HIPAP 8: HAZOP Guidelines | January 2011
Figure 3: Example P&ID (Original)
27 | Department of Planning
HIPAP 8: HAZOP Guidelines | January 2011
DOP REFINERY
HAZOP MINUTE SHEET
Project: PRODUCT DISTILLATION UNIT WASTE OIL (kerosene ex engine washing)
Node: L0
Page: 1
Node Description: Product feed line
Date:
07.09.94
Drw No DOP 001 Rev 1
GUIDEWORD
1. High Flow
CAUSE
CONSEQUENCE
Flow controller
Level in column rises and hence
fault
temperature falls. Product
reboiler will attempt to
maintain temperature in
column until reboiler capacity
is reached. After this point
liquid level will rise arid -Mood
line LS. Column stops
operating.
2. Low Flow
1. Product feed
Temperature rise in column.
pump failed.
2. Isolating
Drop in liquid level in column.
Overheating. Reboiler can
valve jammed
handle this. TIC will in
addition control gas/air feed to
furnace H1. Not a problem.
3. Zero Flow
As above
28 | Department of Planning
As above
SAFEGUARD
REC#
1
RECOMMENDATION
Independent high flow
alarm on LO.
INDIV
NJ
ACTION
HIPAP 8: HAZOP Guidelines | January 2011
DOP REFINERY
HAZOP MINUTE SHEET
Project: PRODUCT DISTILLATION UNIT WASTE OIL (kerosene ex engine washing)
Node: H3
Page: 2
Node Description: Distillation column
Date:
07.09.94
Drw No DOP 001 Rev 1
GUIDEWORD
4. High Level
CAUSE
CONSEQUENCE
Level controller
Flooding of L6 and reboiler
fault
operation stops.
SAFEGUARD
REC#
2
RECOMMENDATION
High level alarm
INDIV
NJ
independent, of level
controller LIC. Alarm
level below L6.
5. Low Level
6. High Pressure
Level controller
Not a problem (as for No
malfunction or
low flow.
Flow).
Water failure in
condenser.
Condenser vent will act as
relief device. No adverse effect.
Low level alarm.
NJ
Pressure indicator on
column. High pressure
NJ
alarm + trip on gas/air
control valve V1.
7. High
Loss of feed.
Temperature
No adverse effect.
Temperature alarm
(high & low) on TIC.
Additional high temp
alarm linked to
furnace gas inlet shut
off.
29 | Department of Planning
NJ
ACTION
HIPAP 8: HAZOP Guidelines | January 2011
DOP REFINERY
HAZOP MINUTE SHEET
Project: PRODUCT DISTILLATION UNIT WASTE OIL (kerosene ex engine washing)
Node: C1
Page: 3
Node Description: Condenser, water cooled
Date:
07.09.94
Drw No DOP 001 Rev 1
GUIDEWORD
CAUSE
CONSEQUENCE
8. Reverse Flow
Cooling of
Suck back of air into H3 on
condenser and H3
cooling.
SAFEGUARD
REC#
6
RECOMMENDATION
Consider nitrogen
INDIV
JS
purge.
after shutdown.
9. High Pressure
Water failed or
[low.
Excess pressure
1. backup cooling water
2. Thermocouple on
vent.
3. Reorient water line
for counter-current
flow.
30 | Department of Planning
JS
system.
JS
JS
ACTION
HIPAP 8: HAZOP Guidelines | January 2011
DOP REFINERY
HAZOP MINUTE SHEET
Project: PRODUCT DISTILLATION UNIT WASTE OIL (kerosene ex engine washing)
Node: T1, LS, L9
Node Description: Product receiver and associated pipework
Page: 4
Date:
07.09.94
Drw No POP 001 Rev 1
GUIDEWORD
10. High Level
11. Low Level
CAUSE
CONSEQUENCE
Pump P2 fault
T1 overfills. High pressure in C1
LIC fault
V10 fault
and H3 if CI floods.
LIC fault
Pump damage
V10 fault
31 | Department of Planning
SAFEGUARD
REC#
8
RECOMMENDATION
LAH (independent) on
INDIV
NJ
T1.
Consider LAL
(independent)
NJ/JS
ACTION
HIPAP 8: HAZOP Guidelines | January 2011
DOP REFINERY
HAZOP MINUTE SHEET
Project: PRODUCT DISTILLATION UNIT WASTE OIL (kerosene ex engine washing)
Node:
L3, P1, L4, H1, L2
Node Description: Hot oil furnace, Hot oil circulation pump and pipework
Page: 5
Date:
07.09.94
Drw No DOP 001 Rev 1
GUIDEWORD
CAUSE
CONSEQUENCE
12. Low Flow
P1 fails
Loss of heat to H2; TIC will call
for further opening of V1
SAFEGUARD
REC#
10
Heating/
INDIV
Install flow sensor/
indicator/alarm to trip
NJ
furnace via V1 or other.
resulting in temperature rise in
H1.
13. High Pressure
RECOMMENDATION
Burst pipe, etc.
11
Surge tank in oil
expansion of hot
system. Evaluate
oil
location of tank: on L3
(at pump suction) or
JS
on L2. Check: Dead leg
and condensation of
moisture in oil.
14, High
1. High product
Temperature
load on H3
causing high
High temperature in furnace.
12
JS
Pyrometer in furnace
to alarm/trip gas
supply.
flame in H1
2. TIC on H3 failed
V1 failed open
3. H2 partly
blocked or heat
transfer poor
15. Contamination
Water from
Water turns to steam and
(water in oil)
atmosphere
through vent
explodes.
13
Locate surge tank to be
in hot system. Avoid
dead legs. Steam vents
at high points in pipe
system. Nitrogen
connection on vent
32 | Department of Planning
JS
ACTION
