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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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

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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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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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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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