SUMMARY OF FINIDINGS & OUTCOME OF THE HAZOP

STUDY

Sr.
No.

Observation

Action Recommended

01

As of now process is not

defined,
only
facilities
HAZOP were carried out.

NFIL has to carried out,

process HAZOP based on the
process. And has to prepare
SOPs for respective process.

02

SPCPL to ensure that all the

interlocks and
safety
parameters to be covered in
DCS

Following major safety

points were discussed in
hydrogenation reaction
area.

Followings
safety
precautions were taken.

03

Separate cooling water

line with On/OFF valve to
be provided on inlet &
outlet of external coil. will
operate
based
on
interlocks from DCS.

Steam control & ON/OFF

valve will operate based
on interlocks from DCS.

ON/OFF valve is provided

on hydrogen line and will
be operated based on
interlocks from DCS.

SPCPL to check
specification.

Locate water pot at 5 mtr

or mezzanine level inside
the hydrogenation area,

1. Pressurization & Loss

of strength due to
high temp.

2. To control heating
rate in reactor.

3. Reaction
exotherm,
Due
to
excess
addition of hydrogen.
4. On/off valves on LPS
line and hydrogen
line were fail to close
top, whereas on/off
valves on cold utility
line were fail to open
type.

DCS HAZOP to be carried

out with DCS vendor.
SPCPL to provide separate
interlock
list
to
DCS
vendor
as
discussed
during HAZOP study.

valve

provision of local level

indicator
and
pressure
gauge,
SPCPL
to
incorporate it in layout
and P&ID and NFIL to
incorporate in operational
SOP.

5. Reverse flow of water

from hydrogen vent
line.

To be confirm during PSSR.

6. Venting of hydrogen
will
be
at
safe
location.
04

Following major safety

points were discussed in
Intermediate
glass
reactor.
1

Pressurization & Loss

of strength due to
high temp.

Followings
safety
precautions were taken.

Steam control & ON/OFF

valve will operate based
on interlocks from DCS.

ON/OFF valve is provided

on hydrogen line and will
be operated based on
interlocks from DCS.

SPCPL
to
incorporate
Additional
temperature
transmitter on vapour line.

Vent is connected directly

to
Scrubber,
Scrubber
running status will be
provided in DCS. NFIL to
generate venting SOP.

Pressure safety valve to be

provided on utility supply
line after isolation valve,
which will operation on
required utility pressure,
SPCPL to incorporate in
P&ID.

To control heating
rate in reactor.

Malfunctioning
temperature
transmitter
reactor.

of
on

Due to pressurization
or gas venting /
Vacuum at the end of
batch,
hazardous
gases will be present
and will get released
in atm.
High
pressure
at
utility side will break
the tubes in glass
condensers, result in
cross contamination.

05

Gas leakages
plant

inside

06

NFIL
have
to
following SOPs

the

prepare

1. SOPs as per process

2. Operation
start-up
SOP
3. Operational SOP
4. Venting SOP
5. Safety SOP
6. Equipment
&
Instrument calibration
& maintenance SOP.
7. Material loading and
unloading SOP
to

be

Hydrogen, oxygen and

bromine gas detection
system is provided

NFIL has to prepare all these

documents,
based
on
process.

08

Motor no alarm
provided on DCS

SPCPL to incorporate in DCS

09

Design calculation back for

all safety installation like
Rupture disk, Safety valve
etc

SPCPL to provide the design

backup

10

Hydrogen & other gas bank

system to be shown in
layout

SPCPL
layout

11

NFIL have to carry out the

Process HAZOP as per the
products

NFILs has to prepare process

HAZOP and SOPs as per
product.

to

incorporate

in

Only facility HAZOP is carried out for typical high pressure hydrogenation
reactor, Intermediate glass reactor, and CF system.
Same philosophy will be carried out for other equipments.
HAZOP study is done based on approved Piping and instrumentation
diagrams (P&IDs) & approved facility layout. In addition to this HAZOP,
study to be done considering specific product manufacturing since facility
will be used for multipurpose application.
NFIL has to carry out process HAZOP as per specified product and
prepared the operational SOPs as per requirement.
Following drawings were refer for preparation of HAZOP report
Equipment layout
Men material movement layout
Hazardous area classification layout

 HVAC classification layout

Safety shower & fire exit layut
Fire hydrant layout
Gas detection system layout
P&ID
Parameters covered in HAZOP reports are as follows
Flow
Temperature
Pressure
Level
Contamination
Relief
Electrical
Corrosion