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What's the agitator failure response for R-401, and has this happened before?

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✦ Answer

Immediate response

When agitator failure is detected on R-401:

  • Reduce reactor temperature setpoint to 65 °C to prevent local hot-spotting. 1
  • Open the emergency cooling jacket valve CV-401A to maximum. 1
  • Notify the shift supervisor and DCS operator within 60 seconds.
Safety note: Do not restart the agitator until contents have cooled below 80 °C — restart under exothermic conditions has caused two documented incidents. 2

Prior incidents

This failure mode has occurred twice in the past 18 months:

  • Incident 2024-09 — bearing seizure on M-401-A. Resolved via planned shutdown. 2
  • Incident 2025-03 — VFD trip during summer peak load, triggered emergency cooldown. 3

Citing these sources

SOP-R401-Cold-Startup.docxDOCX
p.120.873 days ago
On agitator failure, reduce setpoint to 65 °C and open jacket valve CV-401A to maximum…
Incident-2024-09.pdfPDF
p.30.81Sept 2024
Bearing seizure on M-401-A caused agitator failure. Restart attempted before contents cooled below 80 °C — escalated.
Maintenance-2025-03.docxDOCX
p.10.74March 2025
VFD trip on M-401-A during summer peak load. Emergency cooldown completed without escalation.

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