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HAZOP Study Part II
HAZOP Study Part II
HAZOP Study Part II
HAZOP
STUDY
Pump Flow
PU-01
Less
1. NH3 storage Pump cavitates Damage to pump Use level alarm in NH3
empty Storage
2. LCV-01 fails Deadhead pump Damage to pump Use by pass manual
closed valve system at LCV-01
3. NRV-01 fails Deadhead pump Damage to pump Use Flow Indicator
closed
4. Line 100 plugs Pump cavitates Damage to pump Use flow Indicator
5. Line 101 plugs Deadhead pump Damage to pump Use by pass manual
valve system
6. LIC-1 fails, Deadhead pump Damage to pump
closing LCV-01
More
7. LCV-01 fails open Upset in vaporizer Liquid level Use by pass manual
increases valve system
Pressure increases Use drain valve before
pump
8. LIC-1 fails, Upset in vaporizer Liquid level Use by pass manual
opening LCV-01 increases valve system
Pressure increases
Pressure
More 9. LCV-01 fails Deadhead pump Damage to pump Use by pass manual
closed valve system
10. NRV-01 fails Deadhead pump Damage to pump Use pressure Indicator
closed
11. LIC-1 fails, Deadhead pump Damage to pump Use by pass manual
closing LCV-01 valve system
12. Line 101 plugs Deadhead pump Damage to pump Use pressure Indicator
Less 13. LCV-01 fails open Liquid level Upset in vaporizer Use by pass manual
increases valve system
14. LIC-1 fails, Liquid level Upset in vaporizer Use by pass manual
opening LCV-01 increases valve system
15. NH3 storage Pump cavitates Damage to pump Use level alarm in NH3
empty Storage
16. Line 100 plugs Pump cavitates Damage to pump
Temperature
More 17. LCV-01 fails Deadhead pump Damage to pump Use temperature
closed Indicator
18. NRV-01 fails Deadhead pump Damage to pump Use temperature
closed Indicator
19. LIC-1 fails, Deadhead pump Damage to pump Use temperature
closing LCV-01
Indicator
20. Line 101 plugs Deadhead pump Damage to pump
10 | P a g e UNIVERSITY OF KARACHI
HAZOP STUDY REPORT
11 | P a g e UNIVERSITY OF KARACHI
HAZOP STUDY REPORT
Vaporizer Level
VE-01 Less 21. Line 101 plugs Heat/steam loss Excessive Use cascade loop with
vaporization PIC for level
controlling
22. Rupture line 101 Heat/steam loss Excessive
vaporization
23. PCV-01 fails open Heat loss/steam loss Side reaction will Use by pass manual
Excessive occur in the reactor valve system
vaporization Ammonia loss
24. PIC-1 fails Heat loss/steam loss Side reaction will Use by pass manual
opening PCV-01 Excessive occur in the reactor valve system
vaporization Ammonia loss
25. LCV-01 fails Heat/steam loss Excessive
closed vaporization
26. NRV-01 fails Heat/steam loss Excessive
closed vaporization
27. LIC-1 fails, Heat/steam loss Excessive
closing LCV-01 vaporization
28. FCV-01 fails open Heat loss/steam loss Side reaction will Use by pass manual
occur in the reactor valve system
Ammonia loss
29. FFC-1 fails, Heat loss/steam loss Side reaction will Use by pass manual
opening FCV-01 occur in the reactor valve system
12 | P a g e UNIVERSITY OF KARACHI
HAZOP STUDY REPORT
Ammonia loss
More 32. FCV-01 fails close Vaporizer Overflow Reaction seize Use by pass manual
valve system
33. FFC-1 fails, Vaporizer Overflow Reaction seize Use by pass manual
closing FCV-01 valve system
34. LCV-01 fails open Vaporizer Overflow Insufficient
vaporization
35. LIC-1 fails, Vaporizer Overflow Insufficient
opening LCV-01 vaporization
No
Same as less
Pressure
More 36. LCV-01 fails open Tank rupture
37. LIC-1 fails, Tank rupture
opening LCV-01
38. FCV-01 fails close Tank rupture Use safety valve in VE-
01
39. FFC-1 fails, Tank rupture Use safety valve in VE-
closing FCV-01 01
40. PCV-01 fails open Tank rupture Use pressure Indicator
41. PIC-1 fails, Tank rupture
opening
13 | P a g e UNIVERSITY OF KARACHI
HAZOP STUDY REPORT
14 | P a g e UNIVERSITY OF KARACHI
HAZOP STUDY REPORT
Temperature 52. LCV-01 fails close Excessive Side reaction will Use temperature
More vaporization occur in the reactor Indicator
Less 59. PCV-01 fails close No vaporization Reaction seize Use temperature
occurs in VE-01 Indicator
60. PIC-1 fails, No vaporization Reaction seize Use temperature
closing occurs in VE-01 Indicator
15 | P a g e UNIVERSITY OF KARACHI
HAZOP STUDY REPORT
16 | P a g e UNIVERSITY OF KARACHI
HAZOP STUDY REPORT
Compressor Flow
C-01 High 63. Piece of filter Damage to Another filter
material (i.e. compressor should be installed
cloth) breaks free as standby
Less 64. Filter saturated Damage to Insufficient air for Another filter
compressor reaction in the should be installed
reactor as standby
65. Line 103 chock Damage to Insufficient air for
compressor reaction in the
reactor
Composition
As well as 66. Line 103 rupture Load increases on Damage to
the compressor compressor
Side reaction may
occur in the reactor
67. Filter saturated
Damage to
Load increases on
the compressor compressor
Side reaction may
occur in the reactor
68. Atmosphere Load increases on Damage to Moisture collector
humidity the compressor should be installed
compressor
increases
Potential to
corrodes
17 | P a g e UNIVERSITY OF KARACHI
HAZOP STUDY REPORT
Pressure
More 69. Piece of filter Damage to
material (i.e. compressor
cloth) breaks free
70. Line 106 chock Surge the Damage to Blow off valve
compressor compressor should be installed
Insufficient air for
reaction in the
reactor
Temperature
More 71. Ambient Performance Reaction condition Use temperature
temperature decreases will not meet indicator
increases
18 | P a g e UNIVERSITY OF KARACHI
HAZOP STUDY REPORT
19 | P a g e UNIVERSITY OF KARACHI
HAZOP STUDY REPORT
Reactor Composition
RE-01
Other than 72. Wrong reagent Another possible Side reaction will Use analyzer indicator
reaction occur in the reactor
No reaction
Pressure
More 74. FCV-01 fails open Stress on catalyst Tank rupture Installed rupture disk
bed at reactor (RE-01)
75. FFC-1 fails, Stress on catalyst Tank rupture
opening FCV-01 bed
Use pressure
Less 76. Rupture line 106 NH3 and O2 loss Insufficient ratio of indicator with
NH3 and O2 in the alarming system
reactor
77. Rupture line 107 NO and NO2 loss Damage the
catalyst bed
78. FCV-01 fails close NH3 and O2 will not Reaction seize
enter in the reactor
79. FFC-1 fails, NH3 and O2 will not Reaction seize
closing FCV-01 enter in the reactor
20 | P a g e UNIVERSITY OF KARACHI
HAZOP STUDY REPORT
Temperature
More 80. PCV-01 fails open Thermal Stress on Side reaction will There must be inter
catalyst bed occur in the reactor cooling system in
the reactor
81. PIC-1 fails, Thermal Stress on Side reaction will
opening catalyst bed occur in the reactor
21 | P a g e UNIVERSITY OF KARACHI
HAZOP STUDY REPORT
22 | P a g e UNIVERSITY OF KARACHI
HAZOP STUDY REPORT
23 | P a g e UNIVERSITY OF KARACHI