HAZOP STUDY REPORT

HAZOP

STUDY

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HAZOP STUDY REPORT

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HAZOP STUDY REPORT

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HAZOP STUDY REPORT

Equipment

reference and

operating condition

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)

Pump PU-01

Flow

Less

More

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

7. LCV-01 fails open

8. LIC-1 fails, opening LCV-01

Pump cavitates

Deadhead pump

Deadhead pump

Pump cavitates

Deadhead pump

Deadhead pump

Upset in vaporizer

Upset in vaporizer

Damage to pump

Damage to pump

Damage to pump

Damage to pump

Damage to pump

Damage to pump

Liquid level increases

Pressure

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

Use by pass manual valve system

Use drain valve before pump

Use by pass manual valve system

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HAZOP STUDY REPORT

increases

Liquid level increases

Pressure increases

Pressure

More

Less

9. LCV-01 fails closed

10.NRV-01 fails closed

11.LIC-1 fails, closing LCV-01

12.Line 101 plugs

13.LCV-01 fails open

14.LIC-1 fails, opening LCV-01

15.NH3 storage empty

16.Line 100 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

Upset in vaporizer

Upset in vaporizer

Damage to pump

Damage to pump

Use by pass manual valve system

Use pressure Indicator

Use by pass manual valve system

Use pressure Indicator

Use by pass manual valve system

Use by pass manual valve system

Use level alarm in NH3

Storage

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HAZOP STUDY REPORT

Temperature

More17.LCV-01 fails

closed18.NRV-01 fails

closed19.LIC-1 fails,

closing LCV-0120.Line 101 plugs

Deadhead pump

Deadhead pump

Deadhead pump

Deadhead pump

Damage to pump

Damage to pump

Damage to pump

Damage to pump

Use temperature Indicator

Use temperature Indicator

Use temperature Indicator

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HAZOP STUDY REPORT

Equipment

reference and

operating condition

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)

VaporizerVE-01

LevelLess 21. Line 101

plugs

22. Rupture line 101

23. PCV-01 fails open

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

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

Excessive vaporization

Excessive vaporization

Side reaction will occur in the reactor

Ammonia loss

Side reaction will occur in the reactor

Ammonia loss Excessive

vaporization Excessive

vaporization Excessive

vaporization

Side reaction will occur in the reactor

Ammonia loss Side reaction will

Use cascade loop with PIC for level controlling

Use by pass manual valve system

Use by pass manual valve system

Use by pass manual valve system

Use by pass manual valve system

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HAZOP STUDY REPORT

More

No

29.FFC-1 fails, opening FCV-01

30.PCV-01 fails close

31.PIC-1 fails, closing

32.FCV-01 fails close

33.FFC-1 fails, closing FCV-01

34.LCV-01 fails open

35.LIC-1 fails, opening LCV-01

Same as less

loss

Insufficient vaporization

Insufficient vaporization

Vaporizer Overflow

Vaporizer Overflow

Vaporizer Overflow

Vaporizer Overflow

occur in the reactor

Ammonia loss

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

PressureMore 36.LCV-01 fails

open37.LIC-1 fails,

opening LCV-0138.FCV-01 fails

close

Tank rupture Tank rupture

Tank rupture

Tank rupture

Use safety valve in VE-01

Use safety valve in VE-01

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HAZOP STUDY REPORT

Less

39.FFC-1 fails, closing FCV-01

40.PCV-01 fails open

41.PIC-1 fails, opening

42.Rupture discharge line

43.Rupture line 101

44.Tank rupture

45.FCV-01 fails open

46.FFC-1 fails, opening FCV-01

47.PCV-01 fails close

48.PIC-1 fails, closing

49.LCV-01 fails closed

Tank rupture Tank rupture

NH3 loss

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 oxygen from ground up

Insufficient NH3

in the reactor Insufficient NH3

in 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

Use pressure Indicator

Alarming system should be installed

Alarming system should be installed

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HAZOP STUDY REPORT

50.LIC-1 fails, closing LCV-01

51.NRV-01 fails closed

reactor

Temperature

More

Less

52.LCV-01 fails close

53.LIC-1 fails, closing LCV-01

54.NRV-01 fails closed

55.FCV-01 fails close

56.FFC-1 fails, closing FCV-01

57.PCV-01 fails open

58.PIC-1 fails, opening

59.PCV-01 fails close

60.PIC-1 fails, closing

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

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

Use temperature Indicator

Use temperature Indicator

Use temperature Indicator

Use temperature Indicator

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HAZOP STUDY REPORT

61.LCV-01 fails open

62.LIC-1 fails, opening LCV-01

less vaporization occurs in VE-01

Incomplete reaction in the reactor

Incomplete reaction in the reactor

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HAZOP STUDY REPORT

Equipment

reference and

operating condition

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)

Compressor

C-01

FlowHigh

Less

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

64.Filter saturated

65.Line 103 chock

Damage to compressor

Damage to compressor

Damage to compressor

Insufficient air for reaction in the reactor

Insufficient air for reaction in the reactor

Another filter should be installed as standby

Another filter should be installed as standby

CompositionAs well as

66.Line 103 rupture

67.Filter saturated

68.Atmosphere humidity increases

Load increases on the compressor

Load increases on the compressor

Load increases on the compressor

Damage to compressor

Side reaction may occur in the reactor

Damage to compressor

Side reaction may occur in the reactor

Damage to

Moisture collector should be installed

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HAZOP STUDY REPORT

compressor Potential to

corrodes

PressureMore 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

More71.Ambient

temperature increases

Performance decreases

Reaction condition will not meet

Use temperature indicator

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HAZOP STUDY REPORT

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HAZOP STUDY REPORT

Equipment

reference and

operating condition

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)

ReactorRE-01

Composition

Other than

As well as

72.Wrong reagent

73.Impurities in reagent

Another possible reaction

No reaction

Another possible reaction

Side reaction will occur in the reactor

Side reaction will occur in the reactor

Use analyzer indicator

PressureMore

Less

74.FCV-01 fails open

75.FFC-1 fails, opening FCV-01

76.Rupture line 106

77.Rupture line

Stress on catalyst bed

Stress on catalyst bed

NH3 and O2 loss

NO and NO2 loss

NH3 and O2 will not enter in the

Tank rupture

Tank rupture

Insufficient ratio of NH3 and O2 in the reactor

Damage the catalyst bed

Reaction seize

Installed rupture disk at reactor (RE-01)

Use pressure indicator with alarming system

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HAZOP STUDY REPORT

107

78.FCV-01 fails close

79.FFC-1 fails, closing FCV-01

reactor NH3 and O2 will

not enter in the reactor

Reaction seize

Temperature

More

Less

80.PCV-01 fails open

81.PIC-1 fails, opening

82.FCV-01 fails open

83.FFC-1 fails, opening FCV-01

84.Rupture line 106

85.FCV-01 fails close

Thermal Stress on catalyst bed

Thermal Stress on catalyst bed

Thermal Stress on catalyst bed

Thermal Stress on catalyst bed

NH3 and O2 loss

Desired Reaction seize

Desired Reaction seize

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

There must be inter cooling system in the reactor

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HAZOP STUDY REPORT

86. FFC-1 fails, closing FCV-01

reactor

Side reaction will occur in the reactor

Side reaction will occur in the reactor

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