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HAZOP RECORD FORM Facility/Project MEG Reclamation Pilot Plant
Date 10/12/2014 Team Members Ana Carmem G. B.; Ana Maria G. L.; Bernardo de Sa R.; Gabriel V. S.; Gabriela F. F.; Maximiano K. F.; Raphael de Souza R.
Drawing No./Procedure 26164_P&ID_001 Subject From Chemical Dosing Tank (F100) to the Flash Separator (K200), passing through Pump J100
DEVIATION
CAUSE
High Mixing
Agitator failure (1)
Low Mixing
As for (1); paddle stirrers corrosion and/or erosion High feed rate to dosing tank (F100)
High Level
Low Level
High Flow
EFFECT
SAFEGUARDS
Temperature rise; salt’s properties alteration; vortex formation; paddle stirrers corrosion and/or erosion Desired homogeneity not achieved; pump’s erosion
Speed indicator (SIC100); mixing motor (M100); hand switch (HS100) (2)
Flooding; pressure surges (4)
Level transmitter (L100); manual drain connected to a valve (V100) (5)
Pump (J100) or valve (V101) failure
As for (4)
As for (5); Flow controller (FC102); hand switch (HS102) (6)
Low feed rate to dosing tank (F100) Pump (J100) racing
Paddle stirrers corrosion; sludge formation (8) As for (8)
Level transmitter (L100)
Pump (J100) racing
Dosing tank (F100) pressure lost; flash separator (K200) pressure gain; low level on dosing tank; high level on flash separator (K200); pump (J100) cavitation
As for (6); valve (V103) and manual drain point – valve (V100)
As for (2)
As for (6)
ACTION Send a specialist to fix the motor in order to control the agitator’s velocity (3) As for (3) Install a high level alarm; automatic switch of valve (V100) connected to level transmitter (L100) Pump and valve regular maintenance; install a speed frequency controller (7) Install a low level alarm As for (7) Install a flow transmitter (9); pump regular maintenance (10)
DEVIATION
CAUSE
EFFECT
Low Flow
Pump (J100) racing; pump (J100) cavitation;
High level on dosing tank(F100); low level on flash separator (K200); dosing tank pressure gain; flash separator pressure lost (11) As for (11)
As for (6)
As for (9); as for (10)
As for (6)
As for (9); valve regular maintenance (12)
As for (11)
As for (6)
As for (9); as for (12)
As for (11);
As for (6); manual drain point from valve (V100) (13) Chemical dosing tank mixing motor controller (SIC100)
As for (9);
No Flow
Manual drain point failure (valve V100 failure : opened all time); Valve (V101,V102,NRV201) failure: obstructed route Pump (J100) failure
Commissioning
Wrong installation of an equipment or instrument such as a mixing motor, a pump or a valve
Dosing tank (F100) mixing motor failure; Pump (J100) failure; valve (V100, V101, V102, NRV201) failure
Contaminants
Paddle stirrers corrosion; pump (J100) corrosion; pump (J100) erosion;
Contaminate the solution; change solution’s properties;
SAFEGUARDS
No safeguards
ACTION
Install a motor controller on pump J100; pump and valve regular maintenance (14) As for (14)
HAZOP RECORD FORM Facility/Project MEG Reclamation Pilot Plant
Date 10/12/2014
Drawing No./Procedure 26164_P&ID_001
Team Members Ana Carmem G. B.; Ana Maria G. L.; Bernardo de Sa R.; Gabriel V. S.; Gabriela F. F.; Maximiano K. F.; Raphael de Souza R.
Subject From Pump J100 to the Pump J101 passing through the Feed Tank (F101)
DEVIATION
CAUSE
High Level
Increase in the input flow on the feed tank (F101) due to the higher pump (J100) race
Low Level
EFFECT
SAFEGUARDS
ACTION
Flooding; pressure surges
Hand switch on pump J100 (HS102); flow controller on pump J100 (FC102) (1); manual drain connected to a valve (V107); manual drain connected to a valve (V109) (2)
Pump (J101) or valve (V108) failure
Flooding; pressure surges
As for (2); feed pump (J101) over temperature; feed pump (J101) motor controller
Low feed rate on the feed tank (F101) due to a failure on pump J100
Process inefficiency since the feed tank F101 is the mainly tank in the system (6)
Pump J101 failure
As for (6)
As for (1); level switch indicating the feed tank F101 low level (LSL101) (7) As for (7); feed pump (J101) over temperature; feed pump (J101) motor controller
Install a level transmitter; install a high level alarm on the feed tank F101 (3); pump regular maintenance (4) As for (3); install an automatic switch of valve (V107,V109) connected to level transmitter; as for (4); valve regular maintenance (5) Increase the inlet flow of reagents (8) As for (8)
DEVIATION
CAUSE
High Flow
Pump (J100) racing
Low Flow
Pump (J100) racing; valve V103 failure; pump (J100) cavitation
No Flow
Pump (J100) failure; closed valve
High Concentration
Low Concentration
EFFECT Feed tank (F101) pressure gain; high level on feed tank (F101); pump (J101) cavitation Feed tank (F101) pressure lost; low level on feed tank (F101) (9)
SAFEGUARDS
ACTION Install a flow transmitter
As for (9)
As for (1); manual drain connected to a valve (V107); manual drain connected to a valve (V109); As for (1); Level switch indicating the feed tank F101 low level (LSL101) (10) As for (10)
Pump J100 racing (12)
Flash separator inefficiency (13)
Valve V103 and flow controller FC102 (14)
As for (12)
As for (13)
As for (14)
Install a flow transmitter before entering the feed tank (15) As for (15)
Commissioning
Wrong installation of an equipment such as a pump or a valve
Pump (J100,J101) failure; valve failure (V103,V107,V108,V109)
Feed pump (J101) over temperature alarm (TSH101)
As for (11)
Contaminants
Pump (J100) corrosion; pump (J100) erosion; valve (V103,V108) corrosion due mechanical friction
Contaminate the solution; change solution’s properties
No safeguards
As for (11)
Pump and valve regular maintenance (11) As for (11)
HAZOP RECORD FORM Facility/Project MEG Reclamation Pilot Plant
Date 10/12/2014
Drawing No./Procedure 26164_P&ID_001
Team Members Ana Carmem G. B.; Ana Maria G. L.; Bernardo de Sa R.; Gabriel V. S.; Gabriela F. F.; Maximiano K. F.; Raphael de Souza R.
Subject Feed recycle loop from the Pump J101 back to the Feed Tank (F101)
DEVIATION High Flow
Low Flow
No Flow
CAUSE
EFFECT
SAFEGUARDS
ACTION
Pump (J101) racing
Increase in the recycle flow (1) Feed pump (J101) over temperature sensor (TE101), feed pump (J101) motor controller (SIC101) and feed pump (J101) over temperature alarm (TSH101) (2)
Install a flow transmitter (3); pump regular maintenance (4)
Valve (V111,V112) failure: opened route
As for (1)
As for (3); valve regular maintenance (6)
Pump (J101) racing; pump (J101) cavitation
Decrease in the recycle flow (6)
The valve type can be considered a safeguard since a globe valve uses a plug closing against the flow being good for regulating flow while the ball valve has a gate that closes across the flow that is better for on/off control without pressure drop (5) As for (2)
Valve (V111, V112) failure: obstructed route
As for (6)
As for (5)
As for (4)
As for (2); as for (5)
Pump and valve maintenance (7)
Pump (J101) or valve No recycle loop back to the (V111,V112) failure feed tank (F101)
As for (3)
DEVIATION
CAUSE
Commissioning
Wrong installation of an equipment such as a pump or a valve Pump (J101) corrosion; pump (J101) erosion; valve (V111,V112) corrosion due mechanical friction
Contaminants
EFFECT Pump (J101) failure; valve failure (V111,V112)
SAFEGUARDS As for (2)
Contaminate the solution; No safeguards change in solution’s properties
ACTION As for (7) As for (7)
HAZOP RECORD FORM Facility/Project MEG Reclamation Pilot Plant
Date 10/12/2014
Drawing No./Procedure 26164_P&ID_001
Team Members Ana Carmem G. B.; Ana Maria G. L.; Bernardo de Sa R.; Gabriel V. S.; Gabriela F. F.; Maximiano K. F.; Raphael de Souza R.
Subject Feed line from the Pump (J101) up to the Flash Separator (K200)
DEVIATION High Flow
CAUSE Pump (J101) racing
No Flow
SAFEGUARDS
ACTION
Feed tank (F101) pressure lost, flash separator (K200) pressure gain, low level on feed tank, high level on flash separator (K200) and pump (J101) cavitation (1) As for (1)
Feed pump (J101) over temperature sensor (TE101), feed pump (J101) motor controller (SIC101) and feed pump (J101) over temperature alarm (TSH101) (2) No safeguards
Pump (J101) racing; pump (J101) cavitation
Feed tank (F101) pressure gain, flash separator (K200) pressure lost, high level on feed tank and low level on flash separator (K200) (7)
As for (2)
Install a flow controller; install a flow transmitter; valve regular maintenance (4) As for (3)
Valve (V113, NRV200) failure: obstructed route
As for (7)
No safeguards
As for (4)
Pump (J101) failure
As for (7)
As for (2)
As for (3)
Valve (V113,NRV200) failure
As for (7)
No safeguards
As for (4)
Valve (V113, NRV200) failure: opened route
Low Flow
EFFECT
Install a flow controller, install a flow transmitter and pump regular maintenance (3)
HAZOP RECORD FORM Facility/Project MEG Reclamation Pilot Plant
Date 10/12/2014 Team Members Ana Carmem G. B.; Ana Maria G. L.; Bernardo de Sa R.; Gabriel V. S.; Gabriela F. F.; Maximiano K. F.; Raphael de Souza R.
Drawing No./Procedure 26164_P&ID_001 Subject From Storage Tank (R500) to the Feed Tank (F101)
DEVIATION
CAUSE
EFFECT Flooding; high pressure on storage tank (R500)
SAFEGUARDS
High Level (R500)
Failure of pump J400
Valve leaving the storage tank
Low Level (F101)
Failure of pump J500 (1) Inefficiency of the process since feed tank (F101) must always have a minimum level
Level control with pump J101
High Flow
As for (1)
Level rise on feed tank (F101) and level drop on storage tank (R500)
Valves installed before and after pump J500 allow regular maintenance of the pump; flow transmitter (FT101) (2)
Low Flow
As for (1)
Failure to increase the level on feed tank (F101) and/or failure to decrease the level on storage tank (R500)
As for (2)
ACTION Install a level transmitter and controller on storage tank (R500), connected to pump J500 Install a level transmitter and controller on feed tank (F101), connected to pump J500 as a second alternative Regular maintenance of the pump (3) As for (3)
DEVIATION
CAUSE
EFFECT
Contaminants
Corrosion/erosion of pump J500 and/or corrosion/erosion of valve leaving the storage tank (R500) and valve V106
Inefficiency of the process since it won’t have pure MEG
SAFEGUARDS Valves installed before and after pump J500 allow regular maintenance of the pump
ACTION Regular maintenance of the valves and the pump
HAZOP RECORD FORM Facility/Project MEG Reclamation Pilot Plant
Date 10/12/2014 Team Members Ana Carmem G. B.; Ana Maria G. L.; Bernardo de Sa R.; Gabriel V. S.; Gabriela F. F.; Maximiano K. F.; Raphael de Souza R.
Drawing No./Procedure 26164_P&ID_001 Subject From the Flash Separator (K200) to Valves V200, V201 and V203
DEVIATION
CAUSE
High Temperature
Failure in communication between controllers of the flash separator with controllers of the heat exchanger (H300) (1); overheat in the flash separator due to: heat exchanger (H300) and/or HS204, TE211, TT211, TIR211, TE212, TSH212, TZAH212 malfunction As for (1); heat exchanger (H300) and/or HS204, TE211, TT211, TIR211, TE212, TSH212, TZAH212 malfunction; malfunction of valves V309 and/or V310, PCV300
Low Temperature
EFFECT Change in solution and salt crystals properties; MEG degradation
SAFEGUARDS
Valve V204; instruments HS204, TT211, TIR211, TSH212, temperature sensors (TE211,TE212), high temperature alarm (TZAH212) and communication between controllers of the flash separator with controllers of the heat exchanger (H300); temperature sensor TE202 and transmitter TT202 could predict this outcome Inefficient MEG separation; Instruments HS204, TT211, lower salt concentration due TIR211, TSH212; to the higher presence of temperature sensors MEG, leading to a salt (TE211,TE212) and solution provided by the pipe communication between containing the valve V203 with controllers of the flash less salt than expected for the separator with controllers of heating recycle flow, and the heat exchanger (H300) probably more water and MEG
ACTION Decrease the temperature by less steam input into the heat exchanger (H300); maintenance and, if that is the case, fixing of the pipelines
Increase the temperature by more steam input on heat exchanger H300; maintenance and, if that is the case, fixing of the pipelines
DEVIATION High Pressure
High Level
Low Level
CAUSE Failure of the vacuum system; high flow into the flash separator (K200) from heat exchanger (H300) and from the feed and dosing tank (F101 and F100 respectively) combined or not with failure (not opening) of the valves V200, V201, V202, V203 (2); malfunction of the safeguards related to pressure, temperature and level (3) As for (2); as for (3)
As for (3); pump racing (J300); low flow into the flash separator (K200) from heat exchanger (H300) and from the feed and dosing tank (F101 and F100 respectively) combined or not with failure (not closing) of the valves V200, V201, V202, V203, V302, V303, V305; failure (closure) of valve NRV200
EFFECT
SAFEGUARDS
A flammable atmosphere at a temperature above the flash point may be created in the gas space within the Flash Separator, which can result in explosions
Valve V222; pressure instruments PI202, PT203, PIR203 and PIC203 connected to the pressure control valve PCV203; level instruments LT200, LTC200, LR200 and level controller LTC200 connected with heat exchanger (H300) controllers (4)
Can lead to a high pressure problem, as stated above; flooding
As for (4); valve V200 leading to a manual bleed point; flow transmitter FT200 and controller FCT200 Vortex breaker connected with As for (4); valve V202 may not deliver flow transmitter FT200 and the correct amount and controller FCT200 concentration of solution for the heating recycle flow; corrosion of equipment
ACTION Use the valve V222 and the vacuum system, always avoiding sources of ignition anywhere within the flash separator (K200)
Maintenance of the valves of the MEG Rig plant Maintenance of the valves of the MEG Rig plant; fix the pump J300
DEVIATION
CAUSE
Static Build-up
Presence of salts and variations in pressure, temperature and composition of liquid/gas Vortex formation due to vortex breaker malfunction
High Mixing
EFFECT
SAFEGUARDS
ACTION
Source of ignition
Instruments CT200, TI200, TIR200, CI200, CIR200
Correct concentration of salts into the solution
Vapour may go into the liquid, which make the separation process not as efficient as it would and should be
Vortex breaker located inside Maintenance and fixing the Flash Separator (K200) of the vortex breaker
HAZOP RECORD FORM Facility/Project MEG Reclamation Pilot Plant
Date 10/12/2014 Team Members Ana Carmem G. B.; Ana Maria G. L.; Bernardo de Sa R.; Gabriel V. S.; Gabriela F. F.; Maximiano K. F.; Raphael de Souza R.
Drawing No./Procedure 26164_P&ID_001 Subject From the Valve V202 to the Heat Exchanger (H300)
DEVIATION
CAUSE
High Temperature
Overheat in the flash separator due to: heat exchanger (H300) and/or HS204, TE211, TT211, TIR211, TE212, TSH212, TZAH212 malfunction; failure in communication between Controllers of the flash separator with controllers of the heat exchanger (H300) (1) The overheat in flash separator (K200) leads to a high temperature liquid arriving into the recycle pump Recycle pump (J300) racing (4)
EFFECT
SAFEGUARDS
ACTION
Change in solution and salt crystals properties; MEG degradation (2)
Valve V204; hand switch HS204; temperature instruments TT211, TIR211, TSH212; temperature sensors (TE211,TE212); communication between controllers of the flash separator with controllers of the heat exchanger (H300); high temperature alarm (TZAH212)
Decrease the temperature by less steam input into the heat exchanger (H300); maintenance and, if that is the case, fixing of the pipelines (3)
As for (2)
Temperature Instruments TE315, TSH315 and high temperature alarm (TZAH315)
As for (3)
High flow of a liquid with higher temperature
Temperature instruments TW322, TE322, TIR320, TDIR321, TIR322 and temperature controller TDCR321 (5)
Fix the recycle pump
DEVIATION
CAUSE
EFFECT
SAFEGUARDS
Low Temperature
As for (1); heat exchanger (H300) and/or HS204, TE211, TT211, TIR211, TE212, TSH212 malfunction; malfunction of valves V309 and/or V310, PCV300
Inefficient MEG separation; lower salt concentration due to the higher presence of MEG, leading to a salt solution provided by the pipe containing the valve V203 with less salt than expected for the heating recycle flow, and probably more water and MEG High flow into the heat exchanger (H300) may lead to an insufficient heating of the solution
As for (4); As for (5); temperature sensor (TE315)
Increase the temperature by more steam input on heat exchanger H300; maintenance and, if that is the case, fixing of the pipelines
Flow control instruments SIC300, SIR300, HS304, FT302, DIR302, FIR302, TIR323 (6); valves V303, V305 (leading to a manual drain point) As for (6); level controllers connected to the flash separator vessel (K200) As for (6)
Maintenance and fixing of the pump, the last one only if it’s necessary
As for (6)
Maintenance of the pipeline, paying special attention to the valves V303 and V305, that shouldn’t be always opened, and the valve V302 that mustn’t be always jammed or closed
High Flow
As for (4)
Low Flow
Low Level in Flash Separator (K200)
Pump failure
Recycle pump (J300) failure related to poor suction conditions
Cavitation; low flow into the heat exchanger (H300) may lead to a solution overheated; cavitation inside the recycle pump (J300) Low flow into the heat exchanger (H300) may lead to a solution overheated; cavitation inside the recycle pump (J300)
Drain leaking; valve jammed
ACTION
Look for problems related to the level of solution inside the flash Maintenance and fixing of the pump, the last one only if it’s necessary
DEVIATION
CAUSE
EFFECT
Low Flow
High concentration of salt due to low level inside the flash or errors related to the concentration of salt given by the dosing tank Recycle pump (J300) failure Valve V302 jammed and not opening at all
Blockage of pump and/or valves; low flow into the heat exchanger (H300) may lead to a solution overheated; cavitation inside the recycle pump (J300) Failure of all the heating system of the flash Failure of all the heating system of the flash
As for (6)
Gas locking due to presence of gas if the vortex breaker doesn’t work properly Recycle pump (J300) failure (pump reversed)
Heating system inefficient
As for (6)
Failure of all the heating system of the flash
As for (6)
No Flow
Reverse Flow
SAFEGUARDS
As for (6) As for (6)
ACTION Maintenance of the system and attention to the concentration of salt measured in the bottom part of the flash separator Fix the pump Change or maintenance of the valve V302 Maintenance of the vortex breaker Fix the recycle pump (J300)
HAZOP RECORD FORM Facility/Project MEG Reclamation Pilot Plant
Date 10/12/2014 Team Members Ana Carmem G. B.; Ana Maria G. L.; Bernardo de Sa R.; Gabriel V. S.; Gabriela F. F.; Maximiano K. F.; Raphael de Souza R.
Drawing No./Procedure 26164_P&ID_001 Subject From the Heat Exchanger (H300) to the Flash Separator (K200)
DEVIATION
CAUSE
EFFECT
SAFEGUARDS
ACTION
High Temperature
Overheat in the flash separator due to: heat exchanger (H300) and/or HS204, TE211, TT211, TIR211, TE212, TSH212, TZAH212 malfunction
Change in solution and salt crystals properties; MEG degradation; If the fluid is overheated, the flash separator (K200) may have its temperature risen, which can cause high pressure problems into the vessel
Valve V204; hand switch HS204; temperature instruments TT211, TIR211, TSH212; temperature sensors (TE211,TE212) (1); high temperature alarm (TZAH212); communication between controllers of the flash separator with controllers of the heat exchanger (H300) (2) temperature instruments TE315, TSH315, TW322, TE322, TIR320, TDIR321, TIR322, TW320, TE320, TW319, TE319, TSH319 and temperature controller TDCR321 (3); high temperature alarm TZAH315; high temperature alarm TZAH319; valve V205
Decrease the temperature by less steam input into the heat exchanger (H300); maintenance and, if that is the case, fixing of the pipelines
DEVIATION
CAUSE
EFFECT
High Temperature
Failure of communication among the following controllers: TDCR321, LTC200 and PCV300 (4)
If the fluid is overheated, the flash separator (K200) may have its temperature risen, which can degrade MEG and cause high pressure problems into the flash vessel as well (5)
Failure (not opening) of valves V311, V312 and V313 As for (4)
As for (5)
Failure (not closing) of valves V311, V312 and V313 Not enough steam from building supply into the heat exchanger (H300) due to: pressure indicator PI204 malfunction; valves V309 and/or V310 jammed or fail to open
As for (9)
Low Temperature
If the fluid is not hot enough, the flash separator (K200) may not be efficient to vaporize the MEG/water mixture (9)
As for (9)
SAFEGUARDS Temperature controller TDCR321, temperature instruments TIR320, TDIR321, TIR322, TW320, TE320, TW319, TE319, TSH319 (6); high temperature alarm TZAH319 (7); valve V205 (8) As for (6); as for (8) Temperature instruments TW322, TE322, TIR320, TDIR321, TIR322, TW320, TE320, TW319, TE319, temperature controllers TDCR321 (10) As for (10) As for (10); pressure indicator PI204
ACTION Maintenance and if it is necessary, change or fix the controllers
Maintenance and if it is necessary, change of fix the valves Maintenance and if it is necessary, change or fix the controllers
Maintenance and if it is necessary, change of fix the valves Maintenance and if it is necessary, change or fix the controllers and valves
DEVIATION
CAUSE
EFFECT
Low Temperature
Heat exchanger (H300) and/or HS204, TE211, TT211, TIR211, TE212, TSH212, TZAH212 malfunction
As for (1); as for (2); as for (3)
Increase the temperature by more steam input on heat exchanger H300; maintenance and, if that is the case, fixing of the pipelines
High Flow
Leak in heat exchanger (H300), promoting steam and solution mixture
Inefficient MEG separation; lower salt concentration due to the higher presence of MEG, leading to a salt solution provided by the pipe containing the valve V203 with less salt than expected for the heating recycle flow, and probably more water and MEG Solution overheated, composition changed, ingress of steam can lead to presence of contaminants that can react with the solution or equipment, damaging the operation As for (9); high flow into the heat exchanger (H300) may lead to an insufficient heating of the solution
Pressure indicator PI204; speed viewing device SG301; temperature instruments TE320, TW320, TW319, TE319, TSH319; high temperature alarm TZAH319; valve V205 As for (10); speed/frequency instruments SIC300, SIR300, hand switch HS304 and flow control instruments FT302, DIR302, FIR302, TIR323 (11); valves V303, V305 (leading to a manual drain point)
Fix the heat exchanger
Pump failure
As for (11); level controllers connected to the flash separator Vessel (K200)
Look for problems related to the level of solution inside the flash
Recycle pump (J300) racing
Low Flow
Low level in flash separator (K200)
SAFEGUARDS
ACTION
Maintenance and fixing of the pump, the last one only if it’s necessary
DEVIATION Low Flow
CAUSE Recycle pump (J300) failure related to poor suction conditions
High concentration of salt due to low level inside the flash or errors related to the concentration of salt given by the dosing tank Valve V205 malfunction, half or completely opened when it shouldn’t be Drain leaking
No Flow
Valve V302, V304 or V204 jammed and not opening at all Gas locking due to presence of gas if the vortex breaker doesn’t work properly Heat exchanger (H300) leaking all the fluid outside the system
EFFECT
SAFEGUARDS
ACTION
As for (5); cavitation; low flow into the heat exchanger (H300) may lead to a solution overheated, which can rise the pressure in the flash vessel (K200); cavitation inside the recycle pump (J300) As for (5); blockage of pump and/or valves; low flow into the heat exchanger (H300) may lead to a solution overheated, which can rise the pressure in the flash vessel (K200) Less volume of heated solution into the flash vessel can lead to an inefficient separation of MEG/water from salt As for (5); low flow into the heat exchanger (H300) may lead to a solution overheated, which can rise the pressure in the flash vessel (K200); Failure of all the heating system of the flash (13)
As for (6); as for (7); as for (11)
Maintenance and fixing of the pump, the last one only if it’s necessary
As for (6); as for (7); as for (11)
Maintenance of the system and attention to the concentration of salt measured in the bottom part of the flash separator
Level controller LTC200 and level recorder LR200 (12)
Maintenance and if it is necessary, fix the valve
Flow control instruments FT302, DIR302, FIR302, TIR323
Check valves V303 and V305
As for (11)
As for (13)
As for (11)
Change or maintenance of the valve V302 Maintenance of the vortex breaker
As for (13)
As for (12)
Fix or change the heat exchanger (H300)
DEVIATION Reverse Flow High Pressure
CAUSE Recycle pump (J300) reversed High temperature
EFFECT
SAFEGUARDS
As for (13)
As for (12)
Rise of pressure in the flash separator (K200)
As for (6); as for (7); as for (8)
ACTION Maintenance of the plant Use valve V222 and check possible problems in the plant that led to high temperature
HAZOP RECORD FORM Facility/Project MEG Reclamation Pilot Plant
Date 10/12/2014 Team Members Ana Carmem G. B.; Ana Maria G. L.; Bernardo de Sa R.; Gabriel V. S.; Gabriela F. F.; Maximiano K. F.; Raphael de Souza R.
Drawing No./Procedure 26164_P&ID_001 Subject From the Separation Column (E200) to the Bleed Down (R403) and the Sampling Receiver (R404)
DEVIATION
CAUSE
EFFECT
SAFEGUARDS
ACTION
Temperature sensors (TE306,TE308,TE310,TE312); high temperature alarms (TZAH306,TZAH308,TZAH310, 312) Temperature sensors (TE306,308,310,312); sampling receiver (R404)
Decrease the temperature by less steam input on heat exchanger H300
High temperature
Overheat in the flash separator
Change in solution and salt crystals properties; MEG degradation
Low temperature
Flash separator temperature under set point
Inefficient MEG separation; lower salt concentration due to the higher presence of MEG
Blockage in separation column due to incrustation and/or salt accumulation Failure in vacuum pump (J200); failure in valves V409 and/or V411
Flooding; corrosion; erosion; break of salt loop operation.
Bleed down (R403); high level alarms (LZAH300, LZAH301,LZAH302,LZAH303)
No testing (no sample collection due to the lack of pressure difference). The separation column (E200) will be at the same pressure as the bleed down (R403) and the sampling receiver (R404) Motor temperature rise; vortex formation
Pressure indicators (PI400,PI401,PI402,PI403).
High level
High pressure testing
High speed
Motor malfunction (M300,301,302,303) (1)
Temperature controllers (TIC305,307,309,311); hand switches (HS300,HS301,HS302,HS303)
Increase the temperature by more steam input on heat exchanger H300 Regular maintenance of the separation column (E200) Install high pressure alarms; vacuum pump (J200) regular maintenance; valves V409 and V411 regular maintenance Motor (M300,M301,M302, M303) regular maintenance (2)
DEVIATION Low speed
CAUSE As for (1)
EFFECT Insufficient wash of the MEG residue from the salts
SAFEGUARDS Conductivity transmitters (CT300,CT301,CT302, CT303,CT304); sampling receiver (R404) to analyse MEG concentration
ACTION As for (2)
HAZOP RECORD FORM Facility/Project MEG Reclamation Pilot Plant
Date 10/12/2014 Team Members Ana Carmem G. B.; Ana Maria G. L.; Bernardo de Sa R.; Gabriel V. S.; Gabriela F. F.; Maximiano K. F.; Raphael de Souza R.
Drawing No./Procedure 26164_P&ID_001 Subject Salt loop (from R400 to R401 and back to R400)
DEVIATION No Flow
CAUSE
EFFECT
SAFEGUARDS
No feed to salt tank
No production of brine (1); column full of salt
Conductivity control in the column
Pump J401 failure
As for (1)
Speed frequency control, temperature control and pressure control in the pump Flow rate transmitters (FT400,401,402)
No water feed into the brine tank; valve V428 closed in error Line blockage/closed valve Line fracture High Flow
Pump J401 racing
Low Flow
Pump J401 failure
ACTION Install level alarm on R400 (2)
As for (2); regular maintenance in the pump As for (1); Regular maintenance high salt concentration in the in the valve (3); stream install level alarm on R401; composition transmitter in pipelines As for (1); Temperature sensor (TE403); Regular maintenance overload of the pump J401 FT400,FT401,FT402 in the valves As for (1); FT400,FT401,FT402 Regular inspection in leakage the lines Low level of salt tank; high Speed frequency control, Regular maintenance pressure stream in brine tank; temperature control and in the pump (4); low pressure in salt tank; pump pressure control in the pump; open valves V416, temperature rise manual drain; V419 or V420 FT400,FT401,FT402 Low production of brine (5) Speed frequency control, As for (4) temperature control, pressure control in the pump; FT400,FT401,FT402
DEVIATION
CAUSE
Low Flow
Sedimentation of salts in pipes
High Concentration Low Concentration
High Level (R400)
High Level (R401)
EFFECT
SAFEGUARDS
As for (5); line blockage; change in desired fluid properties and concentration As for (5)
FT400,FT401,FT402
As for (5)
FT402
High water feed to R401 J401 failure
Change in desired fluid properties (6) As for (5); as for (6)
FT402
High feed to R400 from the column
Flooding in R400 (7)
High feed from brine tank J401 failure
As for (7)
Line blockage
As for (7)
High water feed
Flooding in R401 and change in brine composition (9)
Low water influx to R401 Low water feed to R401
As for (7)
Flow transmitter (FT402)
Speed frequency control; temperature control; pressure control in the pump Conductivity control in the column; manual drain point (V416) FT400; Manual drain point (V416) Speed frequency control, temperature control and pressure control in the pump; manual drain point (V416 and V419) FT400,FT401,FT402; manual drain point (V416, V419 and V420) FT402; manual drain point (V425); valves V428 and V429
ACTION Regular inspection in the lines; install composition transmitter in pipelines Increase water feed Increase water feed; install composition transmitter in pipelines Decrease water feed As for (4) Install high level alarm in R400 (8); open drain point As for (8); open drain point As for (4); as for (8); open drain point As for (8); regular inspection in the lines; open drain point Install high level alarm in R401 (10); open drain point; close V428 or V429
DEVIATION
CAUSE
EFFECT
High Level (R401)
High feed from salt tank (J401 racing)
As for (9); pump temperature rise
Low Level (R400)
Low feed from the column
Change in brine composition (11)
Low feed from brine tank J401 racing
As for (11)
Low water feed
As for (11); accumulation of salt in pipelines As for (11)
Low Level (R401)
Low feed from salt tank (J401 failure)
As for (11); pump temperature rise
SAFEGUARDS
ACTION
Speed frequency control, temperature control, pressure control in the pump; manual drain point (V425); valve V417 Conductivity control in the column; level switches in column FT400
As for (4); as for (10); close V417; open drain point
Speed frequency control, temperature control, pressure control in the pump FT402
As for (12)
Speed frequency control, temperature control and pressure control in the pump
As for (12); regular maintenance in the pump
Install low level alarm in R400 (12) As for (12)
As for (12); increase water feed
HAZOP RECORD FORM Facility/Project MEG Reclamation Pilot Plant Drawing No./Procedure 26164_P&ID_001 Subject From the Flash Separator (K200), to the Condensate Separator Tank (K300) passing through condenser C201 and sub-cooler C301
DEVIATION
Date 10/12/2014 Team Members Ana Carmem G. B.; Ana Maria G. L.; Bernardo de Sa R.; Gabriel V. S.; Gabriela F. F.; Maximiano K. F.; Raphael de Souza R.
CAUSE
High Flow
Pump (J200) racing
Low Flow
Pump (J200) failure
High Temperature
Low/no flow of chilled water input on condenser C201 and sub-cooler C301; valves jammed (V221 and V306)
Low temperature
High flow of chilled water input on condenser C201 and sub-cooler C301
EFFECT Inefficient process of condensation in condenser C201 and sub-cooler C301 (1); leak in condenser C201 and sub-cooler C301; flash separator (K200) pressure loss Flash separator (K200) pressure gain; cavitation in pipelines; presence of foreign body from corrosion; sedimentation; leak in condenser C201 and subcooler C301 As for (1); change in solution properties (4)
As for (4)
SAFEGUARDS
ACTION
Hand switch (HS200); vacuum control valve PCV203 (2)
Install a speed frequency controller in pump J200 and a flow transmitter (3)
As for (2)
As for (3); regular maintenance of condensers
Flow indicators (FI202,301); temperature sensors (TE204,205,316,317), transmitters (TT204,205,316,317) and indicators & recorders (TIR204,205,316,317) (5) As for (5)
Install a flow controller in the chilled water feed associated with the temperature indicators & recorders (TIR204,316) (6) As for (6)
DEVIATION
CAUSE
High Pressure
Failure of condenser C201 and/or sub-cooler C301 in cooling the solution of MEG/water
EFFECT Insufficient MEG/water solution recovered; high pressure in condensate separator tank (K300)
SAFEGUARDS No safeguards
ACTION Install a high pressure alarm; install a pressure indicator on K300
HAZOP RECORD FORM Facility/Project MEG Reclamation Pilot Plant Drawing No./Procedure 26164_P&ID_001 Subject From Condenser 201 to Storage Tank (R500), passing through Vacuum Trap (K201), Vacuum Receiver (K202) and Condensate Separator Tank (K300)
DEVIATION High Temperature
Low Temperature High Pressure
Date 10/12/2014 Team Members Ana Carmem G. B.; Ana Maria G. L.; Bernardo de Sa R.; Gabriel V. S.; Gabriela F. F.; Maximiano K. F.; Raphael de Souza R.
CAUSE
EFFECT
SAFEGUARDS
ACTION
Ventilated place without hot surfaces for the J200 pump work Ventilated place without hot surfaces for the J400 pump work Temperature indicators TW318, TE318, TT318, TIR318, valve V431 Presence of vacuum trap K200 and receiver K201
Install temperature indicator in the pump (2) As for (2)
No ventilation around the J200 pump
Pump damage and/or malfunction (1)
No ventilation around the J400 pump
As for (1)
Failure of sub-cooler C301, leading J400 pump to heat Cold fluid entrance in J200 pump
As for (1)
Obstruction in the line connected to the J200 pump
Pump damage; failure of J200 Valves V213 and V214,; to provide vacuum vacuum trap K200 and receiver K201 (3)
Liquid entrance in the J200 Water vapour entrance above J200 pump capacity Obstruction in the line connected to the J400 pump
J200 pump damage, lubrication oil compromised Condensing fluid dissolves in pump oil; pump corrosion
J200 pump damage, condensing fluid
As for (3) As for (3)
Pump damage; failure of J400 No safeguards to drive the MEG/water liquid mixture
Regular maintenance of sub-cooler C301 Temperature control of the air entering the pump Install relief valve downstream from the pump (4) Install extra pressure indicator/controller No action As for (4)
DEVIATION Low Pressure
Failure of Vent Failure of Power
Failure of Vacuum
Reverse Flow
CAUSE
SAFEGUARDS
ACTION
Low flow and poor efficiency of J200 Risk of J400 pump to air suction; cavitation
Vacuum control valve PCV203
Correct dimensioned pipes Regular maintenance (5)
Rise in J200 pump temperature and pressure Failure of J200 to provide vacuum and drive the MEG/water mixture (6)
Vent to a safe location
As for (5)
Computer monitoring of the hand switch
Electrical failure of hand switch HS400
Failure of J400 to drive the MEG/water mixture (7)
Computer monitoring of the hand switch
Internal/component problem of J200 pump
As for (6)
Obstruction in line near J200 pump
As for (6)
Respect the working conditions, lifetime and lubrication of the pump No safeguards
Install backup generator; check the connection between the switch and the J200 pump Install backup generator; check the connection between the switch and the J400 pump Regular maintenance, testing and lubrication As for (4)
Failure of valves V411 or V409
Failure of J200 to provide vacuum to bleed down R403 and sampling receiver R404 As for (7)
Narrow diameter pipes High flow in J400 pump, stoking so fast that the fluid can’t be pulled or sucked into the chamber as fast as the diaphragm is withdrawing, lowering pressure Failure of vent to drive the output of J200 pump Electrical failure of hand switch HS200
Failure of J400 diaphragm pump internal check valves
EFFECT
Hand switch HS400
Pressure indicators PI400, PI401, PI402, PI403
As for (5)
No safeguards
Install check valve before the entrance of the J400 pump
DEVIATION
CAUSE
Reverse Flow
Sudden power cut to J200 pump leads to low inertial force of rotating parts, that can’t overcome system head (blowback) Overpressure in pipeline; failure of vacuum Line blockage near J200 pump Line blockage near J400 pump
No Flow
High Flow
Low Flow
Vapour appearance near J400 pump, cavitation Failure of valve V222 Failure of vacuum control valve PCV203 Failure of speed indicator controller SIC400 Partial blockage near J200 pump J200 pump malfunction Partial blockage near J400 pump J400 pump malfunction Failure of speed indicator controller SIC400 (jammed low)
EFFECT
SAFEGUARDS
ACTION
As for (6)
No safeguards
Install check valve before the entrance of J200
As for (6)
As for (3)
Install extra pressure indicator/controller
As for (6)
As for (3)
As for (4)
Danger to the process No safeguards stability and continuation, as it stops the MEG/water drive Pump damage, stop to the Speed indicator controller process SIC400 (8)
As for (4)
Vacuum control valve PCV203 won’t control the adequate level of vacuum (9) As for (9)
Hand switch HS200 (10) As for (10)
Install flow rate controller/transmitter (11) As for (11)
Risk of J400 pump to air suction, cavitation
Hand switch HS400
As for (5)
As for (6)
Vacuum control valve PCV203
As for (11)
As for (6) As for (7)
Vacuum control valve PCV203 As (8)
As for (11) As for (5)
As for (7) Low J400 pump efficiency
As (8) No safeguards
As for (5) As for (5)
Install temperature indicator
DEVIATION
CAUSE
Contaminants
Failure of sintered filter Z203, allowing contaminated air to enter the vacuum system Water or any other liquid entering the pump J200 Contaminant in the oil lubricant of the J200 pump
As for (1)
Valve V205
As for (5)
As for (1)
As for (3)
As for (5)
As for (1)
Check lubricant and clean filters regularly, replace when necessary
As for (5)
Contaminant in the oil lubricant of the J400 pump Corrosion of vessels or instrument near J400 pump, contaminating fluid Condenser C201, flash separator K200 or mixing tank F101 failure
As for (1)
Check oil level and clean filters regularly, replace when necessary Valve V205
As for (5)
Temperature indicators and transmitters in the condenser C201 and flash separator K200 (12) As for (12)
As for (5)
Valve V205; vacuum control valve PCV203 (13)
Install level indicator (14)
As for (13)
As for (14)
Valves V408 and V433
As for (14)
High Concentration
Low Concentration
Condenser C201, flash separator K200 or mixing tank F101 failure
High Level
Failure of valve V213 to open Failure of valve V214 to open Failure of valve V412 to open
EFFECT
As for (1)
High concentration of MEG/water vapour (>90%) causes J200 pump to fail to drive the mixture Low concentration of MEG/water vapour (
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