02 tank so
that
enough
water is
still
available
for
normal
shut
down.
10. H2O/C -ratio too low 10.2 Water Coking in SRR. FI-02 Add
(below 4) pump FFP2 WGS reaction H2O/C
not operating conditions not ratio
due to air optimal, too high CO calculatio
bubbles concentration for n which
component PSA. triggers
failure. EM-SD, if
ratio goes
below 3.
Consider
adding
alarm
related to
limits of
FFP2
control
10. H2O/C -ratio too low 10.3 Leakage Coking in SRR. FI-02 Consider
(below 4) in water line WGS reaction (relevant if carrying
conditions not leakage point out
optimal, too high CO is before FI- pressure
concentration for 02). test
PSA. PI-01 before
Consequences and start up, if
related detection possible.
and safeguards of
water leakage to be
covered later in
section Leaks from
system inside
container.
 10.4 Blockage Coking in SRR. FI-02
10. H2O/C -ratio too low in water line WGS reaction
(below 4) due to conditions not
impurities in optimal, too high CO
H2O tank. concentration for
PSA.

10.5 EtOH Coking in SRR. FFP1 Consider

10. H2O/C -ratio too low feed too high WGS reaction control adding
(below 4) due to failure conditions not voltage alarm
of FI-01 optimal, too high CO related to
concentration for limits of
PSA. FFP1
control
voltage
(RPM
control)
using on
lookup
table or
formula
based on
normal
10.6 Water Coking in SRR.  SRR If
10. H2O/C -ratio too low tank contains WGS reaction temperature needed,
(below 4) traces of conditions not indicators (7 samples
ethanol (or optimal, too high separate of
some alike CO concentration indicators). condense
reaction for PSA. d water
intermediate) should be
originating
taken
from
from product
VLS1.
gas line Analyse
vapour-liquid the
separator compositi
(VLS1) due to on of
incomplete condense
reformation in d water
SRR. during
system
initial
testing at
VTT
laboratori
es.
Comme
nt:
Ethanol
traces
may start
to
accumula
11. H2O/C -ratio too high 11.1 Ethanol No product gas Both LI-01 Configur
(above 4) tank empty flow to PSA, and FI-01 e in the
temporary trigger automati
increase in AUTO-SD. on system
EVA1&2 and SRR appropria
temperatures. te scripts
AUTO-SD takes for
place.
automatic
shut
down
(AUTO-
SD) and
for
emergenc
y shut
down
(EM-SD).
11. H2O/C -ratio too high 11.2 Air in Temporary or FI-01 (see Configur
(above 4) ethanol pump permanent suggested e
inlet due to decrease/stop of actions) following
leakage in ethanol feed. functional
pipe fittings AUTO-SD takes ities in
e.g. place. the
automati
on
system:
Short-
term
decrease
of ethanol
11. H2O/C -ratio too high 11.3 Ethanol No product gas FI-01 (see Configur
(above 4) pump FFP1 flow to PSA, suggested e
not operating temporary actions) following
due to increase in functional
diaphragm EVA1&2 and SRR ities in
rupture e.g. temperatures. the
AUTO-SD takes automati
place.
on
system:
Short-
term
decrease
of ethanol
flow (FI-
01)
triggers
alarm for
operator,
continued… 11.4 Leakage Too little or no FI-01 Configur
11. H2O/C -ratio too high in ethanol line product gas flow, (relevant if e
(above 4) (after pump) increase in leakage point following
EVA1&2 and SRR is before FI- functional
temperatures. 01). ities in
Consequences Pressure the
and related indicator PI- automati
detection and
01 on
system:
safeguards of
Short-
ethanol leakage to term
be covered later decrease
in section Leaks of ethanol
from system inside flow (FI-
container. 01)
triggers
alarm for
operator,
longer-
lasting
decrease
triggers
AUTO-SD.
Carry
out
pressure
test
before
start up, if
possible.

continued… 11.5 Blockage Too little or no FI-01 (see Configur

11. H2O/C -ratio too high in ethanol line product gas flow, suggested e
(above 4) due to increase in actions) following
impurities in EVA1&2 and SRR functional
ethanol tank. temperatures. ities in
the
automati
on
system:
Short-
term
decrease
continued… 11.6 Water Decrease in EVA1&2 Output Consider
11. H2O/C -ratio too high feed too high and SRR signal of adding in
(above 4) due to failure temperatures, FFP2 PID the
of FI-02 product gas controller is automati
composition may abnormally on system
change. high. automatic
Higher water feed monitorin
not a problem, g of feed
lower temperatures pump
in reactors might control
cause problems. signals or
limiting
pump
controller
output
signals to
certain
value, e.g.
30 %.

12. Liquid phase 12.1 Ethanol SRR catalyst SRR Ethanol

impurities in SRR fuel tank contains in deactivation and temperature should be
flow addition to later WGSR gradient purchase
ethanol small catalyst changes over d from
amounts of deactivation. time. reliable
higher alcohols supplier
or other heavier or
or- analysed
ganic in detail.
impurities.
13. High tem- 13.1 Heat SRR catalyst SRR
perature after SRR generation in damage and temperature
AFB1 too high further equipment indicators (7
damage possible. separate
indicators).
High
temperature
in first SRR
temperature
indicator
triggers
AUTO-SD.

14. Low temperature 14.1 Heat Product gas SRR

after SRR generation in composition temperature
AFB1 too low wrong. indicators (7
separate
indicators).
Low
temperature
in first SRR
temperature
indicator
triggers
AUTO-SD.

15. High feed Comme

gas flow to WGSR (correct nt: Not
composition) very
probable
because
dosing of
both H2O
and EtOH
should be
16. Low feed 16.1 Leakage Less product gas to Large Carry
gas flow to WGSR (correct in SRR or HX1 PSA, WGSR leakage: PI- out
composition) temperatures 01 and PI-04. pressure
possibly decrease. WGSR tests at
Gas burns in both temperature least after
cases in AFB1 indicators (7 any
causing temperature separate modificati
increase in indicators) on to the
AFB1/SRR, possible SRR system.
equipment damage. temperature
indicators (7
separate
indicators)
16. Low feed 16.2 Leakage Less product gas, Large Carry
gas flow to WGSR (correct in pipeline WGSR temperatures leakage: PI- out
composition) between SRR possibly decrease. 01 and PI-04. pressure
and WGSR Consequences and WGSR tests at
related detection temperature least after
and safeguards of indicators (7 any
combustible gas separate modificati
discharge into indicators) on to the
system surroundings system.
to be covered later
more detail in
section Leaks from
system
inside container.

17. No feed gas flow to 17.1 Blockage No product gas. Pressure Add EM-
WGSR in SRR or HX1 indicator PI- SD
due to coking 01 triggered
in SRR or SRR by PI-01
catalyst high
flaking. pressure
(9 bar(g))
17. No feed gas flow to 17.2 Major No product gas. Pressure Add
WGSR pipe failure Consequences indicator PI- emergenc
between SRR and related 01 y shut
and WGSR. detection and down
safeguards of triggered
combustible gas by PI-01
discharge into low
system
pressure
(6 bar(g))
surroundings to
be covered later
more detail in
section Leaks from
system
inside container.

18. High temperature of 18.1 Too low Change in the TI-FP3 Add
WGSR feed gas air flow behaviour of (main AUTO-SD
through HX1, WGRS, product detection down
fouling of heat gas contains too measure) triggered
exchanger much CO. WGSR by high
surfaces Possible damage temperature WGSR
to WGSR catalyst. indicators (7 inlet
separate temperat
indicators) ure
(inside
reactor).
19. Low temperature of 19.1 Too high Product gas TI-FP3 Add
WGSR feed gas air flow contains too much (main AUTO-SD
through HX1 CO. detection triggered
Possible damage measure) by low
to WGSR catalyst. WGSR WGSR
temperature inlet
indicators (7 temperat
separate ure
indicators)

20. High pressure of 20.1 Blockage Equipment design Pressure Add

WGSR feed gas in WGSR or pressure might be indicator PI- emergenc
equipment exceeded. 01 y shut
after it due to Product gas down
SRR or WGSR composition triggered
catalyst changes (methane by PI-01
flaking. increases). high
pressure
(> 9
bar(g)).
Consider
adding
pressure
relief
valve to
the inlet
side of
21. Low pressure of 21.1 Big Product gas Pressure Add EM-
WGSR feed gas leakage escapes from indicators PI- SD
system. 01 and PI-04 triggered
Consequences by PI-01
and related low
detection and pressure
safeguards of (< 6 barg).
combustible gas
Add
after the
discharge into
tail gas
system tank a
surroundings to shut-off
be covered later valve that
more detail in closes if
section Leaks from the
system inside system
container. pressure
goes too
low. SV5
should
open
simul-
taneously
.
22. Wrong composition in 22.1 SRR WGSR feed FCS cell
WGSR feed gas catalyst contains too high voltages
deactivation/d amount of CO, SRR
amage due to causing CO in temperature
too high SRR excess of 1-vol % indicators.
temperature, to flow to PSA. Temperature
higher WGSR feed gradient
alcohols etc. contains too much
changes over
time. (When
in fuel CH4. Complete
SRR
processor system efficiency functions
feed mixture is decreased with normally,
lower H2 yield. temperature
is in inlet
higher than
in outlet.)
23. Impurities in WGSR 23.1 SRR Ethanol and possibly SRR
feed gas catalyst other residues in temperature
deactivation WGSR feed gas. indicators.
(see above) Deactivation/ Temperature
leading to possible damage to gradient
unreacted WGSR catalyst. changes over
impurities Change in the time. (When
flowing to
behaviour of WGRS: SRR
Possibly reforming functions
WGSR
of ethanol or coke normally,
(ethanol and formation. temperature
other organic Wrong FP product is in inlet
compounds) gas composition higher than
(contains e.g. too in outlet.)
much CO). WGSR
temperature
indicators.

24. High PSA Comme

feed flow (correct nt: Not
composition) very
probable
because
dosing of
both H2O
and EtOH
25. Low PSA 25.1 Small Less product gas. Temperatur Add
feed flow (correct leakage in Increase of e indicators AUTO-SD
composition) WGSR combustible gas to inside EVA1 triggered
AFB2. AFB2 outlet by high
H2concentration in temperature temperat
AFB2 increases. If indicator (TI- ure at
leak large enough, FP5). AFB2 inlet
flame front may Temperatur (> 750
proceed upstream e °C).
up to HX2. measuremen Add
t in pipeline AUTO-SD
before AFB2 triggered
inside FP. by high
(Not shown temperat
in PI ure at
diagram.) AFB2
outlet (>
300
°C).
Comme
nt: HX2
temperat
ure below
H2autoig
nition
temperat
ure (536
°C), so
combusti
on takes
25. Low PSA 25.2 Small Comme
feed flow (correct leakage in nt:
composition) COND1. Unlikely
because
condense
r can
 25.3 Small Combustible gas H2detector Comme
25. Low PSA leakage in may flow to H2O tank. in container nt:
feed flow (correct DV1 due to Gas vented from
tank malfuncti
composition) malfunctionin into container. oning of
g Less product gas. DV1 very
Consequences unlikely,
and related because
detection and
liquid
does not
safeguards of
contain
combustible gas objects
leakage to be above 1
covered later mm size
more detail that could
in section Leaks block the
from system inside valve
container. open.

25.4 Small Less product gas. Carry

25. Low PSA leakage in Consequences out
feed flow (correct pipeline and related pressure
composition) between detection and tests at
WGSR and safeguards of least after
PSA feed inlet combustible gas any
discharge into modificati
system
on to the
system.
surroundings to
be covered later
more detail
in section Leaks
from system inside
container.
 25.5 Small Less product gas. Vent
25. Low PSA leakage Combustible gas pipe
feed flow (correct through PRV1 flows through vent should be
composition) due to line out of container. located so
triggered that, it is
relief valve not
not resealing hazardou
properly.
s to
people or
property
even in
case of
gas
ignition.
26. No PSA feed flow 26.1 Big Product gas Pressure Add EM-
leakage escapes from indicators PI- SD
system. 01, PI-04 and triggered
Consequences PI-05. by PI-04
and related and PI-05
detection and low
safeguards of pressure
combustible gas
(6 barg).
discharge into
system
surroundings to
be covered later
more detail in
section Leaks from
system
inside container.

26. No PSA feed flow 26.2 Combustible gas Pressure Add EM-
Malfunctioning flows through vent indicators PI- SD
of SV2, valve line out of 01, PI-04 and triggered
opens. container PI-05. by PI-04
and PI-05
low
pressure
(6 barg).
Vent
pipe
should be
located so
27. High temperature of Comme
PSA feed nt: Heat
up of gas
not
possible
28. Low temperature of Comme
PSA feed nt: Low
temperat
ure not
detriment
29. High pressure of PSA 29.1 PSA gas Pressure increase Pressure Add EM-
feed consumption in system indicators PI- SD
stops due to upstream PSA. 04 and PI-05. triggered
malfunction in SV2 triggers by PI-04
PSA cycle. open at 10 and PI-05
bar(g) at PI- high
04. pressure
PRV1 opens (10 barg)
at 11 bar(g). Add
AUTO-SD
when PSA
stops
running.
30. Low pressure of PSA 30.1 Big Product gas Pressure Add EM-
feed leakage escapes from indicators PI- SD
system. 01, PI-04 and triggered
Consequences PI-05. by PI-04
and related and PI-05
detection and low
safeguards of pressure
combustible gas
(6 barg)
discharge into
system
surroundings to
be covered later
more detail in
section Leaks from
system
inside container.

30. Low pressure of PSA 30.2 Combustible gas Pressure Add EM-
feed Malfunctioning flows through vent indicators PI- SD
of SV2, valve line out of 01, PI-04 and triggered
opens. container PI-05. by PI-04
and PI-05
low
pressure
(6 barg).
Vent
pipe
should be
located so
 30.3 SV1 Pressure Pressure Add EM-
30. Low pressure of PSA closes due to downstream SV1 indicator PI- SD
feed malfunction. decreases slowly 05. triggered
due to feed tank by PI-05
volume. low
(Pressure in pressure
system upstream (6 barg)
SV1 increases
much faster.)

31. High pressure 31.1 Feed Fluctuations in FP Pressure Check

fluctuation in FP product tank hand pressure. Small indicators PI- feed tank
gas upstream feed tank valve MV6 temperature 01, PI-04 and hand
unintentionall and/or gas PI-05. valve
y closed. composition MV6
fluctuations. position
Feed pump (= open)
control signals
before
start-up.
fluctuating under
Comme
PID control. nt: Point
of
examinati
on in this
deviation
is
between
SV1 and
feed tank
pipe
branch.
32. High CO 32.1 WGSR Too high CO WGSR Add
concentration of PSA feed reaction concentration in temperature AUTO-SD
conditions hydrogen fed to H2 indicators (7 triggered
wrong, too high tank. separate by high
temperature. Reduced efficiency indicators) WGSR
WGSR catalyst of FCS due to anode FCS cell outlet
deactivation. catalyst poisoning. voltage temperat
monitoring ure (> 350
FCS shuts °C)
down when
voltage
drops too
low, triggers
AUTO-SD.

33. High water 33.1 No/low Steam enters PSA Temperatur Add EM-
vapour concentration of coolant flow to and causes water e indicator SD
PSA feed COND1. Coolant condensation in TI05 triggered
circuit/pipeline adsorbent columns. Temperatur by TI-05
failure. High temperature e indicator high
Coolant gas may damage TI06 temperat
temperature components ure (> 30
too high. downstream. °C).
Cooling system Add
not functioning. AUTO-SD
triggered
by TI-06
high
temperat
ure (> 15
°C).
34. Low H2 Comme
concentration ( = high nt: PSA
viscosity) of PSA feed malfuncti
ons if H2
concentra
tion in
PSA feed
gas < 50
%, due to
35. Wrong FCS cell valves
Add anot
35.1 Droplets enter
phase in PSA feed (water voltages designed
water
Malfunctioning PSA. PSA for high
droplets in PSA of VLS1. adsorbents start coalescin
feed) flooding. More CO in gas g filter
feed to H
2 tank.
upstream
PSA inlet.
Droplets
detected
from filter
inspectio
n
port.
35.2 COND1 Condensing taking Temperatur Add
35. Wrong not cooling place downstream e indicators warning
phase in PSA feed (water enough. VLS1. Droplets enter TI05 and TI- triggered
droplets in PSA feed) PSA. 07. by TI-05
PSA adsorbents start FCS cell and TI-07
flooding. More CO in voltages high
gas feed to H2tank. temperat
ure (> 25
°C).
Add EM-
SD
triggered
by TI-05
high
temperat
ure (> 30
°C).
Add
AUTO-SD
triggered
by TI-07
36. Other impurities in 36.1 Components WGSR Add a
PSA feed Impurities in downstream WGSR temperature coalescin
FP product are not likely to indicators (7 g filter
gas flow due block due to large separate upstream
to SRR or channel dimensions, indicators) PSA inlet.
WGSR catalyst but WGSR operation Visual Droplets
flaking e.g. is disturbed. inspection of are
Particle impurities H2O tank detected
washed away in from filter
VLS1, and may inspectio
accumulate to H2O n port
tank or proceed to during
F1 and F2. shutdown
Small particle period.
impurities may
accumulate to PSA
adsorbent beds
without
considerable effect
to functionality.
37. High pressure of tail 37.1 PSA adsorbent not PI-07 Consider
gas flow at end of PSA Malfunctioning fully regenerated, FCS cell adding
desorption phase of valve CV1 because too high voltage pressure
(does not pressure, > 0.5 monitoring sensor for
open or opens bar(a), at end of FP AUTO-SD absolute
limitedly) and desorption phase. triggered by ambient
vacuum pump Too high CO content PSA pressure.
VP1 not
in product H2. shutdown.
PSA shuts
running.
automatically down
if pressure inside
vessel > 100 mbar(g)
at end of desorption
phase. No reformate
intake and tail gas
pro-
duction. System
shuts down.
37. High pressure of tail 37.2 VP1 not able to PI-07 Consider
gas flow at end of PSA Malfunctioning generate vacuum. FCS cell eliminatin
desorption phase of valve CV1, PSA adsorbent not voltage g CV1 and
permitting fully regenerated, monitoring running
flow in because too high (in long only with
opposite pressure, > 0.5 term) VP1.
direction. bar(a), at end of Check if
desorption phase. VP1 can
Too high CO content pass
in product H2. enough
PSA shuts flow
automatically down through
if pressure inside in case of
vessel > 100 mbar(g) CV1
at end of desorption malfuncti
phase. No reformate on.
intake and tail gas
production. System
shuts down.

38. High temperature of 38.1 Can be Comme

tail gas caused only nt: PSA
by high operation
ambient isotherma
temperature l. Tail gas
in container. temperat
To be covered ure does
later in
not
deviate
section
from PSA
Conditions inlet.
inside
container.
39. Impurities in tail gas 39.1 Particles possibly Filter F8 Comme
Adsorbent getting in tail gas Tail gas gets nt:
released from tank are not very in tail gas Adsorben
PSA. harmful. tank at t particles
Filter may be bottom and not large
clogged over long exits from enough to
period of time. top. cause e.g.
PI-11 pipeline
blockages
. Would
possibly
be
harmful
to MFM4
and
40. High flow of tail gas
MFM5.
Comme
nt: Not
relevant
deviation.
41. Low flow of tail gas 41.1 Pump Pressure in PSA tail PI-07
VP1 gas outlet increases FP AUTO-SD
malfunctionin > 100 mbar(g), and triggered by
g. causes PSA to stop. PSA
System shuts down. shutdown.
 41.2 Leakage Tail gas tank PI-10 Perform
41. Low flow of tail gas after VP1 and pressure starts to Container leak test
before tank. decrease. H2detectors for tail
Less tail gas for SRR gas line
combustion in FP. temperature when
Temperatures s compone
decrease in FP nts
reactors. changed
Consequences and or fittings
related detection opened.
and safeguards of
combustible gas
discharge into the
system surroundings
to be covered later
in section Leaks
from system inside
container.

42. High pressure of tail 42.1 Pump No tail gas for PI-10 Consider
gas TGP1 not combustion in FP. FI-04 adding
functioning Temperatures PRV2 opens following
decrease in FP at 450 safety
reactors. mbar(g) function:
System AUTO-SD SRR Opening
triggered by SRR temperature of SV5
temperatures.
s triggered
by P10
high
pressure,
> 400
mbar(g),
to
preserve
PRV2
gaskets.
42. High pressure of tail 42.2 Valve No tail gas for PI-11, PI-10 Consider
gas SV6 closed combustion in FP. FI-04 adding
Temperatures PRV2 opens following
decrease in FP at 450 safety
reactors. mbar(g) function:
System AUTO-SD SRR Opening
triggered by SRR temperature of SV5
temperatures.
s triggered
by P10
high
pressure,
> 400
mbar(g),
to
preserve
PRV2
gaskets.

42.3 Filter F8 No tail gas for PI-11, PI-10 Comme

42. High pressure of tail clogged combustion in FP. FI-04 nt: Filter
gas Temperatures PRV2 opens may be
decrease in FP at 450 clogged
reactors. mbar(g) over long
System AUTO-SD SRR period of
triggered by SRR temperature time.
temperatures.
s
43. Low pressure of tail ga43.1 Flow Temporarily too PI-10 Consider
through pump much tail gas for FI-04 controllin
TGP1 higher combustion in FP. SRR g TGP1
than PSA tail temperatures temperature speed by
gas increase in FP s PI10.
production. reactors.
Vacuum generated
in tail gas tank. Air
may leak inside the
tank.

43. Low pressure of tail ga43.2 Valve Very low amount of PI-10 low
SV5 open due tail gas for pressure
to malfunction combustion in FP. FI-04
or power loss. temperatures SRR
decrease in FP temperature
reactors. s
System AUTO-SD
triggered by SRR
temperatures.
 43.3 Small Less tail gas for PI-10 low Perform
43. Low pressure of tail leakage combustion in FP. pressure, leak test
gas outside More EtOH needed however for tail
between to keep up FP hard to gas line
pumps VP1 temperatures. detect small when
and TGP1. Lower efficiency of decrease compone
the system. Container nts
Consequences and H2detectors changed
related detection or fittings
and safeguards of opened.
combustible gas
discharge into the
system surroundings
to be covered later
more detail in
section Leaks from
system inside
container.

44. Air among tail gas 44.1 Leak in Combustible and PI-07 Ground
pipeline possibly explosive all
upstream VP1 mixture created compone
causing VP1 inside piping and nts in
to suck air tail gas tank. pipeline
into tail gas properly
line. to avoid
build-up
of static
electricity
.
Add
AUTO-SD
triggered
by PI-07 if
45. High flow of tail gas 45.1 Pump Temporarily too FI-04 Consider
TGP1 much tail gas for PI-10 low controllin
malfunctionin combustion in FP. pressure g TGP1
g, gas temperatures PI-11 high speed by
throughput increase in FP pressure PI10.
too high. reactors. SRR
Vacuum generated temperature
in tail gas tank. Air s
may leak inside the
tank.

46. Low flow of tail gas 46.1 Pump Too little tail gas for FI-04 Consider
TGP1 combustion in FP. PI-10 high adding
malfunctionin Temperatures pressure following
g, gas decrease in FP SRR safety
throughput reactors. temperature function:
too low. Pressure increase in s Opening
tail gas tank. PRV2 opens of SV5
at 450 triggered
mbar(g) by P10
high
pressure,
> 400
mbar(g),
to
preserve
PRV2
gaskets.
 46.2 Small Too little tail gas for FI-04 Perform
leakage combustion in FP. SRR leak test
outside Temperatures temperature for tail
downstream decrease in FP s gas line
pump TGP1. reactors. PI-11 when
Consequences and Container compone
related detection H2detectors nts
and safeguards of changed
combustible gas or fittings
discharge into opened.
system surroundings
to be covered later
more detail in
section Leaks from
system
inside container.

47. No flow of 47.1 Valve No tail gas for FI-04, FI-05 Comme
tail gas SV6 closed combustion in FP. PI-11 and nt: TGP1
due to Temperatures PI-10 high max.
malfunction or decrease in FP pressure pressure
power loss. reactors. SRR increase
System AUTO-SD temperature 1.38 bar
triggered by SRR s above
temperatures.
inlet
level, not
detriment
al to
other
compone
nts.
Add
AUTO-SD
triggered
by PI-11
pressure
> 1 bar(g).
47. No flow of 47.2 Filter F8 No tail gas for FI-04, FI-05Comme
tail gas clogged combustion in FP. PI-11 and nt: Filter
Temperatures PI-10 high may be
decrease in FP pressure clogged
reactors. SRR over long
System AUTO-SD temperature period of
triggered by SRR s time.
temperatures.
Comme
nt: TGP1
max.
pressure
increase
1.38 bar
above
inlet
level, not
detriment
al to
other
48. High pressure of tail PI-11 Comme
gas nt: Both
tail gas
pipelines
49. Low pressure of tail 49.1 Pump Too little tail gas for FI-04 Consider
gas TGP1 combustion in FP. PI-10 high adding
malfunctionin Temperatures pressure following
g, gas decrease in FP SRR safety
throughput reactors. temperature function:
too low. Pressure increase in s Opening
tail gas tank. PRV2 opens of SV5
at 450 triggered
mbar(g) by P10
high
pressure,
> 400
mbar(g),
to
preserve
PRV2
gaskets.
49. Low pressure of tail 49.2 Leak Too little tail gas for PI-11 Perform
gas outside combustion in FP. Container leak test
between Temperatures H2detectors for tail
pump TGP1 decrease in FP SRR gas line
and valve CV3 reactors. temperature when
and/or CV4. Consequences and s compone
related detection FI-04 nts
and safeguards of changed
combustible gas or fittings
discharge into opened.
system surroundings
to be covered later
more detail
in section Leaks
from system inside
container.
50. Air among tail gas 50.1 Leak in First tail gas leaks PI-10 Consider
pipeline/syste out from system into (pressure adding
m between container. decreases) AUTO-SD
pump VP1 / Once pressure in tail CI-02 triggered
valve CV1 and gas tank (H2concentr by PI-10 <
pump TGP1. / in system (PI-10) ation 50
below atmospheric, decreases) mbar(g).
air starts to be Container
sucked from system H2detectors
surroundings to gas
flow.
Formation of
explosive gas
mixture first inside
container then in tail
gas tank / in tail gas
system.
Consequences and
related detection
and safeguards of
combustible gas
discharge into
system surroundings
to be covered later
more detail in
section Leaks from
system
inside container.
 50.2 Leak to First tail gas leaks PI-10 Consider
50. Air among tail gas vent line due out from system (pressure adding
to SV5 through vent line. decreases) AUTO-SD
malfunction. Once pressure in CI-02 triggered
tail gas tank (H2concentr by PI-10 <
/ in system (PI-10) ation 50
below decreases) mbar(g).
atmospheric, air
starts to be
sucked from vent
line to gas flow.
Formation of
explosive gas
mixture in tail gas
tank / in tail gas
system.

51. High H2 Comme

content in tail gas nt: Should
not be
possible
assuming
52. Impurities in tail gas Comme
nt: Not
likely
because
53. High temperature of 53.1 Too low WGSR inlet WGSR inlet
Comme
air air flow rate temperature temperature
nt: WGSR
due to blower increases, may TI-FP3 inlet 400-
AB1 affect FP product 430 °C.
malfunctionin gas composition Add air
g. after WGSR. flow
Possible damage meter
to WGSR catalyst.
between
PI-03 and
airline
branch.
Add
AUTO-SD
triggered
by high
WGSR
inlet
temperat
ure (450
53. High temperature of 53.2 Too low WGSR inlet WGSR inlet Add air
air air flow rate temperature temperature flow
due to PV2 increases, may TI-FP3 meter
unintentionall affect FP product between
y open. gas composition airline
after WGSR. branch
Possible damage and PV2.
to WGSR catalyst.
Add
AUTO-SD
triggered
by high
WGSR
inlet
temperat
ure (450
°C).

53. High temperature of 53.3 Leak WGSR inlet PI-03 Leak

air outside temperature WGSR inlet checking.
between increases, may affect temperature
blower AB1 FP product gas TI-FP3
and HX1 or composition after
from HX1. WGSR. Possible
damage to WGSR
catalyst.
54. Low temperature of 54.1 Too high WGSR inlet TI-FP3 Add air
air air flow rate temperature WGSR inlet flow
due to blower decreases, temperature meter
AB1 kinetics of WGS between
malfunctionin reactions slowed PI-03 and
g. down and FP airline
product gas may branch.
contain more CO.
Add air
flow
CO concertation of
meter
PSA product gas between
increases, FCS airline
efficiency branch
decreases. and PV2.
Add
AUTO-SD
triggered
by low
WGSR
inlet tem-
perature(
380 °C)
54. Low temperature of 54.2 Too high WGSR inlet TI-FP3 Add air
air air flow rate temperature WGSR inlet flow
due to PV2 decreases, kinetics temperature meter
unintentionall of WGS reactions between
y closed. slowed down and FP PI-03 and
product gas may airline
contain more CO. branch.
CO concertation of Add air
PSA product gas flow
increases, FCS meter
efficiency decreases. between
airline
branch
and PV2.
Add
AUTO-SD
triggered
by low
WGSR
inlet
temperat
ure(380
°C)

54. Low temperature of 54.3 Low air Comme

air temperature nt: Not
at blower AB1 likely
intake. because
container
interior
heated by
waste
heat from
FP.
55. High flow of 55.1 WGSR inlet TI-FP3 Add air
air Malfunctioning temperature WGSR inlet flow
of blower AB1. decreases, kinetics temperature meter
of WGS reactions between
slowed down and FP PI-03 and
product gas may airline
contain more CO. branch.
CO concertation of Add
PSA product gas AUTO-SD
increases, FCS triggered
efficiency decreases. by low
WGSR
inlet
temperat
ure(380
°C)
55. High flow of 55.2 PV2 WGSR inlet TI-FP3 Add air
air unintentionall temperature WGSR inlet flow
y closed. decreases, kinetics temperature meter
of WGS reactions between
slowed down and FP PI-03 and
product gas may airline
contain more CO. branch.
CO concertation of Add air
PSA product gas flow
increases, FCS meter
efficiency decreases. between
airline
branch
and PV2.
Add
AUTO-SD
triggered
by low
WGSR
inlet tem-
perature(
380 °C)

56. Low flow of 56.1 WGSR inlet WGSR inlet Add air
air Malfunctioning temperature temperature flow
of blower AB1. increases, may TI-FP3 meter
affect FP product between
composition after PI-03 and
WGSR. Possible airline
damage to WGSR branch.
catalyst.
Add
AUTO-SD
triggered
by low
WGSR
inlet
temperat
ure(380
°C)
 56.2 PV2 WGSR inlet WGSR inlet Add air
56. Low flow of unintentionall temperature temperature flow
air y open. increases, may TI-FP3 meter
affect FP product between
gas composition airline
after WGSR. branch
Possible damage and PV2.
to WGSR catalyst
Add
AUTO-SD
triggered
by high
WGSR
inlet
temperat
ure (450
°C).

56.3 Leak WGSR inlet WGSR inlet Leak

56. Low flow of outside temperature temperature checking
air between AB1 increases, may affect TI-FP3
and HX1 or FP product gas PI-03
from HX1. composition after
WGSR. Possible
damage to
WGSR catalyst.
57. No flow of 57.1 Blower No cooling to HX1. PI-03 Add air
air AB1 stopped. WGSR inlet TI-FP3 flow
temperature WGSR inlet meter
increases, may temperature between
affect FP product PI-03 and
gas composition airline
after WGSR. branch.
Possible damage
Add
AUTO-SD
to WGSR catalyst.
triggered
No oxidant to by air
AFB1, to be flow
covered under meter
Fuel-air ratio (lambda <
(lambda) too rich. 1.5)
Add
AUTO-SD
triggered
by high
WGSR
inlet
temperat
ure (450
°C).
 57.2 Pipeline No cooling to HX1. PI-03 Comme
57. No flow of failure or WGSR inlet TI-FP3 nt: Not
air SUB2 rupture. temperature WGSR inlet very
increases, may temperature likely.
affect FP product Comme
gas composition nt:
after WGSR. temperat
Possible damage
ure
cycling of
to WGSR catalyst.
SUB2
No oxidant to could
AFB1, to be cause
covered under leaks in
Fuel-air ratio the long
(lambda) too rich. run
Carry
out
pressure
tests at
least after
any
modificati
on to the
system.
Add
AUTO-SD
triggered
by high
WGSR
inlet
temperat
ure (450
°C).

58. High presure of air 58.1 Blockage PI-03 Comme

in pipeline nt: Not
between HX1 very
and AFB1. likely.
Blower
pmax ≈ 1
bar(g).
Check
pressure
tolerance
of SUBs.
59. Low pressure of 59.1 Leak Less air or fuel-air PI-12 Leak
air outside mixture to AFB1. Container testing of
between HX1 Consequences H2detectors tail gas
and AFB1. and related SRR line when
detection and temperature compone
safeguards of indicators nts
combustible gas changed
discharge into
or fittings
opened.
system
surroundings to
be covered later
more detail in
section Leaks from
system
inside container.
60Wrong composition 60.1 Possibly explosive HX1 air side Carry
Reformate gas gas mixture outlet out
leak inside downstream HX1. temperature pressure
HX1. Temperature in HX1 AFB1 inlet tests of
close to temperature main
H2autoignition indicator process
temperature and SRR line at
may ignite. In case temperature least after
of combustion, HX1 indicators any
not cooling process PI-04 modificati
stream and WGSR TI-FP3 on to the
inlet temperature WGSR system.
increase. temperature Add
Less product gas to indicators AUTO-SD
PSA. PI-12 triggered
by AFB1
high inlet
temperat
ure (800
°C).
60Wrong composition 60.2 Air Possibly explosive Container Add
blower AB1 gas mixture inside H2detectors EtOH
sucks in air blower AB1 and AUTO-SD detector
and downstream it. Gas and inside
combustible mixture may ignite ventilation container.
gases due to a in SUB2 because of increase Placeme
leak in catalyst. triggered at nt of air
system.
Explosive 25% LEL. blowers
gases/vapours inside EM-SD vertically
Container air
container. EtOH triggered at at middle
contains vapour stays bottom 50% LEL, in
ethanol, (46.07 g/mol vs. electricity container,
reformate or 28.97 g/mol of air) cut-off from or routing
hydrogen. of container, H2 container. air intake
rises to upper part Container by tube to
of container (2.016 ventilation container
g/mol vs. 28.97 SUB2 fresh air
g/mol of air) temperature intake
indicators grille.
Check if
separate
ventilation
blower(s)
is needed
at the floor
level of the
container
(for
possible
ethanol va-
pours).

61. Impurities 61.1 Dust or Blockage of AB1, PI-03 Add

particulates SUB2 and other filters to
from outside components AB1 (and
or inside of downstream. AB2)
container. intake
ports.
Add air
flow
meter
after PI-
03.
62. High temerature of Comme
fuel-air mixture nt: No
identified
causes for
high
temperat
63. Low temperature of 63.1 Impaired Afterburner AFB1 Internal
fuelair mixture heat cools down. All insulation
insulation the fuel processor of FP
inside FP. components cool casing
down. should be
checked
for leaks
after
moving
casing or
container.

64. High flow of Commen

fuel-air mixture t: No
identified
causes for
high flow
65. Low flow of 65.1 Small Less combustible SRR Consider
fuel-air mixture leakage after mixture for temperature adding
TG1 or SU- afterburner AFB1. indicators small
EtOH-3 mixing AFB1 temperatures ventilatio
point. decrease. See n hole to
deviation Low FP casing
temperature after to
SRR. prevent
Consequences and H2
related detection accumulat
and safeguards of ion inside
the gas discharge it.
into the system Leak
surroundings to be testing of
covered later in tail gas
section Leaks from lines
system inside when
container. compone
nts
changed
or fittings
opened.
Add
EtOH
detector
inside
container.
66. No flow of 66.1 Broken Explosive gases PI-12, PI-03 Add
fuel-air mixture pipeline inside container. EtOH
between HX1 No combustible detector
and AFB1. mixture for AFB1, inside
temperatures container.
decrease. Consider
Consequences and adding
related detection small
and safeguards of ventilatio
combustible gas n hole to
discharge into FP casing
system surroundings to
to be covered later prevent
more detail in H2
section Leaks from accumulat
system ion inside
inside container it.
Pressure
testing of
air and
tail gas
lines
during on
system
commissi
oning.
67. Fuel-air ratio 67.1 Too high AFB1 catalyst FI-05, FI-04 Add air
(lambda) too rich TG1 or coking. AFB1 FC-06 flow meter
SUEtOH-3 reactions decrease SRR between
flows. and temperatures temperature PI-03 and
decrease. indicators airline
EVA2/HX3 EVA2 branch.
temperatures temperature Add
decrease. indicators lambda
Combustible gas calculation
mixture proceeds to in AFB1
exhaust line and using and
after that to vent. AUTO-SD
triggered
by lambda
< 1.5.
Top of
the vent
line should
be located
high
enough to
prevent
personnel
or material
damage in
case of
ignition.
Entry of
water/impu
rities into
vent line
68. Fuel-air ratio 68.1 Too low AFB1 SRR Add air
(lambda) too lean TG1 or temperatures temperature flow
SUEtOH-3 decrease, causing indicators meter
flows. problems in SRR EVA2 between
and EVA2. temperature PI-03 and
indicators airline
FI-05, FI-04 branch.
FC-06
69. High temperature of 69.1 Too low WGSR outlet WGSR Comme
air air flow rate temperature outlet nt: WGSR
due to blower increases slowing temperature inlet 400-
AB2 down WGS PI-02 430 °C.
malfunctionin reactions. FP Add air
g. product gas flow
contains more CO. meter
CO concertation of
after PI-
02.
PSA product gas
Consider
increases, FCS adding
efficiency temperat
decreases. ure probe
Too rich fuel-air at
mixture fed to OFFGAS-1
AFB2. To be outlet
covered under (not easy
Fuel-air ratio to get
(lambda) too data that
rich. represent
s HX2
outlet).
69. High temperature of 69.2 Leak WGSR outlet WGSR Comme
air outside temperature outlet nt: WGSR
between increases, WGS temperature inlet 400-
blower AB2 reactions limited PI-02 430 °C.
and HX2 or by equilibrium and Add air
from HX2. FP product gas flow
contains more CO. meter
CO concertation of
after PI-
02.
PSA product gas
Consider
increases, FCS adding
efficiency temperat
decreases. ure probe
Too rich fuel-air at
mixture fed to OFFGAS-1
AFB2. To be outlet
covered under (not easy
Fuel-air ratio to get
(lambda) too data that
rich. represent
s HX2
outlet)
70. Low temperature of 70.1 Too high WGSR outlet WGSR Comme
air air flow rate temperature outlet nt: WGSR
due to blower decrease, kinetics of temperature inlet 400-
AB2 WGS reactions PI-02 430 °C.
malfunctionin slowed down. FP Add air
g. product gas contains flow
more CO. meter
CO concertation of after PI-
PSA product gas 02.
increases, FCS Consider
efficiency decreases. adding
EtOH-1 not temperat
evaporating before ure probe
AFB2 (not very at
likely). OFFGAS-1
outlet to
detect if
EtOH-1 is
evaporate
d.

70. Low temperature of 70.2 Low air Comme

air temperature nt: Not
at blower AB2 likely
intake. because
container
interior
heated by
waste
heat from
71. High flow of 71.1 WGSR outlet WGSR Comme
air Malfunctioning temperature outlet nt: WGSR
of blower AB2. decreases, temperature inlet 400-
kinetics of WGS PI-02 430 °C.
reactions slowed Add air
down. FP product flow
gas contains more meter
CO.
after PI-
02.
CO concertation of
PSA product gas
increases, FCS
efficiency
decreases.
72. Low flow of 72.1 WGSR outlet WGSR Comme
air Malfunctioning temperature outlet nt: WGSR
of blower AB2. increases slowing temperature inlet 400-
down WGS PI-02 430 °C.
reactions. FP Add air
product gas flow
contains more CO. meter
CO concertation of
after PI-
02.
PSA product gas
increases, FCS
efficiency
decreases.
Too rich fuel-air
mixture fed to
AFB2. To be
covered under
Fuel-air ratio
(lambda) too
rich.
72. Low flow of 72.2 Leak WGSR outlet WGSR Comme
air outside temperature outlet nt: WGSR
between AB2 increases, WGS temperature inlet 400-
and HX2 or reactions limited PI-02 430 °C.
from HX2. by equilibrium and Leak
FP product gas checking.
contains more CO.
CO concertation of
PSA product gas
increases, FCS
efficiency
decreases.
Too rich fuel-air
mixture fed to
AFB2. To be
covered under
Fuel-air ratio
(lambda) too
rich.

73. No flow of 73.1 Blower No cooling to PI-02 Add air

air AB2 stopped. WGSR. WGSR flow
No oxidant to outlet meter
AFB2. To be temperature after PI-
covered under 02.
Fuel-air ratio Add
(lambda) too rich. AUTO-SD
triggered
by air
flow
meter
(lambda <
1.5), or
PID not
reaching
SP.
73. No flow of 73.2 Pipeline No cooling to PI-02 Comme
air failure or WGSR. WGSR nt: Not
SUB1 rupture. No oxidant to outlet very
AFB2. To be temperaturelikely.
covered under Pressure
Fuel-air ratio testing of
(lambda) too rich. the
system
during
commissi
oning
Comme
nt: Could
temperat
ure
74. High pressure of 74.1 Blockage PI-02 cycling
Comme of
air in pipeline nt: Not
between HX2 very
and AFB2. likely.
Blower
pmax ≈ 1
bar(g).
Check
75. Low pressure of 75.1 Leak Less air or fuel-air PI-13 pressure
Leak
air outside mixture to AFB1. Container tolerance
testing of
between HX2 Consequences H2detectors of
tailSUBs.
gas
and AFB2. and related line when
detection and compone
safeguards of nts
combustible gas changed
discharge into
or fittings
opened.
system
surroundings to
be covered later
more detail in
section Leaks from
system
inside container
76. Wrong composition 76.1 WGSR Less product gas to PI-04 Consider
leak to HX2 PSA. EVA1 adding
Possibly explosive temperature temperat
gas mixture already indicators ure probe
downstream HX2. AFB2 inlet at
Temperature low temperature OFFGAS-1
until AFB2, so indicator outlet to
ignition before AFB2 WGSR detect
not probable. temperature possible
However, indicators combusti
combustion front PI-13 on front.
may proceed Add
upstream if H2 AUTO-SD
concentration in triggered
WGSR/tail gas-air by AFB2
mixture is high high inlet
enough. temperat
ure (800
°C).
Leak
testing of
main
process
line after
modificati
ons or
addition
of new
compone
nts.
 76.2 Air Possible explosive Container Add
76. Wrong composition blower AB2 gas mixture inside H2detectors EtOH
sucks in air blower AB2 and AUTO-SD detector
and downstream it. Gas and inside
combustible mixture may ignite ventilation container.
gases due to a in SUB1 because of increase Placeme
leak in catalyst. triggered at nt of air
system.
Explosive 25 % LEL. blowers
gases/vapour inside EM-SD vertically
Container air
container. EtOH triggered at at middle
contains vapour stays bottom 50% LEL, in
ethanol, of container, H2 electricity container,
reformate or rises to upper part cut-off from or routing
hydrogen. of container. container. air intake
Container by tube to
ventilation container
SUB1 fresh air
temperature intake
indicators grille.
Check if
separate
ventilatio
n
blower(s)
is needed
at the
floor level
of the
container
(for
possible
ethanolva
pours).

77. Impurities 77.1 Dust or Blockage of AB2, PI-02 Add

particulates SUB1 and other filters to
from outside components air
or inside of downstream. blowers
container. AB2 (and
AB1)
inlets.
Add air
flow
meter
after PI-
78. High temperature of Comme
fuel-air mixture nt: No
identified
causes for
high
temperat
ure in
79. Low temperature of 79.1 Impaired Afterburner AFB2 Internal
fuelair mixture heat cools down. All insulation
insulation the fuel processor of FP
inside FP. components cool casing
down. should be
checked
for leaks
after
moving
casing or
container.
80. High flow of Comme
fuel-air mixture nt: No
identified
causes for
high flow
81. Low flow of 81.1 Small Less combustible EVA1 Consider
fuel-air mixture leakage after mixture for temperature adding
TG2 or EtOH-1 afterburner AFB2. indicators small
mixing point. AFB2 temperatures ventilatio
decrease. See n hole to
deviation Low FP casing
temperature after to
EVA1. prevent
Consequences and H2
related detection accumulat
and safeguards of ion inside
combustible gas it.
discharge into Leak
system surroundings testing of
to be covered later tail gas
more detail in lines
section Leaks from when
system compone
inside container. nts
changed
or fittings
opened.
Add
EtOH
detector
inside
container.
82. No flow of 82.1 Broken Explosive gases PI-13, PI-02 Add
fuel-air mixture pipeline inside container. EtOH
between HX2 No combustible detector
and AFB2. mixture for AFB2, inside
temperatures container.
decrease. Consider
Consequences and adding
related detection small
and safeguards of ventilatio
combustible gas n hole to
discharge into FP casing
system surroundings to
to be covered later prevent
more detail in H2
section Leaks from accumulat
system ion inside
inside container. it.

83. Fuel-air ratio 83.1 Too high AFB2 catalyst FI-05 Add air
(lambda) too rich TG2 and/or coking. AFB2 FC-05 flow
EtOH-1 flows. reactions decrease EVA1 meter
and temperatures temperature after PI-
decrease. indicators 02.
Combustible gas Add
mixture proceeds to lambda
exhaust line and calculatio
after that to vent. n in AFB2
using and
AUTO-SD
triggered
by
lambda <
1.5.
Top of
the vent
line
should be
located
high
enough to
prevent
personnel
or
 83.2 Air flow AFB2 catalyst FI-05Add air
83. Fuel-air ratio needed for coking. AFB2 FC-05flow
(lambda) too rich WGSR cooling reactions decrease EVA1 meter
too low for and temperature temperature
after PI-
AFB2. decreases. indicators
02.
Combustible gas Add
mixture proceeds to lambda
exhaust line and calculatio
after that to vent. n in AFB2
using and
AUTO-SD
triggered
by
lambda <
1.5.
Top of
the vent
line
should be
located
high
enough to
prevent
personnel
or
material
84. Fuel-air ratio 84.1 Too low AFB2 EVA1 Add air
(lambda) too lean TG2 or EtOH-1 temperatures temperature flow
flows. decrease, causing indicators meter
problems in EVA1. FI-05 after PI-
FC-05 02.

84.2 Air flow FI-05 Comme

needed for FC-05 nt: Not
WGSR cooling very
too high for relevant.
AFB2. Can be
compensa
ted by
increasing
TG2 or
EtOH-
85. High temperature of 85.1 Heat DV2 gaskets may Comme
exhaust gas conduction damage. nt:
and Not enough temperat
convection condensed water, ure at
from AFB2 DV2 may dry up and AFB2 and
and HX3 start to leak gas to HX3
outlet. drain pipe leading outlets ≈
outside of container. 100200 °C
Pipeline
before
water
separatio
n should
be long
enough to
ensure
cooling of
the gas.
Pipelines
to be
located so
that
condense
d water
droplets
flow to
86. Low temperature of Comme
exhaust gas nt: Not
relevant
deviation.
Subzero
environm
87. Wrong composition 87.1 Possibly explosive Top of
Combustible gas mixture in top the vent
components of vent line. line
in AFB should be
exhaust gas located
due to high
incomplete enough to
combustion in
prevent
personnel
AFB1 and/or
or
AFB2. material
damage
in case of
ignition.
Entry of
water/im
purities
into vent
line
88. High PSA Comme
product gas flow (correct nt: Not
composition) very
probable
because
dosing of
both H2O
and EtOH
should be
89. Low PSA 89.1 Small Less product gas. PI-06 and Consider
product gas flow (correct leak outside in Consequences PI-08 adding
composition) PSA or and related Container AUTO-SD
pipeline detection and H2 detectors triggered
downstream. safeguards of by PI-06,
combustible gas if much
discharge into lower
system
than PI-
08 (<50
surroundings to
mbar
be covered later lower)
more detail in
section Leaks from
system
inside container.
90. No PSA 90.1 Big No H2feed to FCS. PI-06 and Consider
product gas flow leakage in Consequences and PI-08 adding
PSA or related detection Excess flow shut-off
pipeline and safeguards of valves EFV1 valve
downstream. combustible gas & 2 restrict inside
discharge into tank from container
system surroundings emptying to
to be covered later with high gas prevent
more detail in flow. release of
section Leaks from whole H2
system inside tank
container. content
into
container.
Shut-off
valve
triggered
if
PI06more
than 50
mbar
lower
than PI08,
and in
AUTOSD
and EM-
SD.
Move PI-
08 and
TI10 to
the H2
tank in-
stead of
feed
pipeline.

91. PSA product gas flow 91.1 No or less H2feed to PSA unit’s Comme
elsewhere Malfunctioning FCS. Possible own control nt: Not
of control damage to PSA. system very
system of PSA detects such likely.
unit: PSA takes failures. Comme
in PSA product nt: H2
gas through H2 purge
purge port in used in
normal steady shut-
state run. down.
92. High pressure 92.1 Restriction PSA conditions non- PI-06 Comme
fluctuation in PSA product between PSA optimal, leading to PSA STOP nt: Some
gas product gas higher CO state triggers pressure
outlet and H2 concentration in PSA system fluctuatio
tank, e.g. product gas. AUTO-SD. n is
partially closed If control pressure of normal.
MV2 and/or PSA product gas line
MV4. is not reached, PSA
Also H2 bottles control system
(that “form” H2 triggers PSA to go to
tank) have their STOP state.
own valves,
which can be
partially closed.

93. High CO 93.1 PSA not Reduced FCS cell Comme

concentration of PSA functioning as efficiency of FCS voltage nt: Cause
product gas expected, e.g. due to anode monitoring of low cell
adsorbent catalyst poisoning. FCS shuts voltages
performance down when investigat
decreased. voltage ed
drops too afterward
low (~ 0,57 s. System
V), triggers operation
system should
AUTO-SD. not be
aborted
just
because
of
decreasin
g
cell
voltages.
94. Impurities in PSA 94.1 Particles possibly Comme
product gas Adsorbent getting in H2tank are nt:
released from not very harmful. Adsorben
PSA. t particles
not large
enough to
cause e.g.
pipeline
blockages
95. No flow of 95.1 Hand No H2feed to FCS FI-03 Restrict
PSA product gas valves MV4 or either immediately FCS cell unauthori
MV5 (or both) or with a delay. voltage zed
are closed FCS shuts down monitoring access to
unintentionall when voltage drops FCS shut system
y or too low (~0.57 V). down with a
deliberately triggers fence.
by vandal etc.
system Consider
AUTO-SD. adding
(Hand valve
locks to
MV3 normally MV4 and
closed during MV5, and
run.) to MV3.
Comme
nt: Hand
valve
MV3
normally
closed
during
run.
 95.2 Big No H2feed to FCS. PI-08 (used In
leakage, Formation of also to placemen
broken pipe explosive gas indicate t of
etc. mixture inside or amount of indicators
outside of container, H2currently PI-08 and
at least around stored). TI-10 take
leakage point. PI-09, PI-06 into
Consequences and Flow rate account
related detection restricted by results of
and safeguards of excess flow H2 tank
combustible gas valves EFV1 EX-zone
discharge into and EFV2. classificati
system surroundings FI-03 on.
to be covered later FCS cell Pipeline
more detail in voltage outside
section Leaks from monitoring container
system inside FCS triggers should be
container and Leaks shutdown at properly
or low pressure grounded
gas release from and when to
system to outside voltage prevent
drops too build-up
low. of static
FCS electricity
shutdown .
triggers
system
AUTO-SD.

95.3 Large Formation of PI-08 Comme

95. No flow of leakage in H2 explosive gas nt: H2
PSA product gas tank. mixture around bottles (2
leakage point. pcs.) that
“form” H2
tank,
specified
to hold
200
bar(g),
96. High temperature of 96.1 High Pressure increases in PI-08, PI-06 Add
PSA product gas ambient H2 tank and in TI-10 pressure
temperature. related pipelines. relief
Max. pressure valve to
increase ~ 20 H2 tank.
%, when Opening
temperature pressure
changes from -20 to ca. 11
+35 °C. bar(g).
Comme
nt: No
harm to
FCS due
to
increased
PSA
product
gas
temperat
ure.

96.2 Fire or Pressure increases in PI-08, PI-06 Add

96. High temperature of other H2 tank and in TI-10 pressure
PSA product gas unexpected related pipelines. relief
intense heat Possible failure of valve to
source nearby SV3, SV4, MFM3 H2 tank.
H2 tank. (max operating Opening
pressure 10bar(g)), pressure
PR1 etc. or rupture ca. 11
of H2 tank. bar(g).
Place
MFM3
downstre
am PR1
(allows
usage of
11 bar(g)
relief
valve).
Consider
adding
controlled
valve in
parallel
with
pressure
97. Low temperature of 97.1 Low Cooling capacity TI-10, TI-11 Comme
PSA product gas ambient needed by FCS nt: In case
temperature. decreases. of low
No harm for ambient
system. temperat
ure PSA
product
gas most
probably
cools
down
98. Impurities in PSA 98.1 May cause blockage Comme
product gas Impurities of microporous nt: Under
released from structures in anode normal
H2 tank electrodes. operation
surfaces at Presumably washed ,
low pressure. away with water pressures
droplets. < 1 bar(g)
No considerable at H2tank
effects during first not likely.
5000 hours of FCS stops
operation. at 1
May cause MFM3 bar(g)
malfunction. H2tank
pressure.
Pay
attention
that when
H2bottles
emptied
e.g. for
transport
/storage,
residual
gas is not
directed
into
system
but is
vented
into
atmosphe
re e.g.
Comme
nt:
Particles
not large
enough to
 98.2 May cause blockage Comme
98. Impurities in PSA Adsorbent of microporous nt:
product gas released from structures in anode Adsorben
PSA. electrodes. t particles
Presumably washed not large
away with water enough to
droplets. cause e.g.
No considerable pipeline
effects during first blockages
5000 hours of .
operation. Consider
May cause MFM3 adding
malfunction. filter
before
MFM3.
99. High FCS 99.1 Solenoid Significant amount FI-03 Add
feed gas flow (correct valve or or all of H2 flows to Pressure AUTO-SD
composition) valves (SV vent through SV sensors triggered
FCS3 and SV FCS3 / SV FCS2, and inside FCS by FI-03 if
FCS2) not through stack. FCS cell reading
unintentionall Loss of H2in stack, voltage very high
y open inside cell voltages monitoring for
FCS.
decrease. extended
H2starvation may period (>
cause damage to 100 nlpm
cathode catalyst. for 510 s).
 99.2 Big H2released inside FCS and
99. High FCS leakage inside FCS and eventually container H2
feed gas flow (correct FCS. to container. detectors.
composition) Consequences and H2detector
related detection s inside FCS
and safeguards of trigger FCS
combustible gas shutdown.
discharge into
system surroundings
to be covered later
more detail in
section Leaks from
system
inside container.
100. Low FCS 100.1 Small Less H2feed to FCS. FI-03 Consider
feed gas flow (correct leakage in FCS shuts down if PI-09 adding
composition) pipeline after voltage drops too system
pipe branch low (~0.57 V) or if AUTO-SD
downstream inlet pressure is low triggered
MV3 and MV5 (<0.7 bar(g)). by PI 09
(i.e. after the Consequences and low
previous point
related detection pressure
and safeguards of (< 0.7
of
combustible gas bar(g)).
examination). discharge into
system surroundings
to be covered later
more detail in
section Leaks from
system
inside container.
101. No FCS feed gas 101.1 SV3 or No H2feed to FCS. FI-03
flow SV4 PI-09
unintentionall FCS cell
y closed, voltage
malfunctionin monitoring
g of PR1. FCS triggers
shutdown at
low pressure
and when
voltage
drops too
low.
FCS
shutdown
triggers
system
AUTO-SD.
 101.2 Big No H2feed to FCS. PI-09
101. No FCS feed gas leakage in Consequences and FI-03 (high
flow pipeline after related detection reading if
pipe branch and safeguards of leakage
downstream combustible gas downstream
MV3 and MV5 discharge into of it, in
(i.e. after the system surroundings opposite
previous point
to be covered later case no flow
more detail in reading).
of
section Leaks from
examination). system
inside container.

102. High pressure of 102.1 No harmful PI-09

Comme
FCS feed gas Malfunctioning consequences FCSnt: Not
of PR1 because of controller
very
safeguards. closes SV
likely.
FCS1 if
Consider
pressure too
adding
high.
system
AUTO-SD
if PI-09 >
Not enough H2feed PI-09 5 bar(g).
Comme
103Low pressure of FCS 103.1
feed gas Malfunctioning to FCS. FCS shuts nt: PR
of PR1. down if FCS1
pressure too requires
low (tank 0,7 bar(g)
empty) to
function.
103Low pressure of FCS 103.2 Small Not enough H2feed PI-09 Consider
feed gas leakage in to FCS. FCS shuts adding
pipeline after Consequences and down if AUTO-SD
pipe branch related detection pressure too triggered
downstream and safeguards of low (tank by PI 09
MV3 and MV5 combustible gas empty) low
(i.e. after the discharge into pressure
previous point
system surroundings (< 0,7
to be covered later bar(g)).
of
more detail in
examination). section Leaks from
system
inside container.

104High concentration of 104.1 PSA not Inert accumulation FCS cell Comme
“inert gas” in FCS feed working as in FCS. Slightly voltage nt: Inert
gas specified. decreased FCS monitoring gases
performance. from the
point of
view of
FCS
e.g. CH4,
CO2.
Comme
nt: High
105. Rapid 105.1 MV3 Gas not mixing FCS cell Restrict
CO
changes of CO open, flow properly in H2 tank. voltage unauthori
concentra
concentration in FCS feed shorts through Cell voltages may monitoring zed
gas it. fluctuate. access to
system
with a
fence.
Consider
adding
lock to
MV3.
106. No flow 106.1 No Water not Difference Comme
condensation collected, system between TI- nt: No
in COND2 due runtime reduced. 07 and TI-12 detection
to low coolant Hot and humid indicate heat of low
flow or high exhaust gas goes transfer. coolant
coolant to vent (70 °C, RH Low level of flow.
temperature. = 100 %). water in H20 Comme
Condensation of
tank, LI-03. nt:
Exhaust
water in vent
air cooled
pipe. to 30 °C.
Consider
adding
temperat
ure
indicator
in air
exhaust
line after
COND2.

106. No flow 106.2 Water not Low level of Comme

Malfunctioning collected, system water in H20 nt:
of VLS3. runtime reduced. tank, LI-03. Droplets
Droplets entering may also
vent line. back-flow
to VLS3
due to
gravity.

107. Impurities 107.1 Wash- Particle impurities Filters F1 Comme

out of eroded proceed to H20 tank, and F2 nt:
FCS cathode and possibly to H20 feed. Chemical
catalyst contamin
carrier. ants from
Impurities air intake
from air not (e.g.
caught in FCS
sulphur
compoun
air intake
ds) very
filter. unlikely.
Fluor traces Placeme
from FCS nt of AFB
membrane or exhaust
membrane vent as
humidifier far
MH1. possible
from FCS
air intake.
108. High temperature 108.1 High VP1 diaphragm may TI-13 Add
inside container ambient be damaged > 60 °C. Container system
temperature, Electrical equipment ventilation. EM-SD
fire near or inside FCS may triggered
inside overheat. by TI-13
container, high
insufficient temperat
ventilation.
ure (> 80
°C).

109. Animal(s) Possible damage Prevent

inside container (e.g. e.g. to electrical access of
squirrels, mice, birds, equipment or animals
insects…). plastic pipelines. inside
container
by
appropria
te means,
installing
chicken
wire
to large
openings
110. Water enters inside 110.1 Heavy Flooding of Take
of
container rain and container floor, care of
container
related possible damage possibility
flooding in to electrical of
surroundings equipment. flooding
of container. in
placemen
t of
container.

111. External FCS unaffected. UPS for PLC Consider

power grid outage Grid outage system installatio
triggers FP and n of 2nd
PSA emergency UPS to
shutdown. enable
AUTO-SD
for
FP and
PSA.
112. Liquid EtOH or 112.1 Liquid spills on Container Add
EtOH/water mixture Equipment container floor or ventilation EtOH
leakage inside container failure equipment below Splash- detector
leakage, possibly proof casing inside
causing damage used for container.
to electrical electronics. Check if
equipment. PLC control liquid can
EtOH vaporizes
system and flow out
power of
and accumu-
supplies container
lates at the located in floor.
bottom of the separate gas
container. proof
segment of
container.

113. Liquid water 113.1 Liquid spills on Splash- Check if

leakage Equipment container floor or proof casing liquid can
failure equipment below used for flow out
leakage, possibly electronics. of
causing damage PLC control container
to electrical system and floor.
equipment. power
supplies
located in
separate gas
proof
segment of
container.
114. Leakage 114.1 Depending on Container Add
from system inside FP Equipment leakage location, H2detectors EtOH
casing (fuel or failure state of leaking AUTO-SD detector
combustible gas mixture) substance may be and inside
liquid or gaseous ventilation container.
and thus can exit increase Consider
casing as liquid or triggered at installing
vapour. 25 % LEL. perforatio
In case of fuel EM-SD n at top
leakage and if EtOH triggered at of FP
vapour separates 50 % LEL, casing for
from H2O vapour, electricity ventilatio
EtOH vapour may cut-off from n of
ignite. container. combusti
In case of reformate Container ble gases.
gas leakage, gas may ventilation Place
ignite from hot additional
surfaces. H2
detector
close to
perforatio
ns.
During
H2or
EtOH
alarm,
personnel
should
not enter
in
container.
Personn
el
entering
container
should
carry
115. Combustible gas 115.1 Combustible gas Container During
mixture leakage inside Equipment released inside H2detectors H2alarm,
container (reformate gas, failure container. AUTO-SD personnel
FP product gas, tail gas) and should
ventilation not enter
increase in
triggered at container.
25 % LEL. Personn
EM-SD el
triggered at entering
50 % LEL, container
electricity should
cut-off from carry
container. portable
Container CO
ventilation detectors
and
container
doors
should
be open
for CO
ventilatio
n.
116. Hydrogen 116.1 Released Container During
leakage inside container Equipment hydrogen H2detectors H2alarm,
(PSA product gas) failure accumulates near AUTO-SD personnel
container roof, and should
forming explosive ventilation not enter
mixture. increase in
triggered at container.
25 % LEL. Personn
EM-SD el
triggered at entering
50 % LEL, container
electricity should
cut-off from keep
container. container
Container doors
ventilation open for
H2
ventilatio
n.
117. AFB exhaust gas 117.1 Water vapour Container
leakage inside container Equipment released into ventilation
failure container, which Splash-
may condense on proof casing
surfaces, possibly used for
causing damage to electronics.
electrical PLC control
equipment. system and
Oxygen content power
inside container supplies
decreases. located in
separate gas
proof
segment of
container.

118. Hydrogen 118.1 Released PI-08

leakage from H2 tank or Equipment hydrogen forms EFV1, EFV2
pipeline outside container failure with air explosive
gas mixture near
leak source.

119. Combustible gas 119.1 Too Explosive gas

mixture release from high pressure mixture at vent
system pressure relief in system line outlet.
valves causing some
pressure relief
valve to open.