2nd Assignment - Furnace(1)
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Transcript of 2nd Assignment - Furnace(1)
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PROCESS
SECTIONDATE
NODE 100
NO PARAMETER Guide Words Deviation posssible causes possible consequences
1 PRESSURE MORE - MORE - PRESSUREcontinously high flame
to the furnace.
Piping/tube thermal shock and craking lead to lea
the heating oil to the furnace and get contact with
flame and resulting to high temperature in furnac
cracking and Explosion
fuel gas valve
malfuction - more fuel
gas into the furnace
More fuel gas in the furnace, lead to high temper
normal operation and may cause explosion durin
up.
Explosion at furnace stack or Fuel gas release to
atmosphere in normal operation
Flue gas control valve,
PIC 1 malfaction - close
position
High temperature of hot oil to reboiler, Distillatio
experience high pressure that possible to crack an
explosion.
Air supply to the
furnace high flow &
pressure
2 PRESSURE LESS - LESS - PRESSURE
Less combustion
(May caused by either
less air pressure or less
fuel gas)
The oil has not been heating up. The reboiler not
HC, the distillation flooding, liquid HC over flow toupper stream of distillation column.
Less air pressure to
furnace for combustion
More fuel gas in the furnace, lead to explosion es
during start-up or fuel gas release to atmosphere
stack due to low combustion
Less fuel gas to the
furnace
The oil has not been heating up. The reboiler not
HC, the distillation flooding, liquid HC over flow to
upper stream of distillation column.
3 TEMPERATURE MORE -MORE -
TEMPERATURE
High flame in the
furnace (high fuel and
air)
Piping/tube crack or burst due to overheating, m
oil burn and cause black smoke release
High coke in furnace and piping, less heat transfe
less hot oil flow to the
tubing (less heat
transfer )
Thermal craking to the furnace - fuel gas release ca jet fire
TEMPERATURE LESS -LESS -
TEMPERATURE
No ignition and No
flame in the furnace
High Fuel gas in the furnace - when it ignited it w
exploded during start-up
No heat transfer to Hot oil - No heating to reboile
distalltion column, if the Feed of the distillation i s
the distillation will flooding
No air Flow High Fuel gas in the furnace - when it ignited it wexploded
No heat transfer to Hot oil No heating to reboile
HAZOP STUDYFurnace/burner used to heat up using fuel oil + air Heating oil to 250 C to sup
FURNACE
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PROCESS
Section
Date
NODE
200NO PARAMETER Guide Words DeviationFLOW
MORE - MORE - FLOW
LESS - LESS - FLOW
NO - NO - FLOW
OTHERS THAN
VALVE Valve malfuction
MAINTENANCE
SHUT DOWN &START UP
Not follow Procedure
HFurnace/burner used t
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posssible causes possible consequences Safe Guard/Protection
the valve or control valve malfuctionair to fuel ratio not as per
stoikiometric,FT 2
high presure in the
furnacePT 1, PI 4 & PI 5
more gas rushing out to
atm, PIC 1
piping leaking
air to fuel ratio not as per
stoikiometric, more fuel
coming out from the stack
can cause
detonation/explosion
FT 2 & PI 2
piping leaking
pump/compressor failure
Piping blockage/valve malfuction
un-edequate maintenance
air supply to actuator block
controller malfuction
cost cutting
equipment malfuction and
error can occurred may
lead to explosion
Human Factor
Explosion can happen if
not following the SU and
SD procedure.
ZOP STUDY
Air line supply to the furnace
heat up using fuel oil + air Heating oil to 250 C to supply to Distillation re
more fuel gas in the
furnace can cause
explosion
more flow or no flow of
air to furnace
FT 2 & PI 2
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action required/Recommendation
Air Flow Alarm Low and automatic
shut down the fuel supply or heater on
low air flow and/or low air/fuel ratio.
Periodic Piping inspection, Risk based
inspection (RBI)
boiler
Air Flow Alarm Low and automatic
shut down the fuel supply or heater on
low air flow and/or low air/fuel ratio.
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PROCESS
section
date
study node 300
NO PARAMETER Guide Words Deviation
1 PRESSURE MORE - MORE - PRESSURE
LESS - LESS - PRESSURE
NO - NO -PRESSURE
3 TEMPERATURE MORE - MORE - TEMPERATURE
4 FLOW REVERSE - REVERSE - FLOW
MORE - MORE - FLOW
LESS - LESS - FLOW
NO - NO - FLOW
OTHERS THAN
VALVE Valve malfuction
MAINTENANCE
SHUT DOWN &
START UPNot follow Procedure
HAZO
Fuel ga
Furnace/burner used to he
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posssible causes possible consequences
Safe
Guard/Protectio
n
Fuel gas control valve
malfunction
more fuel in the furnace, can cause
explosion during start-up
PI 3 & PI 6
piping leaking
valve malfuctionvalve malfuction
piping leaking
external heating cause the
gas expanded explosion when enter furnace.TI 11
Fuel gas control valvemalfunction - fully open more fuel in the furnace, can causeexplosion
FI 3
piping leaking
valve malfuction
un-edequate maintenance
air supply to actuator block
controller malfuction
cost cuttingequipment malfuction and error can
occurred may lead to explosion
Human FactorExplosion can happen if not following the
SU and SD procedure.
more flow or no flow to furnace
PI 3 & PI 6
FI 3
P STUDY
s line supply to Furnace
at up using fuel oil + air Heating oil to 250 C to supply to Distillation r
more air in the furnace, no enough heat
to heat up hot oil to desiredtemperature.
more air in the furnace, no enough heat
to heat up hot oil to desired
temperature.
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Action required/Recommendation
Fuel Pressure Alarm High and automatic shut
down the fuel supply or heater on low air
low air/fuel ratio or high fuel supply
Automatic shut down fuel gas supply and
heater
Fuel control valve - Fail close
Fuel Flow Alarm High and automatic shut
down the fuel supply or heater on low air
low air/fuel ratio or high fuel supply
Fuel Perssure Alarm Low and automatic shut
down heater if Alarm Low Low triggered.
Fuel Flow Alarm Low
boiler
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PROCESS
section
date
study node 400
NO PARAMETER Guide Words Deviation
1
PRESSURE MORE - MORE - PRESSURE
LESS - LESS - PRESSURE
NO - NO -PRESSURE
2
TEMPERATURE MORE - MORE - TEMPERATURE
3
LESS - LESS - TEMPERATURE
4
UN-EVEN TEMP
5
COMPOSITION OTHERS THEN - OTHERS THEN - COMPOSITION
Furnace/burner used to heat up using fu
HA
Heating oil piping/t
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FLOW LESS - LESS - FLOW
NO - NO - FLOW
OTHERS THAN
VALVE Valve malfuction
MAINTENANCE
SHUT DOWN & START UP Not follow Procedure
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posssible causes possible consequences Safe Guard/Protection
HC from reboiler leaking
into heating oil tube
Possible fie inside the tube and lead
to explosion of tube and burst
heating oil burn in furnace - black
smoke ,
less heating oil to reboiler - column
flooding with HC
high combustion in furnace -
more fuel and air
distillation column high pressure and
can cause explosion.TI 1 ~ TI 10 (exclude TI 8)
Low combustion in furnace column flooding with liquid HC TI 1 ~ TI 10 (exclude TI 8)
coking in the tubingpiping craking and less flow to
reboilerTI 1 ~ TI 10 (exclude TI 8)
HC leaking to the heating
oil, Reboiler crack, or tube
cracking
Possible fire inside the tube and lead
to explosion of tube and burst-
l oil + air Heating oil to 250 C to supply to Distillation re boiler
piping leaking - in the
furnace
OP STUDY
ubing going to furnace and out from furnace
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High moisture content tube hammmering -
piping leaking to furnace heating oil burn in furnace - blacksmoke ,
coking in tubing column flooding with liquid HC -
piping leaking FT 1
pump failure
Piping blockage/valve
malfuction
un-edequate maintenance
air supply to actuator block
controller malfuction
cost cuttingequipment malfuction and error can
occurred may lead to explosion
Human FactorExplosion can happen if not following
the SU and SD procedure.
more flow or no flow of to furnace,
no heating reboiler
column flooding with liquid HC
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Action
required/Recom
mendation
Indication of
pressure at tube
Indication of
pressure at tube
Indication of
pressure at tube
Temperature
High Alarm and
automatic shut
down the heater
if TemperatureAlarm High High
Temperature
Alarm Low and
automatic shut
down the heater
if Temperature
Alarm Low Low
Temperature
Alarm Low and
automatic shut
down the heater
if Temperature
Alarm Low Low
Indication of
composition at
tube
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Vaporiser
instalation at
heating oil prior
to inlet to
furnace
Indication of
flow at exitstream of
furnace
Online decoking
peridically
Indication of
flow at exit
stream of
furnace
Standby pump,automatically cut
in if another fail
to function
Online decoking
peridically