HAZOP STUDY REPORT
HAZOP STUDY
6|Page UNIVERSITY OF KARACHI
HAZOP STUDY REPORT
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UNIVERSITY OF KARACHI
HAZOP STUDY REPORT
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UNIVERSITY OF KARACHI
HAZOP STUDY REPORT
Equipment reference and operating condition Pump PU-01
Deviation from operating condition Flow Less
What event can cause this deviation
Consequences of this deviation on item of equipment under consideration
Additional implication of this sequences
Action Required (recommendation)
1. NH3 storage empty 2. LCV-01 fails closed 3. NRV-01 fails closed 4. Line 100 plugs 5. Line 101 plugs 6. LIC-1 fails, closing LCV-01 More 7. LCV-01 fails open
Pump cavitates Deadhead pump Deadhead pump Pump cavitates Deadhead pump Deadhead pump
Damage to pump Damage to pump Damage to pump Damage to pump Damage to pump Damage to pump
Use level alarm in NH3 Storage Use by pass manual valve system at LCV-01 Use Flow Indicator Use flow Indicator Use by pass manual valve system
Upset in vaporizer
Liquid level increases Pressure increases Liquid level increases Pressure increases
8. LIC-1 fails, opening LCV-01
Upset in vaporizer
Use by pass manual valve system Use drain valve before pump Use by pass manual valve system
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UNIVERSITY OF KARACHI
HAZOP STUDY REPORT
Pressure More 9. LCV-01 fails closed 10. NRV-01 fails closed 11. LIC-1 fails, closing LCV-01 12. Line 101 plugs Deadhead pump Deadhead pump Deadhead pump Deadhead pump Liquid level increases Liquid level increases Pump cavitates Pump cavitates Damage to pump Damage to pump Damage to pump Damage to pump Use by pass manual valve system Use pressure Indicator Use by pass manual valve system Use pressure Indicator
Less
13. LCV-01 fails open 14. LIC-1 fails, opening LCV-01 15. NH3 storage empty 16. Line 100 plugs
Upset in vaporizer Use by pass manual valve system Upset in vaporizer Use by pass manual valve system Damage to pump Damage to pump Use level alarm in NH3 Storage
Temperature More 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 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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Equipment reference and operating condition Vaporizer VE-01
Deviation from operating condition Level Less
What event can cause this deviation
Consequences of this deviation on item of equipment under consideration
Additional implication of this sequences
Action Required (recommendation)
21. Line 101 plugs
Heat/steam loss Heat/steam loss Heat loss/steam loss Excessive vaporization Heat loss/steam loss Excessive vaporization Heat/steam loss Heat/steam loss Heat/steam loss Heat loss/steam loss Heat loss/steam loss
Excessive vaporization
22. Rupture line 101 23. PCV-01 fails open
Use cascade loop with PIC for level controlling
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 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
24. PIC-1 fails opening PCV-01 25. LCV-01 fails closed 26. NRV-01 fails closed 27. LIC-1 fails, closing LCV-01 28. FCV-01 fails open
29. FFC-1 fails, opening FCV-01 12 | P a g e
HAZOP STUDY REPORT
Ammonia loss 30. PCV-01 fails close Insufficient vaporization Insufficient vaporization Vaporizer Overflow Vaporizer Overflow Vaporizer Overflow Vaporizer Overflow Incomplete reaction in the reactor Incomplete reaction in the reactor Reaction seize Reaction seize Insufficient vaporization Insufficient vaporization Use by pass manual valve system Use by pass manual valve system
31. PIC-1 fails, closing
More
32. FCV-01 fails close 33. FFC-1 fails, closing FCV-01 34. LCV-01 fails open 35. LIC-1 fails, opening LCV-01
No Same as less Pressure More
36. LCV-01 fails open 37. LIC-1 fails, opening LCV-01 38. FCV-01 fails close 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 Tank rupture Tank rupture Use safety valve in VE01 Use safety valve in VE01 Use pressure Indicator
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HAZOP STUDY REPORT
Less
42. Rupture discharge line
NH3 loss
43. Rupture line 101 44. Tank rupture 45. FCV-01 fails open
NH3 loss NH3 loss More heat is required in VE-01 More heat is required in VE-01 Vaporization seize Vaporization seize Vaporization seize Vaporization seize Vaporization seize
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 Side reaction will occur in the reactor 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
46. FFC-1 fails, opening FCV-01 47. PCV-01 fails close
48. PIC-1 fails, closing 49. LCV-01 fails closed 50. LIC-1 fails, closing LCV-01 51. NRV-01 fails closed
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HAZOP STUDY REPORT
Temperature 52. LCV-01 fails close More 53. LIC-1 fails, closing LCV-01 54. NRV-01 fails closed 55. FCV-01 fails close
Excessive vaporization Excessive vaporization Excessive vaporization Excessive vaporization Excessive vaporization Excessive vaporization Excessive vaporization No vaporization occurs in VE-01 No vaporization occurs in VE-01 less vaporization occurs in VE-01 less vaporization occurs in VE-01
Side reaction will occur in the reactor Side reaction will occur in the reactor Side reaction will occur in the reactor Reaction seize in the reactor Reaction seize in the reactor Side reaction will occur in the reactor Side reaction will occur in the reactor Reaction seize Reaction seize Incomplete reaction in the reactor Incomplete reaction in the reactor
Use temperature Indicator Use temperature Indicator
56. FFC-1 fails, closing FCV-01 57. PCV-01 fails open
58. PIC-1 fails, opening Less 59. PCV-01 fails close 60. PIC-1 fails, closing 61. LCV-01 fails open
Use temperature Indicator Use temperature Indicator
62. LIC-1 fails, opening LCV-01
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Equipment reference and operating condition Compressor C-01
Deviation from operating condition Flow High
What event can cause this deviation
Consequences of this deviation on item of equipment under consideration
Additional implication of this sequences
Action Required (recommendation)
63. Piece of filter material (i.e. cloth) breaks free 64. Filter saturated
Damage to compressor Damage to compressor Damage to compressor 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 Another filter should be installed as standby
Less
65. Line 103 chock
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
Load increases on the compressor
Moisture collector should be installed
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Pressure More
69. Piece of filter material (i.e. cloth) breaks free 70. Line 106 chock
Damage to compressor Surge the compressor Damage to compressor Insufficient air for reaction in the reactor Blow off valve should be installed
Temperature More 71. Ambient temperature increases
Performance decreases
Reaction condition will not meet
Use temperature indicator
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Equipment reference and operating condition Reactor RE-01
Deviation from operating condition Composition Other than
What event can cause this deviation
Consequences of this deviation on item of equipment under consideration
Additional implication of this sequences
Action Required (recommendation)
72. Wrong reagent
Another possible reaction No reaction Another possible reaction
Side reaction will Use analyzer indicator occur in the reactor Side reaction will occur in the reactor
As well as
73. Impurities in reagent
Pressure More
74. FCV-01 fails open 75. FFC-1 fails, opening FCV-01
Stress on catalyst bed Stress on catalyst bed NH3 and O2 loss NO and NO2 loss NH3 and O2 will not enter in the reactor NH3 and O2 will not enter in the reactor
Tank rupture Tank rupture
Installed rupture disk at reactor (RE-01)
Less
76. Rupture line 106
77. Rupture line 107 78. FCV-01 fails close 79. FFC-1 fails, closing FCV-01 20 | P a g e
Insufficient ratio of NH3 and O2 in the reactor Damage the catalyst bed Reaction seize Reaction seize
Use pressure indicator with alarming system
UNIVERSITY OF KARACHI
HAZOP STUDY REPORT
Temperature More 80. PCV-01 fails open Thermal Stress on catalyst bed Thermal Stress on catalyst bed Thermal Stress on catalyst bed Thermal Stress on catalyst bed NH3 and O2 loss Side reaction will occur in the reactor Side reaction will occur in the reactor Side reaction will occur in the reactor Side reaction will occur in the reactor Incomplete reaction in the reactor Side reaction will occur in the reactor Side reaction will occur in the reactor Side reaction will occur in the reactor There must be inter cooling system in the reactor
81. PIC-1 fails, opening
82. FCV-01 fails open
83. FFC-1 fails, opening FCV-01
Less
84. Rupture line 106
85. FCV-01 fails close
Desired Reaction seize Desired Reaction seize
86. FFC-1 fails, closing FCV-01
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