HAZOP study (part II)

HAZOP STUDY REPORT

HAZOP STUDY 6|Page

UNIVERSITY OF KARACHI

HAZOP STUDY REPORT

7|Page

UNIVERSITY OF KARACHI

HAZOP STUDY REPORT

8|Page

UNIVERSITY OF KARACHI

HAZOP STUDY REPORT

Equipment reference and operating condition Pump PU-01

Deviation from operating condition

What event can cause this deviation

Consequences of this deviation on item of equipment under consideration

Additional implication of this sequences

Action Required (recommendation)

Flow Less 1. NH3 storage empty 2. LCV-01 fails closed 3. NRV-01 fails closed 4. Line 100 plugs

 Pump cavitates

 Damage to pump

 Deadhead pump

 Damage to pump

 Deadhead pump

 Damage to pump

 Use level alarm in NH3 Storage  Use by pass manual valve system at LCV-01  Use Flow Indicator

 Pump cavitates

 Damage to pump

 Use flow Indicator

5. Line 101 plugs

 Deadhead pump

 Damage to pump

6. LIC-1 fails, closing LCV-01

 Deadhead pump

 Damage to pump

 Use by pass manual valve system

7. LCV-01 fails open

 Upset in vaporizer

 Liquid level increases  Pressure increases

8. LIC-1 fails, opening LCV-01

 Upset in vaporizer

 Liquid level increases  Pressure increases

More

9|Page

 Use by pass manual valve system  Use drain valve before pump  Use by pass manual valve system

UNIVERSITY OF KARACHI

HAZOP STUDY REPORT

Pressure More

Less

 Use by pass manual valve system  Use pressure Indicator

9. LCV-01 fails closed 10. NRV-01 fails closed 11. LIC-1 fails, closing LCV-01 12. Line 101 plugs

 Deadhead pump

 Damage to pump

 Deadhead pump

 Damage to pump

 Deadhead pump

 Damage to pump

 Deadhead pump

 Damage to pump

13. LCV-01 fails open

 Liquid level increases  Liquid level increases

 Upset in vaporizer  Use by pass manual valve system  Upset in vaporizer  Use by pass manual valve system

15. NH3 storage empty 16. Line 100 plugs

 Pump cavitates

 Damage to pump

 Pump cavitates

 Damage to pump

17. LCV-01 fails closed 18. NRV-01 fails closed 19. LIC-1 fails, closing LCV-01 20. Line 101 plugs

 Deadhead pump



 Deadhead pump



 Deadhead pump



 Deadhead pump



14. LIC-1 fails, opening LCV-01

 Use by pass manual valve system  Use pressure Indicator

 Use level alarm in NH3 Storage

Temperature More

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Damage to pump  Use temperature Indicator Damage to pump  Use temperature Indicator Damage to pump  Use temperature Indicator Damage to pump

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HAZOP STUDY REPORT

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UNIVERSITY OF KARACHI

HAZOP STUDY REPORT

Equipment reference and operating condition Vaporizer VE-01

Deviation from operating condition Level Less

What event can cause this deviation

Additional implication of this sequences

Action Required (recommendation)

21. Line 101 plugs

 Heat/steam loss

 Excessive vaporization

22. Rupture line 101

 Heat/steam loss

23. PCV-01 fails open

 Heat loss/steam loss  Excessive vaporization

 Excessive vaporization  Use by pass manual  Side reaction will valve system occur in the reactor  Ammonia loss

24. PIC-1 fails opening PCV-01

 Heat loss/steam loss  Excessive vaporization  Heat/steam loss

25. LCV-01 fails closed 26. NRV-01 fails closed 27. LIC-1 fails, closing LCV-01

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Consequences of this deviation on item of equipment under consideration

 Heat/steam loss  Heat/steam loss

28. FCV-01 fails open

 Heat loss/steam loss

29. FFC-1 fails, opening FCV-01

 Heat loss/steam loss

 Use cascade loop with PIC for level controlling

 Use by pass manual  Side reaction will valve system occur in the reactor  Ammonia loss  Excessive vaporization  Excessive vaporization  Excessive vaporization  Use by pass manual  Side reaction will valve system occur in the reactor  Ammonia loss  Use by pass manual  Side reaction will valve system occur in the reactor UNIVERSITY OF KARACHI

HAZOP STUDY REPORT

 Ammonia loss

More

30. PCV-01 fails close

 Insufficient vaporization

31. PIC-1 fails, closing

 Insufficient vaporization

32. FCV-01 fails close

 Vaporizer Overflow

 Reaction seize

33. FFC-1 fails, closing FCV-01 34. LCV-01 fails open

 Vaporizer Overflow

 Reaction seize

 Vaporizer Overflow

35. LIC-1 fails, opening LCV-01

 Vaporizer Overflow

 Insufficient vaporization  Insufficient vaporization

 Incomplete reaction in the reactor  Incomplete reaction in the reactor  Use by pass manual valve system  Use by pass manual valve system

No Same as less Pressure More

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36. LCV-01 fails open 37. LIC-1 fails, opening LCV-01 38. FCV-01 fails close

 Tank rupture  Tank rupture

39. FFC-1 fails, closing FCV-01 40. PCV-01 fails open 41. PIC-1 fails, opening

 Tank rupture

 Tank rupture

 Tank rupture  Tank rupture

 Use safety valve in VE01  Use safety valve in VE01  Use pressure Indicator

UNIVERSITY OF KARACHI

HAZOP STUDY REPORT

Less

42. Rupture discharge line

 NH3 loss

43. Rupture line 101

 NH3 loss

44. Tank rupture

 NH3 loss

45. FCV-01 fails open

 More heat is required in VE-01

 NH3 Displaces  Alarming system oxygen from should be installed ground up  Insufficient NH3 in the reactor  Insufficient NH3 in  Alarming system should be installed the reactor  Insufficient NH3 in the reactor  Side reaction will occur in the reactor

46. FFC-1 fails, opening FCV-01

 More heat is required in VE-01

 Side reaction will occur in the reactor

47. PCV-01 fails close

 Vaporization seize

48. PIC-1 fails, closing

 Vaporization seize

49. LCV-01 fails closed

 Vaporization seize

50. LIC-1 fails, closing LCV-01

 Vaporization seize

 Incomplete reaction in the reactor  Incomplete reaction in the reactor  Incomplete reaction in the reactor  Incomplete reaction in the reactor  Incomplete reaction in the reactor

51. NRV-01 fails closed

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

 Vaporization seize

UNIVERSITY OF KARACHI

HAZOP STUDY REPORT

Temperature 52. LCV-01 fails close More

Less

 Excessive vaporization

 Side reaction will occur in the reactor

 Use temperature Indicator

53. LIC-1 fails, closing LCV-01

 Excessive vaporization

 Side reaction will occur in the reactor

 Use temperature Indicator

54. NRV-01 fails closed

 Excessive vaporization

 Side reaction will occur in the reactor

55. FCV-01 fails close

 Excessive vaporization

 Reaction seize in the reactor

56. FFC-1 fails, closing FCV-01

 Excessive vaporization

 Reaction seize in the reactor

57. PCV-01 fails open

 Excessive vaporization

 Side reaction will occur in the reactor

58. PIC-1 fails, opening

 Excessive vaporization

 Side reaction will occur in the reactor

59. PCV-01 fails close

 No vaporization occurs in VE-01  No vaporization occurs in VE-01

 Reaction seize

61. LCV-01 fails open

 less vaporization occurs in VE-01

62. LIC-1 fails, opening LCV-01

 less vaporization occurs in VE-01

 Incomplete reaction in the reactor  Incomplete reaction in the reactor

60. PIC-1 fails, closing

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 Reaction seize

 Use temperature Indicator  Use temperature Indicator

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HAZOP STUDY REPORT

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UNIVERSITY OF KARACHI

HAZOP STUDY REPORT

Equipment reference and operating condition Compressor C-01

Deviation from operating condition Flow High

Less

What event can cause this deviation

Consequences of this deviation on item of equipment under consideration

63. Piece of filter material (i.e. cloth) breaks free

 Damage to compressor

64. Filter saturated

 Damage to compressor

65. Line 103 chock

 Damage to compressor

Composition As well as 66. Line 103 rupture

 Load increases on the compressor

67. Filter saturated  Load increases on the compressor 68. Atmosphere humidity increases

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 Load increases on the compressor

Additional implication of this sequences

Action Required (recommendation)

 Another filter should be installed as standby  Insufficient air for reaction in the reactor  Insufficient air for reaction in the reactor  Damage to compressor  Side reaction may occur in the reactor  Damage to compressor  Side reaction may occur in the reactor  Damage to compressor  Potential to corrodes

 Another filter should be installed as standby

 Moisture collector should be installed

UNIVERSITY OF KARACHI

HAZOP STUDY REPORT

Pressure More

69. Piece of filter material (i.e. cloth) breaks free

 Damage to compressor

70. Line 106 chock

 Surge the compressor

 Damage to compressor  Insufficient air for reaction in the reactor

 Blow off valve should be installed

 Performance decreases

 Reaction condition will not meet

 Use temperature indicator

Temperature More 71. Ambient temperature increases

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HAZOP STUDY REPORT

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UNIVERSITY OF KARACHI

HAZOP STUDY REPORT

Equipment reference and operating condition Reactor RE-01

Deviation from operating condition

What event can cause this deviation

Additional implication of this sequences

Action Required (recommendation)

Composition Other than

72. Wrong reagent

 Another possible reaction  No reaction

 Side reaction will  Use analyzer indicator occur in the reactor

As well as

73. Impurities in reagent

 Another possible reaction

 Side reaction will occur in the reactor

74. FCV-01 fails open

 Stress on catalyst bed  Stress on catalyst bed

 Tank rupture

Pressure More

75. FFC-1 fails, opening FCV-01 Less

76. Rupture line 106

 NH3 and O2 loss

77. Rupture line 107

 NO and NO2 loss

78. FCV-01 fails close

 NH3 and O2 will not enter in the reactor  NH3 and O2 will not enter in the reactor

79. FFC-1 fails, closing FCV-01 20 | P a g e

Consequences of this deviation on item of equipment under consideration

 Installed rupture disk at reactor (RE-01)

 Tank rupture

 Insufficient ratio of NH3 and O2 in the reactor  Damage the catalyst bed  Reaction seize

 Use pressure indicator with alarming system

 Reaction seize

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HAZOP STUDY REPORT

Temperature More

Less

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80. PCV-01 fails open

 Thermal Stress on catalyst bed

 Side reaction will occur in the reactor

81. PIC-1 fails, opening

 Thermal Stress on catalyst bed

 Side reaction will occur in the reactor

82. FCV-01 fails open

 Thermal Stress on catalyst bed

 Side reaction will occur in the reactor

83. FFC-1 fails, opening FCV-01

 Thermal Stress on catalyst bed

 Side reaction will occur in the reactor

84. Rupture line 106

 NH3 and O2 loss

 Incomplete reaction in the reactor  Side reaction will occur in the reactor

85. FCV-01 fails close

 Desired Reaction seize

 Side reaction will occur in the reactor

86. FFC-1 fails, closing FCV-01

 Desired Reaction seize

 Side reaction will occur in the reactor



There must be inter cooling system in the reactor

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HAZOP STUDY REPORT

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HAZOP STUDY REPORT

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UNIVERSITY OF KARACHI