2nd Assignment - Furnace(1)

HAZOP STUDY PROCESS

Furnace/burner used to heat up using fuel oil + air Heating oil to 250 C to supply to Distillation re boiler

SECTION DATE

FURNACE

NODE NO

1

100 PARAMETER

PRESSURE

Guide Words

Deviation

MORE -

MORE - PRESSURE

posssible causes

possible consequences

Piping/tube thermal shock and craking lead to leakage of continously high flame the heating oil to the furnace and get contact with the to the furnace. flame and resulting to high temperature in furnace cause cracking and Explosion fuel gas valve malfuction - more fuel gas into the furnace

More fuel gas in the furnace, lead to high temperature in normal operation and may cause explosion during startup. Explosion at furnace stack or Fuel gas release to atmosphere in normal operation

Safe Guard/Prote Action required/Recommendation ction PIC 1, PT-1, PI- High Alarm, 4, PI-5 High-high Alarm, Fuel gas control valve - fail close PI 3, PI 6 & FI Interlock shut off valve 3 Pressure Safety Valve to flare Fuel gas control valve - fail close PI 3, PI 6, FI 3 Interlock shut off valve & AT-1 Pressure Safety Valve to flare

Flue gas control valve, High temperature of hot oil to reboiler, Distillation column PIC 1 malfaction - close experience high pressure that possible to crack and position explosion.

-

Air supply to the furnace high flow & pressure

2

PRESSURE

LESS -

LESS - PRESSURE

FT 2 & PI 2

TEMPERATURE

TEMPERATURE

COMPOSITION

MORE -

LESS -

NOT CORRECT -

MORE TEMPERATURE

LESS TEMPERATURE

NOT CORRECT COMPOSITION

Flow Recordable Control Alarm (FRCA) link to fuel control sytem

Less combustion The oil has not been heating up. The reboiler not reboil the (May caused by either PIC 1, PT-1, PIHC, the distillation flooding, liquid HC over flow to the Pressure Low Alarm less air pressure or less 4, PI-5 upper stream of distillation column. fuel gas) More fuel gas in the furnace, lead to explosion especially Less air pressure to during start-up or fuel gas release to atmosphere through FT 2 & PI 2 furnace for combustion stack due to low combustion

3

Pressure Safety Valve to flare

Additional one parallel air compressor by automatic cut in.

Less fuel gas to the furnace

The oil has not been heating up. The reboiler not reboil the FI 3, PI 3 & PI HC, the distillation flooding, liquid HC over flow to the 6 and bypass Flow Low alarm upper stream of distillation column. valve

High flame in the furnace (high fuel and air)

Piping/tube crack or burst due to overheating, mixture of oil burn and cause black smoke release

TI 8

Automatic shut down heater on low air flow and/or low air/fuel ratio.

High coke in furnace and piping, less heat transfer

TI 8

Maintenance (cleaning)

less hot oil flow to the tubing (less heat transfer )

Thermal craking to the furnace - fuel gas release can cause FT 1 a jet fire

BCPS link to FT 1 and Low flow alarm

No ignition and No flame in the furnace

High Fuel gas in the furnace - when it ignited it will exploded during start-up

pilot light

Temperature alarm low, additional one pilot light , automatic cut off the fuel and air supply

No heat transfer to Hot oil - No heating to reboiler of the distalltion column, if the Feed of the distillation is liquid, the distillation will flooding

pilot light

Temperature alarm low, additional one pilot light , automatic cut off the fuel and air supply

No air Flow

High Fuel gas in the furnace - when it ignited it will exploded

FT 2, PI 2

Air Flow Alarm Low and automatic shut down the fuel supply on low air flow and/or low air/fuel ratio.

No fuel flow

No heat transfer to Hot oil - No heating to reboiler of the distalltion column, if the Feed of the distillation is liquid, the distillation will flooding

FI 3

Fuel Flow Alarm Low and automatic shut down the air supply on low air flow and/or low air/fuel ratio.

-

Automatic shut down the heater on low air flow and/or low air/fuel ratio.

not corret stoikometri for perfect combustion High black smoke release to Atmosphere. of fuel gas Less heat transfer to the hot oil tubing/piping, less separation in distillation column, can lead to tower flooding,

4

OTHERS VALVE

PILOT LIGHT

MAINTENANCE SHUT DOWN & START UP

fuel gas valve un-adequate malfuction - cause maintenance of valve leakage to and instrument furnace. no pilot light

un-adequate maintenance of valve and instrument

un adequate maintenance of Budget Control and unPiping and aware of the risk instrumentation Not follow Human Factor Procedure

explosion when fuel gas over filling in the furnace with out combustion, and operator tried to start up the plant.

explosion when main firing started. explosion when the enough pressure of fuel gas in the furnace Instrument malfunction - lead to false reading and indication and can lead to Explosion. Piping will crack Furnace will crack Explosion can happen if not following the SU and SD procedure.

Periodic Maintenance

HAZOP STUDY

Furnace/burner used to heat up using fuel oil + air Heating oil

PROCESS

Air line supply to the furnace

Section Date NODE

200

NO

PARAMETER

Guide Words

Deviation

MORE -

MORE - FLOW

LESS -

LESS - FLOW

NO -

NO - FLOW

VALVE

Valve malfuction

FLOW

OTHERS THAN

MAINTENANCE SHUT DOWN & START UP

Not follow Procedure

HAZOP STUDY

er used to heat up using fuel oil + air Heating oil to 250 C to supply to Distillation re boiler Air line supply to the furnace

posssible causes

possible consequences

the valve or control valve malfuction

air to fuel ratio not as per FT 2 stoikiometric, high presure in the furnace more gas rushing out to atm,

piping leaking

piping leaking pump/compressor failure Piping blockage/valve malfuction

un-edequate maintenance air supply to actuator block controller malfuction cost cutting

Human Factor

Safe Guard/Protection

PT 1, PI 4 & PI 5 PIC 1

air to fuel ratio not as per stoikiometric, more fuel coming out from the stack FT 2 & PI 2 can cause detonation/explosion more fuel gas in the furnace can cause explosion

more flow or no flow of air to furnace equipment malfuction and error can occurred may lead to explosion Explosion can happen if not following the SU and SD procedure.

FT 2 & PI 2

llation re boiler

action required/Recommendation

Air Flow Alarm Low and automatic shut down the fuel supply or heater on low air flow and/or low air/fuel ratio.

Periodic Piping inspection, Risk based inspection (RBI)

Air Flow Alarm Low and automatic shut down the fuel supply or heater on low air flow and/or low air/fuel ratio.

HAZOP STUDY

Furnace/burner used to heat up using fuel oil + air Heating

PROCESS

Fuel gas line supply to Furnace

section date study node

300

NO

PARAMETER

Guide Words

Deviation

1

PRESSURE

MORE -

MORE - PRESSURE

LESS -

LESS - PRESSURE

NO -

NO -PRESSURE

3

TEMPERATURE

MORE -

MORE - TEMPERATURE

4

FLOW

REVERSE -

REVERSE - FLOW

MORE -

MORE - FLOW

LESS NO -

LESS - FLOW NO - FLOW

VALVE

Valve malfuction

OTHERS THAN

MAINTENANCE SHUT DOWN & START UP

Not follow Procedure

HAZOP STUDY

sed to heat up using fuel oil + air Heating oil to 250 C to supply to Distillation re boiler Fuel gas line supply to Furnace

posssible causes

possible consequences

Fuel gas control valve malfunction

more fuel in the furnace, can cause explosion during start-up

piping leaking valve malfuction valve malfuction piping leaking external heating cause the gas expanded

more air in the furnace, no enough heat to heat up hot oil to desired temperature.

explosion when enter furnace.

Safe Guard/Protectio n PI 3 & PI 6

PI 3 & PI 6

TI 11

FI 3 Fuel gas control valve malfunction - fully open

piping leaking valve malfuction

more fuel in the furnace, can cause explosion more air in the furnace, no enough heat to heat up hot oil to desired temperature.

un-edequate maintenance air supply to actuator block

more flow or no flow to furnace

controller malfuction cost cutting Human Factor

equipment malfuction and error can occurred may lead to explosion Explosion can happen if not following the SU and SD procedure.

FI 3

tillation re boiler

Action required/Recommendation Fuel Pressure Alarm High and automatic shut down the fuel supply or heater on low air low air/fuel ratio or high fuel supply

Fuel Perssure Alarm Low and automatic shut down heater if Alarm Low Low triggered.

Automatic shut down fuel gas supply and heater

Fuel control valve - Fail close Fuel Flow Alarm High and automatic shut down the fuel supply or heater on low air low air/fuel ratio or high fuel supply

Fuel Flow Alarm Low

HAZOP STUDY

Furnace/burner used to heat up using fuel oil + air Heati

PROCESS

Heating oil piping/tubing going to fur

section date

400

study node

NO

PARAMETER PRESSURE

Guide Words

Deviation

MORE -

MORE - PRESSURE

LESS -

LESS - PRESSURE

NO -

NO -PRESSURE

MORE -

MORE - TEMPERATURE

LESS -

LESS - TEMPERATURE

1

TEMPERATURE

2

3

UN-EVEN TEMP

4 COMPOSITION 5

OTHERS THEN -

OTHERS THEN - COMPOSITION

FLOW

LESS -

LESS - FLOW

NO -

NO - FLOW

VALVE

Valve malfuction

OTHERS THAN

MAINTENANCE

SHUT DOWN & START UP

Not follow Procedure

HAZOP STUDY

p using fuel oil + air Heating oil to 250 C to supply to Distillation re boiler

oil piping/tubing going to furnace and out from furnace

posssible causes

possible consequences

HC from reboiler leaking into heating oil tube

Possible fie inside the tube and lead to explosion of tube and burst

piping leaking - in the furnace

Safe Guard/Protection

heating oil burn in furnace - black smoke , less heating oil to reboiler - column flooding with HC

high combustion in furnace - distillation column high pressure and TI 1 ~ TI 10 (exclude TI 8) more fuel and air can cause explosion.

Low combustion in furnace column flooding with liquid HC

TI 1 ~ TI 10 (exclude TI 8)

coking in the tubing

piping craking and less flow to reboiler

TI 1 ~ TI 10 (exclude TI 8)

HC leaking to the heating oil, Reboiler crack, or tube cracking

Possible fire inside the tube and lead to explosion of tube and burst

High moisture content

tube hammmering

piping leaking to furnace

heating oil burn in furnace - black smoke ,

coking in tubing

column flooding with liquid HC

piping leaking

pump failure

-

FT 1

column flooding with liquid HC

Piping blockage/valve malfuction

un-edequate maintenance air supply to actuator block

-

more flow or no flow of to furnace, no heating reboiler

controller malfuction cost cutting

equipment malfuction and error can occurred may lead to explosion

Human Factor

Explosion can happen if not following the SU and SD procedure.

Action required/Recom mendation Indication of pressure at tube Indication of pressure at tube Indication of pressure at tube

Temperature High Alarm and automatic shut down the heater if Temperature Alarm High High Temperature Alarm Low and automatic shut down the heater if Temperature Alarm Low Low Temperature Alarm Low and automatic shut down the heater if Temperature Alarm Low Low Indication of composition at tube

Vaporiser instalation at heating oil prior to inlet to furnace Indication of flow at exit stream of furnace Online decoking peridically Indication of flow at exit stream of furnace Standby pump, automatically cut in if another fail to function Online decoking peridically