Hazop

HAZOP STUDY REPORT

Client

Nagarjuna Oil Corporation Ltd.

PROCESS

SO2331

CS-140-PR-47-0001

Plant

DHU Unit (Unit -1400)

Dept.

Project

Document Number

OWNER PMC LICENSOR EPC CONTRACTOR

: : : :

0 Rev.

NAGARJUNA OIL CORPORATION LTD. CB&I, LUMMUS AXENS, IFP GROUP TECHNOLOGY SAMSUNG ENGINEERING INDIA PVT. LTD.

HAZOP Study Report For

Diesel Hydrodesulphurization Unit Unit 1400

0

17.12.10

Issued for Design

PDA

KA

GCM

REV.

DATE

DESCRIPTION

PREPARED BY

CHECKED BY

APPROVED BY

RS

PM

HAZOP STUDY REPORT

Client

Nagarjuna Oil Corporation Ltd.

PROCESS

SO2331

CS-140-PR-47-0001

0

Plant

DHU Unit (Unit -1400)

Dept.

Project

Document Number

Rev.

Contents 1. Introduction……………………………………………………………………………….… 3 2. Executive Summary……………………………………………………………………....…4 3. Unit Description………………..………………………………………………………..……5 4. Objective of Study..………………………………………………………………….………5 5. HAZOP Methodology & Techniques………………………………………………..………6 6. HAZOP Assumptions………………………………………………………………..………8 7. Basis of HAZOP Study……………………………………………………………………..12 8. Documents Referred for HAZOP study………………………………………………...…14 9. HAZOP Team …………………………………………………………………………..……16 10. Recommendations…………………………………………………………………….……18

Annexure I: Node details & HAZOP P&IDs( 60 sheets ) Annexure II: Recommendations( 15 sheets ) Annexure III: HAZOP Worksheets( 104 sheets ) Annexure IV: Attendance( 2 sheets )

Page 2 of 136

HAZOP STUDY REPORT

Client

Nagarjuna Oil Corporation Ltd.

PROCESS

SO2331

CS-140-PR-47-0001

0

Plant

DHU Unit (Unit -1400)

Dept.

Project

Document Number

Rev.

1. Introduction

The Hazard and operability study (HAZOP) has been carried out for Diesel Hydrodesulphurization unit (DHU-Unit 1400), which forms part of Cuddalore Refinery project at Cuddalore,Tamil-Nadu. The HAZOP proceeding was conducted at Samsung Engg. India Pvt. Ltd. w.e. f. 06/12/10 to 14/12/10. The HAZOP study team consists of representative from the SEI, PMC, Licensor, NOCL and was lead by an independent Chairman, HAZOP study was conducted by a multi discipline group. The action points that have emerged from the study are presented in the action list appended at the end of this report. Each action item is subjected to a number. A given action item may pertain to more than one points. However priority categorization shall be done based on SIL study.

Page 3 of 136

HAZOP STUDY REPORT

Client

Nagarjuna Oil Corporation Ltd.

PROCESS

SO2331

CS-140-PR-47-0001

0

Plant

DHU Unit (Unit -1400)

Dept.

Project

Document Number

Rev.

2. Executive Summary A total 31 nodes are identified for analysis resulting to- no. of action points. These nodes have been described in outline enclosed in the report. Report is based on the HAZOP study conducted in presence of concerned department officers/PMC/Licensors/NOCL representatives. All recommendations are listed & annexed in the reports. Some of the information which were not available (seal system of hydrogen compressor BHEL, backwashing system of filters etc.) needs to be identified & P&IDs shall be upgraded accordingly.

Page 4 of 136

HAZOP STUDY REPORT Client

Nagarjuna Oil Corporation Ltd.

PROCESS

SO2331

CS-140-PR-47-0001

0

Plant

DHU Unit (Unit -1400)

Dept.

Project

Document Number

Rev.

3. Unit Description The unit consists of the following sections: • Reaction • Recycle Gas Loop • Stripper and LP Absorber - Reaction Section The feed consists of SRHD, LVGO, LCGO, and LCO streams supplied from battery limits. The gas oil blend flows to the back wash Feed Filter,A4 140-F-001, before entering theFeed Surge Drum, 140-V-001. The feed drum is nitrogen blanketed and the drum pressureis under level controlled using a split range control scheme. The oil feed is pumped to the reactor circuit on flow control using the Gas Oil Feed Pump, 140-P-001 A/B. The feed drum level is controlled by supplying excess DHU feed from storage. The level controller is sent to storage, Unit 2500, outside battery limits. Make-up hydrogen is supplied at 20 bar g, to the Make-up Gas Compressor K.O. Drum 140-V002, and then is compressed by the Hydrogen Make-up Compressor 140-K-001 A/B. The make-up compressor has two stages and the interstage gas cooling is done with cooling water in the Make-Up Compressor Interstage Cooler, 140-EE-008 A/B. The makeup gas flowrate to the reaction section is controlled by means of a compressor spillback to the Make-up Gas Compressor K.O. Drum, 140-V-002. The spill back is cooled by the Hydrogen Make-Up Kick Back Cooler, 140-EE-004. A line is provided on the Make-up Gas Compressor discharge to send Hydrogen to bullet storage. Before being sent to storage outside battery limits the hydrogen is cooled in the Hydrogen Cooler, 140-EE-009. The make-up and recycle gas streams are combined with the feed, and the total feed mixture is heated up against the reactor effluent in the Reactor Feed / Effluent Exchanger, 140-EE-001 A/B/C/D. A bypass of all the shells is provided on the gas oil feed line to facilitate the Hydrotreater Reactor Feed Heater, 140-H-001, operation at minimum turndown. The preheated oil and hydrogen mixture is heated to the reactor inlet temperature in the Hydrotreater Reactor Feed Heater, 140-H-001. The Hydrotreater Reactor, 140-R-001, contains five catalytic beds. Recycle hydrogen is used as the quench gas, for maintaining the desired WABT in each of the catalytic bed. The top layer of the first catalytic bed in the reactor operates at a lower temperature, and this bed saturates the feed olefins and diolefins. The inlet temperature to the Reactor is adjusted so that the required inlet temperature is obtained for the subsequent HDS catalyst in the same catalytic bed. The effluent from the first catalytic bed is quenched to control the inlet temperature of the second catalytic bed. In the remaining four catalytic beds, the targeted average WABT is about the same to complete the remaining reactions. The quench gas is supplied on flow control, reset by the catalytic bed inlet temperature. The reactor effluent is cooled by preheating the stripper feed in the Stripper Feed Preheater, 140-EE-002, then by preheating the oil/hydrogen feed in the Feed/Effluent Exchanger, 140-EE-001 A/B/C/D. Wash water is injected into the reactor effluent at the outlet of the final Feed/Effluent Exchangers shell, in order to prevent any deposit of ammonium salts. The wash water is a mixture of recycled water from the Stripper Reflux Drum, 140-V-008, and the Coalescer, 140-V-009, plus make-up stripped sour water from battery limits. Additional water injection facilities are provided for the last two shells, tube side, of the Feed/Effluent Exchanger to wash out any salt deposits. This injection is normally intermittent and usually not required. The wash water is pumped by the Wash Water Pump, 140-P-002 A/B, from the Wash Water Drum, 140-V-004, on flow control to the reactor effluent upstream of the Reactor Effluent Air Cooler, 140-EA-001, to avoid ammonium salt deposit and the risk of corrosion. The Wash Water Drum, 140-V-004 is nitrogen blanketed and the drum pressure is under level controlled using a split range control scheme. The Reactor Effluent then is cooled in the Reactor Effluent Air Cooler, 140-EA-001, and the Reactor Effluent Trim Cooler, 140-EE-003. The reactor effluent is collected in the Page out 5 of of 136the Separator Drum consists of the Separator Drum, 140-V-006. The vapor phase recycle and quench gas circulated by the recycle compressor. The Separator Drum is

used as the quench gas, for maintaining the desired WABT in each of the catalytic bed. The top layer of the first catalytic bed in the reactor operates at a lower temperature, and this bed saturates the feed olefins and diolefins. The inlet temperature to the Reactor is adjusted so that the required inlet temperature is obtained for the subsequent HDS catalyst in the same catalytic bed. The effluent from the first catalytic bed is quenched to control the inlet temperature of the second catalytic bed. In the remaining four catalytic beds, the HAZOP REPORT targeted average WABT is about the same to complete theSTUDY remaining reactions. The quench gas is supplied on flow control, reset by the catalytic bed inlet temperature. The reactor effluent is cooled by preheating the stripper feed in the Stripper Feed Client Nagarjuna Oil SO2331 0 Preheater, 140-EE-002, then by PROCESS preheating the oil/hydrogen feedCS-140-PR-47-0001 in the Feed/Effluent Corporation Ltd. Exchanger, 140-EE-001 A/B/C/D. Wash water is injected into the reactor effluent at the Plant Unit (Unit -1400) Dept. Document Number outlet of the finalDHU Feed/Effluent Exchangers shell,Project in order to prevent any deposit Rev. of ammonium salts. The wash water is a mixture of recycled water from the Stripper Reflux Drum, 140-V-008, and the Coalescer, 140-V-009, plus make-up stripped sour water from battery limits. Additional water injection facilities are provided for the last two shells, tube side, of the Feed/Effluent Exchanger to wash out any salt deposits. This injection is normally intermittent and usually not required. The wash water is pumped by the Wash Water Pump, 140-P-002 A/B, from the Wash Water Drum, 140-V-004, on flow control to the reactor effluent upstream of the Reactor Effluent Air Cooler, 140-EA-001, to avoid ammonium salt deposit and the risk of corrosion. The Wash Water Drum, 140-V-004 is nitrogen blanketed and the drum pressure is under level controlled using a split range control scheme. The Reactor Effluent then is cooled in the Reactor Effluent Air Cooler, 140-EA-001, and the Reactor Effluent Trim Cooler, 140-EE-003. The reactor effluent is collected in the Separator Drum, 140-V-006. The vapor phase out of the Separator Drum consists of the recycle and quench gas circulated by the recycle compressor. The Separator Drum is equipped with a water boot, and adequate residence time is provided for obtaining a good separation of the liquid and sour water streams. Sour water is separated from the hydrocarbon liquid phase on HC/water interface level control from the settling zone of the separator. Then the sour water is routed to the Sour Water Flash Drum, 140-V-017, before being sent to FCC Sour Water Unit, Unit 550 outside battery limits. The hydrocarbon liquid flows on level control to the stripping section. The separator also contains a coalescing pad close to the feed inlet nozzle. In addition to coalescing the small water droplets, the coalescing pad helps to streamline the HC/H2O flow in the settling zone. - Recycle Gas Section The recycle hydrogen stream leaving the Separator Drum, 140-V-006, is routed to the HP Amine Absorber, 140-C-001 for HsS removal, through the HP Amine Absorber KO Drum, 140-V-007. The lean amine is a 40 wt% MDEA solution, supplied on flow control to the HP Amine Absorber using the Lean Amine Booster Pump, 140-P-003 A/B. The rich amine from the HP absorber bottoms is sent to the LP Amine Absorber, 140-C-003, on level control, for flashing off the dissolved light ends. The recycle gas leaving the HP Amine Absorber is routed to the Recycle Compressor, 140K-002, through the Recycle Compressor K.O. Drum, 140-V-005. There is a provision to remove a small amount of the sweetened gas stream leaving the HP absorber on flow control as a high pressure purge, to provide added flexibility during operation. However, the unit is designed based on no purge gas flow, and hence normally there is no high pressure purge gas leaving the unit. The recycle compressor is driven by a back-pressure type steam turbine, 140-KT-002. The reactor circuit pressure is controlled at the Separator Drum, 140-V-006. The pressure is controlled through a hand switch sending a signal adjusting either the make-up hydrogen supply to the reactor circuit or/and the HP purge gas. The Recycle Compressor discharge is split into recycle gas and quench gas streams. The recycle gas is combined with the make-up hydrogen and the gas oil feed. Then, the total feed enters the reaction circuit. - Stripper Section The Stripper, 140-C-002, fractionates the diesel product and the wild naphtha from the reactor effluent liquid stream supplied from the Separator Drum, 140-V-006. Liquid Feed from the Separator is first preheated by heat exchange with the stripper bottoms in the Stripper Feed/Bottoms Exchanger, 140-EE-006 A/B/C/D, followed by the final heating with the reactor effluent in the Stripper Preheater, 140-EE-002. The stripper feed temperature is controlled by varying the feed flow through the Stripper Feed Preheater and the exchanger bypass streams. The hot feed enters the Stripper onto the 22nd tray (counting from the bottom). The feed is stripped of H2S and light ends from the diesel product using MP steam, which is superheated to 237°C. The MP Steam comes from the Recycle Compressor Steam Page 6 of 136 Turbine, 140-KT-002. The Stripper overhead vapor is condensed in an air cooled condenser, 140-EA-002, and the

supply to the reactor circuit or/and the HP purge gas. The Recycle Compressor discharge is split into recycle gas and quench gas streams. The recycle gas is combined with the make-up hydrogen and the gas oil feed. Then, the total feed enters the reaction circuit. - Stripper Section The Stripper, 140-C-002, fractionates the diesel product the wildREPORT naphtha from the HAZOPand STUDY reactor effluent liquid stream supplied from the Separator Drum, 140-V-006. Liquid Feed from the Separator is first preheated by heat exchange with the stripper bottoms in the Stripper Exchanger, 140-EE-006 A/B/C/D, followed 0by the Client Nagarjuna Feed/Bottoms Oil PROCESS SO2331 CS-140-PR-47-0001 Ltd. effluent in the Stripper Preheater, 140-EE-002. The stripper final heating withCorporation the reactor Plant DHU (Unit -1400)by Dept. Project Document Number feed temperature is Unit controlled varying the feed flow through the Stripper FeedRev. Preheater and the exchanger bypass streams. The hot feed enters the Stripper onto the 22nd tray (counting from the bottom). The feed is stripped of H2S and light ends from the diesel product using MP steam, which is superheated to 237°C. The MP Steam comes from the Recycle Compressor Steam Turbine, 140-KT-002. The Stripper overhead vapor is condensed in an air cooled condenser, 140-EA-002, and the trim condenser, 140-EE-005. The sour off-gas product from the Stripper Reflux Drum, 140-V-008, is sent to the LP Amine Absorber K.O. Drum, 140-V-010, where it is mixed with any Flash Gas coming out of the Sour Water Flash Drum, 140-V-017. Then the sour off-gas is sent to the LP Amine Absorber, 140-C-003, where it is contacted with lean amine from battery limits. In the LP Absorber, H2S is removed from the offgas, which then flows to the Off Gas K.O Drum, 140-V-018 before being directed to battery limits. The stripper circuit pressure is controlled by the pressure controller located on the LP Amine Absorber overhead, downstream of the Off Gas K.O. Drum, 140-V-018. The LP Amine absorber is operated at a high enough pressure to route the sweet off-gas product to either Unit 350 or to fuel gas. High pressure rich amine from the HP Amine Absorber is let down to LP Amine Absorber, and the combined rich amine is sent from the LP Amine Absorber under level control to the Amine Regeneration Unit. The water condensate containing dissolved H2S and traces of NH3 is removed from the Stripper Reflux Drum waterboot on interface level control. This sour water is recycled to the Wash Water Drum, 140-V-004, for water injection upstream of the Reactor Effluent Air cooler, 140-EA-001. The stripper reflux is returned to the tower on flow control, and the Wild Naphtha overhead product is sent to the battery limits on flow control, reset by the reflux drum level. The wild naphtha product is normally sent to Unit 200, with provisions for routing to Unit 160. The stripped diesel product is pumped by the Stripper Bottoms Pump, 140-P-005 A/B, to the battery limits on level control of the stripper bottoms. Heat is recovered from the diesel product by preheating the stripper feed in the Stripper Feed/Bottom Exchanger, 140-EE006 A/B/C/D, and the Stripper Preheater, 140-EE-002. The diesel product is further cooled in the Gas Oil Air Cooler, 140-EA-003 and Gas Oil Trim Cooler, 140-EE-007. The dissolved water in the diesel product settles out as free water as the product stream is cooled. The entrained water is first taken out in the Product Coalescer, 140-V-009. The Product Coalescer, 140-V-009 water is recycled under interface level control to the Wash Water Drum, 140-V-004 to be used as Wash Water. Water is further removed from the diesel product to meet water specification in the Salt Dryer, 140-V-019 before being routed to the storage, Unit 2500, outside battery limits.

Page 7 of 136

HAZOP STUDY REPORT Client

Nagarjuna Oil Corporation Ltd.

PROCESS

SO2331

CS-140-PR-47-0001

0

Plant

DHU Unit (Unit -1400)

Dept.

Project

Document Number

Rev.

Page 8 of 136

HAZOP STUDY REPORT

Client

Nagarjuna Oil Corporation Ltd.

PROCESS

SO2331

CS-140-PR-47-0001

0

Plant

DHU Unit (Unit -1400)

Dept.

Project

Document Number

Rev.

4.Objective of study The objective of HAZOP study was to identify the potential hazard and the operability problem by systematic review of the Diesel hydrodesulphurization unit and to identify the action items to alleviate such problems. The objective of the HAZOP study in nutshell is - To provide process safety information - Finding out of different HAZARD during plant operation - To establishing safe operating procedure. - To maintain safe work practice.

Page 9 of 136

HAZOP STUDY REPORT

Client

Nagarjuna Oil Corporation Ltd.

PROCESS

SO2331

CS-140-PR-47-0001

0

Plant

DHU Unit (Unit -1400)

Dept.

Project

Document Number

Rev.

5. HAZOP Methodology & Technique 5.1 Methodology HAZOP studies are undertaken by application of formal, systematic and critical approach to examine the process the process engineering intentions of process design. The potential of hazard is thus assessed, and the chances of malfunction of individual equipment and its consequences for the whole system are identified. Identical equipment and associated system are subjected to a generic approach including where two or more system operate in partial. 5.2 Technique The HAZOP study involve a rigorous and systematic examination of all known deviations from normal operating condition using a series of guidewords and covering every parameter of system under review. Deviation (ie-guideword+chosen parameter) are identified by application of standard list guide words. The guide words are used were: No,More,Less,Reverse other than etc. The following parameters relevant to the system under review were considered: Flow, temperature, Pressure, Level, Composition, Others. 5.3 Intention: The intention defines how the system is expected to operate at the nodes. It thus provides a point of reference for developing deviations. 5.4 Deviation: These are departures from the design intention that are discovered by systematically applying the guidewords to each parameter at each node (e.g. HIGH + TEMPERATURE = HIGH TEMPERATURE). It is not unusual to have more than one deviation from the application of a same guideword. For example, "MORE FLOW" could mean either that there is a higher FLOWRATE, or more quantity is flowed. 5.5 Causes: These are the reasons why deviations may occur. Not all possible deviations are meaningful and tehh HAZOP team identified meaningful deviations with credible causes. These causes can be equipment failures, human errors or external (e.g. loss of power). 5.6 Consequences: These are the results of the deviations should they occur (e.g. release of toxic materials). Note that the consequences of a deviation offten differ for each cause of the deviation. 5.7 Actions/Recommendations These are either suggested actions to prevent the consequences of a deviation, or a need to obtain further information before the particular deviation can be properly assessed. The HAZOP study is intended to identify problems, not necessarily solve them where a solution is not obvious, a potentila problem existes and recommends that someone review it for potential solutions.

5.8 Recording: Records are documented through "recording by exception", i.e. to only record the deviations that cause particular hazards or operating problems. If no deviations are discovered "N.A" /"NOW NEW CAUSE" may be recorded against that node. In this way the amount of documentation can be kept at a reasonable level. 5.9 Undertaking the study: From the description of the HAZOP study it is clear that a study team will consider part of a process design for a number of Deviation and Guidewords. Thus, a study meeting will follwo through a series of steps repeatedly. The sequence of action for the HAZOP can be represented as given below. These are Page 10 the of 136 seven steps, whichare repeated, many times during HAZOP.

problem existes and recommends that someone review it for potential solutions.

HAZOP STUDY REPORT 5.8 Recording: Records Nagarjuna are documented through "recording by exception", to only record the deviations that cause 0 Client Oil Corporation Ltd. PROCESS i.e. SO2331 CS-140-PR-47-0001 particular hazards or operating problems. If no deviations are discovered "N.A" /"NOW NEW CAUSE" Plant DHU Unit (Unit -1400) Dept. Project Document Number Rev. may be recorded against that node. In this way the amount of documentation can be kept at a reasonable level. 5.9 Undertaking the study: From the description of the HAZOP study it is clear that a study team will consider part of a process design for a number of Deviation and Guidewords. Thus, a study meeting will follwo through a series of steps repeatedly. The sequence of action for the HAZOP can be represented as given below. These are seven steps, whichare repeated, many times during the HAZOP. a) Apply the guideword b) Develop a deviation c) Examine possible causes d) Examine consequences e) Consider hazards or operatability problems f) Decide upon action g) Make a record of the discussion and decision

A full record of the HAZOP study was made on worksheets and these are presented in the Appendices (Refer Annexure-III).. HAZOP has been done on Excel work sheets.

Page 11 of 136

HAZOP STUDY REPORT

Client

Nagarjuna Oil Corporation Ltd.

PROCESS

SO2331

CS-140-PR-47-0001

0

Plant

DHU Unit (Unit -1400)

Dept.

Project

Document Number

Rev.

6. HAZOP ASSUMPTIONS The following assumptions have been considered during HAZOP study: - Mechanical protection device (PSV,TSV etc.) is expected to work. - No quantitative analysis will be done during HAZOP session. - Single check valve is adequate unless reverse flow may cause pressure exceeding the test pressure. - No design work will be done. The following have not been considered: - Simultaneous occurrence of two unrelated incidents. - Operator negligence. - Simultaneous failure of more than one independent protection device. - Natural calamity (flood earth quake etc.) - Objects falling from sky. - Sabotage.

Page 12 of 136

HAZOP STUDY REPORT

Client

Nagarjuna Oil Corporation Ltd.

PROCESS

SO2331

CS-140-PR-47-0001

0

Plant

DHU Unit (Unit -1400)

Dept.

Project

Document Number

Rev.

GUIDE WORD PARAMETER

NO

MORE LESS AS WELL AS

PART OF

REVERSE

OTHER THAN

FLOW *

y

y

y

n

n

y

n

PRESSURE *

n

y

y

n

n

n

n

TEMPERATURE *

n

y

y

n

n

n

n

LEVEL

y

y

y

n

n

n

n

PHASE

n

n

n

n

n

n

n

COMPOSITION (SPECIFIC COMPONENT)

y

y

y

n

n

n

n

OPERATION **

y

y

y

n

n

n

y

Page 13 of 136

HAZOP STUDY REPORT

Client

Nagarjuna Oil Corporation Ltd.

PROCESS

SO2331

CS-140-PR-47-0001

0

Plant

DHU Unit (Unit -1400)

Dept.

Project

Document Number

Rev.

* Normal Parameters ** Start-up / shutdown, isolation philosophy, different operating modes, maintenance access, blow down, etc.

Not Used

n

Normally Used

y

HAZOP STUDY REPORT

Client

Nagarjuna Oil Corporation Ltd.

PROCESS

SO2331

CS-140-PR-47-0001

0

Plant

DHU Unit (Unit -1400)

Dept.

Project

Document Number

Rev.

Most hazards will be protected against by a combination of hardware, instrumentation and / or operating practices. Protection may be provided by a combination of the following: x The intrinsic mechanical strength of the plant x Process control response

Page 15 of 136

HAZOP STUDY REPORT

TECHNIP KT INDIA LTD.

Client

Nagarjuna Oil Corporation Ltd.

PROCESS

SO2331

CS-140-PR-47-0001

0

Plant

DHU Unit (Unit -1400)

Dept.

Project

Document Number

Rev.

7. BASIS OF HAZOP STUDY Nodes considered for Diesel Hydrodesulphurizing unit HAZOP study: Refer to Annexure-I for Node details & Scanned copies of P&IDs used during HAZOP study.

Page 16 of 136

HAZOP STUDY REPORT

Client

Nagarjuna Oil Corporation Ltd.

PROCESS

SO2331

CS-140-PR-47-0001

0

Plant

DHU Unit (Unit -1400)

Dept.

Project

Document Number

Rev.

8 Documents referred for HAZOP study Following is the list of documents referred during this study:

S.No.

Title

1

Process Data Book

2

Process flow diagram

3 4

Document No. C450-1400-PB-REV0

CA-140-PR-11-0001 to 0006

Material Selection Diagram

CS-140-PR-19-0001 to 0003

Plot Plan

CS-140-PI-16-0001,Rev1

Piping & instrumentation diagram (Process)

CS-140-PR-15-0001 to 0027

Piping & instrumentation diagram (Utilities)

CS-140-PR-15-0030 to 0041 CS-140-PR-15-0043 to 0044

5

6 7

Equipment List

CS-140-PR-50-0001

8

Flare load summary

CS-140-PR-50-0008

9

Area Classification layout

CS-140-EL-12-0001

10

Process data sheet of equipments

-

11

Cause and effect Diagram

CS-140-PR-24-0001

12

Safeguarding Memorandum

CS-140-PR-45-0001

13

Vendor P&IDs

Refer Annexure 1

Page 17 of 136

Page 18 of 136

HAZOP STUDY REPORT

Client

Nagarjuna Oil Corporation Ltd.

PROCESS

SO2331

CS-140-PR-47-0001

0

Plant

DHU Unit (Unit -1400)

Dept.

Project

Document Number

Rev.

9. HAZOP TEAM

The HAZOP was carried out from 6th Dec. to 14th Dec.2010. A team of experienced engineers from Process, Operations/Commissioning and Engineering were formed the list of participants is as below: HAZOP Chairman: Mr. Gour Chandra Mitra. SAMSUNG ENGG. INDIA PVT. LTD.

PMC

NOCL

Licensor

Vendors

Mr. P. K. Gupta-Part Mr. V. K. Bansal-Part Mrs. Ketaki Adhikaray Mr. K. Y. Nam-Part Mr. Pawan K. Sharma-Part Mrs. A. Chamundeswari-Part Mr. Riji P. day Mr. R. Manna-Part Mr. Arun Goel-Part Mr. Pradeep Amale Mr. Ambrish Bajpai-Part Mr. Amiya Ray Mr. Ankur Agarwal-Part Mr. Mayank Gupta

Mr. Y. K. Joshi Mr. R. Y. Bloem-Part

Mr. S. Ravishankar Mr. Bhaskar Das Mr. Rajashekhran-Part Mr. Raj Kumar-Part Mr. Sebastian-Part Mr. Aravindan-Part

Mr. Stephane Chapot

BHEL Mr.Krishnan-Part

NEA Mr. Yogesh Kohil-Part Mr. Subramanium-Part

Detailed attendence list is attached as Annexure-V)

Page 19 of 136

HAZOP STUDY REPORT

Client

Nagarjuna Oil Corporation Ltd.

PROCESS

SO2331

CS-140-PR-47-0001

0

Plant

DHU Unit (Unit -1400)

Dept.

Project

Document Number

Rev.

10. RECOMMENDATIONS

The total number of recommendations are 147. (Attached as Annexure II)

Page 20 of 136

Annexure I Node No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

24 25

26 27

28 29

30 31

Node Description

Feed from B/L to Feed Surge Drum Feed Surge Drum to Reactor Feed Heater Reactor Feed Heater Reactor Feed Heater Outlet to Reactor, Effluent Air Cooler, Trim Cooler Up to separator inlet Wash Water System Separator bottom to Sour water Flash Drum and B/L Separator Drum to Stripper Inlet Separator Overhead to Recycle gas compressor Inlet Recycle Gas compressor to Mixing Point Lean Amine from B/L to LP and HP Amine Absorber column Rich Amine from HP Amine Absorber ,LP Amine Absorber bottom to B/L. LP Amine Absorber system (LP Amine column KOD, Off Gas KOD) to B/L Stripper bottom to Gas oil Air cooler, Coalescer and Salt Dryer to B/L Stripper Overhead system Makeup H2 Compressor system Chemical Injection System Fuel oil, Fuel gas and Heater Firing System HP/MP Steam & MP BFW Cooling water system Portable/Service Water, LP Steam, Plant /Instrument Air and Nitrogen Flare system Amine drain system Hydrocarbon drain system Condensate Collection system Makeup H2 Compressor-Lube oil System Makeup H2 Compressor- Closed cooling water System Makeup H2 Compressor- Distance piece/packing purge Recycle Compressor- Lube oil Recycle Compressor- Seal Gas ( Vendor is expected to revise the seal gas system P&ID,Accordingly no HAZOP was done. Recycle Compressor- Steam & drain Recycle Compressor- cooling water System ( No HAZOP was done. The same need to be carried out later with the vendor).

Page 21 of 136

HAZOP STUDY REPORT

Client

Nagarjuna Oil Corporation Ltd.

PROCESS

SO2331

CS-140-PR-47-0001

0

Plant

DHU Unit (Unit -1400)

Dept.

Project

Document Number

Rev.

The recommendations of HAZOP study are listed below: (Annexure II) S.No

Recommendations

P&ID no

Responsibility

CS-140-PR-15-0001

1

Provide low alarm for PC-343.

2

Design case for overpressure in filter is to be reviewed.

3

High temperature alarm to be provided on TI-107 and TI-343.

CS-140-PR-15-0001

SEI

4

LCO,LCGO flow rate indications to be duplicated in DHU graphics.

CS-140-PR-15-0001

PMC/SEI

5

Feed stream ratio indication with alarm to be repeated in DHU graphics.

CS-140-PR-15-0001

PMC/SEI

6

Provide TDI (TI-129 and TC-124)on the first bed with high alarm set at differential temp. of 30 C.

7

Ensure proper thermal expansion in Mechanical design is considered in case of depressurization temp. of 405 C for all shells.

8

Operating manual/SOP should ensure periodical checking of LG506

9

Manual isolation valves downstream of FCV-407A/B,to be LO.

10

Operating procedure should ensure periodical checking of LG-506.

11

CS-140-PR-15-0001, CS-140-PR-15-0002, CS-140-ME-E-03800002

SEI

Vendor/SEI

PMC/SEI

CS-140-PR-15-0002, CS-140-PR-15-0003, CS-140-PR-15-0004

SEI

CS-140-PR-15-0002

SEI/NOCL

CS-140-PR-15-0002

SEI

CS-140-PR-15-0002

SEI/NOCL

Provision of local temp. gauge to be provided for ascertaining the temperature before taking the sample.

CS-140-PR-15-0002, CS-140-PR-15-0003, CS-140-PR-15-0004

SEI/NOCL

12

Operating procedure should ensure temp. of sampling fluid below 80 C.

CS-140-PR-15-0002, CS-140-PR-15-0003, CS-140-PR-15-0004

SEI/NOCL

13

Provide low pressure alarm at PC358 at 140-V-006 gas outlet.

CS-140-PR-15-0007

SEI

Page 22 of 136

Status

HAZOP STUDY REPORT

Client

Nagarjuna Oil Corporation Ltd.

PROCESS

SO2331

CS-140-PR-47-0001

0

Plant

DHU Unit (Unit -1400)

Dept.

Project

Document Number

Rev.

The recommendations of HAZOP study are listed below: (Annexure II) S.No

Recommendations

P&ID no

Responsibility

14

Operating procedure should ensure safe shutdown of the plant.

CS-140-PR-15-0004, CS-140-PR-15-0006

15

All pump motor trip alarms to be provided in DCS.

CS-140-PR-15-0003, CS-140-PR-15-0005, CS-140-PR-15-0006, CS-140-PR-15-0007, CS-140-PR-15-0017

SEI

16

Maintenance schedule for vibration checking is to be strictly followed on regular basis.

CS-140-PR-15-0006

NOCL

17

Manual isolation valves downstream of FCV-455A/B,to be LO.

CS-140-PR-15-0008

SEI

18

Confirm gas break through LCV542A case is considered for PSV310A/B

19

Provide additional control scheme on V-008 boot with LT (Low low level signal), new shutdown valve on recycle water line from V-008 to avoid gas break through.

20

Review the impact of vapor break through/liquid HC in unit 550.

21

Provide low alarm for LI-560A at V009 boot

22

Operating procedure should ensure periodical checking of PI369A/B at pump suction..

23

24

Provide high temp. Alarm at TI210.

Operating procedure to ensure Increase of injection water flow rate and/or plant capacity to be decreased. To be further checked for the feasibility of this operation.

SEI/NOCL

CS-140-PR-15-0008, CS140-PR-15-0021

CS-140-PR-15-0021

SEI

SEI/ PMC/ NOCL/ Axens

CS-140-PR-15-0003, CS140-PR-15-0006, CS-140PR-15-0008, CS-140-PR15-0021, CS-140-PR-150022, CS-140-PR-15-0030, CS-140-PR-15-0037

NOCL

CS-140-PR-15-0022

SEI/NOCL

CS-140-PR-15-0008

SEI/NOCL

CS-140-PR-15-0008

Axens/SEI

CS-140-PR-15-0003, CS140-PR-15-0006, CS-140PR-15-0008, CS-140-PR15-0021, CS-140-PR-150022, CS-140-PR-15-0030, CS-140-PR-15-0037

Page 23 of 136

Axens/SEI

Status

HAZOP STUDY REPORT

Client

Nagarjuna Oil Corporation Ltd.

PROCESS

SO2331

CS-140-PR-47-0001

0

Plant

DHU Unit (Unit -1400)

Dept.

Project

Document Number

Rev.

The recommendations of HAZOP study are listed below: (Annexure II) S.No

Recommendations

25

Operating procedure should ensure periodical checking of FI458/459/460/461

26

check working of P-002A/B,when operating only on BFW(128 C)

27

P&ID no

Responsibility

CS-140-PR-15-0006

SEI/NOCL

CS-140-PR-15-0008

SEI

Operating procedure should ensure periodical checking of LG515

CS-140-PR-15-0006, CS-140-PR-15-0007

SEI/NOCL

28

Ensure LG-515 facing with LCV-514 bypass valve

CS-140-PR-15-0006

SEI

29

Consider FC-416 low alarm is set below turndown flow.

CS-140-PR-15-0007

SEI / AXENS

CS-140-PR-15-0008

SEI / AXENS

CS-140-PR-15-0007, CS140-PR-15-0017, CS-140PR-15-0018

SEI/NOCL

30

Consider installation of limiting temp. controller (TI-120) in heater inlet.

31

SOP to address lining of quench gas in the bottom bed which will help in reducing the reactor outlet temp. minimizing the disturbance.

32

Check the impact on the inlet piping and equipments due to increased inlet temp. to EE-001A/B/C/D and reactor effluent air cooler EA-001

CS-140-PR-15-0003, CS-140-PR-15-0006

SEI

33

Check the impact on the inlet piping and equipments due to increased inlet temp. to EE-006A/B/C/D and gas oil air cooler EA-003.

CS-140-PR-15-0018, CS-140-PR-15-0019

SEI

34

Provide DCS PI with high alarm upstream of EE-006A/B/C/D.

CS-140-PR-15-0018

SEI

35

Provide high alarm at analyzer AI003.

CS-140-PR-15-0022

SEI

Page 24 of 136

Status

HAZOP STUDY REPORT

Client

Nagarjuna Oil Corporation Ltd.

PROCESS

SO2331

CS-140-PR-47-0001

0

Plant

DHU Unit (Unit -1400)

Dept.

Project

Document Number

Rev.

The recommendations of HAZOP study are listed below: (Annexure II) S.No

Recommendations

P&ID no

Responsibility

36

Provide high temp. alarm TI-192.

CS-140-PR-15-0017

SEI

37

Consider converting TI-192 to TC and put reflux on TC/FC cascade.

CS-140-PR-15-0017

Axens/PMC/SEI

38

Check the system integrity upstream of TCV-191A/B during gas break through.

CS-140-PR-15-0017

SEI

39

Check the impact on the inlet piping and equipments due to increased inlet temp. to EE-001A/B/C/D and reactor effluent air cooler EA-001

CS-140-PR-15-0017

SEI

40

Check the impact on the inlet piping and equipments due to increased inlet temp. to EE-006A/B/C/D and gas oil air cooler EA-003.

CS-140-PR-15-0017

SEI

41

Check if downstream product tank can be pressurized due to tube rupture.

CS-140-PR-15-0018

SEI

42

Consider increase in operating pressure of product.

43

Check the overpressurization of system and confirm that PSVs are sized for this case.

44

Operating procedure to include operation of HS-822 to select FCV423 to purge H2S to flare header

CS-140-PR-15-0007, CS-140-PR-15-0009, CS-140-PR-15-0010, CS-140-PR-15-0012

45

low low suction pressure compressor trip PZ-378 is not required as per process reason and to be deleted.

CS-140-PR-15-0011

CS-140-PR-15-0018, CS-140-PR-15-0022

CS-140-PR-15-0017

Page 25 of 136

SEI

SEI

SEI/NOCL

SEI

Status

HAZOP STUDY REPORT

Client

Nagarjuna Oil Corporation Ltd.

PROCESS

SO2331

CS-140-PR-47-0001

0

Plant

DHU Unit (Unit -1400)

Dept.

Project

Document Number

Rev.

The recommendations of HAZOP study are listed below: (Annexure II) S.No

Recommendations

P&ID no

Responsibility

46

Operating instruction to include feed cut-off if system pressure is below 80% of the normal pressure.

CS-140-PR-15-0007

AXENS

47

BHEL to confirm if low low suction pressure trip is required for machine protection.

CS-140-PR-15-0007

BHEL

48

Ensure refinery fuel gas composition has considered addition of hydrogen from this unit.

CS-140-PR-15-0007

NOCL

49

Flow indication of hydrogen to fuel gas unit is to be repeated in fuel gas unit.

CS-140-PR-15-0012

NOCL

50

Move high alarm from PC-394 to PI-999.

CS-140-PR-15-0012

SEI

51

Provide high alarm on PDI-688.

CS-140-PR-15-0011

SEI

52

BHEL recommends the closing of MOVs with a time delay while rpm is reduced to 500.

CS-140-PR-15-0011

BHEL/ PMC/ SEI/ NOCL/ Axens

53

System to be reviewed for required protection, when potential liquid carryover tocompressor as there is a time delay in closer of suction MOV.

CS-140-PR-15-0011

BHEL/ PMC/ SEI/ NOCL/ Axens

54

Check the feasibility of Nitrogen startup operation for refractory dryout feed heaterresulting in Possible high suction temp. leading to high discharge temp. (higher than current design).

CS-140-PR-15-0007, CS-140-PR-15-0009, CS-140-PR-15-0010, CS140-PR-15-0012

SEI

55

Operating procedure to monitor LG522 for HC carry over. When HC level builds up it should be drained to CBD by using Skim line.

CS-140-PR-15-0010

Page 26 of 136

SEI/NOCL

Status

HAZOP STUDY REPORT

Client

Nagarjuna Oil Corporation Ltd.

PROCESS

SO2331

CS-140-PR-47-0001

0

Plant

DHU Unit (Unit -1400)

Dept.

Project

Document Number

Rev.

The recommendations of HAZOP study are listed below: (Annexure II) S.No

Recommendations

Confirm that the max. allowable trip temp. (while running in nitrogen service) & all trip set points for machine safeguards for startup nitrogen case are not different from the normal operating case.

P&ID no

Responsibility

CS-140-PR-15-0011, CS-140-PR-15-0012

BHEL

57

If set points are different separate modes of operation to be programmed in DCS and in safeguarding system.

CS-140-PR-15-0011, CS-140-PR-15-0012

BHEL

58

Operating procedure to include operation of HS-822 to select FCV423 to purge H2S to flare header.

CS-140-PR-15-0012

59

Considering full flow through FCV427, verify low-low flow alarm on FZ-428.

CS-140-PR-15-0003, CS-140-PR-15-0005, CS-140-PR-15-0006, CS-140-PR-15-0011

SEI

CS-140-PR-15-0009, CS-140-PR-15-0010, CS-140-PR-15-0016

SEI

56

60

61

For low flow alarm FC-424 and low low trip FZ-443,trip values are presently given as per process point of view, which needs to be verified based on pump vendor min flow requirement. So UZ-720 should also activate UZ-710 to trip pump (P-003A/B)-logic to be implemented Consider clubbing of UZ-710 & UZ-720).

Operating procedure should ensure routing of off gas to flare header when there is disturbance in lean amine supply to C-003

62

Provide high alarm at AI-002.

63

Check unit 350 design for possible increase of H2S in feed gas from DHU.

CS-140-PR-15-0009

SEI/NOCL

SEI/NOCL

CS-140-PR-15-0016

SEI

CS-140-PR-15-0016

NOCL/PMC

Page 27 of 136

Status

HAZOP STUDY REPORT

Client

Nagarjuna Oil Corporation Ltd.

PROCESS

SO2331

CS-140-PR-47-0001

0

Plant

DHU Unit (Unit -1400)

Dept.

Project

Document Number

Rev.

The recommendations of HAZOP study are listed below: (Annexure II) S.No

64

65

66

67

Recommendations

UZ-720 should activate UZ-710 to trip pump (P-003A/B)

Provide low alarm at TI-170.

Ensure the provision of Hot insulation on the lean amine line coming from ARU (Outside DHU B/L). Provide High alarm on TI-170 at lean amine B.L

P&ID no

Responsibility

CS-140-PR-15-0009

SEI

CS-140-PR-15-0009

SEI

CS-140-PR-15-0009

PMC/NOCL

CS-140-PR-15-0009

SEI

68

SOP to address regular sampling of recycle gas for CO/CO2.

CS-140-PR-15-0009

69

LG-522A/B (Magnetic type) are to be provided with high high alarm with switch.

CS-140-PR-15-0010, CS-140-PR-15-0016

SEI

70

Ensure this gas breakthrough case has been considered in design of safety valve in ARU (Receiving flash drum vessel).

CS-140-PR-15-0009

PMC/NOCL

71

LG-552 to be converted to Mag. Type with provision of high level alarm with switch.

CS-140-PR-15-0021, CS-140-PR-15-0016, CS-140-PR-15-0006

SEI

72

Periodical checking of interface in LG-533A/B/C/D.

CS-140-PR-15-0016

73

Keep the spectacle blind located in startup recirculation line in open position to maintain unit under circulation during upset without loosing much time.

CS-140-PR-15-0017, CS-140-PR-15-0018, CS-140-PR-15-0019, CS-140-PR-15-0022

SEI

74

FC-436 should be force closed when UZ-717 is activated.

CS-140-PR-15-0017

SEI

Page 28 of 136

SEI/NOCL

SEI/NOCL

Status

HAZOP STUDY REPORT

Client

Nagarjuna Oil Corporation Ltd.

PROCESS

SO2331

CS-140-PR-47-0001

0

Plant

DHU Unit (Unit -1400)

Dept.

Project

Document Number

Rev.

The recommendations of HAZOP study are listed below: (Annexure II) S.No

Recommendations

P&ID no

Responsibility

Provide high alarm for FC-442.

CS-140-PR-15-0022

SEI

76

Provide independent DCS low low alarm from LZ-537

CS-140-PR-15-0022

SEI

77

Possibility of dissolution of salt in gas oil product is to be confirmed.

CS-140-PR-15-0022

Vendor/SEI

78

Operating procedure should ensure draining of salt dryer at regular intervals by checking LG554.

CS-140-PR-15-0022

SEI/NOCL

79

Regular top up procedures/schedules to be mentioned in SOP.

CS-140-PR-15-0022

SEI/NOCL

80

P&ID is to be updated for maintenance /Top up discharge/bypassing salt dryer procedure.

CS-140-PR-15-0022

Vendor/SEI

81

Confirm that hydrocarbon detectors are provided in cooling tower area.

CS-140-PR-15-0019

NOCL

82

TBC from vendor regarding the requirement of min. flow to avoid churning.

CS-140-PR-15-0017, CS-140-PR-15-0020, CS-140-PR-15-0021, CS-140-PR-15-0023

SEI

83

Consider providing independent level transmitters with high alarm and delete the high alarm from LC540

CS-140-PR-15-0021

SEI

CS-140-PR-15-0021

SEI

CS-140-PR-15-0021

SEI

75

84

85

Consider Providing independent level transmitters with high alarm and delete the high alarm from LC540

Consider Providing independent level transmitters with high alarm and delete the high alarm from LC540

Page 29 of 136

Status

HAZOP STUDY REPORT

Client

Nagarjuna Oil Corporation Ltd.

PROCESS

SO2331

CS-140-PR-47-0001

0

Plant

DHU Unit (Unit -1400)

Dept.

Project

Document Number

Rev.

The recommendations of HAZOP study are listed below: (Annexure II) S.No

Recommendations

P&ID no

Responsibility

86

Provide high temp alarm on TI-192

CS-140-PR-15-0017

SEI

87

Confirm that hydrocarbon detectors are provided in cooling tower area.

CS-140-PR-15-0020

NOCL

88

SOP to ensure that the proper dosing rate is maintained and confirmed with proper lineup.

CS-140-PR-15-0023

89

Provide low alarm at PI-358A on separator drum.

CS-140-PR-15-0007

SEI

90

Check the time required to startup spare compressor .

CS-140-PR-15-0014, CS-140-PR-15-0015

SEI/NOCL

91

PT with high alarm is to be provided instead of PI-953.

CS-140-PR-15-0013

SEI

92

Low pressure alarm at PC-358 is to be provided on V-006.

CS-140-PR-15-0007

SEI

93

Confirm that the suction system can either withstand with the high suction pressure and PSV is designed for the same.

CS-140-PR-15-0013

SEI

94

HydroCOM vendor to clarify for the consequences of sudden loading and how tp prevent tripping of compressor and implement solution to provide the same.

CS-140-PR-15-0013, CS-140-PR-15-0014,

SEI/NEA

95

Consider forced PCV-922 close when compressor trips.

CS-140-PR-15-0013, CS-140-PR-15-0014,

SEI

96

Confirm that hydrocarbon detectors are provided in cooling tower area.

CS-140-PR-15-0013, CS-140-PR-15-0014,

NOCL

Page 30 of 136

SEI/NOCL

Status

HAZOP STUDY REPORT

Client

Nagarjuna Oil Corporation Ltd.

PROCESS

SO2331

CS-140-PR-47-0001

0

Plant

DHU Unit (Unit -1400)

Dept.

Project

Document Number

Rev.

The recommendations of HAZOP study are listed below: (Annexure II) S.No

Recommendations

P&ID no

Responsibility

97

Provide High alarm at TI-176.

CS-140-PR-15-0013,

SEI

98

Provide High high level compressor trip for 2nd stage suction vessel

CS-140-PR-15-0013, CS-140-PR-15-0014,

NEA

99

Confirm that hydrocarbon detectors are provided in cooling tower area.

CS-140-PR-15-0013, CS-140-PR-15-0014,

NOCL

100

Provide low point drain valve at the shell side outlet of EE-009 and SOP to ensure checking of leakage of cooling water after any maintenance.

CS-140-PR-15-0013, CS-140-PR-15-0014,

SEI

101

Inspection opening of 2nd stage suction vessel shall be located closer to the vanepack for inspection purpose.

CS-140-PR-15-0013, CS-140-PR-15-0014,

NEA/SEI

102

Venting/purge facility to flare at EE009 outlet is to be provided near B/L.

CS-140-PR-15-0013

SEI

103

PI-304 to be provided with low pressure alarm.

CS-140-PR-15-0023, CS-140-PR-15-0025

SEI

104

Ensure that blockage of carbon canister is not possible.

CS-140-PR-15-0023, CS-140-PR-15-0025

NOCL

105

Provide additional flushing oil return taping upstream of XZV-718 M for flushing.

CS-140-PR-15-0024, CS-140-PR-15-0026

SEI

CS-140-PR-15-0004

SEI

CS-140-PR-15-0004

SEI

106

107

Damper open/close indications are provided (P&ID is to be updated accordingly). Startup and shut down overrides for damper control to be included in P&ID note.

Page 31 of 136

Status

HAZOP STUDY REPORT

Client

Nagarjuna Oil Corporation Ltd.

PROCESS

SO2331

CS-140-PR-47-0001

0

Plant

DHU Unit (Unit -1400)

Dept.

Project

Document Number

Rev.

The recommendations of HAZOP study are listed below: (Annexure II) S.No

Recommendations

P&ID no

Responsibility

108

Low oxygen alarm at AI-004 is to be provided

CS-140-PR-15-0004

SEI

109

Ensure that upstream system is properly monitored to avoid any vaporization.

CS-140-PR-15-0024, CS-140-PR-15-0026

NOCL

110

MP steam for soot blower tapping to be downstream of FI-409.(P&ID to be updated).

CS-140-PR-15-0004

SEI

111

HH pressure trip PZ-678A/B/C requirement is to be reviewed from vendor in view of turbine back pressure.

CS-140-PR-15-0030

BHEL/SEI

112

Line from Desuperheater downstream upto steam trap is to be designed for two phase flow.

CS-140-PR-15-0030

SEI

113

Vendor to provide min. temp. of steam acceptable at turbine inlet, irrespective of min. operating temp. specified in B/L condition.

CS-140-PR-15-0030

BHEL

114

TI-627 is to be provided with low temp. alarm in DCS.

CS-140-PR-15-0011

SEI

115

SOP to ensure checking of leakage of cooling water after any maintenance.

CS-140-PR-15-0032

SEI/NOCL

116

Confirm that hydrocarbon detectors are provided in cooling tower area.

CS-140-PR-15-0032

NOCL

117

Provide 3" jumpover connection line (with valve and spec. blind) between cooling water supply and return headers near dead end. Jumpover will be used for initial passivation during commissioning.

CS-140-PR-15-0032

SEI

Page 32 of 136

Status

HAZOP STUDY REPORT

Client

Nagarjuna Oil Corporation Ltd.

PROCESS

SO2331

CS-140-PR-47-0001

0

Plant

DHU Unit (Unit -1400)

Dept.

Project

Document Number

Rev.

The recommendations of HAZOP study are listed below: (Annexure II) S.No

Recommendations

P&ID no

Responsibility

118

Ensure different connections are available for air and nitrogen hose stations to avoid wrong connections.

CS-140-PR-15-0031, CS-140-PR-15-0033, CS-140-PR-15-0034

SEI

119

SOP to ensure Manual intervention of HS-908

CS-140-PR-15-0037, CS-140-PR-15-0038

SEI/NOCL

120

Provide high high alarm at LI-800

CS-140-PR-15-0044

SEI

121

Provide low low alarm at LI-801

CS-140-PR-15-0044

SEI

122

Provide high high alarm at LI-902

CS-140-PR-15-0040

SEI

123

Provide NRV in the flare KOD pump discharge line no. P803 near to tie in point to slop header.

CS-140-PR-15-0038

SEI

124

Operating procedure should prevent draining of hot hydrocarbon in Hydrocarbon drain drum.

CS-140-PR-15-0040

SEI / NOCL

125

Provide low low alarm at LI-902

CS-140-PR-15-0040

SEI

126

Provide differential pressure gauge across the suction strainer.

CS-140-PR-D-06600002

NEA

127

Consider PSV set point change to 8.7 barg as per project philosophy.

900001-1-05 (NEA P&ID)

NEA

128

Trip of aux. pump with time delay is to be ensured when compressor is tripped (refer vendor cause and effect diagram).

900001-1-05 (NEA P&ID)

NEA

Page 33 of 136

Status

HAZOP STUDY REPORT

Client

Nagarjuna Oil Corporation Ltd.

PROCESS

SO2331

CS-140-PR-47-0001

0

Plant

DHU Unit (Unit -1400)

Dept.

Project

Document Number

Rev.

The recommendations of HAZOP study are listed below: (Annexure II) S.No

Recommendations

P&ID no

Responsibility

129

Manual sampling arrangement is to be provided.

900001-1-05 (NEA P&ID)

NEA

130

Provide possible leakage quantity to process gas and specification, including all impurities in the oil used for cylinder lubrication.Axens will confirm the acceptance.

900001-1-05 (NEA P&ID)

NEA / AXENS

131

Vendor operation manual should mention bypass operation.

CS-140-PR-D-06600006

NEA

132

Vendor operating manual should mention closing of manual isolation valve located in pump minimum circulation line in case both compressors are in operation during changeover.

900001-1-09 (NEA P&ID)

NEA

133

Gate valve in min circulation line to be changed to globe valve.

900001-1-09 (NEA P&ID)

NEA

134

Vendor to recheck requirement of low temp alarmTI-932 and compressor start permissive (refer vendor cause & effect page 4).

900001-1-09 (NEA P&ID)

NEA

135

Gas dew point to be confirmed.

900001-1-09 (NEA P&ID)

NEA

136

Suitable makeup water connection to cooling water tank is to be provided.

900001-1-09 (NEA P&ID)

NEA

137

Cooling water tank vent should be provided at safe location.

900001-1-09 (NEA P&ID)

NEA

138

PCV-902/903 set points to be reviewed in view of max. flare back pressure of 2 barg (during general power failure).

CS-140-PR-D-06600003

NEA / SEI

Page 34 of 136

Status

HAZOP STUDY REPORT

Client

Nagarjuna Oil Corporation Ltd.

PROCESS

SO2331

CS-140-PR-47-0001

0

Plant

DHU Unit (Unit -1400)

Dept.

Project

Document Number

Rev.

The recommendations of HAZOP study are listed below: (Annexure II) S.No

Recommendations

P&ID no

Responsibility

139

Isolation valve in vent line to flare is to be LO.

900001-1-06 (NEA P&ID)

NEA

140

PSV discharge and Goose neck provided on distance piece, to be routed to safe location.

900001-1-06 (NEA P&ID)

NEA

141

Drain line from packing drain pot to be routed to CBD

900001-1-06 (NEA P&ID)

NEA / SEI

CS-140-PR-15-0011, CS-140-PR-15-0030, 1-336-00-33049(BHEL)

BHEL/SEI

CS-140-PR-15-0011, CS-140-PR-15-0030, 1-336-00-33049(BHEL)

BHEL/SEI

1-336-00-33049(BHEL P&ID)

BHEL/SEI

145

Standby PSV requirement for PSV691 is to be checked as per project standards (considering PSV-691 failure).

1-336-00-33049(BHEL P&ID)

BHEL/SEI

146

All condensate collections having temp 70 C will be routed to condensate collection system.

1-336-00-33049(BHEL P&ID)

BHEL/SEI/NOCL

147

SOP to ensure mentioning of gland steam condenser isolation and steam is to be vented out through local vent.

1-336-00-33049(BHEL P&ID)

BHEL/SEI/NOCL

142

143

144

All drains to be properly routed.

All condensate collections having temp 70 C will be routed to condensate collection system.

BHEL confirmed that PCV-691 is fail to close.

Page 35 of 136

Status

HAZOP WORKSHEET

(Annexure-III)

Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

NODE NO: 01

Gas oil feed From B/L to Feed Surge Drum, including gas oil feed from CDU

DESIGN INTENTION

To Supply Gas Oil Feeds from Unit B/L to Feed Surge Drum through Back Wash Filter.

DRAWINGS

CS-140-PR-15-001, CS-140-PR-15-002,CS-140-ME-E-03800002

EQUIPMENT

Feed Filter (140-F-001), Feed Surge Drum(140-V-001)

STREAM DETAILS

Gas Oil Feed from B/L (including feed from CDU) to Feed Filter (F-001) and send to Feed Surge Drum (V-001)

AVAILABLE CONTROL SCHEMES

PC-343

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

Operating/Design Parameters SERVICE

Temperature (°C)

Gas Oil Feed from B/L to Feed Surge Drum

Pressure ( bar g)

Flow rate (Kg/hr)

63 / 120

3.4/15.5

120,083

Note:

Node

Deviation

1. Feed from B/L to Feed Surge Drum

1.Low/No Flow

Causes

1.U/S disturbance in Gas Oil Feed from storage.

Consequences

1.Low level in FSD likely leading to No level causing damage to pump accessories.

Safeguards

Ref. No.

Recommendations

1.Low level alarm (LC501) provided at 1.1.1.1.1 FSD.

2.Low Low Level Trip alarm (LZ504).

1.1.1.1.2

3. Feed from CDU is available through 1.1.1.1.3 PCV-343. 2.U/S disturbance in 1.Low level in FSD likely Gas Oil Feed from leading to No level causing CDU damage to pump accessories.

1.Low level alarm (LC501) provided at 1.1.2.1.1 FSD.

2.Low Low Level Trip alarm (LZ504).

1.1.2.1.2

3. Feed from 1.1.2.1.3 storage is available. 3.Choking of Back wash Filter (140-F-001).

2.High Pressure drop in Feed filter

1.Refer safeguards 1.1.1.1.1, 1.1.1.1.2 and 1.1.1.1.3

1.1.3.2.1

2.High Alarm of PDI329 provided 1.1.3.2.2

Page 36 of 136

Responsibility

Remarks

1.Low/No Flow

HAZOP WORKSHEET

(Annexure-III)

Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

NODE NO: 01

Gas oil feed From B/L to Feed Surge Drum, including gas oil feed from CDU

DESIGN INTENTION

To Supply Gas Oil Feeds from Unit B/L to Feed Surge Drum through Back Wash Filter.

DRAWINGS

CS-140-PR-15-001, CS-140-PR-15-002,CS-140-ME-E-03800002

EQUIPMENT

Feed Filter (140-F-001), Feed Surge Drum(140-V-001)

STREAM DETAILS

Gas Oil Feed from B/L (including feed from CDU) to Feed Filter (F-001) and send to Feed Surge Drum (V-001)

AVAILABLE CONTROL SCHEMES

PC-343

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

Operating/Design Parameters SERVICE

Temperature (°C) 3.Choking of Back 2.High Pressure drop in Feed wash Filter filter (140-F-001). 63 / 120

Gas Oil Feed from B/L to Feed Surge Drum

Pressure ( bar g)

Flow rate (Kg/hr)

3.4/15.5

120,083

Note:

Node

Deviation

Causes

Consequences

Safeguards

3-Automatic backwash facility is available.

4.Automatic backwash filter system fails.

1. Refer Cause-1 consequence-1

5. Low/No flow of backwash fluid to filter.

1.No adequate backwash leading to more frequent backwash cycle.

1.PDI-310 is provided. Also PDI329 with high alarm is provided.

Ref. No.

Recommendations

1. High flow from upstream.

1.Feed Flow to FSD will increase .Liquid Overfilling can be possible.

Remarks

1.1.3.2.3

Details to discussed separately in vendor package HAZOP.

1.1.4.1.1

1.PDI-329 with high alarm is provided. Currently there is no control of backwash fluid. This can result in intermittent high peak flow rate from the stripper through the coalescer and the salt dryer leading to loss of product quality and plant stability. This has to be discussed with filter vendor for reduction in backwash flow.

1.1.5.1.1

2.High Flow

Responsibility

1. High alarm (LC501) and independent High High alarm (LI-503) provided.

1.2.1.1.1

Page 37 of 136

HAZOP WORKSHEET

(Annexure-III)

Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

NODE NO: 01

Gas oil feed From B/L to Feed Surge Drum, including gas oil feed from CDU

DESIGN INTENTION

To Supply Gas Oil Feeds from Unit B/L to Feed Surge Drum through Back Wash Filter.

DRAWINGS

CS-140-PR-15-001, CS-140-PR-15-002,CS-140-ME-E-03800002

EQUIPMENT

Feed Filter (140-F-001), Feed Surge Drum(140-V-001)

STREAM DETAILS

Gas Oil Feed from B/L (including feed from CDU) to Feed Filter (F-001) and send to Feed Surge Drum (V-001)

AVAILABLE CONTROL SCHEMES

PC-343

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

Operating/Design Parameters SERVICE

Temperature (°C)

Gas Oil Feed from B/L to Feed Surge Drum

Flow rate (Kg/hr)

63 / 120 2.High Flow

Note:

Node

Pressure ( bar g)

Deviation

1. High flow from upstream.

Causes

3.4/15.5

Consequences

Safeguards

2. PSV-302A/B is designed for liquid overfilling case.

Ref. No.

Recommendations

1.2.1.1.2

1.2.2.1.1 2.PC-343 failure leading to PCV-343 fully open.

3.LC-501 malfunctions.

1.Feed Flow to FSD will increase .Liquid Overfilling can be possible.

1.Feed Flow to FSD will increase .Liquid Overfilling can be possible.

1.Refer safeguard 1.2.1.1.1 and 1.2.1.1.2

1.2.3.1.1

1.3

3. Reverse flow

4.Low Pressure

1. PC-343 malfunctions and closes PCV-343

1.Same as Low/No flow.

1.4.1.1.1

2.ow supply pressure 1.Same as Low/No flow. from CDU.

1.High supply pressure from CDU.

120,083

1.Feed Flow to FSD will increase .Liquid Overfilling can be possible.

1. System may experience higher than the operating pressure

1.4.2.1.

1. System is designed for maximum U/S pressure.

1.Provide low alarm for PCSEI 343.

1.5.1.1.1

5.High Pressure

Page 38 of 136

Responsibility

Remarks

HAZOP WORKSHEET

(Annexure-III)

Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

NODE NO: 01

Gas oil feed From B/L to Feed Surge Drum, including gas oil feed from CDU

DESIGN INTENTION

To Supply Gas Oil Feeds from Unit B/L to Feed Surge Drum through Back Wash Filter.

DRAWINGS

CS-140-PR-15-001, CS-140-PR-15-002,CS-140-ME-E-03800002

EQUIPMENT

Feed Filter (140-F-001), Feed Surge Drum(140-V-001)

STREAM DETAILS

Gas Oil Feed from B/L (including feed from CDU) to Feed Filter (F-001) and send to Feed Surge Drum (V-001)

AVAILABLE CONTROL SCHEMES

PC-343

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

Operating/Design Parameters SERVICE

Temperature (°C)

Gas Oil Feed from B/L to Feed Surge Drum

Pressure ( bar g)

Flow rate (Kg/hr)

63 / 120

3.4/15.5

120,083

Note:

Node

Deviation

Causes

Consequences

Safeguards

Ref. No.

Recommendations

Responsibility

Remarks

5.High Pressure

2.External fire.

6.High Temperature

1.U/S disturbance

1.Potential overpressure in filter.

1.Interface(LT-505) in FSD may get affected due to high temperature

1..5.2.1

1.System is rated for B/L 1.6.1.1.1 design temperature

No significant cause

1.7

8. High Level

Not applicable

1.8

9 Low level

Not applicable

1.9

10.Composition

1. Composition change due to mixing of different feed streams in upstream unit.

2..Design case for overpressure is to be reviewed.

3.High temperature alarm to be provided on TI-107 and TI-343.

Vendor/SEI

SEI

7.Low Temperature

1. Higher exothermic conditions in reaction section due to more cracked feed.

1.Regular sampling

1.10.1.1.1

2. Lower product Cetane due to high LCO content in feed.

4. LCO, LCGO flow rate indications to be duplicated in DHU graphics. 5. Ratio indication with alarm to be repeated in DHU graphics. 6. Provide TDI (TI-129 and TC-124)on the first bed with high alarm set at differential temp. of 30 C.

11.Others

1. Not applicable

1.11.1

Page 39 of 136

PMC/SEI

Determine cause of overpressure.

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

NODE NO: 02

Feed Surge Drum to Reactor Fired Heater Inlet

DESIGN INTENTION

To Preheat the Gas oil feed and H2 through exchanger train (E-001A/B/C/D) before further heating by reactor feed heater.

DRAWINGS

CS-140-PR-15-002, CS-140-PR-15-003, CS-140-PR-15-004

EQUIPMENT

Feed Surge Drum(140-V-001),Gas Oil Feed Pump(140-P-001),Reactor Feed Effluent Exchanger (140-E-001A/B/C/D) Gas Oil from Feed Surge Drum

STREAM DETAILS AVAILABLE CONTROL SCHEMES

(V-001) pumped to feed Effluent PC-330,LC-501,LC-505,FC-407A/B,FC-408,TC-119,LC-501. Exchanger train (E001A/B/C/D) and then send to Reactor Feed Heater (H-001) Inlet

SERVICE

(°C)

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

Operating/Design Parameters

Temperature

Gas Oil Feed pump to Mixing Point Mixing Point to Feed/ Effluent Exchanger Inlet Feed/Effluent Exchanger to Fired Heater Inlet

:

Pressure ( bar g)

Flow rate (Kg/hr)

63/120

91.3-101.0/127

120083

68.8/120

92.2-94.7/108

113540-121388

307.3-338.7/365

90.7-93.2/106.5

126850-127392

Note: Node 2.Feed Surge Drum to Reactor Feed Heater

Deviation 1.Low/No Flow

Causes 1.Tripping of Gas oil feed pump(P-001A/B)

Consequences

Safeguards

Ref. No.

1.Reaction section losses gas oil feed

1 FC- 408 provided with low alarm.

2.1.1.1.1

2.High level in FSD(V-001)

1. FZ-448 provide with LL alarm to trip the fired heater

2.1.1.2.1

3.Possible overfilling of FSD V-001

1 High alarm LC-501

2.1.1.3.1

2 HH alarm at LI-503

2.1.1.3.2

Recommendations

Responsibility

7. Ensure proper thermal expansion in Mechanical design is considered in case of depressurization temp. of 405 C for all shells.

SEI

3.1 PSV-302A/B is 2.1.1.3.3 designed for overfilling case. 2.FC-408 malfunctions to close

1. Refer 2.1.1.1.1 and 2.1.1.2.1

1 FZ-448 provide with LL alarm to trip the fired heater

2.1.2.1.1

2.P-001A/B likely damage

1. Pump is protected with Min. flow bypass

2.1.2.2.1

3.LC-505 malfunctions to close

1.V-001 water/oil interface may get disturbed 1.Small quantity of 2.1.3.1.1 & possibilities of water going with gas oil water is not desirable feed. but acceptable as the same will be vaporized at operating conditions. Water is not allowed at reactor inlet.

8.Operating manual/SOP should ensure periodical checking of LG-506

4. FCV-407A/B malfunctions to open

1. Refer 2.1.1.1.1 and 2.1.1.2.1

9. Manual isolation valves downstream of FCV-407A/B,to be LO.

2.1.4.1.1

Page 40 of 136

SEI/NOCL

SEI

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

NODE NO: 02

Feed Surge Drum to Reactor Fired Heater Inlet

DESIGN INTENTION

To Preheat the Gas oil feed and H2 through exchanger train (E-001A/B/C/D) before further heating by reactor feed heater.

DRAWINGS

CS-140-PR-15-002, CS-140-PR-15-003, CS-140-PR-15-004

EQUIPMENT

Feed Surge Drum(140-V-001),Gas Oil Feed Pump(140-P-001),Reactor Feed Effluent Exchanger (140-E-001A/B/C/D) Gas Oil from Feed Surge Drum

STREAM DETAILS AVAILABLE CONTROL SCHEMES

(V-001) pumped to feed Effluent PC-330,LC-501,LC-505,FC-407A/B,FC-408,TC-119,LC-501. Exchanger train (E001A/B/C/D) and then send to Reactor Feed Heater (H-001) Inlet

SERVICE

(°C)

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

Operating/Design Parameters

Temperature

Gas Oil Feed pump to Mixing Point Mixing Point to Feed/ Effluent Exchanger Inlet Feed/Effluent Exchanger to Fired Heater Inlet

:

Pressure ( bar g)

Flow rate (Kg/hr)

63/120

91.3-101.0/127

120083

68.8/120

92.2-94.7/108

113540-121388

307.3-338.7/365

90.7-93.2/106.5

126850-127392

Note: Node

Deviation

2.

3.

High Flow

As well as

4. Reverse/Misdirected Flow

Causes

Consequences

Safeguards

Ref. No.

5. XZV-719 malfunctions to close

1. Refer 2.1.1.1.1 and 2.1.1.2.1

1. FC-408 malfunctions to full open

1. H2 to HC ratio will change and may adversely affect the product quality

2. LC-505 malfunctions to full open (sour water)

1. Loss of Gas oil feed to close drain no hazardous consequence

1. Water comes with Gas oil feed

1. Process upset

1. High Level alarm in LC- 505.

2.3.1.1.1

1. P-001 trips

1. Back flow from high pressure side (Reaction section) ,leading to overpressurization of FSD.

1. UZ-719 will activate & close XZV-719.

2.4.1.1.1

1.High flow alarm is available at FI-448.

2.2.1.1.1

2.2.2.1

5.

Low Pressure

1. PC 330 malfunctions to open PCV-330B

6.

High Pressure

1. PC 330 malfunctions to open 1. Over pressurizing of the FSD (VPCV 330A and close PCV-330B 001) 2. Likely loss of feed to FSD.

1. PSV-302A/B provided 2. Refer 1.1.1.1.1

2.6.1.1.1

2. P-001 trips

1. PSV-302A/B is designed for liquid overfilling case

2.6.2.1.1

1. Liquid overfilling of FSD(V-001) may occur

3. FC-408 malfunctions to close 1. Refer 2.1.1.1.1 and 2.1.1.2.1 FCV-408.

Responsibility

2.1.5.1.1

2.Two Check valve 2.4.1.1.2 available. One at pump discharge and double check valves at upstream of 140-EE001. 1. P-001A/B may cavitate

Recommendations

1. Safety margin of 2.3 2.5.1.1.1 m is available in NPSHr even at low FSD pressure.

2.6.3.1.1

Page 41 of 136

10. Operating procedure should ensure periodical checking of LG-506.

SEI/NOCL

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

NODE NO: 02

Feed Surge Drum to Reactor Fired Heater Inlet

DESIGN INTENTION

To Preheat the Gas oil feed and H2 through exchanger train (E-001A/B/C/D) before further heating by reactor feed heater.

DRAWINGS

CS-140-PR-15-002, CS-140-PR-15-003, CS-140-PR-15-004

EQUIPMENT

Feed Surge Drum(140-V-001),Gas Oil Feed Pump(140-P-001),Reactor Feed Effluent Exchanger (140-E-001A/B/C/D) Gas Oil from Feed Surge Drum

STREAM DETAILS AVAILABLE CONTROL SCHEMES

(V-001) pumped to feed Effluent PC-330,LC-501,LC-505,FC-407A/B,FC-408,TC-119,LC-501. Exchanger train (E001A/B/C/D) and then send to Reactor Feed Heater (H-001) Inlet

SERVICE

(°C)

High Pressure

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

Operating/Design Parameters

Temperature

Gas Oil Feed pump to Mixing Point Mixing Point to Feed/ Effluent 6. Exchanger Inlet Feed/Effluent Exchanger to Fired Heater Inlet

:

Pressure ( bar g)

Flow rate (Kg/hr)

63/120

91.3-101.0/127

120083

68.8/120

92.2-94.7/108

113540-121388

307.3-338.7/365

90.7-93.2/106.5

126850-127392

Note: Node

Deviation

Causes 3. FC-408 malfunctions to close FCV-408.

4. XZV-719 malfunctions to close

Consequences 2. Pump discharge line up to FCV408 is subjected to high pressure

Safeguards 2. Pump (P-001A/B) discharge line is designed for pump shutoff pressure

1. Refer 2.1.1.1.1

7. Less/Low Temperature

1.Potential overpressure in the H.P. section causing likely fire and explosion.

2. FC-408 malfunctions to open 1. Low temp. at heater inlet. Upset in FCV-408 fully. downstream section. 8. High Temperature

2.6.4.2 1.Depressureization

2.6.5.1.1

2.PSV-307A/B is provided on Separator drum.

2.6.5.1.2

1. TC-119 malfunctions to open 1. Low temp. at heater inlet may lead to TCV-119 operational upsets

2. Reactor effluent temp., downstream of 140-EE-001 will be high and likely potential corrosion in air cooler due to higher concentration of ammonium bisulfide.

1. TC-119 malfunctions to close 1. No major concern w.r.t. safety. TCV-119.

2.6.3.2.2

2.6.4.1

2. Refer 2.1.1.2.2 5. External Fire

Ref. No.

2.7.1.1

1.High temp. alarm is provided at TI-162.

2.7.1.2.1

High flow alarm at FI448 is provided.

2.7.2.1

2.8.1.1

Page 42 of 136

Recommendations

Responsibility

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

NODE NO: 02

Feed Surge Drum to Reactor Fired Heater Inlet

DESIGN INTENTION

To Preheat the Gas oil feed and H2 through exchanger train (E-001A/B/C/D) before further heating by reactor feed heater.

DRAWINGS

CS-140-PR-15-002, CS-140-PR-15-003, CS-140-PR-15-004

EQUIPMENT

Feed Surge Drum(140-V-001),Gas Oil Feed Pump(140-P-001),Reactor Feed Effluent Exchanger (140-E-001A/B/C/D) Gas Oil from Feed Surge Drum

STREAM DETAILS AVAILABLE CONTROL SCHEMES

(V-001) pumped to feed Effluent PC-330,LC-501,LC-505,FC-407A/B,FC-408,TC-119,LC-501. Exchanger train (E001A/B/C/D) and then send to Reactor Feed Heater (H-001) Inlet

SERVICE

(°C)

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

Operating/Design Parameters

Temperature

Gas Oil Feed pump to Mixing Point Mixing Point to Feed/ Effluent Exchanger Inlet Feed/Effluent Exchanger to Fired Heater Inlet

:

Pressure ( bar g)

Flow rate (Kg/hr)

63/120

91.3-101.0/127

120083

68.8/120

92.2-94.7/108

113540-121388

307.3-338.7/365

90.7-93.2/106.5

126850-127392

Note: Node

Deviation 9.

Less/Low Level

Causes

Consequences

1. FC-408 malfunctions to open 1. Refer 2.2.1.1.1 and 2.2.2.1 FCV-408

Safeguards

Ref. No. 2.9.1.1

Recommendations 11.Provision of local temp. gauge to be provided for ascertaining the temperature before taking the sample. 12.Operating procedure should ensure temp. of sampling fluid below 80 C.

2. LC-505 malfunctions to open 1. Refer 2.2.1.1.1 and 2.2.2.1 LCV-505 3. LC-501 malfunctions to close 1. P-001A/B may cavitate 250 LCV-011A/B/C

2.9.2.1

1. LZ-504 will activate 2.9.3.1.1 UZ701 which will trip the pump

2.Small quantity of 2.9.3.1.2 water is not desirable but acceptable as the same will be vaporized at operating conditions. Water is not allowed at reactor inlet.

10.

High Level

1. FC-408 malfunctions to close 1. Refer Low/No Flow of this node FCV-408

2.10.1.1

2. XZV-719 malfunctions to close

2.10.2.1

1. Refer Low/No Flow of this node

Page 43 of 136

Responsibility SEI/NOCL

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

NODE NO: 02

Feed Surge Drum to Reactor Fired Heater Inlet

DESIGN INTENTION

To Preheat the Gas oil feed and H2 through exchanger train (E-001A/B/C/D) before further heating by reactor feed heater.

DRAWINGS

CS-140-PR-15-002, CS-140-PR-15-003, CS-140-PR-15-004

EQUIPMENT

Feed Surge Drum(140-V-001),Gas Oil Feed Pump(140-P-001),Reactor Feed Effluent Exchanger (140-E-001A/B/C/D) Gas Oil from Feed Surge Drum

STREAM DETAILS AVAILABLE CONTROL SCHEMES

(V-001) pumped to feed Effluent PC-330,LC-501,LC-505,FC-407A/B,FC-408,TC-119,LC-501. Exchanger train (E001A/B/C/D) and then send to Reactor Feed Heater (H-001) Inlet

SERVICE

(°C)

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

Operating/Design Parameters

Temperature

Gas Oil Feed pump to Mixing Point Mixing Point to Feed/ Effluent Exchanger Inlet Feed/Effluent Exchanger to Fired Heater Inlet 10.

:

Pressure ( bar g)

Flow rate (Kg/hr)

63/120

91.3-101.0/127

120083

68.8/120

92.2-94.7/108

113540-121388

307.3-338.7/365

90.7-93.2/106.5

126850-127392

High Level

Note: Node

Deviation

Causes

Consequences

Safeguards

3. LC-505 malfunctions to close 1. Refer Low/No Flow of this node LCV-505

4. LC-501 malfunctions to open 1. Overfilling of FSD (V-001) 250-LCV-011A/B/C (located at OSBL).

2.10.3.1

1. HH Alarm LI-503

2.10.4.1.1

2. PSV-302A/B is designed for Liquid overfilling case

2.10.4.1.2

5.PC-343 malfunctions to open fully 12.Composition 13. Problem/Requirements

1. Tube leakage in (EE001A/B/C/D)

Ref. No.

2.10.5 Refer 1.10.1.1.1 1. Contamination of product with feed

1. Analyzer AI-003 is provided on product line

2.12 2.13.1.1.1

Page 44 of 136

Recommendations

Responsibility

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

NODE NO: 03

Reactor Feed Heater

DESIGN INTENTION

To heat Gas Oil Feed +H2 mixture to Reactor inlet temperature.

DRAWINGS

CS-140-PR-15-0004,CS-140-PR-15-0005

EQUIPMENT STREAM DETAILS

Reactor Feed Heater (140-H001) After preheating from feed/effluent heat exchanger post heating is done in Fired Heater

AVAILABLE CONTROL SCHEMES

PC-899(For Detail see the Heater Firing P&ID for control system)

:

Nagarjuna Oil Corporation Ltd

Project :

Diesel hydro Desulphurization unit

Operating/Design Parameters Pressure ( bar g)

Temperature

Flow rate (Kg/hr)

(°C)

SERVICE Fired Heater Outlet to Hydrotreater Reactor Inlet

86.4-88.9/106.5

318.3-362.5/400

126850-127392

Note: Node 3. Reactor Feed Heater

Deviation 1.

Low/No Flow of liquid feed.

Causes 1. U/S disturbance.

2.Low/No flow of gaseous feed.

4.b. High Flow of gaseous stream 4.c. Reverse flow

Safeguards

1.Possible coking in heater tubes leading to tube failure.

3. Low/No flow of off gas from MEROX unit.

4.a. High Flow of liquid stream

Consequences 1. Loss of liquid feed causing possible overheating of heater tubes leading to tube failure.

1. U/S disturbances

Ref. No.

2. High alarm is provided at TI-121 & 222(Skin temp.), TI122 & 223(COT)

3.1.1.1.2

3. TZ-123 HH temp. will activate UZ-718

3.1.1.1.3

4. Low low flow trip is provided at FZ-448.

3.1.1.1.4

5. Low flow alarm at FC-408 is provided.

3.1.1.1.5

Responsibility

Remarks

3.2. .1.1 1. Low flow at FC-427 and low low trip at FZ428 is provided.

1.No significant consequences.

3.3. .1

1.No major causes identified on safety issues.

3.4a.1.1

1.No major causes identified on safety issues.

3.4b.1.1

1.Tube rupture leading to 1.Fire and explosion reverse flow to heater tubes from downstream system

Recommendations

1. TC-124 controls the 3.1.1.1.1 firing of heater

1.Emergency Depressurization system is available

Page 45 of 136

3.4c.1.1.1

In current practices of licensor is to provide check valve at Heater outlet.

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

NODE NO: 03

Reactor Feed Heater

DESIGN INTENTION

To heat Gas Oil Feed +H2 mixture to Reactor inlet temperature.

DRAWINGS

CS-140-PR-15-0004,CS-140-PR-15-0005

EQUIPMENT STREAM DETAILS

Reactor Feed Heater (140-H001) After preheating from feed/effluent heat exchanger post heating is done in Fired Heater

AVAILABLE CONTROL SCHEMES

PC-899(For Detail see the Heater Firing P&ID for control system)

:

Nagarjuna Oil Corporation Ltd

Project :

Diesel hydro Desulphurization unit

Operating/Design Parameters Pressure ( bar g)

Temperature

Flow rate (Kg/hr)

(°C)

SERVICE Fired Heater Outlet to Hydrotreater Reactor Inlet

86.4-88.9/106.5

318.3-362.5/400

126850-127392

Note: Node

Deviation

Causes

Consequences

Safeguards

Ref. No.

5. Low Temperature from Heater outlet

1. TC-124 malfunctions & less firing in the heater

1. Desired reactor temp. will not be achieved. Leads to gas oil product quality upsets.

1.Low alarm at TI-123 2.5.1.1.1 is provided.

6. High Temperature

1. TC-124 malfunctions and over firing in heater

1. Possible coke formation in heater tubes

1. TI-121,TI-122,TI3.6.1.1.1 222 &TI-223 provided with high alarm

2. TI-101 &TI-102 provided with high alarm

Recommendations

Responsibility

3.6.1.1.2

3. TZ-123 HH will 3.6.1.1.3 activate UZ-718 to trip the heater 7. Low pressure

1.U/S disturbances

1. Desired reactor temp./partial pressure of hydrogen, will not be achieved. Leads to gas oil product quality upsets.

1.Low alarm at PI-689 3.7.1.1.1 is provided at compressor suction.

8.High pressure

1.Coking in furnace tubes.

1.Unequal flow distribution leading to high skin temp.

1. TI-121,TI-122,TI3.8.1.1.1 222 &TI-223 provided with high alarm

9.Composition

1.No new cause.

10. Problem/Requirements

1. Heater tube leak

1. Fire box temp. high, possible heater damage

1.High temp alarm at TI-101&TI-102

3.10.1.1.1

2. Fire box pressure high.

1. PC-899 high alarm provided.PZ-900 provided with HH alarm and activate UZ-718 to trip the heater

3.10.1.2.1

13.Provide low pressure alarm at PC-358 at 140-V006 gas outlet.

SEI

14.Operating procedure should ensure safe shutdown of the plant

SEI/NOCL

3.9.1

Page 46 of 136

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

NODE NO: 04

Reactor ,Effluent air cooler, Trim Cooler up to Separator inlet

DESIGN INTENTION

1.

To hydro treat Gas Oil Feed in Reactor for desulphurization, denitrogenation & aromatic saturation.

2.

To cool reactor effluent by exchangers, air cooler & trim cooler to separate converted H2S, NH3 from gas Oil in Separator drum.

3.

To maintain reactor temperature by Hydrogen Guarding.

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

DRAWINGS

CS-140-PR-15-0003,CS-140-PR-15-0005, CS-140-PR-15-0006, CS-140-PR-15-0007,CS-140-PR-15-0017

EQUIPMENT

140-R-001,140-EE-002,140-EE-001A/B/C/D,140-EA-001,140-EE-003

STREAM DETAILS

After post heating in Heater, Gas Oil is hydrotreated and passes through in feed effluent exchanger for heat transfer to cold feed and then send to air cooler and trim cooler for further cooling and finally to separator.

AVAILABLE CONTROL SCHEMESFC-412,FC-413,FC-414,FC-415,TC-124,TC-131,TC-137,TC-143,TC-151

Operating/Design Parameters SERVICE Temperature (°C) Reactor to stripper feed preheater , Feed effluent exchanger at inlet of Air cooler Air cooler to Separator

Pressure ( bar g)

Flow rate (Kg/hr)

185.5-397/430

80.2-83.4/102

45-65/130

78.8-.79.3/92

137867 144751

Note: Node 4. Reactor inlet , Effluent Air Cooler, Trim Cooler Up to separator inlet

Deviation 1. Low/No Flow of liquid stream

Causes 1. U/S disturbance

Consequences

Safeguards

Ref. No.

1. Potential channeling in rector, below turndown

1 FC- 408 provided with low alarm.

4.1.1.1.1.2

2. Loss of product quality

1. FZ-448 provided with LL alarm to trip the fired heater

4.1.1.2.1.2

1.Low hydrogen ratio leads to catalyst coking. 1. Low flow at FC427 and low low trip at FZ-428 is provided.

4.2.1.1.1

2. Low/No flow of gaseous stream

1. U/S disturbance

3 Low/No flow of Quench gas

1. FC-412 /413/414/415 malfunction to close FCV412/413/414/415 (quench H2)

1. Temperature excursion than normal op. 1. High temp. temp., Likely coke formation in catalyst beds. alarms are provided for each bed.

4.3.1.1.1

4. High Flow of liquid stream

1. U/S disturbance

1. Possible incomplete reaction due to decreased Hydrogen /HC ratio resulting in poor product quality.

4.4.1.1.1

2. Loss of product quality.

2.Increase in Pressure drop across catalyst beds.

4.2.1.2

1. AI-003 is provided on product line

4.4.1.2.1 1.PDI-349~353,are provided with high alarms.

5.High flow of gaseous stream

1. U/S disturbance

1. Increase in Pressure drop across catalyst beds.

1.PDI-349~353,are provided with high alarms.

4.5.1.1.1

6.High flow of Quench gas

1. FC-412 /413/414/415 malfunction to fully open FCV 412/413/414/415

1. Reactor bed temp. decreases & may lead to incomplete reaction resulting in poor product quality.

1. AI-003 is provided on product line

4.6.1.1.1

Page 47 of 136

Recommendations

Responsibility

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

NODE NO: 04

Reactor ,Effluent air cooler, Trim Cooler up to Separator inlet

DESIGN INTENTION

1.

To hydro treat Gas Oil Feed in Reactor for desulphurization, denitrogenation & aromatic saturation.

2.

To cool reactor effluent by exchangers, air cooler & trim cooler to separate converted H2S, NH3 from gas Oil in Separator drum.

3.

To maintain reactor temperature by Hydrogen Guarding.

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

DRAWINGS

CS-140-PR-15-0003,CS-140-PR-15-0005, CS-140-PR-15-0006, CS-140-PR-15-0007,CS-140-PR-15-0017

EQUIPMENT

140-R-001,140-EE-002,140-EE-001A/B/C/D,140-EA-001,140-EE-003

STREAM DETAILS

After post heating in Heater, Gas Oil is hydrotreated and passes through in feed effluent exchanger for heat transfer to cold feed and then send to air cooler and trim cooler for further cooling and finally to separator.

AVAILABLE CONTROL SCHEMESFC-412,FC-413,FC-414,FC-415,TC-124,TC-131,TC-137,TC-143,TC-151

Operating/Design Parameters SERVICE Temperature (°C) Reactor to stripper feed preheater , Feed effluent exchanger at inlet of Air cooler Air cooler to Separator

Flow rate (Kg/hr) 80.2-83.4/102

45-65/130

78.8-.79.3/92

137867 144751

6.High flow of Quench gas Note: Node

Pressure ( bar g)

185.5-397/430

Deviation

1. FC-412 /413/414/415 malfunction to fully open FCV 412/413/414/415 Causes

Consequences 2.Increase in Pressure drop across catalyst beds.

Safeguards

Ref. No.

1.PDI-349~353,are provided with high alarms.

4.6.1.2.1

7.Reverse flow

1.Tube rupture leading to 1.Fire and explosion reverse flow to heater tubes from downstream system

1.Emergency Depressurization system is available

4.7.1.1.1

8. Low Pressure

1.U/S disturbances.

1.Low alarm at PI689 is provided at compressor suction.

4.8.1.1.1

2. AI-003 is provided on product line

4.8.1.1.2

1. PC-358 provided with high alarm.

4.9.1.1.1

2. PSV-307A/B provided.

4.9.1.1.2

9.High Pressure

10. Low Temperature

1. Disturbance in Hydrogen recycle loop.

1. More quench Hydrogen flow to reactor

1. Desired reactor temp./partial pressure of hydrogen, will not be achieved. Leads to gas oil product quality upsets.

1. Likely pressurization of the system.

4.10.1/2.1

1. Refer 4.6.1.1.1

2. U/S disturbances.

11. High Temperature

1. Low quench gas to reactor

2. EA-001 Fan motor trips

1. Refer 4.3.1.1.1

1. Pressure buildup due to less condensation

1. High temp. Alarms are provided for each bed.

4.11.1.1.1

2. Low flow alarm at FC412/413/414/415.

4.11.1.1.2

1 High alarm at TI163

4.11.2.1.1

Page 48 of 136

Recommendations

Responsibility

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

NODE NO: 04

Reactor ,Effluent air cooler, Trim Cooler up to Separator inlet

DESIGN INTENTION

1.

To hydro treat Gas Oil Feed in Reactor for desulphurization, denitrogenation & aromatic saturation.

2.

To cool reactor effluent by exchangers, air cooler & trim cooler to separate converted H2S, NH3 from gas Oil in Separator drum.

3.

To maintain reactor temperature by Hydrogen Guarding.

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

DRAWINGS

CS-140-PR-15-0003,CS-140-PR-15-0005, CS-140-PR-15-0006, CS-140-PR-15-0007,CS-140-PR-15-0017

EQUIPMENT

140-R-001,140-EE-002,140-EE-001A/B/C/D,140-EA-001,140-EE-003

STREAM DETAILS

After post heating in Heater, Gas Oil is hydrotreated and passes through in feed effluent exchanger for heat transfer to cold feed and then send to air cooler and trim cooler for further cooling and finally to separator.

AVAILABLE CONTROL SCHEMESFC-412,FC-413,FC-414,FC-415,TC-124,TC-131,TC-137,TC-143,TC-151

Operating/Design Parameters 11. High Temperature Temperature (°C)

SERVICE Reactor to stripper feed preheater , Feed effluent exchanger at inlet of Air cooler Air cooler to Separator

Flow rate (Kg/hr) 80.2-83.4/102

45-65/130

78.8-.79.3/92

137867 144751

Note: Node

Pressure ( bar g)

185.5-397/430

Deviation

2. EA-001 Fan motor trips Causes

Consequences 2. Higher hydrocarbons may condense in HP Amine column (C-001) leading to foam formation

3. Cooling water failure in EE003

Safeguards

Ref. No.

1. PC-358 is provided with high alarm

4.11.2.2.1

2. PSV-307A/B is provided

4.11.2.2.2

3. TI-167 high alarm and TI-212 high alarm is also provided

4.11.2.2.3

4. Hydrocarbon skimmer for both HP & LP amine absorber (C-001 and C-003) is routed to CBD instead of amine drain.

4.11.2.2.4

5. Trim cooler is designed considering air cooler failure also separator is designed for air cooler failure considering cooling by trim cooler.

4.11.2.2.5

3. High inlet temp. to recycle compressor.

1. Recycle compressor trip

4.11.2.3.1

1. Refer 4.11.2.1.1 and 4.11.2.2.1~5.

1.High temp. alarm at TI-212 is provided.

4.11.3.1.1/2

2. High temp. alarm at TI-167 is provided at 140-V-006 outlet.

Page 49 of 136

Recommendations

15. All pump motor trip alarms to be provided in DCS.

Responsibility

SEI

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

NODE NO: 04

Reactor ,Effluent air cooler, Trim Cooler up to Separator inlet

DESIGN INTENTION

1.

To hydro treat Gas Oil Feed in Reactor for desulphurization, denitrogenation & aromatic saturation.

2.

To cool reactor effluent by exchangers, air cooler & trim cooler to separate converted H2S, NH3 from gas Oil in Separator drum.

3.

To maintain reactor temperature by Hydrogen Guarding.

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

DRAWINGS

CS-140-PR-15-0003,CS-140-PR-15-0005, CS-140-PR-15-0006, CS-140-PR-15-0007,CS-140-PR-15-0017

EQUIPMENT

140-R-001,140-EE-002,140-EE-001A/B/C/D,140-EA-001,140-EE-003

STREAM DETAILS

After post heating in Heater, Gas Oil is hydrotreated and passes through in feed effluent exchanger for heat transfer to cold feed and then send to air cooler and trim cooler for further cooling and finally to separator.

AVAILABLE CONTROL SCHEMESFC-412,FC-413,FC-414,FC-415,TC-124,TC-131,TC-137,TC-143,TC-151

Operating/Design Parameters SERVICE Temperature (°C) Reactor to stripper feed preheater , Feed effluent exchanger at inlet of Air cooler Air cooler to Separator

Pressure ( bar g)

Flow rate (Kg/hr)

185.5-397/430

80.2-83.4/102

45-65/130

78.8-.79.3/92

137867 144751

Note: Node

Deviation 12. Problem/Requirements

13. Composition

Causes

Consequences

Safeguards 1. PDI with high alarm provided for each bed

Ref. No.

1. Coking in reaction bed

1. High pressure drop in reactor bed

2. Vibration in Air cooler (EA001) fans

1. Possible damage of EA-001 components 1.None

4.12.2.1.1

3. Tube leakage EE-003

1. Hydrocarbon may ingress in cooling water

4.12.3.1.1

1.Hydrocarbon detector is provided in cooling water tower at OSBL.

4.14

14. Others

Page 50 of 136

Responsibility

16. Maintenance schedule for vibration checking is to be strictly followed on regular basis.

NOCL

4.12.1.1.1

4.13.1

1.No new cause.

Recommendations

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

NODE NO: 05

Wash Water System

DESIGN INTENTION

Sour Water/MP BFW supply to Wash Water Drum(V-004)

DRAWINGS

CS-140-PR-15-0003,CS-140-PR-15-0006,CS-140-PR-15-0008, CS-140-PR-15-0021, CS-140-PR-15-0022,CS-140-PR-15-0030,CS-140-PR-15-0037

EQUIPMENT

Wash Water Drum(140-V-004) and Wash water pump(140-P-002A/B)

STREAM DETAILS

1.

To supply Stripper Sour Water/BFW/Recycle water to Wash water drum.

2.

To inject wash water in U/S of Reactor Effluent Air Cooler to dissolve ammonium salts and also in EE-001 A/B tube side inlet

AVAILABLE CONTROL SCHEMES

:

Project :

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

FC-419,PC-368,LC-516,FC-451,FC-420,LC-542& LC-544

Operating/Design Parameters SERVICE Temperature(°C) Sour Water/MP BFW supply to Wash water Drum Sour Water from Reflux Drum

Pressure ( bar g)

65-128/150 45.0/140

Flow rate (Kg/hr) 5.0-24.0/25

5221-6212

6.4/9

3310

Note: Node 5. Wash Water System

Deviation 1.

Low/No Flow

Causes 1. U/S disturbance in unit 550.

Consequences 1. Level of (V-004) may go down

Safeguards

Ref. No.

1. BFW & Recycle 5.1.1.1.1 water is available for make up.

2. Low alarm for FC- 5.1.1.1.2 420 is provided.

3. Low alarm for LC- 5.1.1.1.3 516 is provided.

2. FC-420 malfunctions to close FCV-420

1. Level of (V-004) may go down

1. BFW & Recycle 5.1.2.1.1 water is available for make up

2. Low alarm for LC- 5.1.2.1.2 516 is provided.

3. FC-451 malfunctions to close FCV-451

1. Level of (V-004) may go down

1. Stripped sour water and recycle water is available for makeup

5.1.3.1.1

2. Low alarm for LC- 5.1.3.1.2 516 is provided. 4. LC-542 malfunction to close LCV-542A

1. Level of (V-004) may go down

1. Stripped sour water and BFW is available for makeup

5.1.4.1.1

2. Low alarm for LC- 5.1.4.1.2 516 is provided. 5. LC-544 malfunction to close 1. Interface level of V-009 boot will LCV-544 be high

1. LI-560A is provided with HH alarm

Page 51 of 136

5.1.5.1.1

Recommendations

Responsibility

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

NODE NO: 05

Wash Water System

DESIGN INTENTION

Sour Water/MP BFW supply to Wash Water Drum(V-004)

DRAWINGS

CS-140-PR-15-0003,CS-140-PR-15-0006,CS-140-PR-15-0008, CS-140-PR-15-0021, CS-140-PR-15-0022,CS-140-PR-15-0030,CS-140-PR-15-0037

EQUIPMENT

Wash Water Drum(140-V-004) and Wash water pump(140-P-002A/B)

STREAM DETAILS

1.

To supply Stripper Sour Water/BFW/Recycle water to Wash water drum.

2.

To inject wash water in U/S of Reactor Effluent Air Cooler to dissolve ammonium salts and also in EE-001 A/B tube side inlet

AVAILABLE CONTROL SCHEMES

:

Project :

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

FC-419,PC-368,LC-516,FC-451,FC-420,LC-542& LC-544

Operating/Design Parameters SERVICE Temperature(°C) Sour Water/MP BFW supply to Wash water Drum Sour Water from Reflux Drum

45.0/140

Note: Node

Pressure ( bar g)

65-128/150

Deviation

5. LC-544 malfunction to close LCV-544 Causes

Consequences

Safeguards 2. Stripped sour water and BFW is available for makeup(*)

2. Water may carry over with diesel product. 1. SC-015 is provided.

Ref. No. 5.1.5.1.2

5.1.5.2.1

6. LC-516 malfunction to close FCV-420/451& LCV-542B

1. Level of (V-004) may go down

1. LZ-518 LL alarm 5.1.6.1.1 will activate UZ-713 to trip wash water pumps and activate UZ-721to close XZV-721

7. P-002A/B trips

1. Level of (V-004) may go high

1 LI-559 is provided 5.1.7.1.1 with HH alarm

2. Back flow from reaction section

1. LC-516 is provided with high alarm

5.1.7.2.1

2. PSV-310A/B designed for liquid overfilling case

5.1.7.2.2

3. FZ-450 LL alarm 5.1.7.2.3 will activate UZ-721 to close XZV-721

8. FC-419 at pump discharge, malfunction to close FCV-419

1. No wash water to EA-001, will increase salt deposition

4. NRVs are provided at all injection points.

5.1.7.2.4

1.FZ-450 is provided with LL alarm

5.1.8.1.1

Page 52 of 136

Flow rate (Kg/hr) 5.0-24.0/25

5221-6212

6.4/9

3310

Recommendations

Responsibility

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

NODE NO: 05

Wash Water System

DESIGN INTENTION

Sour Water/MP BFW supply to Wash Water Drum(V-004)

DRAWINGS

CS-140-PR-15-0003,CS-140-PR-15-0006,CS-140-PR-15-0008, CS-140-PR-15-0021, CS-140-PR-15-0022,CS-140-PR-15-0030,CS-140-PR-15-0037

EQUIPMENT

Wash Water Drum(140-V-004) and Wash water pump(140-P-002A/B)

STREAM DETAILS

1.

To supply Stripper Sour Water/BFW/Recycle water to Wash water drum.

2.

To inject wash water in U/S of Reactor Effluent Air Cooler to dissolve ammonium salts and also in EE-001 A/B tube side inlet

AVAILABLE CONTROL SCHEMES

:

Project :

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

FC-419,PC-368,LC-516,FC-451,FC-420,LC-542& LC-544

Operating/Design Parameters SERVICE Temperature(°C) Sour Water/MP BFW supply to Wash water Drum Sour Water from Reflux Drum

Pressure ( bar g)

65-128/150 45.0/140

Note: Node

Deviation

8. FC-419 at pump discharge, malfunction to close FCV-419 Causes

Consequences

2. High level in V-004.

Safeguards

9. XZV-721 at pump discharge, 1. Refer 5.1.8.1.1~2 and 5.1.8.2.1~2 malfunction to close

High Flow

1. FC 420 on stripped sour water line from OSBL, malfunctions to open FCV-420.

3310

Recommendations

Responsibility

5.1.8.1.2

5.1.8.2.2

5.1.9.1

1. Less wash water available for injection to 1 FZ-450 is EA-001, resulting salt deposition in tubes. provided with LL alarm

1. Level of (V-004) may go high

Ref. No.

1. LI-559 is provided 5.1.8.2.1 with HH alarm 2.LC-516 is provided with high alarm

2.

5221-6212

6.4/9

1. No wash water to EA-001, will increase salt deposition

2.High tem. Alarm TI-162 is provided at the inlet of air cooler.

10. FC-455A/B at pump min. circulation line, malfunctions to full open FCV-455A/B

Flow rate (Kg/hr) 5.0-24.0/25

5.1.10.1.1

2. FC-419 provided with low alarm.

5.1.10.1.2

3.High tem. Alarm TI-162 is provided at the inlet of air cooler.

5.1.10.1.3

1. LC-516 provided 5.2.1.1.1 with High alarm. 2. LI-559 provided with HH alarm.

5.2.1.1.2

3.PSV-310A/B designed for liquid overfilling case

5.2.1.1.3

Page 53 of 136

17. Manual isolation valves downstream of FCV-455A/B,to be LO.

SEI

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

NODE NO: 05

Wash Water System

DESIGN INTENTION

Sour Water/MP BFW supply to Wash Water Drum(V-004)

DRAWINGS

CS-140-PR-15-0003,CS-140-PR-15-0006,CS-140-PR-15-0008, CS-140-PR-15-0021, CS-140-PR-15-0022,CS-140-PR-15-0030,CS-140-PR-15-0037

EQUIPMENT

Wash Water Drum(140-V-004) and Wash water pump(140-P-002A/B)

STREAM DETAILS

1.

To supply Stripper Sour Water/BFW/Recycle water to Wash water drum.

2.

To inject wash water in U/S of Reactor Effluent Air Cooler to dissolve ammonium salts and also in EE-001 A/B tube side inlet

AVAILABLE CONTROL SCHEMES

:

Project :

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

FC-419,PC-368,LC-516,FC-451,FC-420,LC-542& LC-544 2. High Flow Operating/Design Parameters

SERVICE Temperature(°C) Sour Water/MP BFW supply to Wash water Drum Sour Water from Reflux Drum

Pressure ( bar g)

65-128/150 45.0/140

Flow rate (Kg/hr) 5.0-24.0/25

5221-6212

6.4/9

3310

Note: Node

Deviation

Causes

Consequences

Safeguards

Ref. No.

Recommendations

Responsibility

2. FC-451 in MP BFW line malfunctions to open FCV-451

1. Refer 5.1.1.1.1~3.

3. LC-542 at recycle water line from stripper reflux drum, malfunction to open LCV-542A

1. Level of (V-004) may go high

1. Refer 5.1.1.1.1 and 5.1.1.1.2

5.2.3.1.1

18. Confirm gas break SEI through LCV-542A case is considered for PSV310A/B

2. Boot level of V-008 may go down, HC carry over to V-004 may lead to high pressure

1. PC-368 provided with high alarm.

5.2.3.2.1

19.Provide additional control scheme on V008 boot with LT (Low low level signal), new shutdown valve on recycle water line from V-008 to avoid gas break through.

5.2.4.1

20. Review the impact of NOCL vapor break through/liquid HC in unit 550.

5.2.2.1

4.LC-542 malfunctions to open 1.Boot level of V-008 may go down, HC carry LCV-542B over to unit 550

2.. Possible damage to P-002A/B due to cavitation (due to presence of naphtha).

4. LC-544 at the outlet of V-009 1. Level of (V-004) may go high boot, malfunction to open LCV-544

Remarks

5.2.4.2

1. Refer 5.1.1.1.1 and 5.1.1.1.2

Page 54 of 136

5.2.4.1.1

SEI/PMC/NOCL Low level alarm can /Axens be provided on magnetic LG-543 with switch to enable operator action for closing control valve (upstream isolation valve). Wash water pump operation to be checked for HC carry over in wash water.

NPSHr of P-002A/B is 1.9m and vessel elevation is 5.5m from grade. So no cavitation.

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

NODE NO: 05

Wash Water System

DESIGN INTENTION

Sour Water/MP BFW supply to Wash Water Drum(V-004)

DRAWINGS

CS-140-PR-15-0003,CS-140-PR-15-0006,CS-140-PR-15-0008, CS-140-PR-15-0021, CS-140-PR-15-0022,CS-140-PR-15-0030,CS-140-PR-15-0037

EQUIPMENT

Wash Water Drum(140-V-004) and Wash water pump(140-P-002A/B)

STREAM DETAILS

1.

To supply Stripper Sour Water/BFW/Recycle water to Wash water drum.

2.

To inject wash water in U/S of Reactor Effluent Air Cooler to dissolve ammonium salts and also in EE-001 A/B tube side inlet

AVAILABLE CONTROL SCHEMES

:

Project :

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

FC-419,PC-368,LC-516,FC-451,FC-420,LC-542& LC-544

Operating/Design Parameters SERVICE Temperature(°C) Sour Water/MP BFW supply to Wash water Drum Sour Water from Reflux Drum

Pressure ( bar g)

65-128/150 45.0/140

Flow rate (Kg/hr) 5.0-24.0/25

5221-6212

6.4/9

3310

4. LC-544 at the outlet of V-009 boot, malfunction to open LCV-544

Note: Node

Deviation

Causes

Consequences

Safeguards

2. Boot level of V-009 may go down, HC carry over to the reaction section. As this is stabilized gas oil no pressure increase is expected

5. LC-516 malfunction to open FCV-420/451& LCV-542B

1. Level of (V-004) may go high

5.2.4.2

1. Refer 5.1.1.1.2

6. FC-419 at wash water pump 1. More wash water to EA-001,EEdischarge ,malfunction to open 001 (when in operation) no major concern. FCV-419 2. Likely low level in V-004.

3.Possible water level rise in V-006.

3.Reverse Flow

1.High level In wash water drum.

Ref. No.

5.2.5.1.1

5.2.6.1

1. LZ-518 provided with low low alarm.

5.2.6.2.1

2. LC-516 is provided with low alarm

5.2.6.2.2

1.High high alarm is 5.2.6.3.1 provided at LI-512. 1.Check valves are 5.3.1.1 provided on all feed lines and also in pump discharge.

2.Pump P-002 A/B failure.

3. XZV-721 failure.

4.FCV-419 failure.

Page 55 of 136

Recommendations 21. Provide low alarm for LI-560A at V-009 boot

Responsibility SEI/NOCL

Remarks Operating procedure should ensure periodical checking of LG-545.

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

NODE NO: 05

Wash Water System

DESIGN INTENTION

Sour Water/MP BFW supply to Wash Water Drum(V-004)

DRAWINGS

CS-140-PR-15-0003,CS-140-PR-15-0006,CS-140-PR-15-0008, CS-140-PR-15-0021, CS-140-PR-15-0022,CS-140-PR-15-0030,CS-140-PR-15-0037

EQUIPMENT

Wash Water Drum(140-V-004) and Wash water pump(140-P-002A/B)

STREAM DETAILS

1.

To supply Stripper Sour Water/BFW/Recycle water to Wash water drum.

2.

To inject wash water in U/S of Reactor Effluent Air Cooler to dissolve ammonium salts and also in EE-001 A/B tube side inlet

AVAILABLE CONTROL SCHEMES

:

Project :

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

FC-419,PC-368,LC-516,FC-451,FC-420,LC-542& LC-544

Operating/Design Parameters SERVICE Temperature(°C) Sour Water/MP BFW supply to Wash water Drum Sour Water from Reflux Drum

Pressure ( bar g)

65-128/150 45.0/140

Flow rate (Kg/hr) 5.0-24.0/25

5221-6212

6.4/9

3310

Note: Node

Deviation

Causes

Consequences

Safeguards

4.

As well as

1. Contamination in Stripped sour water.

5.

Low Pressure

1. PC-368 malfunctions to close 1. Pump may cavitate and wash water flow PCV-368A and opens 368B to EA-001 may be lost.

2. Nitrogen supply failure.

1. Water washing of EA-001 may get affected.

Ref. No.

1.vessel operating pressure is disturbed.

1. BFW may enter into sour water line

Responsibility

5.4.1.1

1. NPSHa is calculated considering no overpressure in wash water drum.

5.5.1.1

1. PC-368 provided with low alarm.

5.5.2.1.1

2. PI-806 at B.L is provided with low alarm

5.5.2.1.2

3. Pump is designed 5.5.2.1.3 to work with low NPSH (1.9m) even in absence of nitrogen pressure.

3. Low supply pressure of sour water from unit 550

Recommendations

1. NRV is provided 5.5.3.1.1 downstream of FCV420.

2. Stripped sour water can not be supplied to 1. Recycle water 5.5.3.2.1 wash water drum. from stripper reflux drum, coalescer and MP BFW is available.

Page 56 of 136

Remarks 1. Ensure sampling provision is given in Unit 550 during detailing.

22. Operating procedure should ensure periodical checking of PI369A/B at pump suction..

SEI/NOCL

5.

Low Pressure

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

NODE NO: 05

Wash Water System

DESIGN INTENTION

Sour Water/MP BFW supply to Wash Water Drum(V-004)

DRAWINGS

CS-140-PR-15-0003,CS-140-PR-15-0006,CS-140-PR-15-0008, CS-140-PR-15-0021, CS-140-PR-15-0022,CS-140-PR-15-0030,CS-140-PR-15-0037

EQUIPMENT

Wash Water Drum(140-V-004) and Wash water pump(140-P-002A/B)

STREAM DETAILS

1.

To supply Stripper Sour Water/BFW/Recycle water to Wash water drum.

2.

To inject wash water in U/S of Reactor Effluent Air Cooler to dissolve ammonium salts and also in EE-001 A/B tube side inlet

AVAILABLE CONTROL SCHEMES

:

Project :

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

FC-419,PC-368,LC-516,FC-451,FC-420,LC-542& LC-544

Operating/Design Parameters

3. Low supply pressure of sour water from unit 550

SERVICE Temperature(°C) Sour Water/MP BFW supply to Wash water Drum Sour Water from Reflux Drum

Pressure ( bar g)

65-128/150 2. Stripped sour water can not be supplied to wash water drum.

45.0/140

Flow rate (Kg/hr) 5.0-24.0/25

5221-6212

6.4/9

3310

Note: Node

Deviation

Causes

Consequences

Safeguards

Ref. No.

Recommendations

Responsibility

5.5.3.2.2 2. FC-420 is provided with low alarm. 6.

High Pressure

1. PC-368 malfunctions to open 1. V-004 may experience high pressure. PCV-368A and closes PCV368B.

7.Low temperature

No significant safety issue.

8.High temperature

1. Stripped sour water is not available from unit 550.

9. Problem/Requirements

1. Misdistribution of wash water in air cooler tube bundles.

10.Composition

1. No new cause

11. Part of Maintenance

1. Maintenance

1. PSV-310 A/B is provided to take care of this situation.

5.6.1.1.1

5.7

1. No effective washing and this can not be continued for a long duration due to corrosion and pressure drop issues and cooler efficiency.

1. Salt may deposit on air cooler tubes.

5.8

23.Provide high temp. Alarm at TI-210.

Axens/SEI

24.Operating procedure to ensure Increase of injection water flow rate and/or plant capacity to be decreased. To be further checked for the feasibility of this operation.

1. Individual FI's are 5.9.1.1 available at each injection point.

25. Operating procedure should ensure periodical checking of FI458/459/460/461

SEI/NOCL

26. check working of P002A/B,when operating only on BFW(128 C)

SEI

5.10 1. High temp.(BFW) at suction in case of only 1. Pump P-002A/B BFW is available. Mechanical designed is for 150 C.

Page 57 of 136

5.11.1.1.1

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

NODE NO: 06

Separator bottom to sour water flash Drum and B/L

DESIGN INTENTION

To separate the sour water from HC in Separator and send to B/L.

DRAWINGS

CS-140-PR-15-0006,CS-140-PR-15-0007

EQUIPMENT

Sour water Flash Drum(140-V-017)

STREAM DETAILS

Sour water from Separator (V-006) to Sour water flash drum (V-017) and then water will send to B/L and flash gas will be sent to LP Amine KOD(V-010)

AVAILABLE CONTROL SCHEMES

LC-514.LC-556,LC542

:

Project :

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

Operating/Design Parameters

SERVICE Temperature(°C) Separator bottoms to Sour water flash drum Sour water flash drum to Sour water B/L

Pressure ( bar g)

Flow rate (Kg/hr)

45/130

6.4-78.8/92

10085

45/120

4.0-6.4/9

10080

Note: Node 6. Separator bottom to Sour water Flash Drum and B/L

Deviation 1.

Low/No Flow

Causes

Consequences

Safeguards

1. LC-510 malfunctions to close 1. Boot level of V-006 may go high resulting 1. LI -512 is LCV -510 in water carry over with gas oil product provided with leading to off-spec product. HH alarm. 2. AI-003 is provided at gas oil product line. 2. Potential overpressure upstream TC191A/B due to higher vaporization,

Ref. No.

Recommendations

Responsibility

6.1.1.1.1

6.1.1.1.2

1. PI-903 is provided 6.1.1.2.1 with high pressure alarm at stripper overhead

3. Potential overpressure in stripper, leading to water carryover in wild naphtha as well as in diesel .Major system upset.

2. LC-556 malfunctions to close 1. V-017 water side level may go high LCV-556 leading to water carry over to closed drain system, resulting in water carryover to LP amine absorber KO pot leading to potential foaming in amine system and contamination of amine.

6.1.1.3

1.Low alarm at FI417 is provided..

6.1.2.1.1

2. High alarm at LC- 6.1.2.1.2 514 is provided.

3. Automatic drain facility to closed drain is provided.

6.1.2.1.3

4. High alarm at LC- 6.1.2.1.4 530 is provided.

3. LC-514 malfunctions to close 1. V-017 Hydrocarbon side level may go LCV-514 high and ultimately over the period of time HC carryover to V-010.

1.High alarm at LC556 is provided.

6.1.3.1.1

27. Operating procedure should ensure periodical checking of LG515

SEI/NOCL

28. Ensure LG-515 facing SEI with LCV-514 bypass valve

Page 58 of 136

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

NODE NO: 06

Separator bottom to sour water flash Drum and B/L

DESIGN INTENTION

To separate the sour water from HC in Separator and send to B/L.

DRAWINGS

CS-140-PR-15-0006,CS-140-PR-15-0007

EQUIPMENT

Sour water Flash Drum(140-V-017)

STREAM DETAILS

Sour water from Separator (V-006) to Sour water flash drum (V-017) and then water will send to B/L and flash gas will be sent to LP Amine KOD(V-010)

AVAILABLE CONTROL SCHEMES

LC-514.LC-556,LC542

:

Project :

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

Operating/Design Parameters

SERVICE

Temperature(°C) 3. LC-514 malfunctions to close 1. V-017 Hydrocarbon side level may go 45/130 LCV-514 high and ultimately over the period of time HC carryover to V-010. 45/120

Separator bottoms to Sour water flash drum Sour water flash drum to Sour water B/L

Pressure ( bar g)

Flow rate (Kg/hr) 6.4-78.8/92

10085

4.0-6.4/9

10080

Note: Node

Deviation

2.

High Flow

Causes

Consequences

Safeguards

Ref. No.

2.High alarm at LC530 is provided.

6.1.3.1.2

4. Low pressure in LP amine absorber

1.Over filling of vessel

1.Low pressure alarm PI-999 is provided.

6.1.4.1.1.

1. LC-510 malfunctions to opens LCV -510

1. Boot level of V-006 may go low resulting in hydrocarbon carry over with Sour water to sour water flash drum.

1. LZ 513 is provided with LL alarm will activate UZ-704 to close XZV704.

6.2.1.1.1

2 Potential HC carryover to LP amine absorber KOD and eventually leading to foaming in LP amine absorber.

Recommendations

Responsibility

Remarks

2. High alarm at LC514 is provided. 3. High alarm at LC530 is provided.

2. LC-514 malfunctions to open 1.Gas break through to CBD and potential LCV-514 reduction of pressure in amine column

1. CBD vessel is connected to flare.

6.2.2.1.1

SEI/NOCL

Operating procedure should ensure periodical checking of LG-515/LCV-514.

PMC/\NOCL

1. Provision for HC carryover with sour water to be considered in unit 550.

2. PI-999 is provided 6.2.2.1.2 with low alarm at LP amine absorber top.

3. LC-556 malfunctions to open 1. V-017 water side level may go low and LCV-556 HC may carry over with Sour water to B.L.

6.2.3.1

3. Reverse flow

Refer 6.1.2.1.1 ~ 6.1.2.1.4

6.3

4. High Pressure

Refer 6.1.1.1.1, 6.1.1.1.2, 6.1.1.2.1 and 6.1.1.3

6.4

5. Low pressure

Refer 6.2.2.1.1 and 6.2.2.1.2

6.5

Page 59 of 136

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

NODE NO: 06

Separator bottom to sour water flash Drum and B/L

DESIGN INTENTION

To separate the sour water from HC in Separator and send to B/L.

DRAWINGS

CS-140-PR-15-0006,CS-140-PR-15-0007

EQUIPMENT

Sour water Flash Drum(140-V-017)

STREAM DETAILS

Sour water from Separator (V-006) to Sour water flash drum (V-017) and then water will send to B/L and flash gas will be sent to LP Amine KOD(V-010)

AVAILABLE CONTROL SCHEMES

LC-514.LC-556,LC542

:

Project :

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

Operating/Design Parameters

SERVICE Temperature(°C) Separator bottoms to Sour water flash drum Sour water flash drum to Sour water B/L

Pressure ( bar g)

Flow rate (Kg/hr)

45/130

6.4-78.8/92

10085

45/120

4.0-6.4/9

10080

Note: Node

Deviation

Causes

Consequences

Safeguards

Ref. No.

6.Low temperature

NO new causes

6.6

7. High temperature

NO new causes

6.7

8. Composition

NO new causes

6.8

9. Others

NO new causes

6.9

Page 60 of 136

Recommendations

Responsibility

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

NODE NO: 07

Separator drum to stripper inlet

DESIGN INTENTION

To preheat Gas oil in exchanger trains and send to stripper for strip out to naphtha and lighter components.

DRAWINGS

CS-140-PR-15-0007, CS-140-PR-15-0017, CS-140-PR-15-0018

EQUIPMENT

Separator Drum(140-V-006),Stripper Feed / Bottom Exchanger(140-EE-006),Stripper Preheater (140-V-002)

STREAM DETAILS

Gas oil is separated in separator(V-006) and send for further heating In Stripper feed/bottom (EE-006) and stripper preheater (EE-002A/B) then stripper

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

AVAILABLE CONTROL SCHEMESFC-416,TC-191

Operating/Design Parameters SERVICE Temperature(°C) Separator bottom to stripper Preheater inlet stripper Preheater to Stripper Inlet

Pressure ( bar g)

Flow rate (Kg/hr)

45-51/130

11.9-78.8/92

41810-119768

213-260/390

8.9-10.3/75

119768

Note: Node

Deviation

7. Separator Drum to Stripper Inlet

1.

Low/No Flow

Causes 1. XZV-703 malfunctions to close.

Consequences

Safeguards

1. Level of V-006 increases

1. LC 507 high alarm is provided.

2. Liquid HC carryover in vapor line leading to foaming in HP amine absorber C-001.

1. K.O.D V-007 is 7.1.1.2.1 provided with high level alarm.

Ref. No.

Recommendations

Responsibility

2. Deviation alarm 7.1.1.2.2 at XZV-703 is provided

V-006 is designed for 14min holdup time between normal and high levels.

29. Consider FC-416 low alarm is set below turndown flow.

SEI/AXENS

3. High level alarm 7.1.1.2.3 LI-509 is provided at V-006.

3. High temp to stripper preheater EE-002, leading to high heater temp. Making the heater firing control difficult (firing turn down issues), leading to high temp. to reactor

None

7.1.1.3

30. Consider installation of AXENS/SEI limiting temp. controller (TI-120) in heater inlet.

31. SOP to address lining SEI/NOCL of quench gas in the bottom bed which will help in reducing the reactor outlet temp. minimizing the disturbance.

4. Higher inlet temp. across EE-001 A/B/C/D and inlet of air cooler EA-001.

1. Air cooler is designed for 10% higher heat duty.

Page 61 of 136

Remarks

7.1.1.1.1

7.1.1.4.1

32. Check the impact on the inlet piping and equipments due to increased inlet temp. to EE-001A/B/C/D and reactor effluent air cooler EA-001

SEI

7. Separator Drum to Stripper Inlet

1.

Low/No Flow

1. XZV-703 malfunctions to close.

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

NODE NO: 07

Separator drum to stripper inlet

DESIGN INTENTION

To preheat Gas oil in exchanger trains and send to stripper for strip out to naphtha and lighter components.

DRAWINGS

CS-140-PR-15-0007, CS-140-PR-15-0017, CS-140-PR-15-0018

EQUIPMENT

Separator Drum(140-V-006),Stripper Feed / Bottom Exchanger(140-EE-006),Stripper Preheater (140-V-002)

STREAM DETAILS

Gas oil is separated in separator(V-006) and send for further heating In Stripper feed/bottom (EE-006) and stripper preheater (EE-002A/B) then stripper

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

AVAILABLE CONTROL SCHEMESFC-416,TC-191

Operating/Design Parameters SERVICE Temperature(°C) Separator bottom to stripper Preheater inlet stripper Preheater to Stripper Inlet

Pressure ( bar g)

Flow rate (Kg/hr)

45-51/130

11.9-78.8/92

41810-119768

213-260/390

8.9-10.3/75

119768

Note: Node

Deviation

Causes

2. LC-507/FC-416 malfunctions to close FCV-416.

Consequences

Safeguards

Ref. No.

5. Higher inlet temp. across the EE006A/B/C/D and inlet of air cooler EA-003.

7.1.1.5

1. Refer 7.1.1.1.1, 7.1.1.2.1 and 7.1.1.2.3

7.1.2.1

3. TC-191 malfunctions to close 1. Pressure of system up to EE-002 may TCV-191B increase

2. Low stripper inlet temperature possibly leading to product off spec.

1. PSV-930A/B is provided at tube side inlet line to EE-006.

7.1.3.1.1

Recommendations

Responsibility

33. Check the impact on the inlet piping and equipments due to increased inlet temp. to EE-006A/B/C/D and gas oil air cooler EA-003.

SEI

34. Provide DCS PI with high alarm upstream of EE-006A/B/C/D.

SEI

35. Provide high alarm at analyzer AI-003.

SEI

1. Mechanical 7.1.3.2.1 Limit stop provided at TCV191A for minimum flow to avoid total blockage.

2. TI-192 at stripper overhead with low alarm is provided.

7.1.3.2.2

3. Product 7.1.3.2.3 analyzer AI-003 is provided. 1. Refer 7.1.1.4.1

7.1.3.3.1

3.Reduced duty of EE-002 leading to high temp to EE-001 A/B/C/D

4. TC-191 malfunctions to open 1. Refer 7.1.3.1.1, 7.1.3.2.1~3 and 7.1.3.3.1. TCV-191A

7.1.4.1

Page 62 of 136

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

NODE NO: 07

Separator drum to stripper inlet

DESIGN INTENTION

To preheat Gas oil in exchanger trains and send to stripper for strip out to naphtha and lighter components.

DRAWINGS

CS-140-PR-15-0007, CS-140-PR-15-0017, CS-140-PR-15-0018

EQUIPMENT

Separator Drum(140-V-006),Stripper Feed / Bottom Exchanger(140-EE-006),Stripper Preheater (140-V-002)

STREAM DETAILS

Gas oil is separated in separator(V-006) and send for further heating In Stripper feed/bottom (EE-006) and stripper preheater (EE-002A/B) then stripper

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

AVAILABLE CONTROL SCHEMESFC-416,TC-191

Operating/Design Parameters SERVICE Temperature(°C) Separator bottom to stripper Preheater inlet stripper Preheater to Stripper Inlet

Pressure ( bar g)

Flow rate (Kg/hr)

45-51/130

11.9-78.8/92

41810-119768

213-260/390

8.9-10.3/75

119768

Note: Node

Deviation

4. TC-191 malfunctions to open Consequences Causes TCV-191A 2. Higher outlet temp. at EE-002

5 TC-191 malfunctions to close 1. Higher stripper inlet temp. leading to loss TCV-191A of diesel to wild naphtha.

Safeguards

Ref. No.

Recommendations

Responsibility

36. Provide high temp. alarm TI-192.

SEI

Remarks

1. Line is designed 7.1.4.2.1 for 390 C.

None

7.1.5.1

Axens/PMC/SEI 37. Consider converting TI-192 to TC and put reflux on TC/FC cascade.

2.

3.

High Flow

As well as

1. LC-507/FC-416 malfunctions to open FCV-416.

1. Level of V-006 decreases and down stream system will face high pressure due to gas break through.

1. LZ-509 is provided with low low alarm which will activate UZ703 to trip XZV703.

7.2.1.1.1

2. PSV-319A/B is designed for gas blow case.

7.2.1.1.2

2. TC-191 malfunctions to open 1. Refer 7.1.1.3 TCV-191B

7.2.2.1

No new cause.

7.3

Page 63 of 136

38. Check the system SEI integrity upstream of TCV191A/B during gas break through.

SEI

Min. flow stop limit note ref. from TCV191A is to be removed from P&ID and Data sheet.

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

NODE NO: 07

Separator drum to stripper inlet

DESIGN INTENTION

To preheat Gas oil in exchanger trains and send to stripper for strip out to naphtha and lighter components.

DRAWINGS

CS-140-PR-15-0007, CS-140-PR-15-0017, CS-140-PR-15-0018

EQUIPMENT

Separator Drum(140-V-006),Stripper Feed / Bottom Exchanger(140-EE-006),Stripper Preheater (140-V-002)

STREAM DETAILS

Gas oil is separated in separator(V-006) and send for further heating In Stripper feed/bottom (EE-006) and stripper preheater (EE-002A/B) then stripper

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

AVAILABLE CONTROL SCHEMESFC-416,TC-191

Operating/Design Parameters SERVICE Temperature(°C) Separator bottom to stripper Preheater inlet stripper Preheater to Stripper Inlet

Pressure ( bar g)

Flow rate (Kg/hr)

45-51/130

11.9-78.8/92

41810-119768

213-260/390

8.9-10.3/75

119768

Note: Node

Deviation 4. Low interface level Boot)

Causes

Consequences

Safeguards

1. LC-510 malfunctions to opens LCV -510

1. Boot level of V-006 may go low resulting in hydrocarbon carry over with Sour water to sour water flash drum.

1. LZ 513 is provided with LL alarm will activate UZ-704 to close XZV704.

2 Potential HC carryover to LP amine absorber KOD and eventually leading to foaming in LP amine absorber.

Ref. No. 7.4.1.1.1/2/3

2. High alarm at LC-514 is provided. 3. High alarm at LC-530 is provided.

5. Low level

6. High interface level Boot)

Refer 7.1.1.1.1

7.5

1. LC-510 malfunctions to close 1. Boot level of V-006 may go high resulting 1. LI -512 is LCV -510 in water carry over with gas oil product provided with leading to off-spec product. HH alarm.

7.6.1.1.1

2. AI-003 is 7.6.1.1.2 provided at gas oil product line. 2. Potential overpressure upstream TC191A/B due to higher vaporization,

2. XZV-704 malfunctions to close.

1. PI-903 is 7.6.1.2.1 provided with high pressure alarm at stripper overhead

3 Potential overpressure in stripper, leading to water carryover in wild naphtha as well as in diesel .Major system upset.

7.6.1.3

1. Boot level of V-006 may go high resulting 1. LI 512 is in water carry over with gas oil product. provided with HH alarm.

7.6.2.1.1

Page 64 of 136

Recommendations

Responsibility

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

NODE NO: 07

Separator drum to stripper inlet

DESIGN INTENTION

6. High interface level Boot) To preheat Gas oil in exchanger trains and send to stripper for strip out to naphtha and lighter components.

DRAWINGS

CS-140-PR-15-0007, CS-140-PR-15-0017, CS-140-PR-15-0018

EQUIPMENT

Separator Drum(140-V-006),Stripper Feed / Bottom Exchanger(140-EE-006),Stripper Preheater (140-V-002)

STREAM DETAILS

Gas oil is separated in separator(V-006) and send for further heating In Stripper feed/bottom (EE-006) and stripper preheater (EE-002A/B) then stripper

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

AVAILABLE CONTROL SCHEMESFC-416,TC-191

Operating/Design Parameters SERVICE Temperature(°C) Separator bottom to stripper Preheater inlet stripper Preheater to Stripper Inlet

Pressure ( bar g)

Flow rate (Kg/hr)

45-51/130

11.9-78.8/92

41810-119768

213-260/390

8.9-10.3/75

119768

Note: Node

Deviation

Causes

Consequences

Safeguards

2. Potential overpressure upstream TC191A/B due to higher vaporization,

1. Deviation alarm 7.6.2.2.1 at XZV-704 is provided

Recommendations

Responsibility

3 Potential overpressure in stripper, leading to water carryover in wild naphtha as well as in diesel .Major system upset.

1.Low alarm at LC-510 is provided.

7.9.1.2.1

39. Check the impact on the inlet piping and equipments due to increased inlet temp. to EE-001A/B/C/D and reactor effluent air cooler EA-001

SEI

7.9.1.3

40. Check the impact on the inlet piping and equipments due to increased inlet temp. to EE-006A/B/C/D and gas oil air cooler EA-003.

SEI

Ref. No.

7.6.2.3.1

2. PI-903 is 7.6.2.3.2 provided with high pressure alarm at stripper overhead 7. High level

8. Low Temperature

Refer 7.2.1.1.1 and 7.2.1.1.2

7.7

1. Failure of heating medium in 1. Low stripper inlet temperature possibly EE-006A/B/C/D leading to product off spec

1. TC-191 provided with low alarm.

1. Refer 7.1.3.2.1

9. High Temperature

1. Malfunction of TCV-191 A

7.8.1.1.1

7.8.1

1. Refer 7.1.5.1

2. Higher inlet temp. across EE-001 A/B/C/D and inlet of air cooler EA-001.

7.9.1.1

1. Air cooler is designed for 10% higher heat duty.

3. Higher inlet temp. across the EE006A/B/C/D and inlet of air cooler EA-003.

Page 65 of 136

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

NODE NO: 07

Separator drum to stripper inlet

DESIGN INTENTION

To preheat Gas oil in exchanger trains and send to stripper for strip out to naphtha and lighter components.

DRAWINGS

CS-140-PR-15-0007, CS-140-PR-15-0017, CS-140-PR-15-0018

EQUIPMENT

Separator Drum(140-V-006),Stripper Feed / Bottom Exchanger(140-EE-006),Stripper Preheater (140-V-002)

STREAM DETAILS

Gas oil is separated in separator(V-006) and send for further heating In Stripper feed/bottom (EE-006) and stripper preheater (EE-002A/B) then stripper

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

AVAILABLE CONTROL SCHEMESFC-416,TC-191

Operating/Design Parameters SERVICE Temperature(°C) Separator bottom to stripper Preheater inlet stripper Preheater to Stripper Inlet

Pressure ( bar g)

Flow rate (Kg/hr)

45-51/130

11.9-78.8/92

41810-119768

213-260/390

8.9-10.3/75

119768

Note: Node

Deviation 10. Problem/Requirements

Causes

Consequences

1. Tube leak in EE-006

1. Stripper bottom will ingress in unstable gas oil. Product contamination and potential overpressure in product tank.

2. Tube leak in EE-002

1. Reactor effluent may ingress in Unstable gas oil leading to off-spec product

Safeguards

1. PSV-319A/B is provided for tube rupture case.

Recommendations

Responsibility

7.10.1.1

41. Check if downstream product tank can be pressurized due to tube rupture.

SEI

7.10.1.2

42. Consider increase in operating pressure of product.

SEI

43. Check the overpressurization of system and confirm that PSVs are sized for this case.

SEI

Ref. No.

7.10.2.1.1

2. AI-003 is 7.10.2.1.2 provided at gas oil product line. 2. Potential overpressurization of stripper

11. Operation/Maintenance

1. PI-903 With high alarm is provided.

No new cause.

7.10.2.2.1

7.11

Page 66 of 136

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

NODE NO: 08

Separator over head to Recycle gas compressor inlet

DESIGN INTENTION

1.

To remove H2S from separator overhead stream in HP Amine Absorber.

2.

To feed Recycle Gas to recycle gas Compressor.

DRAWINGS

CS-140-PR-15-0007, CS-140-PR-15-0009, CS-140-PR-15-0010, CS-140-PR-15-0012

EQUIPMENT

Separator (140-V-006),HP Absorber KOD(140-V-007), HP Amine absorber (140-C001),Recycle compressor KOD(140-V-005)

STREAM DETAILS

Separator (V-006) Overhead goes to KOD (V-007)and then HP Amine absorber column (C001) where H2S treated by lean amine solution and send to KOD of Recycle gas compressor (V-005)then finally recycle gas compressor (K-002)

:

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

AVAILABLE CONTROL SCHEMESLC-519,HC-826.LC-521,LC-524

Operating/Design Parameters Pressure ( bar g)

Flow rate (Kg/hr)

Temperature (°C)

SERVICE Separator overhead to HP amine absorber HP Amine absorber to Recycle gas compressor

45 /130

78.8/92

15891-18053

54/130

78.4/92

13337-15497

Note: Node 8. Separator Overhead to Recycle gas compressor Inlet

Deviation 1.

Causes

Low/No Flow to compressor 1. HCV-826 malfunction to full suction open (No flow through to column)

Consequences

Safeguards

Ref. No.

1. High H2S concentration in recycle gas lead to off spec product(*)

1. AI-001 is provided on K-002 suction line

8.1.1.1.1

2. System pressure may increase due to non removal of H2S(*)

1. PC-358 is provided with high alarm(*)

8.1.1.2.1

2. PC-358(at separator)/FC1. Suction pressure comes down and 423(at recycle gas KOD potentially leads to surge. downstream) malfunction to open FCV-423(Less flow in Recycle gas compressor Suction line)

8.1.2.1

1. PI-689/377 is provided with low alarm

8.1.2.1.1

2. FI-429 is provided with low alarm

8.1.2.1.2

2. Low pressure in reaction section leading to 1.Low low suction off spec. product. pressure trip PZ690A/B/C (2oo3) is provided.

8.1.2.2.1

Recommendations

Responsibility

44.Operating procedure to include operation of HS-822 to select FCV-423 to purge H2S to flare header

SEI/NOCL

45.low low suction pressure compressor trip PZ-378 is not required as per process reason and to be deleted.

SEI

46.Operating instruction to include feed cut-off if system pressure is below 80% of the normal pressure. 47.BHEL to confirm if low low suction pressure trip is required for machine protection.

3. Fuel gas line may subjected to high pressure.

1. PSV-941A/B is designed for this case.

8.1.2.3.1

48. Ensure refinery fuel gas composition has considered addition of hydrogen from this unit.

Axens

BHEL

NOCL

49. Flow indication is to be repeated in fuel gas unit.

3. LC-519 malfunction to open LCV-519

4. LC-524 malfunction to open LCV-524

1. Low level in V-007,stripper (C002)/(EE-006A/B/C/D) / (EE002)may subject to high pressure due to gas blow by, possible damage to column internals.

1. PSV-319A/B is designed for this gas blow by case

8.1.3.1.1

2. PI-903 is provided with high alarm.

8.1.3.1.2

1. Level loses in V-005, Gas blow by may 1. PC-394 is provided happen to C-003, damage to C-003 internals with high alarm.

8.1.4.1.1

Page 67 of 136

50. Move high alarm from PC394 to PI-999.

SEI

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

NODE NO: 08

Separator over head to Recycle gas compressor inlet

DESIGN INTENTION

1.

To remove H2S from separator overhead stream in HP Amine Absorber.

2.

To feed Recycle Gas to recycle gas Compressor.

DRAWINGS

CS-140-PR-15-0007, CS-140-PR-15-0009, CS-140-PR-15-0010, CS-140-PR-15-0012

EQUIPMENT

Separator (140-V-006),HP Absorber KOD(140-V-007), HP Amine absorber (140-C001),Recycle compressor KOD(140-V-005)

STREAM DETAILS

Separator (V-006) Overhead goes to KOD (V-007)and then HP Amine absorber column (C001) where H2S treated by lean amine solution and send to KOD of Recycle gas compressor (V-005)then finally recycle gas compressor (K-002)

:

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

AVAILABLE CONTROL SCHEMESLC-519,HC-826.LC-521,LC-524

Operating/Design Parameters Pressure ( bar g)

Flow rate (Kg/hr)

Temperature (°C)

SERVICE Separator overhead to HP amine absorber HP Amine absorber to Recycle gas compressor

Note: Node

Deviation

45 /130

78.8/92

15891-18053

54/130

78.4/92

13337-15497

4. LC-524 malfunction to open LCV-524

1. Level loses in V-005, Gas blow by may happen to C-003, damage to C-003 internals

Causes

Consequences

50. Move high alarm from PC394 to PI-999. Safeguards 2. PSV-318A/B is designed for this gas blowby case.

Ref. No.

1.Compressor is likely to go on surge, in case 1. Anti-surge system is of sudden pressure drop. provided.

6. Compressor suction strainer choked

1. Suction pressure comes down and potentially leads to surge.

1.PDI-688 is provided

8.1.6.1.1

7. Compressor trip.

1. Potential hot spots in the reactor.

1. Bed temp. alarms are provided on reactor.

8.1.7.1.1

2. Activation of UZ-705 leading to trip of heater and liquid feed pumps.

8.1.7.1.2

1.None as anti-surge valve (XCV-715) discharge is not coming back to suction of compressor as suction MOV is closed.

8.1.7.2.1

8.Compressor trip is initiated due 1.Potential liquid carryover to compressor as to high level in the suction there is a time delay in closure of suction KOD(LZ-526). MOV.

None

8.1.8.1

9. MOV-002 misoperate to close.

1. PI-689/377 is provided with low alarm

8.1.9.1.1

2. Low low suction pressure trip PZ690A/B/C (2oo3) is provided.

8.1.9.1.2

1. Suction pressure comes down and potentially leads to surge.

SEI Responsibility

8.1.4.1.2

5. XZV-702A malfunctions to open.

2. Suction and discharge MOVs-002/003 respectively will close automatically leading to compressor in surge

Recommendations

8.1.5.1.1

51. Provide high alarm on PDI688.

SEI

BHEL/PMC/SEI/NOCL/A xens

52. BHEL recommends the closing of MOVs with a time delay while rpm is reduced to 500.

BHEL/PMC/SEI/NOCL/A xens 53. System to be reviewed for required protection.

3.If full open signal is lost 8.1.9.1.3 interlock system will trip the compressor.

Page 68 of 136

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

NODE NO: 08

Separator over head to Recycle gas compressor inlet

DESIGN INTENTION

1.

To remove H2S from separator overhead stream in HP Amine Absorber.

2.

To feed Recycle Gas to recycle gas Compressor.

DRAWINGS

CS-140-PR-15-0007, CS-140-PR-15-0009, CS-140-PR-15-0010, CS-140-PR-15-0012

EQUIPMENT

Separator (140-V-006),HP Absorber KOD(140-V-007), HP Amine absorber (140-C001),Recycle compressor KOD(140-V-005)

STREAM DETAILS

Separator (V-006) Overhead goes to KOD (V-007)and then HP Amine absorber column (C001) where H2S treated by lean amine solution and send to KOD of Recycle gas compressor (V-005)then finally recycle gas compressor (K-002)

:

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

AVAILABLE CONTROL SCHEMESLC-519,HC-826.LC-521,LC-524

Operating/Design Parameters Pressure ( bar g)

Flow rate (Kg/hr)

Temperature (°C)

SERVICE Separator overhead to HP amine absorber HP Amine absorber to Recycle gas compressor

45 /130

78.8/92

15891-18053

54/130

78.4/92

13337-15497

Note: Node

Deviation 2.

High Flow

Causes

Consequences

1. Compressor speed controller 1 Possibility of machine surge as anti-surge malfunctions to high speed. valve XCV-715 opens in case of system could not consume the higher flow.

Safeguards 8.2.1.1.1

2. Possible compressor damage due to max. 1.High high speed trip speed. SZ-002 is available.

8.2.1.2.1

3.

Low Pressure

1. XZV-702A malfunctions to open.

1. Refer 8.1.5.1.1

4.

High Pressure

1. Higher than required flow from MUG compressor/ Reduction in feed.

1. Over pressurizing the system.

6.

High Level

7. Problem/Requirements

Recommendations

1. P&ID is to be updated to show details of anti-surge valve as per vendor P&ID.

1. PC-358 provided with 8.4.1.1.1 high alarm.

8.4.1.1.2

1. Refer Node-4, high temp.

8.5.1.1

2. Nitrogen startup operation for refractory dryout feed heater.

1. Possible high suction temp. leading to high Not known discharge temp. (higher than current design).

8.5.2.1

54. Check the feasibility of this operation

1. LC-519 malfunction to close LCV-519

1. HC Liquid carry over to C-001

8.6.1.1.1

55. Operating procedure to monitor LG-522 for HC carry over. When HC level builds up it should be drained to CBD by using Skim line.

1. LC-521 is provided with High alarm.

Remarks

SEI

1. U/S disturbance

2. LC-524 malfunctions to close 1. Liquid carry over with recycle gas to KLCV-524 002

1. LZ-526 provided with 8.6.2.1.1 HH alarm which will activate UZ-705 to trip the compressor.

1. Over pressurization of the system due to some emergencies

1. Emergency 8.7.1.1.1 depressurization safeguarding system UZ702 is provided.

1. Possible loss of life and property.

Responsibility

8.3.1.1

2. PSV-307 A/B is provided. 5. High Temperature

Ref. No.

1.Anti-surge system is available.

Page 69 of 136

SEI

SEI/NOCL

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

NODE NO: 08

Separator over head to Recycle gas compressor inlet

DESIGN INTENTION

1.

To remove H2S from separator overhead stream in HP Amine Absorber.

2.

To feed Recycle Gas to recycle gas Compressor.

DRAWINGS

CS-140-PR-15-0007, CS-140-PR-15-0009, CS-140-PR-15-0010, CS-140-PR-15-0012

EQUIPMENT

Separator (140-V-006),HP Absorber KOD(140-V-007), HP Amine absorber (140-C001),Recycle compressor KOD(140-V-005)

STREAM DETAILS

Separator (V-006) Overhead goes to KOD (V-007)and then HP Amine absorber column (C001) where H2S treated by lean amine solution and send to KOD of Recycle gas compressor (V-005)then finally recycle gas compressor (K-002)

:

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

AVAILABLE CONTROL SCHEMESLC-519,HC-826.LC-521,LC-524

Operating/Design Parameters Pressure ( bar g)

Flow rate (Kg/hr)

Temperature (°C)

SERVICE Separator overhead to HP amine absorber HP Amine absorber to Recycle gas compressor

45 /130

78.8/92

15891-18053

54/130

78.4/92

13337-15497

Note: Node

Deviation

Causes

Consequences

Safeguards

8. Operation/Maintenance

Ref. No. 8.8

Recommendations

Responsibility

56. Confirm that the max. allowable trip temp. (while running in nitrogen service) & all trip set points for machine safeguards for startup nitrogen case are not different from the normal operating case.

BHEL

Remarks

57. If set points are different separate modes of operation to be programmed in DCS and in safeguarding system.

9.Composition

1. HCV-826 malfunction to full open (No flow through to column)

1. High H2S concentration in recycle gas lead to off spec product

2. System pressure may increase due to non removal of H2S

1. AI-001 is provided on K-002 suction line

8.9.1.1.1

2. AI-003 is provided in final gas oil product line.

8.9.1.1.2

1. PC-358 is provided with high alarm

8.9.1.2.1

Page 70 of 136

58. Operating procedure to include operation of HS-822 to select FCV-423 to purge H2S to flare header.

SEI/NOCL

1.Purity of recycle gas is to maintained as per limitation on primary seal is to be confirmed by seal vendor.

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

NODE NO: 09

Recycle gas compressor to mixing point

DESIGN INTENTION

To supply recycle gas from recycle gas compressor to Reaction section

DRAWINGS

CS-140-PR-15-0003,CS-140-PR-15-0005,CS-140-PR-15-0006,CS-140-PR-15-0011

EQUIPMENT

Recycle gas compressor (140-K-002)

STREAM DETAILS

H2 and lighter gases are recycled through RGC(K-002) to mixing point at the inlet of Reactor feed/effluent exchanger

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

AVAILABLE CONTROL SCHEMESFC-427

Operating/Design Parameters Pressure ( bar g)

Flow rate (Kg/hr)

Temperature (°C)

SERVICE Recycle gas compressor to Mixing point

75.7-79/150

92.5-95.2/108.5

4310-5022

Note: Node 9. Recycle Gas compressor to Mixing Point

Deviation 1.

Low/No Flow

Causes 1. K-002 trip Refer node 8 ,compressor trip)

Consequences 1. No hydrogen supply to reactor.

Safeguards 1. UZ-705 will activate UZ-706

2. Reduction in makeup hydrogen flow and ultimately make hydrogen flow is likely to stop.

Ref. No. 9.1.1.1.1

9.1.1.2

3. Gas oil may enter Compressor discharge 1. NRV is provided. line

9.1.1.3.1

2. UZ-706 will activate 9.1.1.3.2 UZ719(back flow protection system) to close XZV-719

4.Liquid backup in recycle and makeup gas line from mixing point.

2. FC-427 malfunction to close FCV-427(Antisurge line)

3. Malfunctioning of XCV715(Antisurge valve) to open

1.NRV is provided near to tie in point.

1. Possibly more hydrogen to Reactor section. NO major concern.)

9.1.1.4.1

9.1.2.1

1.Low hydrogen-HC ratio leading to catalyst 1.FC-427 low alarm is 9.1.3.1.1 coking and potential damage to heater tubes. provided.FZ-428 will initiate UZ-706.

2.FC-412-415 9.1.3.1.2 provided with low flow alarms.

3. TZ-123 is provided with HH temp. trip.

4. FC-427 malfunction to open 1. Same as low flow in anti-surge line with FCV-427(Recycle gas and less severity quench gas line)

9.1.3.1.3

9.1.4.1

Page 71 of 136

Recommendations

Responsibility

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

NODE NO: 09

Recycle gas compressor to mixing point

DESIGN INTENTION

To supply recycle gas from recycle gas compressor to Reaction section

DRAWINGS

CS-140-PR-15-0003,CS-140-PR-15-0005,CS-140-PR-15-0006,CS-140-PR-15-0011

EQUIPMENT

Recycle gas compressor (140-K-002)

STREAM DETAILS

H2 and lighter gases are recycled through RGC(K-002) to mixing point at the inlet of Reactor feed/effluent exchanger

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

AVAILABLE CONTROL SCHEMESFC-427

Operating/Design Parameters Pressure ( bar g)

Flow rate (Kg/hr)

Temperature (°C)

SERVICE Recycle gas compressor to Mixing point

75.7-79/150

92.5-95.2/108.5

4310-5022

Note: Node

Deviation

Causes

Consequences

5. High pressure drop in the downstream system.

1. Less recycle gas flow will lead to possible surging of compressor.

6. SC-002A malfunctions and lower the speed of turbine.

1.Less recycle gas flow (Refer low flow case of recycle gas)(*)

7. MOV-003 malfunctions to close.

1.Compressor likely to see surge.

Safeguards 1. Anti surge valve XCV715 provided.

High Flow

9.1.7.1.2

9.2.1.1.1

2. FZ-428 is provided 9.2.1.1.2 with LL alarm

1. Refer 8.2.1.1.1 and 8.2.1.2.1

3. Reverse/Misdirected Flow

2. K-002 trips

1. Make up hydrogen may back up in recycle compressor discharge

4.

1.Compressor K-002 high speed. 1. Potential surging of compressor.

High Pressure

Responsibility

1.Anti-surge system is 9.1.7.1.1 provided

1. FC-427 malfunction to open 1. Less Hydrogen to reactor/quench leading 1. FCFCV-427 (high flow in antisurge to low product quality. 412/413/414/415 is line) provided with low alarm.

2. SC-002A malfunctions and increases the speed of turbine.

Recommendations

9.1.6.1

2.If full open signal is lost interlock system will trip the compressor. 2.

Ref. No. 9.1.5.1.1

9.2.2.1

1. NRV is provided.

9.3.2.1.1

1.Anti-surge system is 9.4.1.1.1 provided

Page 72 of 136

59. Considering full flow SEI through FCV-427, verify lowlow flow alarm on FZ-428.

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

NODE NO: 09

Recycle gas compressor to mixing point

DESIGN INTENTION

To supply recycle gas from recycle gas compressor to Reaction section

DRAWINGS

CS-140-PR-15-0003,CS-140-PR-15-0005,CS-140-PR-15-0006,CS-140-PR-15-0011

EQUIPMENT

Recycle gas compressor (140-K-002)

STREAM DETAILS

H2 and lighter gases are recycled through RGC(K-002) to mixing point at the inlet of Reactor feed/effluent exchanger

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

AVAILABLE CONTROL SCHEMESFC-427

Operating/Design Parameters Pressure ( bar g)

Flow rate (Kg/hr)

Temperature (°C)

SERVICE

4.

High Pressure

Recycle gas compressor to Mixing point

75.7-79/150

92.5-95.2/108.5

4310-5022

Note: Node

Deviation

Causes 2.More flow of hydrogen from MUG compressor.

5. High Temperature

1. U/S disturbances.

Consequences 1.Potential overpressure of system

1. High discharge temperature may lead to compressor damage

2.Low quench efficiency leading to potential reactor damage.

2. High speed of compressor

Safeguards

Ref. No.

1.PSV-307A/B is provided at V-006

9.4.2.1.1

1. TI-643 is provided with high alarm.

9.5.1.1.1

2. TZ-644A/B/C will activate UZ-731.

9.5.1.1.2

1.HH alarm TIs are available on the reactor.

9.5.1.2.1

1. Refer 9.4.1.1.1

9.5.2.1

6.High level

NA

9.6

7.Low level

NA

9.7

8.composition

NA

9.8

9.others

NA

9.9

Page 73 of 136

Recommendations

Responsibility

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

NODE NO: 10

Lean Amine from B/L to LP and HP amine absorber column

DESIGN INTENTION

Lean Amine supply to HP and LP amine absorber columns.

DRAWINGS

CS-140-PR-15-0009, CS-140-PR-15-0010, CS-140-PR-15-0016

EQUIPMENT

Lean Amine booster pumps(140-P-003A/B),HP Amine absorber column(140-C-001),LP Amine absorber columns(140-C-003)

STREAM DETAILS

Lean amine comes from B/L and goes to LP Amine absorber column (C-003) and pumped through amine Pump(P-003)to HP Amine absorber column

AVAILABLE CONTROL SCHEMES

FC-434,FC-424

:

Project :

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

Operating/Design Parameters Pressure ( bar g)

Flow rate (Kg/hr)

Temperature (°C)

SERVICE Lean Amine from B/L to LP Amine absorber column Lean Amine from B/L to HP Amine absorber column

50 /85

9.5 /14

17649-18370

50 /130

9.5-86.5/92

57857

Note: Node 10.

Lean Amine from B/L to LP and HP 1. Amine Absorber column

Deviation Low/No Flow

Causes 1. U/S disturbance

Consequences 1. P-003A/B may starve and get damaged

Safeguards 1. PI-373 is provided with low alarm

Ref. No. 10.1.1.1.1

2. No flow will be available to L.P./H.P. Amine 1. FZ-443 provided with Absorbers. LL alarm to activate UZ720(Lean amine to C001)

10.1.1.2.1

3. Less/No removal of H2S from recycle gas 1. FC-434/424 are leading to off spec product hue to high partial provided with low flow pressure of H2S in recycle gas. alarm.

10.1.1.3.1

4. Less/No removal of H2S from off gas leading to high H2S in unit 350.

3. AI-002 provided on off gas drum outlet

10.1.1.4.3

1. Refer 10.1.1.4.3

1. Refer 10.1.1.3.2

10.1.2.1.1

2. back flow from HP Amine absorber to lean amine pump(P003A/B)

1. Refer 10.1.1.1.1

10.1.2.2.1

Page 74 of 136

Responsibility

60. For low flow alarm FC-424 SEI and low low trip FZ-443,trip values are presently given as per process point of view, which needs to be verified based on pump vendor min flow requirement. So UZ-720 should also activate UZ-710 to trip pump (P-003A/B)-logic to be implemented Consider clubbing of UZ-710 & UZ-720).

SEI/NOCL 61. Operating procedure should ensure routing of off gas to flare header when there is disturbance in lean amine supply to C-003

2. AI-001 provided on 10.1.1.3.2 recycle gas line overhead of V-005 for monitoring.

2. P-003A/B trips Lean Amine to C-001)

Recommendations

62. Provide high alarm at AI002.

63. Check unit 350 design for possible increase of H2S in feed gas from DHU.

SEI

NOCL/PMC

Remarks

10.

Lean Amine from B/L to LP and HP 1. Amine Absorber column

Low/No Flow

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

NODE NO: 10

Lean Amine from B/L to LP and HP amine absorber column

DESIGN INTENTION

Lean Amine supply to HP and LP amine absorber columns.

DRAWINGS

CS-140-PR-15-0009, CS-140-PR-15-0010, CS-140-PR-15-0016

EQUIPMENT

Lean Amine booster pumps(140-P-003A/B),HP Amine absorber column(140-C-001),LP Amine absorber columns(140-C-003)

STREAM DETAILS

Lean amine comes from B/L and goes to LP Amine absorber column (C-003) and pumped through amine Pump(P-003)to HP Amine absorber column

AVAILABLE CONTROL SCHEMES

FC-434,FC-424

:

Project :

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

Operating/Design Parameters Pressure ( bar g)

Flow rate (Kg/hr)

Temperature (°C)

SERVICE Lean Amine from B/L to LP Amine absorber column Lean Amine from B/L to HP Amine absorber column

Note: Node

Deviation

50 /85

9.5 /14

17649-18370

50 /130

9.5-86.5/92

57857

2. P-003A/B trips Lean Amine to Causes C-001)

3. FC-434 malfunction to close FCV-434(Lean Amine to C003)

Consequences 2. back flow from HP Amine absorber to lean amine pump(P003A/B)

1. Refer 10.1.2.1.1

4. FC-424 malfunctions to close 1. Refer 10.1.2.1.1 FCV-424(Lean Amine to C001) 5. XZV-720 malfunctions to close Lean Amine to C-001)

High Flow

1. FC-434 malfunction to open FCV-434(Lean Amine to C003)

2. NRVs at the pump discharge and inlet of C003 are provided.

1. C-003 level increases, possible column flooding

Ref. No.

1. AI-001 provide on recycle gas line for monitoring

Responsibility

10.1.2.2.2

10.2.4.1.1

10.2.5.1

1. AI-001 provide on recycle gas line for monitoring

10.2.6.1.1

2. FC-424 provided with Low alarm

10.2.6.1.2

1. LC-532 is provided with 10.2.1.1.1 high alarm 2. LI-560 is provided with HH alarm

10.2.1.1.2

2. FC-424 malfunctions to open 1. C-001 level increases, possible column FCV-424(Lean Amine to Cflooding 001)

1. LC-521 is provided with 10.2.2.1.1 high alarm

3. Reverse/Misdirected Flow

1. U/S disturbance

1. NRVs are provided in both the lines.

4. Low pressure

No new cause

1. Off/Fuel gas may come from OSBL (unit 350/fuel gas return header)

Recommendations

1. AI-002 provided on off 10.2.3.1.1 gas drum outlet

1. Refer 10.1.2.1.1

6. FC-456A/B malfunction to full 1. Refer 10.1.2.1.1 open FCV-456A/B(Low flow of Lean amine to C-001)

2.

Safeguards

10.3.1.1.1

10.4

Page 75 of 136

64. UZ-720 should activate UZ710 to trip pump (P-003A/B)

SEI

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

NODE NO: 10

Lean Amine from B/L to LP and HP amine absorber column

DESIGN INTENTION

Lean Amine supply to HP and LP amine absorber columns.

DRAWINGS

CS-140-PR-15-0009, CS-140-PR-15-0010, CS-140-PR-15-0016

EQUIPMENT

Lean Amine booster pumps(140-P-003A/B),HP Amine absorber column(140-C-001),LP Amine absorber columns(140-C-003)

STREAM DETAILS

Lean amine comes from B/L and goes to LP Amine absorber column (C-003) and pumped through amine Pump(P-003)to HP Amine absorber column

AVAILABLE CONTROL SCHEMES

FC-434,FC-424

:

Project :

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

Operating/Design Parameters Pressure ( bar g)

Flow rate (Kg/hr)

Temperature (°C)

SERVICE Lean Amine from B/L to LP Amine absorber column Lean Amine from B/L to HP Amine absorber column

50 /85

9.5 /14

17649-18370

50 /130

9.5-86.5/92

57857

Note: Node

Deviation 5.

High Pressure

6. Low Temperature

Causes

Consequences

Safeguards

Ref. No.

1. FC-424 malfunctions to close 1. System up to FCV-424 from PFCV-424(Lean Amine to C003 may get pressurized 001)

1. System is designed for 10.5.1.1.1 shut off pressure of the pump P-003.

2. XZV-720 malfunctions to close Lean Amine to C-001)

1. System up to XZV-720 from P003 may get pressurized

1. System is designed for 10.5.2.1.1 shut off pressure of the pump P-003.

1. U/S disturbance

1. HC may condense in amine solution leading to foaming.

1. TI-171 is provided with 10.6.1.1.1 low alarm (for C-001), TI186 is provided with low alarm (for C-003)

Recommendations

Responsibility

2. TDI-213 is provided 10.6.1.1.2 with low alarm (for C001),TDI-214 is provided with low alarm (for C-003)

3. Antifoaming agent dosing is provided

10.6.1.1.3

4. PDI-372/392 are provided with high alarms at C-001 & C-003 respectively.

10.6.1.1.4

2. Temp. drop due to low ambient temp. leading to low amine temp. at B/L.

7. High Temperature

1. U/S disturbance- Refer 10.1.1.4.3

1. Poor removal of H2S from Recycle gas/Off gas

1. AI-001/AI-002 is provided for monitoring

Page 76 of 136

10.6.1.2

65. Provide low alarm at TI170.

SEI

10.6.1.2

66. Ensure the provision of Hot PMC/NOCL insulation on the lean amine line coming from ARU (Outside DHU B/L).

10.7.1.1.1

67. Provide High alarm on TI170 at lean amine B.L

SEI

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

NODE NO: 10

Lean Amine from B/L to LP and HP amine absorber column

DESIGN INTENTION

Lean Amine supply to HP and LP amine absorber columns.

DRAWINGS

CS-140-PR-15-0009, CS-140-PR-15-0010, CS-140-PR-15-0016

EQUIPMENT

Lean Amine booster pumps(140-P-003A/B),HP Amine absorber column(140-C-001),LP Amine absorber columns(140-C-003)

STREAM DETAILS

Lean amine comes from B/L and goes to LP Amine absorber column (C-003) and pumped through amine Pump(P-003)to HP Amine absorber column

AVAILABLE CONTROL SCHEMES

FC-434,FC-424

:

Project :

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

Operating/Design Parameters Pressure ( bar g)

Flow rate (Kg/hr)

Temperature (°C)

SERVICE Lean Amine from B/L to LP Amine absorber column Lean Amine from B/L to HP Amine absorber column

50 /85

9.5 /14

17649-18370

50 /130

9.5-86.5/92

57857

Note: Node

Deviation

Causes

8. High level

1. Refer 10.2.1.1.1~2, 10.2.2.1.1

9. Low level

1. Refer 10.1.1.1.1

10. Composition

1.Contamination of CO/CO2 in lean amine supply

11. Others

No new cause

Consequences

Safeguards

Ref. No.

Recommendations

Responsibility

10.8.1 10.9.1 1.Accumulation of CO/CO2 in the system leading to reduction in catalyst activity.

10.1.1.1.

10.11

Page 77 of 136

68. SOP to address regular sampling of recycle gas for CO/CO2.

SEI/NOCL

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

NODE NO: 11

Rich Amine from HP Amine absorber system to LP amine absorber bottom to B/L

DESIGN INTENTION

To supply Rich amine from HP amine absorber column to LP amine absorber column

DRAWINGS

CS-140-PR-15-0010, CS-140-PR-15-0016

EQUIPMENT

HP Amine absorber column (140-C-001), LP Amine absorber column (140-C-003)

STREAM DETAILS

Rich amine from HP Amine absorber column(C-001) bottom to LP Amine absorber column(C-003)

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

AVAILABLE CONTROL SCHEMESLC-521 Operating/Design Parameters Pressure ( bar g)

Flow rate (Kg/hr)

Temperature (°C)

SERVICE Rich amine from HP amine absorber column to LP Amine absorber column

56-57/130

6.2-78.6/92

60413

Note: Node

Deviation

11. Rich Amine from HP Amine 1. Absorber ,LP Amine Absorber bottom to B/L.

2.

Less/No flow

High Flow

Causes

Consequences

Safeguards

1. LC-521 Malfunctions to Close LCV-521

1. Level of C-001 may go high.

2. XZV-709 Malfunctions to close

1. Level of C-001 may go high.

1. LC-521 is provided with High alarm.

11.1.2.1.1

3. LC-532 Malfunctions to Close LCV-532

1. Level of C-003 may go high.

1. LA-560 is provided with HH alarm.

11.1.3.1.1

1. LZ-523 LL alarm will activate UZ-709.

11.2.1.1.1

1. PSV-318 A/B sized for gas break through case.

11.2.1.2.1

1. LC-521 Malfunctions to open 1. Level of C-001 may go down. LCV-521

2. Possible gas breakthrough leading to overpressurization of C-003. 2. LC-532 Malfunctions to open 1. Level of C-003 may go down. LCV-532

11.1.1.1

4. Low pressure

1. Reverse flow of Rich amine from B.L to C-003 bottom.

1. Level in C-003 may go high

Recommendations

Responsibility

69. LG-522A/B (Magnetic type) are to be provided with high high alarm with switch.

SEI

70. Ensure this gas breakthrough case has been considered in design of safety valve in ARU (Receiving flash drum vessel).

PMC/NOCL

1. Low low alarm at LA- 11.2.2.1.1 560 is provided.

2. Possible gas breakthrough to ARU .

3. Reverse/Misdirected Flow

Ref. No.

11.2.2.2

1. NRV is provided at B.L

11.3.1.1.1

2. LC-532 is provided with high alarm.

11.3.1.1.2

3. LI-560 is provided with high high alarm.

11.3.1.1.3

1.Refer 8.3.1.1

11.4.1

Page 78 of 136

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

NODE NO: 11

Rich Amine from HP Amine absorber system to LP amine absorber bottom to B/L

DESIGN INTENTION

To supply Rich amine from HP amine absorber column to LP amine absorber column

DRAWINGS

CS-140-PR-15-0010, CS-140-PR-15-0016

EQUIPMENT

HP Amine absorber column (140-C-001), LP Amine absorber column (140-C-003)

STREAM DETAILS

Rich amine from HP Amine absorber column(C-001) bottom to LP Amine absorber column(C-003)

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

AVAILABLE CONTROL SCHEMESLC-521 Operating/Design Parameters Pressure ( bar g)

Flow rate (Kg/hr)

Temperature (°C)

SERVICE Rich amine from HP amine absorber column to LP Amine absorber column

56-57/130

6.2-78.6/92

60413

Note: Node

Deviation 5. High pressure

Causes

Consequences

Safeguards

1. Refer 8.4.1.1.1 and 8.4.1.1.2

2.External fire

Ref. No. 11.5.1

1.Overpressurization of Column C-001

1.PSV-312 designed for 11.5.2.1.1 external fire case

2.Overpressurization of Column C-003.

1.PSV-318A/B design covers external fire case

11.5.2.2.1

6. Low Temperature

1. Refer 10.6.1.1.1~4 and 10.6.1.2

11.6.1

7.

1. Refer 10.7.1.1.1

11.7.1

1. Refer 11.1.1.1, 11.1.2.1.1 and 11.1.3.1.1

11.8.1

High Temperature

8. High level

1. Low pressure in C-003

9. Low level

1. Refer 11.2.1.1.1 and 11.2.2.1.1

10. Composition

No new cause.

1.No sufficient pressure in C-003 to push rich 1.Low alarm at PI-999 amine to ARU leading to increase in level in is provided on C-003. column.

11.8.1.1.1

2.LC-532 is provided with high alarm

11.8.1.1.2

3.LI-560 is provided with high high alarm.

11.8.1.1.3

11.9.1

11.1

11. Others

11.11

Page 79 of 136

Recommendations

Responsibility

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

Nagarjuna Oil Corporation Ltd

NODE NO: 12

LP Amine absorber system (LP Amine Column KOD, Off gas KOD) to B/L

DESIGN INTENTION

To Supply Off /Fuel gases from sour water flash drum and stripper reflux drum to B/L Unit-350.

DRAWINGS

CS-140-PR-15-0021, CS-140-PR-15-0016,CS-140-PR-15-0006

EQUIPMENT

Stripper Reflux Drum (140-V-008),LP Amine KOD(140-V-010), LP Amine Absorber Column (140-C-003), Off gas KOD (140-V-018) ,Sour water flash Drum(140-V-017)

STREAM DETAILS

Flash gas from flash drum(V-017)and off gases from Reflux drum (V-008) is collected to KOD of LP Amine absorber column (C-010) where it is treated with amine solution and send to B/L or Fuel gas header

Diesel hydro Desulphurization unit

AVAILABLE CONTROL SCHEMESPC-394,LC-551

Operating/Design Parameters Pressure ( bar g)

Flow rate (Kg/hr)

Temperature (°C)

SERVICE Off gases from reflux drum to KOD of LP Amine absorber Off gases/Fuel gases LP amine KOD to B/L

45.0 /65

6.4 /8

1172-1371

45.0 / 65

2.6 - 6.3 /8

512-741

Note: Node

Deviation

12. LP Amine Absorber system 1. (LP Amine column KOD, Off Gas KOD) to B/L

Less/No flow

Causes

Consequences

1. PC-394 malfunctions to close 1 Increase in pressure in sour water flash PCV-394A/B. drum and stripper resulting in improper flashing of HC leading to HC carryover with Sour water and off spec product due to poor stripping in stripper.

Safeguards

Ref. No.

Recommendations

Responsibility

1. PSV-318A/B is provided 12.1.1.1.1 2. PI-903 is provided with high alarm at C-002 overhead 3. AI-003 is provided

2.

High Flow

2. LC-551 malfunctions to close 1. V-018 level will increase & Liquid may LCV-551 located at Off gas carryover with off gas/fuel gas KOD(V-018).

12.1.2.1

71. LG-552 to be converted to Mag. Type with provision of high level alarm with switch.

SEI

3. LC-530 malfunctions to close 1. V-010 level will increase & Liquid may LCV-530 when required. carryover with off gas to C- 003 leads to foaming in C-003.

12.1.3.1

72. Periodical checking of interface in LG-533A/B/C/D.

SEI/NOCL

1. PC-394 malfunctions to open 1. Column level in C-003 will increase due PCV-394A/B. to fall in system pressure

1. LC-532 is provided with 12.2.1.1.1 high alarm. 2. AI-002 is provided for monitoring. 3. Pressure transmitter PT-999 is provided with low alarm at top of C003.

2. Less removal of H2S from off gas (Also Refer 10.1.1.4.3)

1. LI-560 is provided with HH alarm.

12.2.1.2.1

2. H2S analyzer (AI-002) in the product line indicates off-spec off gas

12.2.1.2.2

2. LC-551 malfunctions to open LCV-551. 1. Gas break through

12.2.2.1

Page 80 of 136

Remarks

12. LP Amine Absorber system (LP Amine column KOD, Off Gas KOD) to B/L

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

Nagarjuna Oil Corporation Ltd

NODE NO: 12

LP Amine absorber system (LP Amine Column KOD, Off gas KOD) to B/L

DESIGN INTENTION

To Supply Off /Fuel gases from sour water flash drum and stripper reflux drum to B/L Unit-350.

DRAWINGS

CS-140-PR-15-0021, CS-140-PR-15-0016,CS-140-PR-15-0006

EQUIPMENT

Stripper 2. HighReflux Flow Drum (140-V-008),LP Amine KOD(140-V-010), LP Amine Absorber Column (140-C-003), Off gas KOD (140-V-018) ,Sour water flash Drum(140-V-017)

STREAM DETAILS

Flash gas from flash drum(V-017)and off gases from Reflux drum (V-008) is collected to KOD of LP Amine absorber column (C-010) where it is treated with amine solution and send to B/L or Fuel gas header

Diesel hydro Desulphurization unit

AVAILABLE CONTROL SCHEMESPC-394,LC-551

Operating/Design Parameters Pressure ( bar g)

Flow rate (Kg/hr)

Temperature (°C)

SERVICE Off gases from reflux drum to KOD of LP Amine absorber Off gases/Fuel gases LP amine KOD to B/L

45.0 /65

6.4 /8

1172-1371

45.0 / 65

2.6 - 6.3 /8

512-741

Note: Node

Deviation

Causes

Consequences

3. LC-530 malfunctions to open 1. Gas break through to CBD leading to low LCV-530. pressure in LP amine absorber.

3. Reverse/Misdirected flow 4.

High Pressure

1. Choking of Packed Beds in C-003

2. External fire

Safeguards

Ref. No.

1. Pressure transmitter PI- 12.2.3.1.1 999 is provided with low alarm at top of C003.

1.Reverse flow from ARU,unit-350,fuel gas return header

1. NRVs are provided on respective lines

1. High Pressure drop in Column leading to Improper H2S removal.

1. PDI-392 provided with 12.4.1.1.1 high alarm.

1. Overpressurization of C-003,V-018,V-017

5. Low temp.

No new cause

6. High Temperature

1. U/S disturbance (from V-008) 1. Possible condensation of Heavier HC in C-003 resulting in foaming in C-003.

12.3.1.1

2. PSV-318A/B is provided.

12.4.1.1.2

1.PSVs are provided covering fire case.

12.4.2.1.1

12.5

1. TI-208 at V-008 top is provided with high alarm.

12.6.1.1.1

2. TI-184 on inlet of C003 is provided with high alarm.

12.6.1.1.2

3. TDI-214 is provided.

12.6.1.1.3 12.7

7. Low level

Same as high flow

8. high level

Same as low flow

12.8

9. composition

No new cause

12.9

10. others

No new cause

12.1

Page 81 of 136

Recommendations

Responsibility

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

Nagarjuna Oil Corporation Ltd

NODE NO: 13

Stripper bottom to Gas oil air cooler , Coalescer and salt dryer to B/L

DESIGN INTENTION

To supply Hydro treated gas oil from Stripper Bottom to B/L.

DRAWINGS

CS-140-PR-15-0017, CS-140-PR-15-0018, CS-140-PR-15-0019, CS-140-PR-15-0022

EQUIPMENT

Stripper(140-C-002),Stripper bottoms pump(140-P-005),Stripper feed/bottom exchanger(140-EE-006),Gas oil air cooler (140-EA-003),Gas oil trim cooler (140-EE-007), Coalescer (140-V-009),Salt dryer (140-V-019)

STREAM DETAILS

Stripper bottoms is cooled in Stripper feed bottoms exchanger, Gas oil air cooler and Gas oil trim cooler. Then it is passed to coalescer and salt dryer to remove moisture. Then it is sent to B.L.

Diesel hydro Desulphurization unit

AVAILABLE CONTROL SCHEMESFC-442,LC-535,LC-544

Operating/Design Parameters SERVICE Temperature(°C) Stripper bottoms to feed bottom exchanger, Gas Oil Air cooler, Trim cooler Gas oil From Coalescer to B.L.

Pressure ( bar g)

Flow rate (Kg/hr)

65-252.1/300 40.0/ 140

7.3-11.8/15

115553

5.0-7.3 /9

115214

Note: Node 13. Stripper bottom to Gas oil Air 1. cooler, Coalescer and Salt Dryer to B/L

Deviation Less/No flow

Causes 1. P-005A/B trips.

Consequences 1. C-002 level will increase, ultimately leading to filling of column.

Safeguards 1. LC-535 on stripper provided with high alarm

Ref. No.

Recommendations

Responsibility

13.1.1.1.1

2. Continued steam supply to the stripper will 1. LZ-537 is provided n 13.1.1.2.1 damage the trays. stripper C-002 with HH alarm & activates UZ-717 to isolate MP Steam to C002

3. System pressure at pump P-005 D/S will come down, will lead to non-availability of backwash fluid for feed filter

2. LC-535/FC-442 malfunctions 1. System will face P-005 shut off pressure to close FCV-442(downstream of salt dryer).

1.Pressure transmitter PT- 13.1.1.3.1 444 is provided with low alarm downstream of V019, before FCV-442 on line P-103.

1. System is designed for pump shut off pressure.

13.1.2.1.1

2. High pressure alarm PI444 is provided.

2. C-002 level will increase, ultimately leading to filling of column.

3. LC-535(maintaing stripper bottom level)/FC-454 malfunctions to close FCV454(Start-up recirculation line).

1. Same as safeguards 1, 13.1.2.2.1 2 for cause 1 in this node.

1. Refer 13.1.2.1.1 and 13.1.2.2.1

13.1.3.1

Page 82 of 136

73. .Keep the spectacle blind located in startup recirculation line in open position to maintain unit under circulation during upset without loosing much time.

SEI

Remarks

13. Stripper bottom to Gas oil Air 1. cooler, Coalescer and Salt Dryer to B/L

Less/No flow

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

Nagarjuna Oil Corporation Ltd

NODE NO: 13

Stripper bottom to Gas oil air cooler , Coalescer and salt dryer to B/L

DESIGN INTENTION

To supply Hydro treated gas oil from Stripper Bottom to B/L.

DRAWINGS

CS-140-PR-15-0017, CS-140-PR-15-0018, CS-140-PR-15-0019, CS-140-PR-15-0022

EQUIPMENT

Stripper(140-C-002),Stripper bottoms pump(140-P-005),Stripper feed/bottom exchanger(140-EE-006),Gas oil air cooler (140-EA-003),Gas oil trim cooler (140-EE-007), Coalescer (140-V-009),Salt dryer (140-V-019)

STREAM DETAILS

Stripper bottoms is cooled in Stripper feed bottoms exchanger, Gas oil air cooler and Gas oil trim cooler. Then it is passed to coalescer and salt dryer to remove moisture. Then it is sent to B.L.

Diesel hydro Desulphurization unit

AVAILABLE CONTROL SCHEMESFC-442,LC-535,LC-544

Operating/Design Parameters SERVICE Temperature(°C) Stripper bottoms to feed bottom exchanger, Gas Oil Air cooler, Trim cooler Gas oil From Coalescer to B.L.

Pressure ( bar g)

Flow rate (Kg/hr)

65-252.1/300 40.0/ 140

7.3-11.8/15

115553

5.0-7.3 /9

115214

Note: Node

Deviation

Causes

Consequences

4. MOV -004 in closed condition 1. Pump will run dry. Refer -13.1.1.1.1, 13.1.1.2.1 and 13.1.1.3.1 for remaining consequences

Safeguards

Ref. No.

Recommendations

Responsibility

1.If MOV-004 full open 13.1.4.1.1 signal is lost, interlock will stop the pump. 2.Start permissive is included as a part of safe guarding system for Pump P-005A/B.

5. Choking of coalescer in V009

Refer 13.1.2.2.1

1.PDI-914 provided with High alarm.

6. Choking of salt dryer in V019

Refer 13.1.2.2.1

1. PDI-923 Provided with 13.1.6.1.1 High alarm

7. FC-436 malfunctions to close 1. Product quality upset (Flash point ,sulfur 1. SC-011(type B) is FCV-436 content of Gas oil) provided at downstream of salt dryer.

2.

High Flow

3. Reverse/Misdirected Flow

13.1.7.1.1

2. AI-003 is provided for monitoring

13.1.7.1.2

13.1.8.1.1

8. XZV-717 malfunctions to close

1. Refer 13.1.7.1.1 and 13.1.7.1.2

1. FC-436 provided with low alarm.

1. LC-535/FC-442 malfunctions to open FCV-442.

1. Level of C-002 may go down. 2. Product quality may get affected due to less residence time in V009/V-019 respectively.

13.1.5.1.1

74. FC-436 should be force closed when UZ-717 is activated.

SEI

1. LZ-538 is provided with 13.2.1.1.1 LL alarm to activate UZ712. 13.2.1.2.1

75. Provide high alarm for FC-442.

SEI

76. Provide independent SEI DCS low low alarm from LZ537

2. LC-535/FC-454 malfunctions to open FCV-454(Start-up recirculation line).

1. Level of C-002 may go down and ultimately pump may run dry damaging the accessories.

1. LZ-538 is provided with LL alarm to activate UZ-712.

13.2.2.1.1

1. P-005 A/B trips

1. Gas oil may backup from storage

1. NRV provided in Rundown line at B.L.

13.3.1.1.1

Page 83 of 136

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

Nagarjuna Oil Corporation Ltd

NODE NO: 13

Stripper bottom to Gas oil air cooler , Coalescer and salt dryer to B/L

DESIGN INTENTION

To supply Hydro treated gas oil from Stripper Bottom to B/L.

DRAWINGS

CS-140-PR-15-0017, CS-140-PR-15-0018, CS-140-PR-15-0019, CS-140-PR-15-0022

EQUIPMENT

Stripper(140-C-002),Stripper bottoms pump(140-P-005),Stripper feed/bottom exchanger(140-EE-006),Gas oil air cooler (140-EA-003),Gas oil trim cooler (140-EE-007), Coalescer (140-V-009),Salt dryer (140-V-019)

STREAM DETAILS

Stripper bottoms is cooled in Stripper feed bottoms exchanger, Gas oil air cooler and Gas oil trim cooler. Then it is passed to coalescer and salt dryer to remove moisture. Then it is sent to B.L.

Diesel hydro Desulphurization unit

AVAILABLE CONTROL SCHEMESFC-442,LC-535,LC-544

Operating/Design Parameters SERVICE Temperature(°C) Stripper bottoms to feed bottom exchanger, Gas Oil Air cooler, Trim cooler Gas oil From Coalescer to B.L.

Pressure ( bar g)

Flow rate (Kg/hr)

65-252.1/300 40.0/ 140

7.3-11.8/15

115553

5.0-7.3 /9

115214

Note: Node

Deviation 4.

Low Pressure

Causes 1. U/S disturbance

Consequences 1. P-005 capacity reduces and level in column will rise.

Safeguards 1. LZ-537 HH will activate UZ-717 to close XZV717 on M.P steam line.

2. Refer low no flow P-005A/B trips conseq. 3.(*) 5. High Temperature

1. EA-003 trips

Ref. No.

Recommendations

Responsibility

13.4.1.1.1

13.4.2

1. Likely Poor performance of V009/V-019. If temp. raises above 60 C melting/caking of salt in salt dryer may take place.

1. High alarm provided at TI-203/204.

13.5.1.1.1

77. Possibility of dissolution Vendor/SEI of salt in gas oil product is to be confirmed.

2. Separate electric 13.5.1.1.2 supply line is provided for the fans in EA-003.

6. Problem/Requirements

2. Cooling water failure in EE007

1. Refer 13.5.1.1.1 ~2

3. Cooling medium failure in EE-006

1. Refer 7.8.1.1.1

13.5.2.1

1. High alarm provided at TI-203.

13.5.3.1.1

2. High alarm provided at TI-204.

13.5.3.1.2

1. Not Draining of salt dryer

1. Water may carry over with diesel product 1.AI-003 is provided leading to off spec product quality

2. Loss of salt in salt dryer

1. Water may carry over with diesel product. 1. SC-011 is provided for 13.6.2.1.1 sampling

2. PDI-923 is provided with high alarm.

Page 84 of 136

13.6.1.1.1

13.6.2.1.2

78. Operating procedure SEC/NOCL should ensure draining of salt dryer at regular intervals by checking LG554.

79. Regular top up SEI/NOCL procedures/schedules to be mentioned in SOP. 80. P&ID is to be updated for maintenance /Top up discharge/bypassing salt dryer procedure.

SEI/VENDOR

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

Nagarjuna Oil Corporation Ltd

NODE NO: 13

Stripper bottom to Gas oil air cooler , Coalescer and salt dryer to B/L

DESIGN INTENTION

To supply Hydro treated gas oil from Stripper Bottom to B/L.

DRAWINGS

CS-140-PR-15-0017, CS-140-PR-15-0018, CS-140-PR-15-0019, CS-140-PR-15-0022

EQUIPMENT

Stripper(140-C-002),Stripper bottoms pump(140-P-005),Stripper feed/bottom exchanger(140-EE-006),Gas oil air cooler (140-EA-003),Gas oil trim cooler (140-EE-007), Coalescer (140-V-009),Salt dryer (140-V-019)

STREAM DETAILS

Stripper bottoms is cooled in Stripper feed bottoms exchanger, Gas oil air cooler and Gas oil trim cooler. Then it is passed to coalescer and salt dryer to remove moisture. Then it is sent to B.L.

Diesel hydro Desulphurization unit

AVAILABLE CONTROL SCHEMESFC-442,LC-535,LC-544 6. Problem/Requirements Operating/Design Parameters SERVICE Temperature(°C) Stripper bottoms to feed bottom exchanger, Gas Oil Air cooler, Trim cooler Gas oil From Coalescer to B.L.

Pressure ( bar g)

Flow rate (Kg/hr)

65-252.1/300 40.0/ 140

7.3-11.8/15

115553

5.0-7.3 /9

115214

Note: Node

Deviation

Causes 3. Leakage through Seal in P005A/B

Consequences 1. Possible fire

Safeguards

2. HZ-850 is provided at safe distance to activate UZ-712.

4. Tube leak in EE-007

Ref. No.

Recommendations

Responsibility

1. Pump is provided with 13.6.3.1.1 double mechanical seal

1. Stripper bottom will ingress in cooling water line

13.6.3.1.2

13.6.4.1

7. Operation/Maintenance

13.7

Page 85 of 136

81. Confirm that hydrocarbon detectors are provided in cooling tower area.

NOCL

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

NODE NO: 14

Stripped overhead system, including corrosion inhibitor injection

DESIGN INTENTION

To Supply Wild Naphtha to B/L.

DRAWINGS

CS-140-PR-15-0017, CS-140-PR-15-0020, CS-140-PR-15-0021,CS-140-PR-15-0023

EQUIPMENT

Stripper Air Condenser(140-EA-002), Stripper Trim Condenser(140-EE-005),Stripper Reflux Drum(140-V-008), Stripper Reflux Pumps(140-P004A/B)

STREAM DETAILS

Stripper Overhead is condensed and sent to B.L for storage. A part is sent back to column as reflux.

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

AVAILABLE CONTROL SCHEMESLC-542,FC-439,FC-441,LC-540

Operating/Design Parameters SERVICE Temperature(°C) Stripper Reflux Wild Naphtha to Storage .

Pressure ( bar g)

Flow rate (Kg/hr)

45/140 45/140

9.5-11.5/15 6.0-11/15

9105 2956

Note: Node 14. Stripper Overhead system

Deviation 1. Low/No Flow of overhead vapors

Causes

Consequences

1. U/S disturbance (stripping steam failure/Low feed inlet temperature to C-002)

1. Product quality may get affected (Gas oil) due to poor stripping.

Safeguards

2. Low/no flow of reflux

1. P-004A/B trips (reflux)

Respons ibility

14.1.2.1

2 Pump running in zero forward flow leading to potential damage.

14.1.2.2

1. V-008 level may go high

1. LC-540 is provided with high alarm.

14.2.1.1.1

2. C-002 overhead pressure & temp. may increase.

1. FC-439/441 is provided with low alarm

14.2.1.2.1

2. PI-903 is provided with 14.2.1.2.2 high alarm. 3. PSV-319A/B is 14.2.1.2.3 designed for reflux failure case 2. FC 439 malfunctions to close 1. Refer 14.1.2.1 and 14.1.2.2 FCV-439

14.2.1

1. LC-540 is provided with high alarm.

Page 86 of 136

14.2.3.1.1

Remarks In case TC/FC cascaded rearrangement is accepted then FC-439 low alarm is there.

14.1.1.1.2

1. No hazardous consequences.

3. FC 441 malfunctions to close 1. V-008 level may go high FCV-441.

Recommendations

1. AI-003 is provided on 14.1.1.1.1 gas oil product line.

2. TI-192 with low alarm is provided. 2. Feed failure

Ref. No.

82. TBC from vendor regarding the requirement of min. flow to avoid churning.

SEI

14. Stripper Overhead system

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

NODE NO: 14

Stripped overhead system, including corrosion inhibitor injection

DESIGN INTENTION

To Supply Wild Naphtha to B/L.

DRAWINGS

CS-140-PR-15-0017, 2. Low/no flow of refluxCS-140-PR-15-0020, CS-140-PR-15-0021,CS-140-PR-15-0023

EQUIPMENT

Stripper Air Condenser(140-EA-002), Stripper Trim Condenser(140-EE-005),Stripper Reflux Drum(140-V-008), Stripper Reflux Pumps(140-P004A/B)

STREAM DETAILS

Stripper Overhead is condensed and sent to B.L for storage. A part is sent back to column as reflux.

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

AVAILABLE CONTROL SCHEMESLC-542,FC-439,FC-441,LC-540

Operating/Design Parameters SERVICE Temperature(°C) Stripper Reflux Wild Naphtha to Storage .

Pressure ( bar g)

Flow rate (Kg/hr)

45/140 45/140

9.5-11.5/15 6.0-11/15

9105 2956

Note: Node

Deviation

Causes 4. LC-540 malfunction to close LCV-540B/FCV-441

Consequences

Safeguards

1. V-008 level may go high causing 1. FI-438 with high alarm overpressurization of stripper, liquid carryover is provided . to V-010 and potential foaming in LP amine absorber.

2. LC-530 is provided with low level alarm.

Ref. No. 14.2.4.1.1

Recommendations

Respons ibility

Remarks

83.Consider providing SEI independent level transmitters with high alarm and delete the high alarm from LC-540

1. Provide flow totalizer (FI-446 & 441) with low alarm

84.Consider Providing independent level transmitters with high alarm and delete the high alarm from LC-540

High level alarm to be provided on magnetic LG541 with switch

2. High level alarm to be provided on magnetic LG541 with switch

14.2.4.1.2

3. PI-903 is provided with 14.2.4.1.3 high alarm. 3.

High Flow

1. FC 439 malfunctions to open 1. Column overhead temperature comes FCV-439 down which lead to gas oil product off spec (Flash point)

1.Low alarm at TI-192 is provided.

14.3.1.1.1

1. LC-540 is provided with low alarm.

14.3.1.2.1

2. FC 441 malfunctions to open 1. V-008 level may go down FCV-441

1. LC-540 is provided with low alarm.

14.3.2.1.1

3. LC-540 malfunction to open LCV-540B/FCV-441

1. FC-441/FC-439 is provided with Low alarm

14.3.3.1.1

2. V-008 level may come down and leading to loss of reflux.

1. V-008 level may go down leading to loss of reflux.

Page 87 of 136

SEI

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

NODE NO: 14

Stripped overhead system, including corrosion inhibitor injection

DESIGN INTENTION

3. High Flow To Supply Wild Naphtha to B/L.

DRAWINGS

CS-140-PR-15-0017, CS-140-PR-15-0020, CS-140-PR-15-0021,CS-140-PR-15-0023

EQUIPMENT

Stripper Air Condenser(140-EA-002), Stripper Trim Condenser(140-EE-005),Stripper Reflux Drum(140-V-008), Stripper Reflux Pumps(140-P004A/B)

STREAM DETAILS

Stripper Overhead is condensed and sent to B.L for storage. A part is sent back to column as reflux.

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

AVAILABLE CONTROL SCHEMESLC-542,FC-439,FC-441,LC-540

Operating/Design Parameters

3. LC-540 malfunction to open LCV-540B/FCV-441

SERVICE Temperature(°C) Stripper Reflux Wild Naphtha to Storage .

Pressure ( bar g)

Flow rate (Kg/hr)

45/140 45/140

9.5-11.5/15 6.0-11/15

9105 2956

Note: Node

Deviation

Causes

Consequences 2. Pump will loose suction.

Safeguards 1. Sufficient time is available for V-008 to loose liq. Level.

Ref. No.

NA

14.4

5.

1. D/S disturbance(PCV-394A/B 1. Carry over of diesel in stripper overhead. 1. LC-540 is provided full open) heavies in wild naphtha to unit -160/200.No with high alarm hazardous consequences.

14.5.1.1.1

6. High Temperature

1. EA-002 partial failure

2. P-004 discharge pressure will come down 1. Low pressure alarm leading to increase of level in V-008. PI-999 is provided at LP amine absorber outlet.

14.5.1.2.1

1. Heavier hydrocarbon carryover with Off gas leading to foaming in C-003.

1.FI-438 is provide with high alarm

14.6.1.1.1

2.TI-208 is provided with high alarm.

14.6.1.1.2

2. Level of V-008 may come down which leads to reflux failure,

Respons ibility

Remarks

14.3.3.1.1

4. Reverse/Misdirected Flow Low Pressure

Recommendations

14.6.1.2

85.Consider Providing independent level transmitters with high alarm and delete the high alarm from LC-540

SEI

High level alarm to be provided on magnetic LG541 with switch

1. PSV-319A/B is 14.6.1.2.1 designed for reflux failure case 2. TI-208 is provided with 14.6.1.2.2 high alarm

Page 88 of 136

86.Provide high temp alarm on TI-192

SEI

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

NODE NO: 14

Stripped overhead system, including corrosion inhibitor injection

DESIGN INTENTION

To Supply Wild Naphtha to B/L.

DRAWINGS EQUIPMENT

CS-140-PR-15-0017, CS-140-PR-15-0020, CS-140-PR-15-0021,CS-140-PR-15-0023 6. High Temperature Stripper Air Condenser(140-EA-002), Stripper Trim Condenser(140-EE-005),Stripper Reflux Drum(140-V-008), Stripper Reflux Pumps(140-P004A/B)

STREAM DETAILS

Stripper Overhead is condensed and sent to B.L for storage. A part is sent back to column as reflux.

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

AVAILABLE CONTROL SCHEMESLC-542,FC-439,FC-441,LC-540

Operating/Design Parameters SERVICE Temperature(°C) Stripper Reflux Wild Naphtha to Storage .

Pressure ( bar g)

Flow rate (Kg/hr)

45/140 45/140

9.5-11.5/15 6.0-11/15

9105 2956

Note: Node

Deviation

7. Low temp.

Causes

Consequences

9. Operation/Maintenance

Ref. No.

2.Reflux failure

1. Refer 14.6.1.2, 14.6.1.2.1 and 14.6.1.2.2

14.6.2.1

3. Cooling water failure in EE005

1. Refer 14.6.1.2, 14.6.1.2.1 and 14.6.1.2.2

14.6.3.1

1.U/S disturbances.

1. Lower temp at the top of stripper overhead 1.Corrosion inhibitor line leading to Corrosion in stripper top trays. injection is provided.

14.7.1.1.1

2.Low alarm TI-192 is provided.

2.Low temp. of feed 8. Problem/Requirements

Safeguards

Recommendations

Respons ibility

14.7.2.1.2

1. Tube leak in EE-005

1. Stripper over head will ingress in cooling water line

14.8.1.1

87.Confirm that hydrocarbon detectors are provided in cooling tower area.

NOCL

1 Less corrosion inhibitor injection

1. Corrosion of overhead line and downstream air cooler

14.9.1.1

88.SOP to ensure that the proper dosing rate is maintained and confirmed with proper lineup.

SEI/NOC L

2. overdosing of corrosion inhibitor

1. No major safety concerns.

14.9.2.1

Page 89 of 136

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

NODE NO: 15

Makeup H2 Compressor System

DESIGN INTENTION

To supply Hydrogen to make-up Compressor supply from B/L.

DRAWINGS

CS-140-PR-15-0013, CS-140-PR-15-0014, CS-140-PR-15-0015

EQUIPMENT

Make Up Gas Compressor K.O.Drum (140-V-002), Make-up Compressor (140-K-001A/B), Make-up Compressor Inter stage Cooler (140-EE-008A/B)

STREAM DETAILS

Make up hydrogen comes from B.L. to K.O.Drum to remove any liquid content and compressed to 95 barg

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

AVAILABLE CONTROL SCHEMES

Operating/Design Parameters SERVICE Temperature(°C) Hydrogen from B.L. .

Pressure ( bar g)

Flow rate (Kg/hr)

45 /120

20 /26

2457

Note: Node 15. Makeup H2 Compressor system

Deviation 1.

Low/No Flow

Causes 1. U/S disturbance

Consequences

Safeguards

Ref. No.

1. Less/No hydrogen make up to reaction section because compressor is in recycle mode leading to low pressure in reaction section.

1. FI-432 at hydrogen makeup line from B/L, is provided with low alarm.

15.1.1.1.1

2. Suction pressure of compressor may go down

1. PC-383 is provided with low alarm

15.1.1.2.1

2. PZ-385/PZ-956 LL alarm will activate UZ707 to trip K-001A/B

15.1.1.2.2

Recommendations 89. Provide low alarm at PI358A on separator drum.

Responsibility SEI

Remarks P&ID is to be updated for HydroCOM signals.

3.Note-13 is provided in 15.1.1.2.3 P&ID stating that signals from non running compressor instruments shall not be used for control and trip of the running compressor.

2. Running compressor K-001A/B trips

1. No hydrogen make up to reaction section.

1.No safeguard till start up of spare compressor (spare compressor will take time for startup).

15.1.2.1.1

90.Check the time required to SEI/NOCL startup spare compressor .

1.DHU feed can be maintained till hydrogen pressure is available upto 63 bar. Meanwhile standby compressor has to be started. The start-up philosophy of keeping the compressor in standby condition accordingly.

2 Vendor P&ID is to be updated for all operator controls, DCS interfaces of HydroCOM. 3. XZV-707 at compressor discharge line to reaction section, malfunction to close

1. No hydrogen make up to reaction section 1. PC-974 is provided with high alarm

15.1.3.1.1

2. Compressor discharge may experience high pressure.

15.1.3.2.1

1. Spill back line is provided.

2. FI-432 is provided with 15.1.3.2.2 low alarm 4. FC-431/PC-383/PC-974 malfunctions to open FCV431(Makeup line)

1. Less hydrogen make up to reaction section

1. FI-432 is provided with low alarm

15.1.4.1.1

5. FC-431/ malfunctions to close FCV431(Spill back line)

1. System pressure may go high

1. PC-974 is provided with high alarm

15.1.5.1.1

Page 90 of 136

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

NODE NO: 15

Makeup H2 Compressor System

DESIGN INTENTION

To supply Hydrogen to make-up Compressor supply from B/L.

DRAWINGS

CS-140-PR-15-0013, CS-140-PR-15-0014, CS-140-PR-15-0015

EQUIPMENT

Make Up Gas Compressor K.O.Drum (140-V-002), Make-up Compressor (140-K-001A/B), Make-up Compressor Inter stage Cooler (140-EE-008A/B)

STREAM DETAILS

Make up hydrogen comes from B.L. to K.O.Drum to remove any liquid content and compressed to 95 barg

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

AVAILABLE CONTROL SCHEMES

Operating/Design Parameters SERVICE Temperature(°C) Hydrogen from B.L. .

Pressure ( bar g) 20 /26

5. FC-431/ malfunctions to close FCV431(Spill back line)

Note: Node

Flow rate (Kg/hr)

45 /120

Deviation

Causes

1. System pressure may go high Consequences

Safeguards 2. PSV-316/317 is provided.

6.PC-383 /PC-974 malfunctions to close FCV431(Spill back line)

1. Low pressure in suction

7. PC-922 malfunction to close, PCV-922,at the inlet line to hydrogen cooler (hydrogen to Unit2500)

1. No major concern as this line is NNF.

8. PC-922 malfunction to open PCV-922(Make up line)

1. System d/s PCV-922 may experience high pressure.

9. Demister choke-up

2. Low/no flow(V),P&ID-0014

1. Pressure buildup in KO drum.

Ref. No. 15.1.5.1.2

Recommendations

Responsibility VENDOR

1. Low low alarm at PZ- 15.1.6.1.1 901 is provided to trip the compressor. 15.1.7.1

1. PSV-952A/B is provided.

15.1.8.1.1

1. PC-383 is provided with low alarm.

15.1.9.1.1

2. PSV-315 is provided.

15.1.9.1.2

3. PZ-901 is provided to trip the compressor.

15.1.9.1.3

10. HydroCOM malfunctions to unload

1.Less flow to reaction section

1.U/S disturbances

1.Low suction pressure.

15.2.1.1

2.Compressor trip.

15.2.1.2

2.Suction strainer choking

2457

1.HydroCOM system can 15.1.10.1.1 be bypassed/spill back system can operate with 100%

1.Low suction pressure.

1. PDI-901 is provided.

15.2.1.1

2. compressor trip., High rod load.

1. Low suction pressure trip PZ-901 is provided.

15.2.2.2.1

3. High discharge temp.

1.High discharge temp. alarm TIH-902 is provided.

15.2.2.3.1

2. High discharge temp. trip TIHH-903 is provided.

15.2.2.3.2

Page 91 of 136

91.PT with high alarm is to be SEI provided instead of PI-953.

92.Low pressure alarm at PC- SEI 358 is to be provided on V006.

Remarks Vendor P&IDs are to be updated for consistency in tag no.

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

NODE NO: 15

Makeup H2 Compressor System

DESIGN INTENTION

To supply Hydrogen to make-up Compressor supply from B/L.

DRAWINGS

CS-140-PR-15-0013, CS-140-PR-15-0014, CS-140-PR-15-0015 2. Low/no flow(V),P&ID-0014

EQUIPMENT

Make Up Gas Compressor K.O.Drum (140-V-002), Make-up Compressor (140-K-001A/B), Make-up Compressor Inter stage Cooler (140-EE-008A/B)

STREAM DETAILS

Make up hydrogen comes from B.L. to K.O.Drum to remove any liquid content and compressed to 95 barg

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

2.Suction strainer choking

AVAILABLE CONTROL SCHEMES

Operating/Design Parameters SERVICE Temperature(°C) Hydrogen from B.L. .

Pressure ( bar g)

Flow rate (Kg/hr)

45 /120

20 /26

2457

Note: Node

Deviation

Causes

Consequences 4. High motor current

Safeguards 1.Motor overload trip is provided (from MCC).

5. High rod load. 3.

High Flow

1. FC-431/PC-383/PC-974 malfunctions to close FCV431(Makeup line)

1. Refer 15.1.5.1.1 and 15.1.5.1.2

4. High flow(V),P&ID-0014

15.2.2.4.1

1.High alarm on PI-904 is 15.3.1.1.1 provided.

15.3.1.1.2

15.3.2.1

1. Refer 15.1.4.1.1

2. High suction pressure

1.Interstage PSVs are provided for each stage.

15.3.2.2.1

3. PC-922 malfunction to open PCV-922(hydrogen to Unit2500)

1. Refer 15.1.7.1

15.3.3.1

4. PC-922 malfunction to close PCV-922(Make up line)

1. Refer 15.1.6.1.1

15.3.4.1

1. Loss of loop pressure

2. High upstream pressure.

1.Spillback valve FCV431 is provided.

15.4.1.1

1. High interstage discharge pressure leading 1.PC-974 is provided to high rod load.

15.4.2.1.1

2.PSV-901 A/B/C are provided.

15.4.2.1.2

3.PI-902 high alarm is provided.

15.4.2.1.3

1.High discharge temp. alarm TIH-902 is provided. 2. High discharge temp. trip TIHH-903 is provided.

15.4.2.2.1

2. Increase in interstage discharge temp.

Recommendations

15.2.2.5

2.High alarm on PC358(at separator outlet) is provided. 2. FC-431/PC-383 /PC-974 malfunctions to open FCV-431(Spill back line)

Ref. No.

Page 92 of 136

15.4.2.2.2

SEI 93.Confirm that the suction system can either withstand with the high suction pressure and PSV is designed for the same.

Responsibility

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

NODE NO: 15

Makeup H2 Compressor System

DESIGN INTENTION

To supply Hydrogen to make-up Compressor supply from B/L.

DRAWINGS

CS-140-PR-15-0013, CS-140-PR-15-0014, CS-140-PR-15-0015

EQUIPMENT

4. High flow(V),P&ID-0014 Make Up Gas Compressor K.O.Drum (140-V-002), Make-up Compressor (140-K-001A/B), Make-up Compressor Inter stage Cooler (140-EE-008A/B)

STREAM DETAILS

Make up hydrogen comes from B.L. to K.O.Drum to remove any liquid content and compressed to 95 barg

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

AVAILABLE CONTROL SCHEMES

Operating/Design Parameters SERVICE Temperature(°C) Hydrogen from B.L. .

Pressure ( bar g)

Flow rate (Kg/hr)

45 /120

20 /26

2457

Note: Node

Deviation

5. Reverse/Misdirected Flow

Causes

7.

Low Pressure

Safeguards

Ref. No.

3. HydroCOM failure to load the machine fully.

1.Low suction pressure, High flow due to sudden loading of machine it is possible that machine may trip due to low suction pressure.

1.Spillback valve FCV431 is provided. PC974 ,PC-383 are provided.

1. K-001A/B trips.

1. Recycle gas containing H2S as well as HCs may backflow in the system and eventually may flow to hydrogen bullet.

1. NRV is provided in 15.5.1.1.1 make up hydrogen line to Recycle gas.

2. U/S disturbance at Unit 1500(start up line to V-008)

6. Reverse/Misdirected Flow(V),P&ID-0014

Consequences

1. Off gas may back up in the system

2. UZ-707 will close XZV- 707 when compressor trips.

15.5.1.1.2

1.NRV is provided at the junction of H-162 and P079 on line H-162.

15.5.2.1.1

Not applicable.

1. Compressor malfunctioning

15.4.3.1.1

16

1. Less makeup hydrogen flow to Reaction section

1. PI-036/037 is provided with low alarm

15.7.1.1.1

2. PZ-385A/956A is 15.7.1.1.2 provided with LL alarm to activate UZ-707.

3. Note-13 is provided in 15.7.1.1.3 P&ID stating that signals from non running compressor instruments shall not be used for control and trip of the running compressor.

8. Low pressure (V),P&ID-0014 Same as low flow.

9.

High Pressure

15.8

same as high flow

15.9

Page 93 of 136

Recommendations

Responsibility

94. HydroCOM vendor to SEI/NEA clarify for the consequences of sudden loading and how tp prevent tripping of compressor and implement solution to provide the same.

95. Consider forced PCV-922 SEI close when compressor trips.

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

NODE NO: 15

Makeup H2 Compressor System

DESIGN INTENTION

To supply Hydrogen to make-up Compressor supply from B/L.

DRAWINGS

CS-140-PR-15-0013, CS-140-PR-15-0014, CS-140-PR-15-0015

EQUIPMENT

Make Up Gas Compressor K.O.Drum (140-V-002), Make-up Compressor (140-K-001A/B), Make-up Compressor Inter stage Cooler (140-EE-008A/B)

STREAM DETAILS

Make up hydrogen comes from B.L. to K.O.Drum to remove any liquid content and compressed to 95 barg

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

AVAILABLE CONTROL SCHEMES

Operating/Design Parameters SERVICE Temperature(°C) Hydrogen from B.L. .

Pressure ( bar g)

Flow rate (Kg/hr)

45 /120

20 /26

2457

Note: Node

Deviation

Causes

Consequences

Safeguards

10.High pressure(V),P&ID-0014 same as high flow 11. High Temperature

1. Cooling water failure in EE008A/B

Ref. No.

Recommendations

Responsibility

15.1 1. Compressor may get damaged

1. TI-904/954 provided with high alarm.

15.11.1.1.1

2. TZ-903/953 HH alarm 15.11.1.1.2 will activate UZ-707/708.

2. Compressor valve (K-001A/B) malfunctions

1. Compressor may get damage

1. TI-904/954 is 15.11.2.1.1 provided with High alarm

2. TZ-903/953 HH alarm 15.11.2.1.2 will activate UZ-707/708.

3. Cooling water failure in EE-004

1. Compressor may get damage

1. TI-178 is provided with HH alarm

15.11.3.1.1

2. TI-901/951 is 15.11.3.1.2 provided with High alarm

3. TZ-903/953 HH alarm 15.11.3.1.3 will activate UZ-707/708.

4. Cooling water failure in EE-009

1. Hydrogen to B.L will go at High temperature, possible damage in d/s

1. TI-211 is provided with high alarm

15.11.4.1.1

5. U/S disturbance

1. Compressor may get damage

1. TI-231/233 is 15.11.5.1.1 provided with High alarm

2. TI-180/182 is 15.11.5.1.2 provided with High alarm.

3. TZ-181/183 HH alarm 15.11.5.1.3 will activate UZ-707.

4. TZ-232/234 HH alarm 15.11.5.1.4 Will activate UZ-707.

12. High temp. (V),P&ID-0014

1.U/S disturbance.

1.Interstage discharge temp. high.

1. TZ-181/183 HH alarm 15.12.1.1 will activate UZ-707.

Page 94 of 136

96. Confirm that hydrocarbon NOCL detectors are provided in cooling tower area. 97.Provide High alarm at TI176.

SEI

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

NODE NO: 15

Makeup H2 Compressor System

DESIGN INTENTION

To supply Hydrogen to make-up Compressor supply from B/L.

DRAWINGS

CS-140-PR-15-0013, CS-140-PR-15-0014, CS-140-PR-15-0015

EQUIPMENT

Make Up Gas Compressor K.O.Drum (140-V-002), Make-up Compressor (140-K-001A/B), Make-up Compressor Inter stage Cooler (140-EE-008A/B)

STREAM DETAILS

Make up hydrogen comes from B.L. to K.O.Drum to remove any liquid content and compressed to 95 barg

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

AVAILABLE CONTROL SCHEMES

Operating/Design Parameters SERVICE Temperature(°C) Hydrogen from B.L. .

Note: Node

Pressure ( bar g)

Flow rate (Kg/hr)

45 /120

12. High temp. (V),P&ID-0014 Deviation

20 /26

Causes

1.Interstage discharge temp. high. Consequences

2.Suction valve leakage.

13.

High Level

1. Tube leak in EE-004 when machine is down and water collection in KOD.

Safeguards

Ref. No.

2457

Recommendations

Responsibility

2. TI-904 is provided with 15.12.2.2 high alarm. 1. Compressor may get damage due to carryover of liquid.

1. LI-527 is 15.13.1.1.1 provided with High alarm. 2. LZ-529 HH alarm will activate UZ707 to trip compressor.

15.13.1.1.2

15.14.1.1.1

14. High Level(V),P&ID-0014

1.High level in 2nd stage suction KO pot( Tube 1. Compressor may get damage due to leak in interstage cooler EE-008A/B when carryover of liquid. machine is down and water collection in KOD).

1.LAH-901 is provided.

15. Problem/Requirements

1. Tube leak in EE- 004/008A/B/009 when unit 1. Hydrogen may ingress in cooling water. is in running condition. No major concern for small leak. For major leak system will loose hydrogen and compressor suction pressure may go down.

1. PC-383 is provided with low alarm

15.15.1.1.1

98.Provide High high level NEA compressor trip for 2nd stage suction vessel

99.Confirm that hydrocarbon detectors are provided in cooling tower area.

NOCL

100. provide low point drain SEI valve at the shell side outlet of EE-009 and SOP to ensure checking of leakage of cooling water after any maintenance.

1.Tube leak in interstage cooler EE-008A/008B 16. Problem/Requirements(V),P&ID0014

17. Operation/Maintenance

1.No purging facility

15.16.1

1.Contamination

1. No safeguard

Page 95 of 136

15.17.1.1.1

101. Inspection opening of VENDOR/SEI 2nd stage suction vessel shall be located closer to the vanepack for inspection purpose. 102. Venting/purge facility to flare at EE-009 outlet is to be provided near B/L.

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

NODE NO: 16

Chemical Injection package (Only DMDS package is covered in HAZOP. All the applicable recommendations in this node are applicable to other injection packages.

DESIGN INTENTION

Chemical injection to prevent Corrosion/undesirable upsets in process.

DRAWINGS

CS-140-PR-15-0023, CS-140-PR-15-0025

EQUIPMENT

Antifoaming Agent /Anti Oxidant /Sulfiding Agent/Anti foulant /Corrosion Inhibitor injection System

STREAM DETAILS

Antifoaming Agent /Anti Oxidant /Sulfiding Agent/Anti foulant /Corrosion Inhibitor injection System

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

AVAILABLE CONTROL SCHEME

Operating/Design Parameters Temperature(°C)

Pressure ( bar g)

Flow rate (Kg/hr)

SERVICE Sulfiding Agent Antifoulant Corrosion Inhibitor Antifoaming Anti Oxidant

Ambient/65 Ambient /65 Ambient /65 Ambient/65 Ambient/65

1.5-7.5/13 0.0-4.0/6 0-10.8/13 0-11/12 0-7.5/10

1600 14.0 1.6 0.34/0.11 6.0

Note: Node

Deviation

16. Chemical Injection System

1.

Low/No Flow

Causes 1. P-007A trips( during sulfidation)

Consequences 1. Discharge pressure will go down. Delaying in sulfiding process.

Safeguards 1. Sulfiding process is attended activity, LG549 is provided for monitoring.

Ref. No.

Recommendations

16.1.1.1.1

Responsibility

Remarks 1. Licensor recommends to have flow meter in DMDS supply line from pump discharge. 2. It is suggested to have installed spare for DMDS pump as to ensure continuous operation of pump during startup period of 26 hrs. Reliability is to be ensured if ware

2. Stop alarm in DCS is provided for DMDS injection pumps. 2.

High Flow

3. Reverse/Misdirected Flow

4. Low pressure

5.

High Pressure

16.1.1.1.2

1. High stroke in P-007A

1. No significant consequences

1. Reverse flow from unit 400

1. possible contamination

1.NRV is provided on line CC020 near B.L.

16.2.1.1 16.3.1.1.1

2. Reverse flow from P-001 suction line.

1. Reactor circuit may get fouled.

1. NRV is provided on the line

16.3.2.1.1

2. Delay in sulfiding process (during sulfiding operation)

1. NRV is provided on the line

16.3.2.2.1

1.Same as no/low flow(*)

16.4.1

2. PCV-332 B failure to close

1. No nitrogen supply to tank leading to low pressure.

1. PCV-332 A failure to close in flare line.

1. Overpressurization of DMDS tank.

16.4.2.1

1. PI-304 with high alarm is provided overhead of tank.

16.5.1.1.1/2

2. PSV-303 A/B are provided.

2. External fire

1. Draining of the OSBL line to be reviewed during detail engineering of Unit 400.

16.5.2

Page 96 of 136

103. PI-304 to be provided SEI with low pressure alarm.

16. Chemical Injection System

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

NODE NO: 16

Chemical Injection package (Only DMDS package is covered in HAZOP. All the applicable recommendations in this node are applicable to other injection packages.

DESIGN INTENTION

Chemical injection to prevent Corrosion/undesirable upsets in process.

DRAWINGS

CS-140-PR-15-0023, CS-140-PR-15-0025

EQUIPMENT

Antifoaming Agent /Anti Oxidant /Sulfiding Agent/Anti foulant /Corrosion Inhibitor injection System

STREAM DETAILS

Antifoaming Agent /Anti Oxidant /Sulfiding Agent/Anti foulant /Corrosion Inhibitor injection System

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

AVAILABLE CONTROL SCHEME

Operating/Design Parameters Temperature(°C)

Pressure ( bar g)

Flow rate (Kg/hr)

SERVICE Sulfiding Agent Antifoulant Corrosion Inhibitor Antifoaming Anti Oxidant

Ambient/65 Ambient /65 Ambient /65 Ambient/65 Ambient/65

1.5-7.5/13 0.0-4.0/6 0-10.8/13 0-11/12 0-7.5/10

1600 14.0 1.6 0.34/0.11 6.0

Note: Node

Deviation 6.

Low Level

7.High level

Causes

Consequences

Safeguards

1. No significant cause as the operation is required during startup only

Ref. No.

Recommendations

Responsibility

16.6.1

1. Continuous filling from tanker 1.Over filling of drum leading to overpressurization of DMDS tank.

1. PI-304 is provided with high alarm.

16.7.1.1.1/2

2. PSV-303A/B design covers overfill case.

8. Low temperature

No major issues.

16.8

9. High temperature

No major issues.

16.9

10. Composition

No major issues.

16.1

11. Others

1.Blockage of carbon canister in the vent line.

1.Over pressurization of chemical injection drums.

16.11.1.1

Page 97 of 136

104. Ensure that blockage NOCL of carbon canister is not possible.

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

NODE NO: 17

Fuel oil, Fuel gas and Heater Firing system.

DESIGN INTENTION

To Supply fuel gas/fuel oil (during startup only) to reactor fire heater.

DRAWINGS

CS-140-PR-15-0024, CS-140-PR-15-0026

EQUIPMENT

Hydro treating reactor feed Heater (140-H-001)

STREAM DETAILS

Heater is Dual fired

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

AVAILABLE CONTROL SCHEMESPC-820,PC-823,UC-001 Operating/Design Parameters

SERVICE Temperature(°C) Fuel Gas Fuel Oil

Pressure ( bar g)

Flow rate (Kg/hr)

25/70 180/210

3.5/5 11/18

416 615

Note: Node 17. Fuel oil, Fuel gas and Heater Firing System

Deviation 1.

Low/No Flow (Fuel Gas)

Causes 1. PC -820 malfunctions to close PCV-820(fuel gas line)

Consequences

Safeguards

Ref. No.

1. Loss of firing of fuel gas leading to process upset/Heater shut down.

1. PZ-821 (2oo3) is provided with low low alarm to activate UZ-718.

17.1.1.1.1

2. Fuel gas pressure will come down.

1. PZ-821 is low low alarm to activate UZ-718.

17.1.1.2.1

2. XZV-718A/C malfunctions to close (fuel gas line)

1. Refer 17.1.1.1.1 and 17.1.1.2.1

3.PCV-830 in pilot line malfunctions to close

1.Loss of pilot gas to all the burners.

1. PZ-823 (2oo3) is provided with low low alarm to activate UZ-718.

17.1.3.1.1

4. XZV-718E/F malfunctions to close (pilot gas line)

1. Pilot flame loss, leading to heater trip.

1. Pilot flame scanner (BZS001/002/003) is provided with scanner alarm. Also if all the pilots are off, heater trip is provided through UZ-718.

17.1.4.1.1

Recommendations

Responsibilit y

Remarks

17.1.2.1

2. PZ-823 is provided with low 17.1.4.1.2 low alarm to activate UZ-718. 3. Deviation alarm is provided for XZV-718 E/F. 5. PC-823 malfunctions to close 1. Loss of firing of fuel oil may lead to PCV-823A(Fuel oil line) ,during startup operation upset startup case .

17.1.4.1.3

1. Low-oil pressure alarm at PI- 17.1.5.1.1 869 is provided.

Page 98 of 136

Fuel gas is provided as alternate fuel to provide adequate firing from UC-001.

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

NODE NO: 17

Fuel oil, Fuel gas and Heater Firing system.

DESIGN INTENTION

To Supply fuel gas/fuel oil (during startup only) to reactor fire heater.

DRAWINGS

CS-140-PR-15-0024, CS-140-PR-15-0026

EQUIPMENT

Hydro treating reactor feed Heater (140-H-001)

STREAM DETAILS

Heater is Dual fired

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

AVAILABLE CONTROL SCHEMESPC-820,PC-823,UC-001 Operating/Design Parameters

SERVICE Temperature(°C) Fuel Gas Fuel Oil

Pressure ( bar g)

Flow rate (Kg/hr)

25/70 180/210

3.5/5 11/18

416 615

5. PC-823 malfunctions to close PCV-823A(Fuel oil line) ,during startup case .

Note: Node

Deviation

Causes

Consequences 2. Fuel oil pressure may come down.

6. XZV-718N malfunctions to close (Fuel oil line)

Safeguards

Ref. No.

17.1.6.1

7. PDC-826(on fuel oil and 1. Loss of fuel oil flame due to failure of atomizing steam) malfunctions to atomizing steam. close PCV-826 2. Fuel oil spillage in heater leading to burner tip choking.

1. PDZ-860 is provided with low low alarm to activate UZ718.

8. Strainer choking.

1. PDI -827 is provided with high alarm (Fuel gas line)

17.1.8.1.1

2. PDI-857 is provided with high alarm (Fuel oil line)

17.1.8.1.2

3. All strainers are provided with spare for change over.

17.1.8.1.3

9. PC-899/HCV-830 malfunctions to close.

1. Box pressure will increase.

Responsibilit y

1. PZ-858 is provided with low 17.1.5.2.1 low alarm to activate UZ-718.

1. Refer 17.1.4.1.1 ~ 3

1. Possible loss of fuel gas/oil leading to flame failure.

Recommendations

17.1.7.1.1

17.1.7.2.1

1. PZ-900 (2oo3) is provided 17.1.9.1.1 with HH alarm to activate to trip UZ-718.

105.Provide additional flushing oil return taping upstream of XZV-718 M for flushing.

SEI

106. Damper open/close indications are provided (P&ID is to be updated accordingly).

SEI

107. Startup and shut down overrides for damper control will be included in P&ID note.

Page 99 of 136

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

NODE NO: 17

Fuel oil, Fuel gas and Heater Firing system.

DESIGN INTENTION

To Supply fuel gas/fuel oil (during startup only) to reactor fire heater.

DRAWINGS

CS-140-PR-15-0024, CS-140-PR-15-0026

EQUIPMENT

Hydro treating reactor feed Heater (140-H-001)

STREAM DETAILS

Heater is Dual fired

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

AVAILABLE CONTROL SCHEMESPC-820,PC-823,UC-001 9. PC-899/HCV-830 malfunctions to close. Temperature(°C)

SERVICE Fuel Gas Fuel Oil

Operating/Design Parameters Pressure ( bar g)

Flow rate (Kg/hr)

25/70 180/210

3.5/5 11/18

416 615

Note: Node

Deviation

Causes

10. 180-FA-001C/D Choking

2.

High Flow

Consequences

3. PDC-826 malfunctions to open PCV-826

Ref. No.

2. Less air flow may lead to incomplete combustion.

1. AI-004 provided for monitoring.

17.1.9.2.1

3. Box temperature likely to increase

1. TI-102 is provided with high alarm.

17.1.9.3.1

1. Unit 1800 may get disturbed (No consequence related to DHU).

1. PDI-010 is provided with high alarm

17.1.10.1.1

2. Spare Flame arrestor is provided.

17.1.10.1.2

1. PDZ-860 with LL alarm will activate UZ-718.

17.2.1.1.1

2. HH oil pressure trip is provided(UZ-718.)

17.2.1.1.2

1. Hard firing may occur, leading to higher Tube metal temperature.

1. Skin temp. indications are provided with high alarm.

17.2.2.1.1

2. Fuel gas line operating pressure will increase

2. PZ-821 HH alarm will activate UZ-718 to trip heater.

17.2.2.2.2

1. Flame lifting/improper atomization may occur, leading to higher Tube metal temperature.

1. Skin temp. indications are provided.

17.2.3.1.1

1. PC-823 malfunctions to open 1. Possible Improper atomization may lead PCV-823A(Fuel oil line), during to flame loss. start up operation only.

2. PC -820 malfunctions to open PCV-820(fuel gas line)

Safeguards

Page 100 of 136

Recommendations 108. Low oxygen alarm at AI-004 is to be provided

Responsibilit y SEI

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

NODE NO: 17

Fuel oil, Fuel gas and Heater Firing system.

DESIGN INTENTION

To Supply fuel gas/fuel oil (during startup only) to reactor fire heater.

DRAWINGS

CS-140-PR-15-0024, CS-140-PR-15-0026

EQUIPMENT

Hydro treating reactor feed Heater (140-H-001)

STREAM DETAILS

Heater is Dual fired

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

AVAILABLE CONTROL SCHEMESPC-820,PC-823,UC-001 Operating/Design Parameters

SERVICE Temperature(°C) Fuel Gas Fuel Oil

Pressure ( bar g)

Flow rate (Kg/hr)

25/70 180/210

3.5/5 11/18

416 615

Note: Node

Deviation

Causes

4. PC-899/HCV-830 malfunctions to open.

3. Reverse/Misdirected flow

4.

Low Pressure

5. High pressure

1.High fuel oil pressure.

Consequences

Safeguards

Ref. No.

2. Steam line operating pressure will increase

2. High alarm at PI-863 is provided.

17.2.3.2.2

1. Fuel efficiency may decrease.

1. Oxygen analyzer AI-004 is provided for monitoring

17.2.4.1.1

2. Draft will be increased, no major safety concern.

1. Damper open/close indications are provided.

17.2.4.2.1

1.Fuel oil back flow in steam line as the steam pressure is constant.

1. PZ-858 with HH alarm will activate UZ-718.

17.3.1.1.1

2.Check valve in steam line is provided for individual burner.

17.3.1.1.2

1. Flame Arrester 180-FA001 is provided.

17.4.1.1.1

1. U/S disturbance (off gas from LPG Merox)

1. Flame may propagate back to line

2. PC -820 malfunctions to close PCV-820(fuel gas line)

1. Refer 17.1.1.1.1 and 17.1.1.2.1

17.4.2.1

3. PC-823 malfunctions to close PCV-823A(Fuel oil line) ,during startup case .

1. Refer 17.1.1.1.1 and 17.1.1.2.1

17.4.3.1

1. Refer 17.2.1.1.1 and 17.2.1.1.2

17.5.1

2. Refer 17.2.2.1.1 and 17.2.2.2.2

17.5.2

3. Refer 17.2.3.1.1 and 17.2.3.2.2

17.5.3

Page 101 of 136

Recommendations

Responsibilit y

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

NODE NO: 17

Fuel oil, Fuel gas and Heater Firing system.

DESIGN INTENTION

To Supply fuel gas/fuel oil (during startup only) to reactor fire heater.

DRAWINGS

CS-140-PR-15-0024, CS-140-PR-15-0026

EQUIPMENT

Hydro treating reactor feed Heater (140-H-001)

STREAM DETAILS

Heater is Dual fired

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

AVAILABLE CONTROL SCHEMESPC-820,PC-823,UC-001 Operating/Design Parameters

SERVICE Temperature(°C) Fuel Gas Fuel Oil

Pressure ( bar g)

Flow rate (Kg/hr)

25/70 180/210

3.5/5 11/18

416 615

Note: Node

Deviation 6. Low Temperature

Causes 1. U/S disturbance (fuel gas line)

2. U/S disturbance (fuel oil line)

Consequences 1. Carryover of condensate with fuel gas line leading to backfiring in the furnace. 1. Increase in fuel oil viscosity leading to improper atomization and sooty flame.

Safeguards 1. Fuel gas KOD is provided and Steam tracing is also provided d/s V-025.

17.6.1.1.1

1.Low alarm at TI-832 is provided.

17.6.2.1.1

3. Steam tracing failure in fuel oil line. 7. High Temperature

1. U/S disturbance (Fuel oil supply)

8. Low level

No new cause.

9.

1. High level in V-025

High Level

Ref. No.

Recommendations

Responsibilit y

17.6.3

1. Fuel oil temp increases leading to vaporization of low boiling point components may result in vapor lock in the burner.

17.7.1.1

109.Ensure that upstream system is properly monitored to avoid any vaporization.

NOCL

17.8

1. Liquid may carry over with fuel gas

10. Problem/Requirements (Soot 1. Low/No flow of M.P steam to 1. Soot blowing will not be possible leading blower) soot blower(Fuel oil operation to lower heat transfer. only).

1. LI-807 is provided with High alarm

17.9.1.1.1

2. LZ-810 HH alarm will activate UZ-718.

17.9.1.1.2

1. PI-730 is provided with low low alarm.

17.10.1.1.1

2. Low low temp. alarm at TI725 is provided.

17.10.1.1.2

Page 102 of 136

110.MP steam for soot blower tapping to be downstream of FI-409. (P&ID to be updated).

SEI

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

NODE NO: 17

Fuel oil, Fuel gas and Heater Firing system.

DESIGN INTENTION

To Supply fuel gas/fuel oil (during startup only) to reactor fire heater.

DRAWINGS

CS-140-PR-15-0024, CS-140-PR-15-0026

EQUIPMENT

Hydro treating reactor feed Heater (140-H-001)

STREAM DETAILS

Heater is Dual fired

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

AVAILABLE CONTROL SCHEMESPC-820,PC-823,UC-001 Operating/Design Parameters

SERVICE Temperature(°C) Fuel Gas Fuel Oil

Pressure ( bar g)

Flow rate (Kg/hr)

25/70 180/210

3.5/5 11/18

416 615

Note: Node

Deviation

Causes

Consequences

Safeguards

11. Operation/Maintenance (Decoking system is not HAZOPed as it is manual & attended operation) 12. Operation/Maintenance (heater maintenance)

Ref. No. 17.11

1.Provide spectacle blind at the inlet of Fuel gas KOD to ensure positive isolation.

Page 103 of 136

17.12.1

Recommendations

Responsibilit y

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

NODE NO: 18

HP/MP Steam & MP BFW

DESIGN INTENTION

To supply HP steam ,MP steam and MP BFW

DRAWINGS

CS-140-PR-15-0030

EQUIPMENT

Distribution system, 140-DS-001

STREAM DETAILS

HP steam, MP Steam and MP BFW will be supplied from B/L to Unit.

AVAILABLE CONTROL SCHEMES

TCV-239

:

Project :

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

Operating/Design Parameters

SERVICE Temperature(°C) HP STEAM MP STEAM MP BFW

Pressure ( bar g)

388/405 184/252 128/150

Flow rate (Kg/hr) 53.5/58 10/12 24/35

27437 1500 7687

Note: Node 18.

HP/MP Steam & MP BFW

Deviation 1.

Low/No Flow

Causes 1. U/S disturbance (HP Steam supply failure)

2. U/S disturbance (MP Steam supply from OSBL fails)

Consequences

Safeguards

Ref. No.

1. KT-002 trips

1. PI-810 is provided with low alarm.

2. MP steam not available to stripper leading to poor stripping and off spec product.

1. Low flow alarm at FI- 18.1.1.2.1 804A/B is provided.

3 No MP steam available to DS-001.

1. XZV-835 in MP boiler feed water line closes if RGC turbine trips(UZ-705)

1. No supply of atomization steam to fuel oil in Fired heater

18.1.1.1.1

18.1.1.3.1

18.1.2.1.1

1. FI-804A is provided with low alarm 2. PI-808 is provided with low alarm. 2. No supply of MP steam to soot-blower when required.

18.1.2.2.2

Page 104 of 136

Recommendations

Responsibility

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

NODE NO: 18

HP/MP Steam & MP BFW

18. HP/MP Steam DESIGN INTENTION & MP BFW

1. Low/No To supply HPFlow steam ,MP steam and MP BFW

DRAWINGS

CS-140-PR-15-0030

EQUIPMENT

Distribution system, 140-DS-001

STREAM DETAILS

HP steam, MP Steam and MP BFW will be supplied from B/L to Unit.

AVAILABLE CONTROL SCHEMES

TCV-239

:

Project :

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

Operating/Design Parameters 2. U/S disturbance (MP Steam supply from OSBL fails) Temperature(°C)

SERVICE HP STEAM MP STEAM MP BFW

Pressure ( bar g)

388/405 184/252 128/150

Flow rate (Kg/hr) 53.5/58 10/12 24/35

27437 1500 7687

Note: Node

Deviation

Causes

Consequences

Safeguards

Ref. No.

3. No MP steam supply leading to lube oil pump turbine (of RGC) trip.

1.It will automatically changeover to motor operated lube oil pump.

4. RGC turbine back pressure reduces , leading to turbine failure.

1. HH turbine speed 18.1.2.4.1 trip SZ-002 is provided.

Page 105 of 136

Responsibility

111.HH pressure trip PZ678A/B/C requirement is to be reviewed from vendor in view of turbine back pressure.

BHEL/SEI

18.1.2.3.1

18.1.2.4.2 2. Low low back pressure trip PZ678A/B/C is provided.

Recommendations

Remarks

18.

HP/MP Steam & MP BFW

1.

Low/No Flow

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

NODE NO: 18

HP/MP Steam & MP BFW

DESIGN INTENTION

To supply HP steam ,MP steam and MP BFW

DRAWINGS

CS-140-PR-15-0030

EQUIPMENT

Distribution system, 140-DS-001

STREAM DETAILS

HP steam, MP Steam and MP BFW will be supplied from B/L to Unit.

AVAILABLE CONTROL SCHEMES

TCV-239

:

Project :

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

Operating/Design Parameters

SERVICE Temperature(°C) HP STEAM MP STEAM MP BFW

Pressure ( bar g)

388/405 184/252 128/150

Flow rate (Kg/hr) 53.5/58 10/12 24/35

27437 1500 7687

Note: Node

Deviation

Causes

Consequences

Safeguards

Ref. No.

3. U/S disturbance (MP BFW supply from OSBL fails)

1. MP steam temp. will be high. No major consequence as the design temp. takes care of turbine exhaust.

18.1.3.1

4. TC-239 malfunctions to close TCV-239

1. Refer 18.1.3.1

18.1.4.1

1. TC-239 malfunctions to open TCV-239

1. BFW may enter MP steam line header leading to hammering.

1. Steam trap is provided.

18.2.1.1.1

3. Reverse/Misdirected flow.

1.Turbine trip.

1.Header steam will come back to turbine and stripper.

1.Check valves are provided.

18.3.1.1.1

4.

Low Pressure

1. Same as low/no flow

18.4.1

5.

High Pressure

1. Refer 18.2.1.1.1

18.5.1

2.

High Flow

Page 106 of 136

Recommendations

112.Line from Desuperheater downstream upto steam trap is to be designed for two phase flow.

Responsibility

SEI

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

NODE NO: 18

HP/MP Steam & MP BFW

DESIGN INTENTION

To supply HP steam ,MP steam and MP BFW

DRAWINGS

CS-140-PR-15-0030

EQUIPMENT

Distribution system, 140-DS-001

STREAM DETAILS

HP steam, MP Steam and MP BFW will be supplied from B/L to Unit.

AVAILABLE CONTROL SCHEMES

TCV-239

:

Project :

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

Operating/Design Parameters

SERVICE Temperature(°C) HP STEAM MP STEAM MP BFW

Pressure ( bar g)

Flow rate (Kg/hr)

388/405 184/252 128/150

53.5/58 10/12 24/35

27437 1500 7687

Note: Node

Deviation 6. Low temp.

Causes 1.Upset in U/S desuperheater

Consequences

Safeguards

Ref. No.

Recommendations

Responsibility BHEL

1.Steam turbine efficiency reduces.

18.6.1.1

113. Vendor to provide min. temp. of steam acceptable at turbine inlet, irrespective of min. operating temp. specified in B/L condition.

2.Low temp may lead to less superheat steam to turbine likely to condense within the turbine and damage the blades

18.6.1.2

114. TI-627 is to be provided with low temp. alarm in DCS.

7. High temp.

No significant cause.

18.7

8. Composition

NA

18.8

9. Others

NA

18.9

Page 107 of 136

SEI

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

NODE NO: 19

Cooling Water System

DESIGN INTENTION

Cooling water supply to exchangers

DRAWINGS

CS-140-PR-15-0032

EQUIPMENT

Cooling water distribution

STREAM DETAILS

Cooling water is supplied to all cooling water exchangers from B/L and similarly cooling water return from all exchangers to header

:

Nagarjuna Oil Corporation Ltd

Project :

Diesel hydro Desulphurization unit

AVAILABLE CONTROL SCHEMES Operating/Design Parameters

SERVICE Temperature(°C) Cooling water supply Cooling water return

Pressure ( bar g)

Flow rate (Kg/hr)

33/70 44/70

4/7 3/7

688411 688411

Note: Node 19. Cooling water system

Deviation 1.

Low/No Flow

Causes

Consequences

Safeguards

Ref. No.

1. U/S disturbance

1. Cooling water exchangers will be starved 1. PI-816 is provided leading to high run down/downstream temp. with low alarm

2.High flow

1. U/S disturbance

1. No major safety consequences.

3.Reverse/Misdirected flow

1. No significant causes identified.

19.3.1

4.Low pressure

1. Refer 19.1.1.1.1

19.4.1

5.High pressure

1. Refer 19.2.1.1

19.5.1

2. Blockage in return line of individual heat exchangers.

1.Return line may see high pressure due to thermal expansion.

6.Low temp.

1. No significant causes identified.

7. High Temperature

1. High inlet temp.

1. Desired cooling of process stream is not achieved in water cooled exchangers

2. High return temp.

1. Expected high return temperature of cooling water

19.1.1.1.1

19.2.1.1

1. TSVs are provided on return line of individual exchangers.

19.5.2.1.1

19.6.1

1. High temp. alarm on process outlet side is provided on all critical cooling water exchangers

19.7.1.1.1

2. TI-816 is provided for monitoring.

19.7.1.1.2

1. TI-818 is provided with 19.7.2.1.1 high alarm

Page 108 of 136

Recommendations

Responsibility

Remarks

7. High Temperature

Node

Deviation

2. High return temp. Causes

Consequences

Safeguards

2. Individual cooler outlet temp. can be high 1. High temp. alarm on because of the fouling of cooler. process outlet side is provided on all critical cooling water exchangers

Ref. No.

Recommendations

Responsibility

19.7.2.2.1

8.Low level

NA

19.8

9. High level

NA

19.9

10. Problem/Requirements

1. Possibilities of cooling water misdistribution

1. Insufficient cooling in some exchangers

11.Composition

1. Water going to process side.

1. Possible process feed contamination

19.11.1.1

115. SOP to ensure checking of leakage of cooling water after any maintenance.

SEI/NOCL

2. process feed going to water side

1. Process fluid may ingress in cooling water. No major concern for small leak. For major leak system will loose process fluid/HC will go to cooling tower area leading to fire and explosion.

19.11.2.1

116.Confirm that hydrocarbon detectors are provided in cooling tower area.

NOCL

1.Hydraulic Check is carried out based on actual plant layout.

12.Others 13. Operation/Maintenance

19.10.1.1.1

19.12 1. Unit shut down, cooling water header maintenance.

1. Loss of circulation may lead to loss of protective coating in cooling water line.

19.13.1.1

Page 109 of 136

117. Provide 3" jumpover connection line (with valve and spec. blind) between cooling water supply and return headers near dead end. Jumpover will be used for initial passivation during commissioning.

SEI

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

NODE NO: 20

Portable/Service Water, LP Steam, Plant /Instrument Air and Nitrogen

DESIGN INTENTION

To supply Portable/Service Water, LP Steam, Plant /Instrument Air and Nitrogen

DRAWINGS

CS-140-PR-15-0031, CS-140-PR-15-0033, CS-140-PR-15-0034

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

EQUIPMENT STREAM DETAILS

Portable/Service Water, LP Steam, Plant /Instrument Air and Nitrogen will be supplied from B/L to Hose station.

AVAILABLE CONTROL SCHEMESPC-330,LC-501,LC-505,FC-407A/B,FC-408,TC-119,FCV-436 Operating/Design Parameters

SERVICE Temperature(°C) LP steam Service water Potable water Plant air Instrument air Nitrogen

Pressure ( bar g)

152/200 Amb. /65 Amb./65 Amb./66 Amb./66 Amb/65

Flow rate (Kg/hr) 4/6 3/8 3/8 4.9/9 6.1/10 8/10

2818 1000(1) 1000(1) 518 215 430(2)

Note:1- Confirmed by DEC 2. Flow rate is based on startup and shutdown requirement

Node 20. Portable/Service Water, LP Steam, Plant/Instrument Air and Nitrogen

Deviation 1.

Low/No Flow

Causes

Consequences

Safeguards

Ref. No.

1. U/S disturbance (Potable water)

1. No significant consequences

20.1.1.1

2. U/S disturbance (Service water)

1. No significant consequences

20.1.2.1

3. U/S disturbance (Plant Air)

1. No significant consequences

4. U/S disturbance (Instrument 1. Instrument air pressure will come down Air) leading to unit shut down

20.1.3.1 1. PI-802 is provided 20.1.4.1.1 with low alarm. 2. Instrument air backup for 20 min. is 20.1.4.1.2 provided from OSBL. 3. All instruments will go to fail safe mode. 20.1.4.1.3

5. U/S disturbance (Nitrogen)

1. No/low pressure of nitrogen for blanketing 1. PI-806 is provided 20.1.5.1.1 and purging (refer individual nodes for with low alarm. possible consequences).

Page 110 of 136

Recommendations

Responsibility

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

NODE NO: 20

Portable/Service Water, LP Steam, Plant /Instrument Air and Nitrogen

DESIGN INTENTION

To supply Portable/Service Water, LP Steam, Plant /Instrument Air and Nitrogen

DRAWINGS 20. Portable/Service Water, LP Steam, Plant/Instrument Air EQUIPMENT and Nitrogen

CS-140-PR-15-0031, CS-140-PR-15-0033, CS-140-PR-15-0034 1. Low/No Flow

STREAM DETAILS

Portable/Service Water, LP Steam, Plant /Instrument Air and Nitrogen will be supplied from B/L to Hose station.

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

AVAILABLE CONTROL SCHEMESPC-330,LC-501,LC-505,FC-407A/B,FC-408,TC-119,FCV-436 Operating/Design Parameters

SERVICE Temperature(°C) LP steam Service water Potable water Plant air Instrument air Nitrogen

Pressure ( bar g)

152/200 Amb. /65 Amb./65 Amb./66 Amb./66 Amb/65

Flow rate (Kg/hr) 4/6 3/8 3/8 4.9/9 6.1/10 8/10

2818 1000(1) 1000(1) 518 215 430(2)

Note:1- Confirmed by DEC 2. Flow rate is based on startup and shutdown requirement

Node

Deviation

Causes 6.

Consequences

U/S disturbance (LP Steam) 1. No/Low flow in header will result in low pressure of snuffing/purging steam available when required

Safeguards

Ref. No.

1. PI-846 is provided 20.1.6.1.1 with low alarm.

2. High flow

1. No significant cause

20.2.1

3. Reverse/misdirected flow

1. No significant cause

20.3.1

4. Low pressure

1. Same as low/no flow

20.4.1

5. High Pressure

1. No significant cause

20.5.1

6. Low level

1. NA

7. High level

1. NA

8. Composition

1. NA

Page 111 of 136

Recommendations

Responsibility

Remarks

20. Portable/Service Water, LP Steam, Plant/Instrument Air and Nitrogen

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

NODE NO: 20

Portable/Service Water, LP Steam, Plant /Instrument Air and Nitrogen

DESIGN INTENTION

To supply Portable/Service Water, LP Steam, Plant /Instrument Air and Nitrogen

DRAWINGS

CS-140-PR-15-0031, CS-140-PR-15-0033, CS-140-PR-15-0034

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

EQUIPMENT STREAM DETAILS

Portable/Service Water, LP Steam, Plant /Instrument Air and Nitrogen will be supplied from B/L to Hose station.

AVAILABLE CONTROL SCHEMESPC-330,LC-501,LC-505,FC-407A/B,FC-408,TC-119,FCV-436 Operating/Design Parameters

SERVICE Temperature(°C) LP steam Service water Potable water Plant air Instrument air Nitrogen

Pressure ( bar g)

152/200 Amb. /65 Amb./65 Amb./66 Amb./66 Amb/65

Flow rate (Kg/hr) 4/6 3/8 3/8 4.9/9 6.1/10 8/10

2818 1000(1) 1000(1) 518 215 430(2)

Note:1- Confirmed by DEC 2. Flow rate is based on startup and shutdown requirement

Node

Deviation 9. Others

Causes 1. wrong connection for hoses

Consequences 1. Hazardous consequence if nitrogen is connected when air is required.

Safeguards

Ref. No. 20.9.1.1

Page 112 of 136

Recommendations 118. Ensure different connections are available for air and nitrogen hose stations to avoid wrong connections.

Responsibility SEI

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

Nagarjuna Oil Corporation Ltd

NODE NO: 21

Flare System

DESIGN INTENTION

To vent PSV discharge gases to main flare header

DRAWINGS

CS-140-PR-15-0037, CS-140-PR-15-0038

EQUIPMENT

Flare K.O drum(140-V-023), Flare K.O drum pump(140-P-015A/B)

STREAM DETAILS

PSV discharge collected in Flare K.O drum (140-V-023) where liquid and gaseous phase is separated .Liquid HC is sent to slop header through flare K.O. drum pump (140-P-015A/B) and gaseous HC is sent to main flare header for burning.

Diesel hydro Desulphurization unit

AVAILABLE CONTROL SCHEMES Operating/Design Parameters

SERVICE Temperature(°C) Flare Gas From Flare KOD to Flare header Flare KOD/CBD Pump to Slops Tank

Flare system

1.

Low/No Flow

2. High flow

45

57/250

5.5/14.5

57

Causes

Consequences

Safeguards

Ref. No.

1. U/S disturbance(No flow of fuel gas to flare header)

1. No purge available to dead end of flare header leading to possible air ingress into flare header.

2. LS-806 malfunctions and P015A/B is not started when required.

1. V-023 level may increase leading to liquid 1. LI-805 provided with overloading in flare header and downstream high high alarm. system.

21.1.2.1.1

1. PSV pop up,depressurization

1. More flaring,condensation in flare KOD leading to high level.

1. Pump to autostart on high level.

21.2.1.1.1

2. LI-805 provided with high high alarm.

21.2.1.1.2

3. Low pressure

1. No significant causes identified

4. High pressure

1. Refer 21.2.1.1.1 and 21.2.1.1.2 1. LS-806 malfunctions ,not stopping the pump-015A/B.

5. Low Level

Flow rate (Kg/hr) 0.25/3.5

Note:1- Confirmed by DEC 2. Flow rate is based on startup and shutdown requirement Node Deviation 21.

Pressure ( bar g)

45/250

1.Low alarm at PI-854 (located at Fuel gas B.L.) is provided.

21.1.1.1.1

2. Nitrogen backup is available.

21.1.1.1.2

Recommendations

Responsibility

21.3.1

21.4.1 1. Pump will run dry.

1. LI-805 is provided with 21.5.1.1.1 LL alarm.

6. High level

1. Refer 21.1.2.1.1, 21.2.1.1.1 and 21.2.1.1.2

21.6.1

7. Low temp.

1. No significant causes identified

21.7.1

8. High temp.

1. No significant causes identified

21.8.1

119. SOP to ensure Manual intervention of HS-908

SEI/NOCL

Remarks

21.

Flare system

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

Nagarjuna Oil Corporation Ltd

NODE NO: 21

Flare System

DESIGN INTENTION

To vent PSV discharge gases to main flare header

DRAWINGS

CS-140-PR-15-0037, CS-140-PR-15-0038

EQUIPMENT

Flare K.O drum(140-V-023), Flare K.O drum pump(140-P-015A/B)

STREAM DETAILS

PSV discharge collected in Flare K.O drum (140-V-023) where liquid and gaseous phase is separated .Liquid HC is sent to slop header through flare K.O. drum pump (140-P-015A/B) and gaseous HC is sent to main flare header for burning.

Diesel hydro Desulphurization unit

AVAILABLE CONTROL SCHEMES Operating/Design Parameters

SERVICE Temperature(°C) Flare Gas From Flare KOD to Flare header Flare KOD/CBD Pump to Slops Tank

Pressure ( bar g)

Flow rate (Kg/hr)

45/250

0.25/3.5

45

57/250

5.5/14.5

57

Note:1- Confirmed by DEC 2. Flow rate is based on startup and shutdown requirement Node Deviation 9. Composition

1. NA

10.Others

1. NA

Causes

Consequences

Safeguards

Ref. No.

Recommendations

Responsibility

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

Nagarjuna Oil Corporation Ltd

NODE NO: 22

Amine System

DESIGN INTENTION

To collect drained Amine

DRAWINGS

CS-140-PR-15-0043, CS-140-PR-15-0044

EQUIPMENT

Amine drain drum (140-V-022), Amine drain drum pump (140-P-014A/B)

STREAM DETAILS

Amine effluent collected in Amine drain drum (140-V-022) where liquid and gaseous phase is separated .Liquid HC is sent to ARU Unit through amine drain pump( 140-P-014A/B) and gaseous HC is sent to flare header for burning.

Diesel hydro Desulphurization unit

AVAILABLE CONTROL SCHEMES Operating/Design Parameters

SERVICE Temperature(°C)

Pressure ( bar g)

57/120

Amine

Flow rate (Kg/hr)

0.25/3.5

27634

Note: Node 22. Amine drain system

Deviation

Causes

Consequences

Safeguards

Ref. No.

1. Low/No Flow of drained amine 1. LS-801 malfunctions, not starting P-014A

1. Level of V-022 will increase

22.1.1.1

2. Low/No flow of nitrogen

1. U/S disturbance

1. Loss of nitrogen blanketing leading to likely 1. Low pressure alam 22.2.1.1.1 degradation of amine. at PI-806 is provided.

3. High flow of nitrogen

1. U/S disturbance

1. Pressure is likely to increase.

1. RO-801 is provided.

22.3.1.1.1

2. Vessel is floating with flare header.

22.3.1.1.2

4. Reverse/Misdirected Flow

1. No new cause

5. Low Level

1. LS-801 malfunctions ,not stopping the pump-014A

6. High level

1. Refer 22.1.1.1

7. Low temp.

1.No significant cause

8 .High temp.

1. U/S disturbance

9.Low pressure

1. No significant cause

22.9.1

10.High pressure

1. Refer 22.3.1.1.1 and 22.3.1.1.2

22.10.1

11.Composition

1. No significant cause

Recommendations

Responsibility

120. Provide high high alarm at LI-800

SEI

121. Provide low low alarm at LI-801

SEI

22.4.1

1. Pump may run dry

22.5.1.1

22.6.1 22.7.1 1. Likely to degrade amine.

1. TI-813A is provided 22.8.1.1.1 with high alarm.

Remarks

22. Amine drain system

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

Nagarjuna Oil Corporation Ltd

NODE NO: 22

Amine System

DESIGN INTENTION

To collect drained Amine

DRAWINGS

CS-140-PR-15-0043, CS-140-PR-15-0044

EQUIPMENT

Amine drain drum (140-V-022), Amine drain drum pump (140-P-014A/B)

STREAM DETAILS

Amine effluent collected in Amine drain drum (140-V-022) where liquid and gaseous phase is separated .Liquid HC is sent to ARU Unit through amine drain pump( 140-P-014A/B) and gaseous HC is sent to flare header for burning.

Diesel hydro Desulphurization unit

AVAILABLE CONTROL SCHEMES Operating/Design Parameters

SERVICE Temperature(°C)

Pressure ( bar g)

57/120

Amine

Flow rate (Kg/hr)

0.25/3.5

27634

Note: Node

Deviation

Causes

12. Others

1. No significant cause

13. Problem/Requirements

1. No significant cause

14. Operation/Maintenance

1. No significant cause

Consequences

Safeguards

Ref. No.

Recommendations

Responsibility

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

Nagarjuna Oil Corporation Ltd

NODE NO: 23

Hydrocarbon drain system

DESIGN INTENTION

To collect drained hydrocarbon from different equipments

DRAWINGS

CS-140-PR-15-0039, CS-140-PR-15-0040

EQUIPMENT

Hydrocarbon drain drum (140-V-021), Closed drain drum pumps (140-P-013A/B)

STREAM DETAILS

HC effluent collected in HC drain drum 140-V-021 where liquid and gaseous phase is separated .Liquid HC is sent to SLOP through closed drain pump 140-013A/B and gaseous HC is sent to flare header for burning.

Diesel hydro Desulphurization unit

AVAILABLE CONTROL SCHEMES Operating/Design Parameters

SERVICE

Temperature(°C)

Hydrocarbon

Pressure ( bar g) 40/150

Flow rate (Kg/hr) 0.25/3.5

7500

Note: Node 23. Hydrocarbon drain system

Deviation

Causes

Consequences

Safeguards

1. Low/No Flow of HC from pump discharge

1. LS-802 malfunctions, not starting P-013A

1. Level of V-021 will increase

2. Low/No flow of nitrogen

1. U/S disturbance

1. Loss of nitrogen blanketing leading to likely 1. Low pressure alam 23.2.1.1.1 ingress of air. at PI-806 is provided.

3. High flow of nitrogen

1. U/S disturbance

1. Pressure is likely to increase.

4. Reverse/Misdirected Flow

1. Possible backup of CBD pump discharge to flare KOD via pump(P-015) min. flow line

23.4.1

5. Low temp.

1. No significant cause

23.5.1

6. High Temperature

1. Draining hot HC material

1. System may experience higher than the design temperature

2. Steam coil operation

1. LI on V-021 is provided.

Ref. No.

1. RO-802 is provided.

Responsibility

122. Provide high high alarm at LI-902

SEI

123. Provide NRV in the flare KOD pump discharge line no. P803 near to tie in point to slop header.

SEI

124. Operating procedure should prevent draining of hot hydrocarbon in Hydrocarbon drain drum.

SEI/NOCL

Remarks

23.3.1.1.1

1. TI-820 is provided 23.6.1.1.1 with high alarm

1. Cooling water provision is there.

1. Pump may run dry

23.1.1.1.1

Recommendations

23.6.2.1.1

7. Low Level

1. LS-802 malfunctions ,not stopping the pump-013A

23.7.1.1

8. High level

1. Refer 23.1.1.1.1

23.8.1

9. Low pressure

1. No significant cause

23.9.1

Flushing oil return connection is to be relocated on line P-803.

Cooling water permanent piping is to be removes as per project philosophy 125. Provide low low alarm at LI-902

SEI

23. Hydrocarbon drain system

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

Nagarjuna Oil Corporation Ltd

NODE NO: 23

Hydrocarbon drain system

DESIGN INTENTION

To collect drained hydrocarbon from different equipments

DRAWINGS

CS-140-PR-15-0039, CS-140-PR-15-0040

EQUIPMENT

Hydrocarbon drain drum (140-V-021), Closed drain drum pumps (140-P-013A/B)

STREAM DETAILS

HC effluent collected in HC drain drum 140-V-021 where liquid and gaseous phase is separated .Liquid HC is sent to SLOP through closed drain pump 140-013A/B and gaseous HC is sent to flare header for burning.

Diesel hydro Desulphurization unit

AVAILABLE CONTROL SCHEMES Operating/Design Parameters

SERVICE

Temperature(°C)

Hydrocarbon

Pressure ( bar g) 40/150

Flow rate (Kg/hr) 0.25/3.5

7500

Note: Node

Deviation

Causes

10. High pressure

1. Refer 23.3.1.1.1

11. Composition

1. No significant cause

12. Others

1. No significant cause

13 . Problem/Requirements

1. No significant cause

14. Operation/Maintenance

1. No significant cause

Consequences

Safeguards

Ref. No. 23.10.1

Recommendations

Responsibility

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

Project :

:

NODE NO: 24

Condensate collection system

DESIGN INTENTION

To collect condensate from different traps

DRAWINGS

CS-140-PR-15-0041

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

EQUIPMENT STREAM DETAILS

Condensate from steam traps is collected in LP/MP/HP headers & drained to ND after cooling

AVAILABLE CONTROL SCHEMES Operating/Design Parameters

SERVICE

Temperature(°C)

Pressure ( bar g)

Flow rate (Kg/hr) 1030

Condensate (Water) in LP/MP condensate header Condensate (Water) in HP condensate header

102/252

0.1/3.5

102/405

0.1/3.5

350

Note: Node 24. Condensate Collection system

Deviation

Causes

1. Low/No Flow

1. No new cause

2. High flow

1. No new cause

3. Low pressure

1. No new cause

4. High pressure

1. No new cause

5. Low Level

1. No new cause

6. High level

1. No new cause

7. Low temp.

1. No new cause

8. High temp. 1. Coolling water failure 9. Composition

1. No new cause

10.Others

1. No new cause

Consequences

1. High temp condensate routed to storm sewer.Possible damage to coating inside the headers.

Safeguards

Ref. No.

1. Low pressure alarm 24.8.1.1.1 at PI-816 is provided

Recommendations

Responsibility

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

NODE NO: 25

Makeup H2 Compressor-Lube oil System

DESIGN INTENTION

To supply lube oil to cylinders and packings

DRAWINGS

CS-140-PR-D-06600002

EQUIPMENT

140-K-001A/B

:

Project :

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

STREAM DETAILS AVAILABLE CONTROL SCHEMES Operating Parameters

SERVICE Temperature(°C)

Pressure ( bar g) 50

Lube oil . Note: Node 25. Makeup H2 Compressor -Lube oil system

Flow rate (Kg/hr)

a} 3 barg for bearings and cross head.

Deviation

Causes

Consequences

1. Low/No Flow

1. Crank case main lube oil pump failure.

1. Less lube oil flow and pressure.

Safeguards

Ref. No.

1. Aux. pump with auto start is provided.

25.1.1.1.1

2. PI-908 is provided with low alarm.

25.1.1.1.2

3. Low low pressure (PT905A/B/C, 2 out of 3) trip the compressor.

25.1.1.1.3

2. Suction strainer upstream of aux. pump choking.

1. Less lube oil flow and pressure leading to compressor damage.

25.1.2.1

3. Cooler leak

1. Less lube oil flow and pressure leading to compressor damage.

1. Cooler is designed following API 10/13 rule.

25.1.3.1.1

4. TCV-901 failure close

1. Less lube oil flow and pressure leading to compressor damage.

1. Thermostatic self actuating type of valve,During any type of failure two ports are available.

25.1.4.1.1

5. PCV-901 failure close

1. Less lube oil flow and pressure leading to compressor damage.

1. PI-908 is provided with 25.1.5.1.1 low alarm.

Recommendations

126. Provide differential pressure gauge across the suction strainer.

Responsibility

NEA

Remarks

25. Makeup H2 Compressor -Lube oil system

1. Low/No Flow

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

NODE NO: 25

Makeup H2 Compressor-Lube oil System

DESIGN INTENTION

To supply lube oil to cylinders and packings

DRAWINGS

CS-140-PR-D-06600002

EQUIPMENT

140-K-001A/B

:

Project :

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

STREAM DETAILS AVAILABLE CONTROL SCHEMES Operating Parameters

SERVICE Temperature(°C)

Pressure ( bar g) 50

Lube oil . Note: Node

Deviation

Causes

Flow rate (Kg/hr)

a} 3 barg for bearings and cross head.

Consequences

Safeguards

Ref. No.

Recommendations

Responsibility

2. Low low pressure (PT- 25.1.5.1.2 905A/B/C, 2 out of 3) trip the compressor.

6. Lube oil filter choked

1. Less lube oil flow and pressure leading to compressor damage.

1.PDI 903 is provided with high alarm.

25.1.6.1.1

2. Spare filter is provided 25.1.6.1.2 3. PI-908 is provided with 25.1.6.1.3 low alarm. 4. Low low pressure (PT- 25.1.6.1.4 905A/B/C, 2 out of 3) trip the compressor.

2.

High Flow

7. Lubricator failure

1. No supply of lube oil to cylinders.

1. PCV-901 failure to open

1. No significant consequances.

1.FAL-901 is provided.

25.1.7.1.1

25.2.1.1

3. Reverse/Misdirected Flow

1. No significant causes.

25.3.1

4.

Low Pressure

1. Same as No/low flow

25.4.1

5.

High Pressure

1. Any blockage in the system

6. High Temperature

1. Cooling water to lube oil cooler failure.

1. PSV-907/908 is provided 1. Reduced lubrication effect leading to damage to compressor parts at high temp. (beyond 60 C).

25.5.1.1

1. TI-935 with high alarm 25.6.1.1.1 is provided.

127. Consider set point change to 8.7 barg as per project philosophy.

NEA

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

NODE NO: 25

Makeup H2 Compressor-Lube oil System

DESIGN INTENTION

To supply lube oil to cylinders and packings

DRAWINGS

CS-140-PR-D-06600002

EQUIPMENT

140-K-001A/B

:

Project :

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

STREAM DETAILS AVAILABLE CONTROL SCHEMES Operating Parameters

SERVICE Temperature(°C)

Pressure ( bar g) 50

Lube oil . Note: Node

6. High Temperature Deviation

Causes

Consequences

Safeguards

2. Malfunction of TCV-901

7.

High Level

8. Low level

Ref. No.

Recommendations

Responsibility

128. Trip of aux. pump with time delay is to be ensured when compressor is tripped(refer vendor cause and effect diagram).

NEA

NEA

25.6.2

1. No significant causes. 1. Low level in oil reservoir due to leakage in lube oil system.

Flow rate (Kg/hr)

a} 3 barg for bearings and cross head.

25.7.1 1. Less lube oil flow and pressure leading to compressor damage.

1.Low level alarm LAL902 is provided.

25.8.1.1.1

2. Low low pressure (PT- 25.8.1.1.2 905A/B/C, 2 out of 3) trip the compressor.

1.Low level alarm LAL903 is provided.

2. Low level in cylinder lubricator

1. Reduced supply of lube oil to cylinders.

10. Composition

1. Lube oil cooler tube leak.

1. Lube oil leak to cooling water

25.10.1.1

129. Manual sampling arrangement is to be provided.

11. Operation/Maintenance

1. Improper Oil specification (Compatibility with Process)

1. Poor Lubrication. Leakage of Oil to Process may contaminate the process fluid leading to off spec. product.

25.11.1.1

130. Provide prossible leackage quantity of oil to process gas and oil specification, including all impurities in the oil used for cylinder lubrication.Axens will confirm the acceptence.

9. Problem/Requirements

25.8.2.1.1 25.9

NEA/Axens

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

NODE NO: 26

Makeup H2 Compressor- Closed cooling water System

DESIGN INTENTION

To supply cooling water to compressor cylinders jackets and packings.

DRAWINGS

CS-140-PR-D-06600006

EQUIPMENT

140-K-001A/B

:

Nagarjuna Oil Corporation Ltd

Project :

Diesel hydro Desulphurization unit

STREAM DETAILS AVAILABLE CONTROL SCHEMES Operating Parameters

SERVICE Temperature(°C)

Pressure ( bar g)

cooling water

Flow rate (Kg/hr)

50

4

Note: Node 26. Makeup H2 Compressor -Closed cooling water system

Deviation 1.

Low/No Flow

Causes 1. main cooling water pump failure.

Consequences 1.Less cooling water flow and pressure leading to higher process gas temp.

Safeguards 1. Cooling water pump with auto start though PT-912 is provided.

26.1.1.1.1

2. High high discharge temp trip TIHH-903 & 906 is available.

26.1.1.1.2

2. Piston rod packing temp. likely to go high. 1. Rod packing high temp. alarm TI-917 & 924 available.

2. cooling water pump suction strainer choking.

1. Less cooling water flow and pressure leading to compressor damage.

3. Cooler leak

1. No significant consequences.

4. Discharge filter blockage

1. Less cooling water flow and pressure leading to high process gas temp.

Ref. No.

Recommendations

Responsibility

26.1.1.2.1

2. High temp. alarm TI933 & 934 is available.

26.1.1.2.2

1. Spare pump with strainer is available.

26.1.2.1.1

26.1.3.1 1.Bypass will be used 26.1.4.1.1 during filter maintinance.

131. Vendor operation manual should mention bypass operation.

NEA

2.Low pressure alarm PI- 26.1.4.1.2 913 is provided.

132. Vendor operating manual should mention closing of manual isolation valve located in pump minimum circulation line in case both compressors are in operation during changeover.

NEA

Remarks

26. Makeup H2 Compressor -Closed cooling water system

1.

Low/No Flow

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

NODE NO: 26

Makeup H2 Compressor- Closed cooling water System

DESIGN INTENTION

To supply cooling water to compressor cylinders jackets and packings.

DRAWINGS

CS-140-PR-D-06600006

EQUIPMENT

140-K-001A/B

:

Nagarjuna Oil Corporation Ltd

Project :

STREAM DETAILS

Diesel hydro Desulphurization unit

1. Less cooling water flow and pressure leading to high process gas temp.

AVAILABLE CONTROL SCHEMES Operating Parameters

SERVICE Temperature(°C) cooling water

2.Low pressure alarm PI913 is provided. Pressure ( bar g)

Flow rate (Kg/hr)

50

4

Note: Node

Deviation

Causes

5. Less cooling water flow to cooling water cooler.

2.

High Flow

Consequences

1. Cooling water temp will increase leading high process gas temp.

Safeguards

1.High temp. alarm TI932 ia provided.

Ref. No.

Recommendations

Responsibility

133. Gate valve in min circulation line to be changed to globe valve.

NEA

134. Vendor to recheck requirement of low temp alarmTI-932 and compressor start permissive(refer vendor cause & effect page 4).

NEA

26.1.5.1.1

1. No significant cause.

26.2.1

3. Reverse/Misdirected Flow

1. No significant causes.

26.3.1

4.

Low Pressure

1. Same as No/low flow

26.4.1

5.

High Pressure

1. Any blockage in the system

1. System is designed for 26.5.1.1 pump max. pressure.

6. High Temperature

1.Cooling water to CW cooler cooler failure.

1. Closed cooling water temp. will increase leading high process gas temp.

7. Low temp.

1. Winter season

1. Likely condensation of process gas in cylinder.

1. TI-932 with high alarm 26.6.1.1.1 is provided.

26.7.1.1

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

NODE NO: 26

Makeup H2 Compressor- Closed cooling water System

DESIGN INTENTION

To supply cooling water to compressor cylinders jackets and packings.

DRAWINGS

CS-140-PR-D-06600006

EQUIPMENT

140-K-001A/B

:

Nagarjuna Oil Corporation Ltd

Project :

Diesel hydro Desulphurization unit

STREAM DETAILS AVAILABLE CONTROL SCHEMES Operating Parameters

SERVICE 7. Low temp.

cooling water

Temperature(°C) 1. Winter season

Pressure ( bar g) 50

Flow rate (Kg/hr)

1. Likely condensation of process gas in cylinder.

4

Note: Node

Deviation

8.

High Level

Causes

Consequences

Safeguards

1. No significant causes.

Ref. No.

Recommendations

Responsibility

135. Gas dew point to be confirmed.

SEI

26.9.1.1.1

136. Suitable makeup water connection to cooling water tank is to be provided.

NEA

26.10.1.1

137. Cooling water tank vent should be provided at safe location.

NEA

26.8.1

9. Low level

1. Low level in closed cooling 1. Less cooling water flow and pressure water tank due to leakage in CW leading to compressor damage. system.

10. Problem/Requirements

1. Packing leakage/failure.

11. Composition

1. Not applicable

12. Operation/Maintenance

1. No significant causes.

1. Process gas will leak to closed cooling water circuit.

1.Low level alarm LAL905 is provided.

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

NODE NO: 27

Makeup H2 Compressor- Distance piece/packing purge

DESIGN INTENTION

To supply Nitrogen purge to distance piece and packing

DRAWINGS

CS-140-PR-D-06600003

EQUIPMENT

140-K-001A/B

:

Nagarjuna Oil Corporation Ltd

Project :

Diesel hydro Desulphurization unit

STREAM DETAILS AVAILABLE CONTROL SCHEMES Operating Parameters

SERVICE Temperature(°C)

Pressure ( bar g)

Nitrogen

Flow rate (Kg/hr)

Amb.

1.5(packing) 1(distance piece)

Note: Node 27. Makeup H2 Compressor -Distance piece/packing purge

Deviation 1. Low/No Flow

Causes 1. External nitrogen supply failure

Consequences 1. Hydrogen accumulation.

Safeguards 1. Vent is connected to flare.Not affecting the environment.

Ref. No. 27.1.1.1.1

2. High alarm TI-907/908 27.1.1.1.2 is available.

2.

High Flow

1.PCV-902/903 fail to open

1. Loss of nitrogen to flare.

3. Reverse/Misdirected Flow

1.Compressor packing leaks

1. Loss of nitrogen to flare.

4.

Low Pressure

1. Refer 27.1.1.1.1 and 27.1.1.1.2

5.

High Pressure

1. Refer 27.2.1.1

Recommendations

Responsibility

138. PCV-902/903 set points to be reviewed in view of max. flare back pressure of 2 barg(during general power failure).

NEA/SEI

139. Isolation valve in vent line to flare is to be LO.

NEA

27.2.1.1 1.NRVs are provided in upstream and downstream of distance piece.

27.3.1.1.1

27.4.1

1. Rod packing damage.

1. PSV-909/910 are provided.

27.5.1.1.1

6. High Temperature

1. No significant causes.

27.6.1

7. Low temp.

1. No significant causes.

27.7.1

140. PSV discharge and NEA Goose neck provided on distance piece,to be routed to safe location.

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

NODE NO: 27

Makeup H2 Compressor- Distance piece/packing purge

DESIGN INTENTION

To supply Nitrogen purge to distance piece and packing

DRAWINGS

CS-140-PR-D-06600003

EQUIPMENT

140-K-001A/B

:

Nagarjuna Oil Corporation Ltd

Project :

Diesel hydro Desulphurization unit

STREAM DETAILS AVAILABLE CONTROL SCHEMES Operating Parameters

SERVICE Temperature(°C)

Pressure ( bar g)

Nitrogen

Flow rate (Kg/hr)

Amb.

1.5(packing) 1(distance piece)

Note: Node

Deviation 8.

High Level

Causes

Consequences

1. High level in packing drain pot.

1. High level leading to liquid carryover to flare.

9. Low level

1. Not applicable

10. Problem/Requirements

1. No significant causes.

11. Composition

1. Not applicable

12. Operation/Maintenance

1. No significant causes.

Safeguards

Ref. No.

1. Very unlikely as dew point of gas is low.

27.8.1.1.1

2. LG-904 is provided for monitoring.

27.8.1.1.2

Recommendations 141. Drain line from packing drain pot to be routed to CBD

Responsibility NEA/SEI

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

NODE NO: 27

Makeup H2 Compressor- Distance piece/packing purge

DESIGN INTENTION

To supply Nitrogen purge to distance piece and packing

DRAWINGS

CS-140-PR-D-06600003

EQUIPMENT

140-K-001A/B

:

Nagarjuna Oil Corporation Ltd

Project :

Diesel hydro Desulphurization unit

STREAM DETAILS AVAILABLE CONTROL SCHEMES Operating Parameters

SERVICE Temperature(°C)

Pressure ( bar g)

Nitrogen

Flow rate (Kg/hr)

Amb.

1.5(packing) 1(distance piece)

Note: Node

Deviation 13. Others

Causes 1. Nitrogen Mode

Consequences

Safeguards

Ref. No. 27.13.1

Recommendations

Responsibility NEA

Remarks 1. Machine needs separate control and trip set points for nitropgen case 2.Separate modes of operation to be pragrammed in DCS and in safeguarding system. 3. Pressure can be developed up to 24 barg with suction pressure of 7 barg. 4. Flow rate of nitrogen

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

NODE NO: 27

Recycle Compressor- Lube oil (No HAZOP was done except for deviation 1 & 2. The same need to be carried out later with the vendor).

DESIGN INTENTION

To supply lube oil to turbine and compressor bearings

DRAWINGS

0-336-00-32088

EQUIPMENT

140-K-002A/B

:

Nagarjuna Oil Corporation Ltd

Project :

Diesel hydro Desulphurization unit

STREAM DETAILS AVAILABLE CONTROL SCHEMES Operating Parameters

SERVICE Temperature(°C) Lube Oil

Pressure ( bar g)

Flow rate (Kg/hr)

Amb.

1.5(packing) 1(distance piece)

Note: Node 28. Recycle Compressor -Lube Oil

Deviation

Causes

Consequences

Safeguards

Ref. No.

1.

Low/No Flow

1. Main Lube Oil Pump failure 2. Suction strainers blockage. 3. Lube oil filter blockage. 4. Lube oil cooler leak. 5. PCV 602 malfunction to close.

1&2. Turbine trips 3, 4 & 5. Lube oil pressure falls to turbine & compressor bearings & turbine trips.

1&2. Auxilliary pump is available. 3,4 & 5. Lube oil pressure low alarm is available & lube oil overhead tank will take care of the oil requirement to bearings.

2.

High Flow

1. PCV 602 malfunction. 2. PCV 601 malfunction. 3. Turbine high speed.

1. More flow through the bearings.

1. PSV is available in 28.2.1.1.1 pump discharge. 2. PCV 602 will maintain the bearing header pressure. 3. PCV 601 will maintain the pump discharge pressure.

1. N/A

1. N/A

1. N/A

3. Reverse/Misdirected Flow

4.

Low Pressure

5.

High Pressure

6.

High Temperature

7. Low temp.

28.1.1.1.1

28.3.1.1.1

Recommendations

Responsibility

Remarks

28. Recycle Compressor -Lube Oil

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

NODE NO: 27

Recycle Compressor- Lube oil (No HAZOP was done except for deviation 1 & 2. The same need to be carried out later with the vendor).

DESIGN INTENTION

To supply lube oil to turbine and compressor bearings

DRAWINGS

0-336-00-32088

EQUIPMENT

140-K-002A/B

:

Nagarjuna Oil Corporation Ltd

Project :

Diesel hydro Desulphurization unit

STREAM DETAILS AVAILABLE CONTROL SCHEMES Operating Parameters

SERVICE Temperature(°C) Lube Oil

Pressure ( bar g)

Flow rate (Kg/hr)

Amb.

1.5(packing) 1(distance piece)

Note: Node

Deviation 8.

High Level

9. Low level

10. Problem/Requirements

11. Composition

12. Operation/Maintenance

13. Others

Causes

Consequences

Safeguards

Ref. No.

Recommendations

Responsibility

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

NODE NO: 29

Recycle Compressor- Seal Gas ( Vendor is expected to revise the seal gas system P&ID,Accordingly no HAZOP was done. The same need to be carried out later once the design is firmed up by the vendor).

DESIGN INTENTION

To supply Seal gas to primary and secondary seals

DRAWINGS

1-336-00-31116

EQUIPMENT

140-K-002A/B

:

Nagarjuna Oil Corporation Ltd

Project :

Diesel hydro Desulphurization unit

STREAM DETAILS AVAILABLE CONTROL SCHEMES Operating Parameters

SERVICE Temperature(°C) Nitrogen

Pressure ( bar g)

Flow rate (Kg/hr)

Amb.

1.5(packing) 1(distance piece)

Note: Node 29. Recycle Compressor -Seal Gas

Deviation 1.

Low/No Flow

2.

High Flow

3. Reverse/Misdirected Flow 4.

Low Pressure

5.

High Pressure

6. High Temperature 7. Low temp. 8.

High Level

9. Low level 10. Problem/Requirements 11. Composition 12. Operation/Maintenance 13. Others

Causes

Consequences

Safeguards

Ref. No.

Recommendations

Responsibility

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

:

Nagarjuna Oil Corporation Ltd

PROJECT NO

: SO 2331

Project :

Diesel hydro Desulphurization unit

NODE NO: 32

Recycle Compressor- Steam & drain

DESIGN INTENTION

To supply HP steam ,MP steam

DRAWINGS

CS-140-PR-15-0011,CS-140-PR-15-0030,1-336-00-33049(BHEL)

EQUIPMENT

Recycle Compressor Steam Turbine (140-KT-002)

STREAM DETAILS

HP Steam will be supplied from B/L to RGC Turbine from where it converts to MP steam and some amount send to Stripper column and rest is send to the return header of MP. MP steam is supplied to main lube oil pump from where it converts to LP steam

AVAILABLE CONTROL SCHEMES

SCV-002A Operating Parameters

SERVICE Temperature(°C) HP STEAM MP STEAM

Pressure ( bar g)

388 184

Flow rate (Kg/hr) 53.5 10

33000 1500

Note: Node 30.

Recycle Compressor- Steam & drain 1.

Deviation Low/No Flow

Causes 1. U/S disturbance (HP Steam Failure)

2. PIC-691 malfunctions to close PCV691.

Consequences 1. KT-002 trips

Safeguards

Ref. No.

1. PI-810 is provided with low alarm.

30.1.1.1.1

2. FI-805 is provided.

30.1.1.1.2

Recommendations

1. HP steam supply to gland steam condensor ejector failure.

30.1.2.1

142. All drains to be properly routed.

2.Steam leaks from gland causing unsafe work environment.

30.1.2.2

143. All condensate collections having temp 70 C will be routed to condensate collection system.

3. Potential contamination of lube oil by steam condensate.

1.Oil clarifier is available.

30.1.2.3.1

144. BHEL confirmed that PCV-691 is fail to close. 145. Standby PSV requirement for PSV-691 is to be checked as per project standards (considering PSV-691 failure).

3. 1. U/S disturbance (MP Steam Failure)

1. Main Lube Oil Pump turbine Failure

1.Aux. pump is available.

30.1.3.1.1

Responsibility

BHEL/SEI

Remarks

30.

Recycle Compressor- Steam & drain 1.

Low/No Flow

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

:

Nagarjuna Oil Corporation Ltd

PROJECT NO

: SO 2331

Project :

Diesel hydro Desulphurization unit

NODE NO: 32

Recycle Compressor- Steam & drain

DESIGN INTENTION

To supply HP steam ,MP steam

DRAWINGS

CS-140-PR-15-0011,CS-140-PR-15-0030,1-336-00-33049(BHEL)

EQUIPMENT

Recycle Compressor Steam Turbine (140-KT-002)

STREAM DETAILS

HP Steam will be supplied from B/L to RGC Turbine from where it converts to MP steam and some amount send to Stripper column and rest is send to the return header of MP. MP steam is supplied to main lube oil pump from where it converts to LP steam

AVAILABLE CONTROL SCHEMES

SCV-002A Operating Parameters

SERVICE Temperature(°C) HP STEAM MP STEAM

Pressure ( bar g)

388 184

Flow rate (Kg/hr) 53.5 10

33000 1500

Note: Node

Deviation

Causes 4. No flow of cooling water to gland steam condensor

Consequences 1. Steam does not condense as in normal operation.Steam leaks from gland causing unsafe work environment.

Safeguards

Ref. No.

1. BHEL confirmed that 30.1.4.1.1 steam going out of glands

Recommendations

Responsibility

146. All condensate collections having temp 70 C will be routed to condensate collection system.

BHEL/SEI/NOCL

147. SOP to ensure mentioning of gland steam condensor isolation and steam is to be vented out through local vent. 2.

High Flow of HP steam

1. No New Cause

30.2.1

3. Reverse/Misdirected Flow

1. No New Cause

30.3.1

4.

1. U/S disturbance (HP Steam Failure)

Low Pressure

1. KT-002 may get tripped

1. PI-810 is provided with low alarm.

30.4.1.1.1

2. Shutdown of DS-001 30.4.1.1.2 is considered when KT-002 trips

5.

High Pressure

1. U/S disturbance (HP Steam high header pressure)

6. High Temperature

1. No New Cause

7. Low temp.

1. No New Cause

1. KT-002 may get tripped

1. PI-810 is provided with high alarm.

30.5.1.1.1

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

:

Nagarjuna Oil Corporation Ltd

PROJECT NO

: SO 2331

Project :

Diesel hydro Desulphurization unit

NODE NO: 32

Recycle Compressor- Steam & drain

DESIGN INTENTION

To supply HP steam ,MP steam

DRAWINGS

CS-140-PR-15-0011,CS-140-PR-15-0030,1-336-00-33049(BHEL)

EQUIPMENT

Recycle Compressor Steam Turbine (140-KT-002)

STREAM DETAILS

HP Steam will be supplied from B/L to RGC Turbine from where it converts to MP steam and some amount send to Stripper column and rest is send to the return header of MP. MP steam is supplied to main lube oil pump from where it converts to LP steam

AVAILABLE CONTROL SCHEMES

SCV-002A Operating Parameters

SERVICE Temperature(°C) HP STEAM MP STEAM

Pressure ( bar g)

388 184

Flow rate (Kg/hr) 53.5 10

33000 1500

Note: Node

Deviation 8.

High Level

Causes 1. NA

9. Low level

1. NA

10. Problem/Requirements

1. NA

11. Composition

1. NA

12. Operation/Maintenance

1. NA

13. Others

1. NA

Consequences

Safeguards

Ref. No.

Recommendations

Responsibility

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

NODE NO: 26

Recycle Compressor- cooling water System (No HAZOP was done. The same need to be carried out later with the vendor).

DESIGN INTENTION

To supply cooling water to gland steam condensor, lube oil coolers and lube oil pump turbine bearings

DRAWINGS

3-336-00-34042

EQUIPMENT

140-K-002A/B

:

Project :

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

STREAM DETAILS AVAILABLE CONTROL SCHEMES Operating Parameters

SERVICE Temperature(°C)

Pressure ( bar g)

Flow rate (Kg/hr)

cooling water

Note: Node 31. Recycle compressor-cooling water system

Deviation 1.

2.

Low/No Flow

High Flow

3. Reverse/Misdirected Flow 4.

Low Pressure

5.

High Pressure

6. High Temperature 7. Low temp. 8.

High Level

9. Low level 10. Problem/Requirements

Causes

Consequences

Safeguards

Ref. No.

1. Less cooling water flow to Gland Steam Condenser.

31.1.1

2. Less cooling water flow to Lube Oil Cooler.

31.1.2

3. Less cooling water flow to lube oil pump turbine bearings

31.1.3

Recommendations

Responsibility

Remarks

HAZOP WORKSHEET Samsung Engineering India Pvt Ltd

Client

PROJECT NO

: SO 2331

NODE NO: 26

Recycle Compressor- cooling water System (No HAZOP was done. The same need to be carried out later with the vendor).

DESIGN INTENTION

To supply cooling water to gland steam condensor, lube oil coolers and lube oil pump turbine bearings

DRAWINGS

3-336-00-34042

EQUIPMENT

140-K-002A/B

:

Project :

Nagarjuna Oil Corporation Ltd Diesel hydro Desulphurization unit

STREAM DETAILS AVAILABLE CONTROL SCHEMES Operating Parameters

SERVICE Temperature(°C)

Pressure ( bar g)

Flow rate (Kg/hr)

cooling water

Note: Node

Deviation 11. Composition 12. Operation/Maintenance

Causes

Consequences

Safeguards

Ref. No.

Recommendations

Responsibility

Remarks