HAazop

Main HAZOP 05/14/2017 12:50:10
Status
CLOSED 115
OPEN 4
HOLD 24
TOTAL 143
Item Recommendations (HAZOP) Place(s) Used ASSIGNED TO
1 To incorporate low alarm at FIC-0302 to alert operator on low flow Causes: 1.1.3 LLWT
in Train No.3
2 To incorporate sludge blanket level indicator with high and low Causes: 1.1.8, 1.2.3, LLWT
alarms at clarifiers 2.1.6, 2.2.3, 3.1.6,
3.2.3
3 To incorporate low alarm at FI-0712 to alert operator on low sludge Causes: 1.1.9 LLWT
recycle in clarifier
4 To provide manual sampling points at field in case of sample line to Causes: 1.1.11, LLWT
mini lab being blocked 1.1.13, 1.1.14,
1.1.16, 2.1.9, 2.1.11,
2.1.12, 2.1.14, 3.1.9,
3.1.11, 3.1.12, 3.1.14,
4.18.1, 5.18.1
5 To incorporate high alarm at FIC-0302 to alert operator on more Causes: 1.2.1 LLWT
flow in Train No.3
6 To indicate complete warehouse spare sludge recirculation pump Causes: 1.2.2, 2.2.2, LLWT
availability on P&ID 3.2.2
7 To include alarm if all pumps, including standby, are running Causes: 1.2.4, 1.2.5, LLWT
simultaneously 2.2.4, 2.2.5, 3.2.4,
3.2.5, 4.2.1, 4.2.2,
5.2.1, 5.2.2, 6.2.2,
6.2.4, 6.2.6, 6.2.7,
12.2.7, 12.2.13
8 To provide backflow prevention at raw water supply line to prevent Causes: 1.3.1, 1.20.4 LLWT
contamination of raw water supply to Train No. 1 & No. 2 from
storm water
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9 To provide prevention of gear oil contamination of the storm water Causes: 1.12.4 LLWT
in 4850-S-003A/B
10 To verify with OUI their ability to handle the overflow of water from Causes: 1.17.1, LLWT
RWTP during commissioning 2.17.1, 3.17.1
11 To provide means to empty out aerators for maintenance Causes: 1.20.2, LLWT
2.20.2, 2.20.4,
3.20.2, 3.20.4
12 To provide facilities to work at the underground sumps considering Causes: 1.20.3, LLWT
confined space conditions 2.20.3, 3.20.3,
6.20.1, 15.20.1
in Train No.1
flow in Train No.1
in 4850-S-001A/B
in Train No.2
flow in Train No.2
in 4850-S-001C/D
21 To install high pressure trip on each blower discharges to stop the Causes: 4.1.9, 5.1.8 LLWT
blowers when the discharge is blocked
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22 To incorporate high alarm at PIA-0062 to alert operator on blocked Causes: 4.1.10, LLWT
air inlet filter 4.1.14, 4.1.18,
4.1.22, 4.1.26, 4.1.30
23 To include regular manual sampling of treated water in OPM as Causes: 4.12.1, LLWT
verification of online pH analyzer output and operator action to 5.12.1
override automatic caustic dosing in case of pH analyzer
malfunction
24 To verify commisioning requirement with OUI on final pH Causes: 4.17.1, LLWT

adjustment based on initial water specifications 5.17.1
25 To provide isolation at MOV-0063 and MOV-0064 to enable Causes: 4.20.1, LLWT

removal of MOVs for maintenance 5.20.1
26 To incorporate high alarm at PIA-0061 to alert operator on blocked Causes: 5.1.10, LLWT
air inlet filter 5.1.14
27 To incorporate low alarm at PIZA-1122/1222/1322 to alert operator Causes: 6.1.14 LLWT

on loss of discharge pressure at 4850-P-105A/B/C
28 To confirm the duration of sludge caking in 4850-T-103 on loss of Causes: 6.1.14 LLWT
mixer agitation and provide appropriate protection for 4850-P-
105A/B/C cavitation
29 To provide spare mixer on 4850-T-103 and indicate on P&ID as it is Causes: 6.1.14 LLWT
on continuous operation
30 To incorporate H and HH alarm at WIZA-1131/1231 to alert Causes: 6.1.18 LLWT

operator on high torque on sludge thickener scraper and trip
scraper on HH torque
31 To include alarm if both MOV-1012/1013 are in the same position Causes: 6.2.8, 6.2.9 LLWT
(open or close)
32 To install check valve downstream of MOV-1013 isolation valve to Causes: 6.2.8, 6.2.9 LLWT
prevent backflow from Train No. 3 aerator inlet into 4850-T-102
33 To incorporate high alarm at FIC-1031 to alert operator on high Causes: 6.2.10 LLWT
sludge flow from 4850-T-103
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34 To incorporate low alarm at LICA-1131 to alert operator on loss of Causes: 6.2.11 LLWT
level in 4850-T-105
35 To route overflow of 4850-T-105 to 4850-T-103 instead of 4850-T- Causes: 6.2.11, 7.1.2 LLWT
102 to limit likelihood of sludge contamination to inlet of Train No. 3
36 To provide prevention of gear oil contamination of the supernatant Causes: 6.12.1 LLWT
in 4850-T-104A/B
37 To provide high pressure water supply line to sludge thickening Causes: 6.20.2 LLWT
system to improve sludge removal and prevent blockage
38 To incorporate low alarm at FIC-1151/1251/1351 to alert operator Causes: 7.1.1, 7.1.2 LLWT
on loss of flow at 4850-P-106A/B/C discharge
39 To confirm the duration of sludge caking in 4850-T-105 on loss of Causes: 7.1.1 LLWT
mixer agitation and provide appropriate protection for 4850-P-
106A/B/C overheating
40 To provide spare mixer on 4850-T-105 and indicate on P&ID as it is Causes: 7.1.1 LLWT
on continuous operation
41 To incorporate low alarm at FIC-1151/1251/1351 for the flushing Causes: 7.1.3 LLWT
sequence to alert operator on insufficient flushing water to the
centrifuges
42 To provide interlock that will stop 4850-P-106A/B/C and 4850-A- Causes: 7.1.4 LLWT
101-S01A/B/C when 4850-A-102 fail and stop
43 To interlock 4850-A-103-A01A/B to stop on failure of the respective Causes: 7.1.5, 7.1.6 LLWT
train at 4850-A-104A/B
44 To provide interlock that will stop 4850-P-106A/B/C and 4850-A- Causes: 7.1.5, 7.1.6 LLWT
101-S01A/B/C on LICA-1051 HH
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45 To provide interlock that will stop 4850-P-106A/B/C and 4850-A- Causes: 7.1.7 LLWT
101-S01A/B/C when 4850-A-107A/B/C/D fail and stop
46 To install check valve at tie-in points of high pressure water into the Causes: 7.2.2 LLWT
4850-P-106A/B/C discharge to prevent contamination of high
pressure water
47 To verify with centrifuges vendor on protection against blockage at Causes: 7.4.1 LLWT
inlet of centrifuges leading to centrifuges stop and interlock to stop
4850-P-106A/B/C
48 To provide appropriate lifting facility for removal of submersible Causes: 7.20.1, LLWT
equipment and mitigation plan in case of equipment unable to be 15.20.2
removed
49 To provide portable pump connection, high pressure water Causes: 7.20.2, LLWT
connection and access to vacuum truck at sumps to facilitate 15.20.3
cleaning if required
50 To incorporate valve position fault alarm on MOV-2004 to alert Causes: 8.1.1 LLWT
operator on failure of air pulsing operation
51 To incorporate requirements for purging of lime powder unloading Causes: 8.1.2 LLWT
line before and after unloading to prevent build up and blockage
52 To indicate alarm on MOVs sequence fault to alert operator on Causes: 8.1.3, 9.1.4, LLWT
failure of MOVs 12.1.2, 13.1.2
53 To provide pressure differential transmitter with alarm across 4850- Causes: 8.1.7, 8.1.8 LLWT
P-201/202/203 suction strainers to provide indication of blockage
54 To incorporate FI-2012/PG-2012 in operator routine round checklist Causes: 8.1.9, LLWT

8.1.13, 8.1.17, 8.1.21
55 To change the flushing sequence of 4850-P-201/202/203 by Causes: 8.1.11, LLWT

stopping the pumps prior to introduction of high pressure water to 8.1.15, 8.1.19
prevent total loss of flow at pump suction during start of sequence
56 To install pressure transmitter with high alarm downstream of PCV- Causes: 8.2.6 LLWT
2013 to alert operator on higher pressure carrier water supply
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57 To provide facility for periodic automatic flushing of analyzer Causes: 8.10.1, LLWT
electrodes/elements 9.10.1, 14.10.1
58 To provide prevention of gear oil contamination of the lime slurry in Causes: 8.12.1 LLWT
4850-T-201A/B
59 To provide appropriate facilities for pre-commisioning and Causes: 8.17.1, LLWT

commisioning of the plant 9.17.1, 10.17.1,
11.17.1, 12.17.1,
13.17.1, 14.17.1
60 To specify requirement of minimum level in 4850-T-201A/B prior to Causes: 8.17.2 LLWT

introduction of slurry, in the operating procedure
61 To provide manual sampling points at field for periodic sampling of Causes: 8.18.1, LLWT
prepared chemicals 9.18.1, 11.18.1,
12.18.1, 13.18.1
62 To provide installed spare pump for 4850-P-201/202/203 due to Causes: 8.19.1 LLWT
required frequent servicing for this pump type
63 To provide manhole at 4850-T-201A/B to enable access for manual Causes: 8.20.2 LLWT
cleaning
64 To install pressure transmitter with low alarm downstream of MOV- Causes: 9.1.2, 9.1.4 LLWT
3007 to alert operator on failure of high pressure water supply to
4850-A-301-M01, and low low to trip 4850-A-301
65 To install pressure transmitter with low alarm downstream of MOV- Causes: 9.1.3, 9.1.5 LLWT
3012 to alert operator on failure of high pressure water supply to
4850-T-301
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66 To provide pressure differential transmitter with alarm across 4850- Causes: 9.1.8 LLWT
P-301/302/303 suction strainers to provide indication of blockage

9.1.18, 9.1.22
68 To change the flushing sequence of 4850-P-301/302/303 by Causes: 9.1.12, LLWT

stopping the pumps prior to introduction of high pressure water to 9.1.16, 9.1.20
69 To incorporate FI-3021/PG-3022 in operator routine round checklist Causes: 9.1.14 LLWT
71 To provide prevention of gear oil contamination of the MgO slurry in Causes: 9.12.1 LLWT
4850-T-301
72 To specify requirement of minimum level in 4850-T-301 prior to Causes: 9.17.2 LLWT

introduction of slurry, in the operating procedure
73 To provide installed spare pump for 4850-P-301/302/303 due to Causes: 9.19.1 LLWT
required frequent servicing for this pump type
74 To provide manhole at 4850-T-301 to enable access for manual Causes: 9.20.2 LLWT
cleaning
75 To enhance protection against dropping of 1T MgO bags and Causes: 9.22.1 LLWT
enable ease of operations
76 To configure sequence of MOV-7101/7201 to be both fully open Causes: 10.1.1 LLWT

during the start of the tank switch over to prevent loss of flow to
pumps

10.1.9, 10.1.16
78 To change the flushing sequence of 4850-P-701A/B by stopping Causes: 10.1.4 LLWT

the pumps prior to introduction of high pressure water to prevent
total loss of flow at pump suction during start of sequence
79 To relocate sampling point of filtered raw water downstream of HCl Causes: 10.1.5, LLWT
dosing point to enable detection of correct HCl dosing 10.1.6, 10.1.8
80 To install pressure transmitter upstream of PCV-7114/7214 and Causes: 10.1.6, LLWT

interlock to stop 4850-P-701A/B on high discharge pressure 10.1.8
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82 To relocate sampling point of filtered storm water downstream of Causes: 10.1.12, LLWT
HCl dosing point to enable detection of correct HCl dosing 10.1.13, 10.1.15

85 To install check valves upstream of MOV-7111/7211 to provide Causes: 10.2.3 LLWT

additional protection against backflow of utility water into 4850-T-
701A/B
86 To install check valves upstream of MOV-7112/7212 to provide Causes: 10.2.4 LLWT
additional protection against backflow of utility water into 4850-T-
701A/B
87 To install check valves upstream of MOV-7311/7411 to provide Causes: 10.2.10, LLWT

additional protection against backflow of utility water into 4850-T- 10.2.11
701A/B
88 To include local high alarm at 4850-T-701A/B for immediate alert to Causes: 10.8.1 LLWT
field operator on high level
89 To re-route overflow line at 4850-701A/B to the covered bund Causes: 10.8.1 LLWT
instead of ACC to prevent excessive fumes at the ACC. SOP for
removal of acid from the bund to be developed
90 To provide facility to neutralize HCl fumes vented from 4850-T- Causes: 10.11.1 LLWT
701A/B
91 To evaluate alternative arrangement of handling HCl leaks e.g. Causes: 10.14.1 LLWT
routing to a neutralization facility from 4850-T-701A/B where the
covered bund may accumulate HCl from leaks above
92 To specify applicable repair methods for tank leaks and provide Causes: 10.14.1, LLWT
facilities and access for removal of non-metal tanks if replacement 11.14.1, 14.14.1
is required.
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93 To prioritize 4850-P-701A/B and 4850-702A/B switchover over Causes: 10.19.1 LLWT

chemical waste neutralization
94 To re-route all HCl drain points to destination other than ACC to Causes: 10.20.1 LLWT
prevent excessive fumes
95 To include drain points at pumps suction to enable draining prior to Causes: 10.20.2, LLWT
handover 11.20.1, 12.20.1,
13.20.1, 14.20.1
96 To provide adequate acid resistance materials for corrosion Causes: 10.21.1 LLWT
protection of steel and concrete structures nearby HCl drain points
97 To provide drain facility for emptying of connection after unloading Causes: 10.22.1 LLWT
of HCl road tanker
98 To configure sequence of MOV-6101/6201 to be both fully open Causes: 11.1.1 LLWT

during the start of the tank switch over to prevent loss of flow to
pumps

11.1.9, 11.1.16
101 To relocate sampling point of filtered raw water downstream of Causes: 11.1.5, LLWT
NaOH dosing point to enable detection of correct NaOH dosing 11.1.6, 11.1.8
104 To relocate sampling point of filtered storm water downstream of Causes: 11.1.12, LLWT
NaOH dosing point to enable detection of correct NaOH dosing 11.1.13, 11.1.15
107 To include local high alarm at 4850-T-601A/B for immediate alert to Causes: 11.8.1 LLWT
field operator on high level
108 To incorporate high alarm on LIZA-6102 with signal to DCS as an Causes: 11.8.2 LLWT
additional protection against high level in 4805-T-601A/B
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109 To install MOVs on the caustic supply from OUI to 4850-T-601A/B Causes: 11.8.2 LLWT
to automatically operate based on level (from LICA-6101/6201)
110 To provide drain with lockable isolation valve from 4850-T-601A/B Causes: 11.14.1 LLWT
bund to the ACC to safely route any leakage/spillage out of the
bund
111 To provide spectacle blinds at 4850-T-601A/B road tanker supply Causes: 11.17.2 LLWT
lines to provide positive isolation when taking NaOH supply
exclusively from OUI
112 To prioritize 4850-P-601A/B and 4850-602A/B switchover over Causes: 11.19.1 LLWT
chemical waste neutralization
113 To provide drain facility for emptying of connection after unloading Causes: 11.22.1 LLWT
of NaOH road tanker
114 To provide pressure differential transmitter with alarm across Causes: 12.1.3, LLWT
polyelectrolyte dosing pumps suction strainers to provide indication 13.1.3
of blockage
12.1.10
12.1.16
117 To change the flushing sequence of polyelectrolyte dosing pumps Causes: 12.1.7, LLWT
by stopping the pumps prior to introduction of high pressure water 12.1.13, 13.1.6,
to prevent total loss of flow at pump suction during start of 13.1.12
sequence
118 To install pressure transmitter upstream of PCV-1195/1295/1395 Causes: 12.1.9 LLWT

and interlock to stop 4850-P-107A/B/C on high discharge pressure

and interlock to stop 4850-P-107A/B/C on high discharge pressure
120 To interlock operation of 4850-P-108/109/110 with 4850-A-110- Causes: 12.1.14 LLWT

S01A and 4850-P-106A to prevent centrifuge and sludge pump
running without polyelectrolyte dosing

and interlock to stop 4850-P-108/109/110 on high discharge
pressure
124 To install check valves downstream of individual pump suction Causes: 12.2.5, LLWT
strainers to provide additional protection against backflow of high 12.2.6, 12.2.11,
pressure water into 4850-A-110-T-01 12.2.12
13.1.9, 13.1.15
126 To provide installed common spare pump for 4850-P-501A/B to Causes: 13.1.7 LLWT
reduce downtime
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128 To provide installed common spare pump for 4850-P-502 to reduce Causes: 13.1.13 LLWT
downtime
129 To install pressure transmitter upstream of PCV-5315 and interlock Causes: 13.1.14 LLWT
to stop 4850-P-502 on high discharge pressure
131 To configure sequence of MOV-4101/4201/4301 to be both fully Causes: 14.1.1 LLWT

open during the start of the tank switch over to prevent loss of flow
to pumps
132 To incorporate FI-4011/PG-4012 in operator routine round checklist Causes: 14.1.2 LLWT
133 To change the flushing sequence of 4850-P-401/402/403 by Causes: 14.1.4 LLWT

stopping the pumps prior to introduction of high pressure water to

and interlock to stop 4850-P-401/402/403 on high discharge
pressure
136 To include local high alarm at 4850-T-401A/B/C for immediate alert Causes: 14.8.1 LLWT
to field operator on high level
137 To provide drain with lockable isolation valve from 4850-T- Causes: 14.14.1 LLWT
401A/B/C bund to the ACC to safely route any leakage/spillage out
of the bund
138 To provide installed common spare pump for 4850-P-401/402/403 Causes: 14.19.1 LLWT
to reduce downtime
139 To install pressure transmitters at 4850-P-901A/B discharge to trip Causes: 15.1.2, LLWT
pumps on HH pressure (with time delay) 15.1.3, 15.1.4
140 To install check valves at 4850-P-901A/B chemical dosing points to Causes: 15.3.2 LLWT
prevent contamination
141 To interlock the dosing of HCl and caustic to MOV-9003 to prevent Causes: 15.3.2 LLWT
unnecessary dosing of HCl or caustic
142 To configure QICA-9001 pH probe so that it is always submerged in Causes: 15.10.1 LLWT
liquid column to minimize potential malfunction
143 To specify protective coating for chemical waste system concrete Causes: 15.21.1 LLWT
sump
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Closure
Contractor Response Reference PMC/OWNER Response after discussion.
signed?
LLWT confirms recommendation is implemented. P&ID - 1003 OK CLOSED

Revised as per P&ID rev. 0
LLWT confirms recommendation is implemented. P&ID - 1005 to OK CLOSED

Revised as per P&ID rev. 0 1008

LLWT confirms recommendation is implemented. P&ID - 1001 to OK. CLOSED

Revised as per P&ID rev. 0 1004, 1009,
1017 to 1019


LLWT confirms recommendation is to be implemented. RAPID-P016B- OK. To issue amended control narrative. CLOSED
Refer revised Control Narrative. LLWT-PRO-
DES-4850-
0301, 0302,
0303.
LLWT recommends use of differential pressure P&ID - 1003 PMC to check with INC whether LLWT recommendation is CLOSED
transmitter upstream and downstream of control valve. acceptable.
To close in the event of -ve differential pressure. To
Discuss. [Post Meeting Note] Sachin:
As per discussion with Contractor's Process we understands
that Contract propose to install Differential pressure
transmitter across MOV Tag no MOV 0301 and In case of
back flow this differential pressure transmitter signal (-ve) to
be used to close MOV 0301.
To prevent back flow in line it is recommended to use

Mechanical device like check valve (NRV) as a general
practice, but as concern raised by contractor for pressure
loss in down stream of check valve will be high if check valve
is to be installed and it is not possible to achieve required
pressure in downstream.
Considering above limitations to installed check valve and

possibility of back pressure scenario is low, contractor's
proposal to installed differential transmitter across MOV 0301
is acceptable with following comments.
a) Contractor shall consider time delay for opening MOV
0301 once it is closed due to back pressure, this is to
prevent frequent opening & closing of MOV due to fluctuation
in back pressure.
b) Contractor shall make sure to consider back pressure
scenario in MOV design (i.e. Torque requirements).
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Closure
signed?
LLWT confirms recommendation is implemented. RAPID-P016B- OK. To issue amended Spec for Top entry mixers. (ROT- CLOSED
Mechanical Specification to mention oil leak LLWT-ROT- SPN-0007)
prevention. Top Entry Mixer Spec Submitted, Gravity SPN-4850-
Thickener (ongoing). VENDOR to confirm / provide 0007, 0009
justification of oil leak prevention.
TEQ sent to PMC. To discuss. RAPID-P016B- PMC to follow up. CLOSED

LLWT-ENG-
TEQ-0072
LLWT propose to add a dedicated drainage line with P&ID - 1001 to OK. CLOSED
isolation valve to drain the aerator. To Discuss 1003
LLWT confirms recommendation is to be implemented. OK. Will be considered under OPM. HOLD
Study confined space requirement (ongoing).






LLWT confirms recommendation is implemented. P&ID - 1020 PMC to check with INC whether LLWT recommendation is CLOSED
Revised as per P&ID rev. 0. Furthermore, the manifold acceptable.
pressure discharge pressure transmitter is removed, as [Post Meeting Note]:
it is redundant. To discuss. 1) Based on Contractor response and P&ID rev.0 Contractor
indicated PIZA-0165, 0265 & 0365 for high pressure trip on
each blower discharge as per HAZOP recommendation.
2) Regarding manifold discharge pressure transmitter

removal, contractor explained that it is redundant after
providing pressure transmitter at each blower discharge,
hence not required and the same is agreed by PMC / Owner
Process. Instrument has no concern as measurement /
transmitter requirement shall be decided by Process.
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Closure
signed?
PIA 0062 is now redundant as per previous P&ID - 1020 PMC to check with INC whether LLWT recommendation is CLOSED
recommendation. LLWT propose to remove. Refer to acceptable.
P&ID rev. 0. To discuss. [Post Meeting Note]:
Refer Reply point 2) of Item 21. As pressure transmitter (PIA-
0062) is removed this point is no longer valid.
LLWT confirms recommendation is to be implemented. Ok. To include in OPM. HOLD

It is to be included in OPM (ongoing)
LLWT checked and confirms OUI does not accept off- OK. To issue the amended P&ID. OPEN
spec water during commissioning. LLWT propose to
have recyled pipe during commissioning.

PIA 0061 is now redundant as per previous P&ID - 1020 OK. CLOSED
recommendation. LLWT propose to remove. To
discuss.
Duration of sludge caking varies and is difficult to P&ID - 1032 PMC to confirm with PRO, Operations the sludge caking HOLD
estimate. Ballpark duration of sludge caking from total duration estimated is acceptable.
shut down of all submersible mixers to be 1 to 2 days [Post meeting Note]: Siti
(Ferric & Magnesium sludge) Since it is not possible to determine when caking will occur,
LLWT to provide protection to agitator to stop mixer at high
torque and interlock with pump. To also provide SOP, that
will require draining and flushing facilities for pump and line
when agitator is down.
LLWT propose to add install additional spare mixer for P&ID - 1032 PMC to confirm with PRO, Operations whether LLWT CLOSED
3 x 50% operation. To discuss. proposal of 3 x 50% is acceptable. PRO, Operations to re-
confirm the necessity of the installed spare mixer since it can
only cover 50% of the tank coverage (mixing area). If not
necessary, LLWT propose to remove as the spare mixer will
only create additional power load.
[Post meeting Note]: Siti
LLWT may revert to 2x50%. To provide spare in warehouse.
To also provide SOP
so that the replacement is conducted as soon as possible
considering the short retention within the system. LLWT to
consider increasing the retention in the upstream thickener to
allow sufficient time for replacement of the mixer.

LLWT propose to remove line to recovery tank and P&ID - 1031 OK CLOSED
direct into storm water train. Hence MOV1012 & 1013
to be removed. Justification is for simpler pumping
operation. Flow to storm water train is still throttled.To
discuss.
LLWT propose to remove line to recovery tank and P&ID - 1031 OK CLOSED
direct into storm water train. Hence MOV1012 & 1013
to be removed. Justification is for simpler pumping
operation. Flow to storm water train is still throttled.To
discuss.

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Closure
signed?


LLWT confirms recommendation is implemented. P&ID - 1033 Ok CLOSED

LLWT confirms recommendation is implemented. P&ID - 1035 OK. CLOSED

Duration of sludge caking varies and is difficult to P&ID - 1034 PMC to confirm with PRO, Operations the sludge caking HOLD
estimate. Ballpark duration of sludge caking from total duration estimated is acceptable.
shut down of all submersible mixers to be 1 to 2 days [Post meeting Note]: Siti
(Ferric & Magnesium sludge) Refer to Item 28.
LLWT propose to add install additional spare mixer for P&ID - 1034 PMC to confirm with PRO, Operations whether LLWT CLOSED
3 x 50% operation. To discuss. proposal of 3 x 50% is acceptable. PRO, Operations to re-
confirm the necessity of the installed spare mixer since it can
only cover 50% of the tank coverage (mixing area). If not
necessary, LLWT propose to remove as the spare mixer will
only create additional power load. [Post Meeting Note] Siti:
Refer to Item 29

LLWT confirms recommendation is to be implemented. RAPID-P016B- OK. To issue amended control narrative. HOLD
DES-4850-
0302.
DES-4850-
0302.
DES-4850-
0302.
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Closure
signed?
DES-4850-
0302.

VENDOR confirms no protection against blockage/ P&ID - 1035 OK CLOSED

high pressure. LLWT propose to add PIZA for pump
protection of 4850-P-106A/B/C.
Refer to Material Handling report. Gantry crane is RAPID-P016B- OK. See Material Handling Study Report. CLOSED
provided for removal. To discuss. LLWT-MEC-
ERP-4850-
0001.
LLWT confirms recommendation is implemented. P&ID - 1034, OK CLOSED

This MOV is relocated under VENDOR package. P&ID - 1040 OK. To ensure VENDOR provide fault alarm. Indicate alarm OPEN
Control for this MOV under Vendor PLC. Vendor to in P&ID
confirm.
LLWT suggests that Chemical Supplier truck operator P&ID - 1040 OK. To include purging of unloading line in Operating HOLD
to conduct the purging of the unloading line before and manual.
after the unloading of Lime to prevent build up and
blockage. To discuss.
DES-4850-
0301, 0302,
0303.


DES-4850-
0303.
Due to PIZA to be installed downstream of individual P&ID - 1043 Ok. CLOSED

pumps, recommendation to install a pressure
transmitter here is considered redundant, as the PIZA
detect the event as pre-alarm H, or trip HH. Moreover,
recommendation item 54, 67, 69, 77, 99, 115, 116,
125, 132 as part of OPM would pickup the failure of
PCV.To discuss.
Open 16 of 35
Main HAZOP 05/14/2017 12:50:10
Closure
signed?
VENDOR familiar with advise that while automatic OK. To be included in OPM. HOLD
flushing is available, manual flushing is still
recommended. Recommended frequency to be weekly,
except for Cl2 (2-3 days)
LLWT confirms recommendation is to be implemented. N/A HOLD

Refer to Commissioning documents, will cover these
requirements.
LLWT confirms recommendation is to be implemented Ok. To include in OPM. HOLD

in the OPM.
LLWT confirms recommendation is implemented. P&ID - 1041 to Manual sample point not required. To amend P&ID. CLOSED

LLWT confirms recommendation is implemented. P&ID - 1041, OK. CLOSED

MOV failure will be picked up as separate alarm. P&ID - 1045 OK CLOSED

Pressure transmitter is installed upstream with low and
high alarm to detect failure of PCV-3003.
Change of design utilising on/off MOV-3012 instead of P&ID - 1046 LLWT to study possibility of incorporating Flow transmitter for CLOSED
control valve MOV-3012. Hence, transmitter is not failure of high pressure water
required. To discuss.
Open 17 of 35
Main HAZOP 05/14/2017 12:50:10
Closure
signed?


DES-4850-
0303.

Due to PIZA to be installed downstream of individual P&ID - 1047 OK. CLOSED

PCV.To discuss.

LLWT disagree with recommendation for this system. P&ID - 1047 OK. CLOSED
As the expected operation run-time is about 6-12
weeks per year. Installed common standby pump is not
justifiable. Preventive maintenance should be planned
and executed prior to expected high-silica period.

LLWT propose this to be transferred to VENDOR P&ID - 1045 OK. To include proper handling of Chemical Bag in Operating OPEN
package HAZOP. To discuss manual.
DES-4850-
0303.

DES-4850-
0303.
LLWT confirms recommendation is implemented. P&ID - 1017 & Ok. CLOSED

LLWT confirms recommendation is implemented. P&ID - 1066 Ok. To reissue amended P&ID CLOSED
Revised as per P&ID rev. 1 (ongoing)
Open 18 of 35
Main HAZOP 05/14/2017 12:50:11
Closure
signed?
DES-4850-
0303.
LLWT confirms recommendation is implemented. P&ID - 1017 & Ok. CLOSED

LLWT confirms recommendation is implemented. P&ID - 1066 Ok. To reissue amended P&ID CLOSED
Due to PIZA to be installed downstream of individual P&ID - 1066 Ok. To reissue amended P&ID CLOSED
PCV.To discuss.
LLWT confirms recommendation is to be implemented. P&ID - 1066 Ok. To reissue amended P&ID CLOSED
LLWT proposes to use ejector and high pressure water P&ID - 1065 Ok. To reissue amended P&ID CLOSED
as scrubber system to scrubber the HCl fumes. It is to
be operated only when HCl is unloaded into the
storage tanks. The scrubbed HCl is channeled to ACC
pit. To discuss.
LLWT proposes a separate ACC2 pit specifically for P&ID - 1065 Ok. To reissue amended P&ID CLOSED
HCl only. The spillage will only be opened in the event
HCl fumes is detected. The collected HCl in the ACC2
pit is then progressively pumped to the ACC1 pit in
controlled volumes for neutralisation and eventually
recycling at the Storm Water Train. To Discuss.

Open 19 of 35
Main HAZOP 05/14/2017 12:50:11
Closure
signed?
DES-4850-
0303.
LLWT proposes a separate ACC2 pit specifically for P&ID - 1065 Ok. To reissue amended P&ID CLOSED
HCl only. The spillage will only be opened in the event
HCl fumes is detected. The collected HCl in the ACC2
pit is then progressively pumped to the ACC1 pit in
controlled volumes for neutralisation and eventually
recycling at the Storm Water Train. To Discuss.
LLWT confirms recommendation is implemented. P&ID - 1043, OK. To issue amended P&ID OPEN
Revised as per P&ID rev. 0, 1(ongoing) 1047, 1051,
1056, 1061,
1066
Acid resistance materials for corrosion protection to be OK. To be included in Civil Drawings. (CVS-DWG-4850-0185 HOLD
indicated in revised Civil drawings (ongoing). Chemical Building)
Refer P&ID rev. 1 (ongoing)
DES-4850-
0303.

DES-4850-
0303.
LLWT clarifies that sampling point was already P&ID - 1018 OK CLOSED
downstream of NaOH dosing point. No action done.
DES-4850-
0303.
LLWT clarifies that sampling point was already P&ID - 1019 OK CLOSED
downstream of NaOH dosing point. No action done.
LLWT confirms recommendation is to be implemented. P&ID - 1061 Ok. CLOSED

Revised as per P&ID.
Open 20 of 35
Main HAZOP 05/14/2017 12:50:11
Closure
signed?
DES-4850-
0303.
LLWT confirms recommendation is implemented. P&ID - 1055, OK. To issue amended P&ID #1080 CLOSED


DES-4850-
0303.

LLWT clarifies PCV-1195/1295/1395. There is no PCV- P&ID - 1081 N/A, See item 121. CLOSED
1196/1296/1396 on rev.C of P&ID #1081. Refer Item
118.
DES-4850-
0302.
LLWT clarifies on rev.C of P&ID #1081, should be P&ID - 1081 OK. CLOSED
PCV-1198/1298/1398. LLWT confirms recommendation
is implemented. Revised as per P&ID rev. 0
LLWT confirms recommendation is to be implemented. P&ID - 1081 OK CLOSED



LLWT does not agree with this requirement. The train P&ID - 1056 OK. Warehouse spare must be supplied. Although 1 train CLOSED
downtime to remove and replace the pump is not shutdown, downstream storage capacity adequate for
significant enough to justify installation of a common 48hours x 3.
spare pump. To discuss.
Due to PIZA to be installed downstream of individual P&ID - 1056 OK CLOSED

PCV.To discuss.
Open 21 of 35
Main HAZOP 05/14/2017 12:50:11
Closure
signed?


DES-4850-
0303.

DES-4850-
0303.
LLWT confirms recommendation is to be implemented. P&ID - 1051 OK. To issue amended P&ID CLOSED

LLWT confirms recommendation is to be implemented. P&ID - 1050 OK. LLWT to issue the amended P&ID CLOSED
LLWT confirms recommendation is to be implemented. P&ID - 1050 OK. LLWT to issue the amended P&ID CLOSED

Revised as per P&ID rev. 0. MOVs were removed for
individual pumps discharge line.

LLWT confirms recommendation is to be implemented. RAPID-P016B- Ok. To reissue amended Control Narrative. CLOSED
DES-4850-
0301, 0302,
0303.
LLWT confirms recommendation is implemented. P&ID - 1090 Ok. CLOSED

Protective coating for chemical waste system to be OK. To be included in Civil Drawings. (CVS-DWG-4850-0185 HOLD
specified in Civil drawings (ongoing) Chemical Building)
Open 22 of 35
Main HAZOP 05/14/2017 12:50:11
Status (PMC verification)

CLOSED 97
OPEN 42
OPEN - LLWT to 4
confirm
TOTAL 143
PMC Verification on
PMC Remarks
Closure
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
OPEN Comment a) and b) are still

open.
Item a) - to attach Control

Narrative Section 4.1.1.4. as
evidence.
Item b) - has this been
considered?
Please add the necessary

response to proper close this
action.
Open 23 of 35
Main HAZOP 05/14/2017 12:50:11
PMC Verification on
PMC Remarks
Closure
OPEN Response is not clear showing

that the action is closed. Has
vendor confirmed that oil leak
prevention is
required/provided?
Please add the corresponding
evidence.
OPEN Wrong TEQ reference no. It is
suppose to be ENG-TEQ-0074.
Please correct.
Giving empty TEQ sheet
CLOSED without PMC response is not
acceptable as close out.
PMC will provide reply to the
OPEN Response is not
TEQ for LLWT clear showing
response,
that the action
subsequent is closed.
action Has
and close
vendor
out. confirmed that oil leak
prevention is
required/provided?
evidence.
CLOSED
CLOSED
CLOSED

prevention is
required/provided?
evidence.
CLOSED
CLOSED
CLOSED

prevention is
required/provided?
evidence.
CLOSED
Open 24 of 35
Main HAZOP 05/14/2017 12:50:11
PMC Verification on
PMC Remarks
Closure
CLOSED
OPEN Pending OPM (Ongoing)
OPEN Response is hanging. Please

revise to indicate that
proposed changes had been
discussed, agreed with PMC. Is
this true?
As per P&ID rev 1, there is no
evidence that this proposal is
implemented.
LLWT to check and confirm
whether P&ID has been
updated. Rev 2?
CLOSED
CLOSED
CLOSED
OPEN The response is hanging and

not acceptable for close out.
What is the evidence that
protection for agitator is
provided?
OPEN The response is hanging.

Please revise this response to
show that changes is already
implemented as per attached
P&ID rev 1.
For SOP, please indicate SOP
is ongoing.
CLOSED
CLOSED
CLOSED
CLOSED
Open 25 of 35
Main HAZOP 05/14/2017 12:50:11
PMC Verification on
PMC Remarks
Closure
CLOSED
CLOSED

prevention is
required/provided?
evidence.
CLOSED
CLOSED
OPEN Response incomplete. Is

protection for P-106A/B/C from
overheating provided?
CLOSED
CLOSED
OPEN - LLWT to In latest design, 4850-A-102

confirm has been deleted. Please add
in the response to better
clarify and easy tracking.
Since A-102 is removed, this
action should be no longer
valid. LLWT to confirm.
OPEN - LLWT to This response is not entirely C

confirm true. h
The scenario is studies in a
n
vendor hazop, however, g
referring to vendor HAZOP e
study report (advanced copy), d
there is no such action item.
Please mention which specific
action item LLWT is referring
to.
Under vendor hazop study,
the action item related to this
scenario is different.
LLWT to confirm.
Suggest LLWT to correct

response with something like:"
"4850-A-103-A01/B and 4850-
A-104A/B has now changed
to....This scenario is studied in
Vendor HAZOP (1), refer
Deviation 1 Cause 3 and
corresponding action item 1."
CLOSED
Open 26 of 35
Main HAZOP 05/14/2017 12:50:11
PMC Verification on
PMC Remarks
Closure
OPEN - LLWT to In latest design, 4850-A-

confirm 107A/B/C/D has been deleted.
Please add in the response to
better clarify and easy
tracking.
Since it is removed, this action
should be no longer valid.
LLWT to confirm.
CLOSED
CLOSED
CLOSED
OPEN Please add response regarding

high pressure water
connection i.e. via hose down.
Is access to vacuum truck
provided?
OPEN This response is no longer

true. This MOV is under LLWT
scope as per P&ID rev 1.
Please provide response for
this item.
CLOSED
CLOSED
CLOSED
CLOSED Response is no longer valid.

Action is implemented with PT
with high alarm is provided as
per indicated on attached
P&ID #1043 rev 1. Please
update this response.
Open 27 of 35
Main HAZOP 05/14/2017 12:50:11
PMC Verification on
PMC Remarks
Closure
OPEN Response not clear. What does

this response mean?
automatic flushing facility is
provided? Please provide
evidence e..g spec document
by vendor.
Include that OPM to include
the manual flushing
requirement.

prevention is
required/provided?
evidence.
CLOSED Recommendation is too

general. Response should be
sufficient.
OPEN Is this response still true?

P&ID rev 1 shows manual SC
is provided.
LLWT please check and revise
the response accordingly.
CLOSED
CLOSED
OPEN Under this scenario, concern

is on loss of water supply to
the vortex mixer when PCV
fail. MOV failure is not
discussed in this scenario.
Please delete statement "MOV
failure will be picked up..."
Implemented action is
sufficient except for low low to
trop 4850-A-301-M01. This
action is not implemented.
LLWT to clarify.
OPEN Response not acceptable as it

is not answering HAZOP
concern. The pressure
transmitter is required to alert
operator during failure of high
pressure water to T-301. This
is irregardless of MOV type.
Open 28 of 35
Main HAZOP 05/14/2017 12:50:11
PMC Verification on
PMC Remarks
Closure
CLOSED
CLOSED
CLOSED Response is no longer valid.

Action is implemented with PT
with high alarm is provided as
per indicated on attached
P&ID #1043 rev 1. Please
update this response.

prevention is
required/provided?
evidence.
CLOSED
CLOSED
OPEN - LLWT to Suggest LLWT to improve

confirm response with something like:"
"This scenario is studied in
Vendor HAZOP (1), refer Node
6 Deviation 22 Cause 1. No
additional recommendation is
proposed by the HAZOP team
member."
Even so, will OP address this

concern?
CLOSED
CLOSED
CLOSED
CLOSED
Open 29 of 35
Main HAZOP 05/14/2017 12:50:11
PMC Verification on
PMC Remarks
Closure
CLOSED
CLOSED
CLOSED
OPEN Response is no longer valid.

Post hazop close out, LLWT
has agreed to implement this
action. Refer other chemical
dosing line where PT with high
alarm is provided.
LLWT to clarify.
CLOSED
OPEN This action should also be

applicable for MOV-7312/7412
due to same scenario and
consequences. LLWT to clarify
why action is not
implemented.
CLOSED
CLOSED
OPEN Response is incomplete.

LLWT to clarify in the response
that design of the HCl storage
tanks are changed where
bund is no longer covered.
Dedicated HCl drain pit is
provided to contain any
overflow and leakage from
bund.
For the second action item

recommended, LLWT to add
that SOP for removal of acid
from bund is still ongoing.
CLOSED
CLOSED
Open 30 of 35
Main HAZOP 05/14/2017 12:50:11
PMC Verification on
PMC Remarks
Closure
OPEN The statement provided in the

control narrative document is
insufficient to meet HAZOP
recommendation.
The next statement in the
control narrative is also not
really meeting the
recommendation proposed by
HAZOP team.
The target is to ensure spare
pump will always be available
since the spare pump is going
to be used for neutralization.
CLOSED
OPEN Action not implemented for

NaOH and HCl pumps. Drain
points not provided at the
pump suction. LLWT to update
P&ID.
OPEN Pending civil drawings update
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
Open 31 of 35
Main HAZOP 05/14/2017 12:50:11
PMC Verification on
PMC Remarks
Closure
CLOSED
OPEN Action not implemented for T-

601A. LLWT to update the
P&ID and markup the
changes.
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
Open 32 of 35
Main HAZOP 05/14/2017 12:50:11
PMC Verification on
PMC Remarks
Closure
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
OPEN Action is not properly

implemented. On P&ID #1050
rev 1, only T-401C is provided
with lockable valve. LLWT to
update the P&ID, markup the
changes and attach in this
report.
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
OPEN Pending civil drawings update
Open 33 of 35
CLOSED 21 40% Status (PMC verification)
OPEN 28 60% CLOSED 34
HOLD 8 OPEN 15
TOTAL 49 100% N/A 8
TOTAL 57
Recommendations (HAZOP) Place(s) Used Contractor Response P&ID # Reference PMC/OWNER Response after discussion. Closure signed?
To incorporate high alarm at LIC -1051 to alert operator on high level in 4850-A-101-
1 Causes: 1.1.1, 1.1.2, 1.1.3 OK. To incorporate in next revision
T01. 1036 OK. OPEN
OK. Cosmetic changes to be
3 To indicate RH meters at dryers. Causes: 1.7.1 OK. To incorporate in next revision
1036 implemented. OPEN
Recommendation not incorporated. VENDOR

adviced against recommendation as sludge
left in centrifuge might cause further serious
To verify that CIP can be stopped when MOV-1652/1752/1852 is not closed at start
4 Causes: 2.2.2 issues in the future if CIP is on hold. There
on sequence.
will be an alarm to indicate the valves is
stuck open.
1035 OPEN
LLWT will incorporate this action into RWTP
Causes: 4.1.3, 4.1.4,
To incorporate action of PSH-8613 to close MOV-8612 and stop 4850-A-801-H01A. ESD system. Set point for PSH 8613/8713
8 4.1.5, 4.1.6, 4.1.7, 4.1.8,
To specify set point of PSH-8613 to cater for MOV-8612 closing time. will take into account closing time for
4.6.1
MOV8612/8712. 1070 to 1073 DCS control Set pressure to be less than 20.6 bar. OPEN
Design pressure for S01A/B and E01A/B will
Causes: 4.1.4, 4.1.5,
10 To specify design pressure of 4850-A-801-S01A same as 4850-A-801-E01A. be updated in vendor mechanical datasheet
4.1.6, 4.1.7, 4.1.8
and LLWT P&IDs. Pending VENDOR.
1070 to 1073 Open. OPEN
Independent trip transmitter(TIZA-
8612/8712) is already provided for both
evaporators. Thermocouple has been
installed on the evaporator (See punch list
To incorporate independent trip transmitter of 4850-A-801-H01A heating element on
11 Causes: 4.6.1 close out).
high high temperature.
LLWT will provide SIL 1 Temperature LLWT to ensure thermocouple is below
transmitter connected to the installed the low level of water bath in
thermocouple. These instruments will be Evaporator. 'Will' to be updated to 'has'
connected to RWTP ESD for control. 1070 to 1073 to indicate action taken. OPEN
Independent trip transmitter(TIZA-

8612/8712) to prevent liquid carry over
when temperature is Low Low has been
provided by LLWT.
PGTSSB informed that it is acceptable to
have HH and LL trip in the same initiator
provided any one or both of the HH trip/LL
trip SIL rating is classified as lower than SIL
To incorporate independent initiator to close PCV-8615 on failure of 4850-A-801- 1. As per IPF studies, SIL rating for TIZALL-
12 Causes: 4.7.1
H01A to prevent liquid carry over to downstream equipment. 8612/8712 loops are less than SIL 1. Hence,
the same transmitter will be used for HH and
LL trip.
Thermocouple has been installed on the
evaporator (See punch list close out).
LLWT will provide SIL 1 Temperature
transmitter connected to the installed
thermocouple. These instruments will be LLWT to reword response, making clear
connected to RWTP ESD for control. that another separate initiator will not
be provided. Instead using the same
1070 to 1073 initiator for (Tiza-8612/8712). OPEN
To limit the area of chlorine discharge from PSV-8614 at the scrubber e.g. LLWT to initiate the scrubber operation
All venting lines will be connecter to Scubber when PSV 8614 pops (via PSH 8613),
13 secondary enclosure/shielding with detector to ensure activation of scrubber upon Causes: 4.11.1
duct inlet. while ensuring no interruption of
release.
1070 to 1073 chlorine supply. OPEN
All venting lines will be connecter to Scubber CLOSED
14 To connect the vent from vacuum regulators to the scrubber system. Causes: 4.11.2
duct inlet. 1070 to 1073 OK.
Purging of Chlorine system will be carried out

as follows:
- Liquid Chlorine drums are disconnected
from the system.
- Evaporators are allowed to run until all
chlorine liquid and gas in the pipe from
Liquid chlorine drums is exhausted.
Exhaustion of gas can be confirmed by
Pressure Transmitter PICA-8606, Pressure
To provide adequate purging points connected to purge gas supply and scrubber
16 Causes: 4.20.1 Gauge PG-8605 (at outlet pipe of chlorine
system to enable preventive maintenance.
drum) and 8611(cabinet mounted on
evaporator).
- Ejectors downstream will ensure all chlorine
(liquid and gas) in the pipe will be dissolved
in water. LLWT to reword response, making clear
- Nitrogen cylinders can then be connected that using the same flexible hose for
to flexible hose at liquid chlorine drum liquid chlorine drum as first point of
connection to purge the system for purge point.
preventive maintenance. SOP for purging to be included in the
1070 to 1073 O&M OPEN
Vendor informed that replacement of rupture

disc will be done as follows:
- Evaporator downstream is allowed to run
until all chlorine liquid and gas in the pipe
from Liquid chlorine drums is exhausted.
Exhaustion of gas can be confirmed by
Pressure Transmitter PICA-8606, Pressure
17 To provide details for replacing rupture disc at 4850-A-801-V01A. Causes: 4.20.2
Gauge PG-8605 (at outlet pipe of chlorine
drum), 8608(at expansion and containment
chamber inlet) and 8611(cabinet mounted
on evaporator).
- Isolation ball valve at inlet of expansion
chamber is closed. Bursting disc can then be
replaced. SOP for replacing Bursting disc to be
1070 to 1073 included in the O&M OPEN
OPEN
Vendor informed that there is no category in
DOSH for certificatin of Lifting bars and
To specify certified equipment e.g. drum hooks, hoist and monorail crane for
19 Causes: 4.22.2 crane scale (within vendor scope of supply).
chlorine drum handling.
DOSH requirement is only limit to Electric Vendor to provide certification of
Overhead Travelling Crane(4850-X-801). Lifting bars and crane scale; design
1070 to 1073 verified and tested
LLWT Rev. 1 P&ID RAPID-P016B-LLWT-PRO-

20 To indicate signal connection between 4850-UZ281 to 4850-UZ283. Causes: 5.1.1 PID-4850-1070 has already shown this
connection. No further action to be done
1075 No action. OPEN
To incorporate high alarm at PIZA-8592 to alert operator on high pressure at 4850-
23 Causes: 5.1.5, 5.2.2 OK. To incorporate in next revision
A-802-P01A/B discharge. 1075 OK. OPEN
Nozzle for utility water has been relocated to
To relocate inlet of utility water line to 4850-A-802-V01 at the top to prevent top of the tank V01. Relevant vendor
24 Causes: 5.3.1
backflow of caustic into the utility water header. documents will be updated to reflect this Utilising the spare nozzle on top of the
change. 1075 absorbent tank. (punch item) OPEN
There is no line between isolation valve and
To install drain point at 4850-A-802-P01A/B strainer to facilitate preventive strainer. Strainer can be drained and should
25 Causes: 5.20.1 SOP for carry preventive maintenance
maintenance. be used to totally drain the 'line' between
isolation valves. Hence, no drain is required. on Y-strainer to be included in the
1075 O&M. OPEN
To incorporate a seal leg on the 4850-A-802-V01 overflow line to maintain a liquid Liquid seal leg is incorporated, between the
26 Causes: 5.22.1
seal and prevent chlorine gas through. tower and tank. 1075 OK. OPEN
UZ-246A will trip the MgO Transfer
To indicate the complete shutdown action of the MgO system on activation of Blower(K01), trip MgO Screw Feeder (A03)
27 Causes: 6.1.2, 6.1.3
4850UZ-246A. and trip MgO Mixer(M-301A). All actions will
be updated into LLWT CEM. 1040, 1045 CEM, ControlOK. OPEN
MOV is not suitable for use in this application

as the opening and closing time is not
sufficiently short. LLWT will provide a
To verify applicability of MOVs for fluidization of silos as KSY cannot be configured Causes: 6.1.4, 6.2.2, vibrator on the conical section of each silo to
28
to have position discrepancy alarm. 7.1.2, 7.2.1 ensure minimal arching of Lime and MgO
powder in the event that KSY is stuck close.
KSY will be placed on preventive
maintenance schedule.
1040, 1045 OK. OPEN
UZ-246A will trip the Lime Screw Feeders
To indicate the complete shutdown action of the lime system on activation of
29 Causes: 7.1.1 (A03A/B) and trip Lime Mixer(M-201/202). All
4850UZ-241A.
actions will be updated into LLWT CEM.
1040, 1045 CEM, ControlOK. OPEN
32 To incorporate high temperature alarm to detect malfunction of 4850-A-501-H01. Causes: 8.6.1 OK. To incorporate in next revision
1055 To incorporate in the P&ID OPEN
Open
Heater is installed between 2 metal plates
on the hopper. Installation of independent
To incorporate independent trip function of 4850-A-501-H01 heating element on
33 Causes: 8.6.1 trip transmitter is not physically possible. Alarm through Package PLC (High
Overcurrent will be used for protection of temperature), for operator manual
heater 1050, 1080 intervention. OPEN
34 To incorporate low temperature alarm to detect failure of 4850-A-501-H01. Causes: 8.7.1 OK. To incorporate in next revision
OK. LLWT to verify the tapping point as
35 To locate the sampling point at the outlet of the 4850-A-501-T02. Causes: 8.18.1 OK. To incorporate in next revision from the side of tank, rather than the
1055 top. OPEN
38 To incorporate high temperature alarm to detect malfunction of 4850-A-110-H01. Causes: 9.6.1 OK. To incorporate in next revision
Heater is installed between 2 metal plates
on the hopper. Installation of independent
To incorporate independent trip function of 4850-A-110-H01 heating element on
39 Causes: 9.6.1 trip transmitter is not physically possible. Alarm through Package PLC (High
Overcurrent will be used for protection of temperature), for operator manual
heater 1050, 1080 intervention. OPEN
40 To incorporate low temperature alarm to detect failure of 4850-A-110-H01. Causes: 9.7.1 OK. To incorporate in next revision
OK. LLWT to verify the tapping point as
41 To locate the sampling point at the outlet of the 4850-A-110-T02. Causes: 9.18.1 OK. To incorporate in next revision from the side of tank, rather than the
1080 top. OPEN
To reword response based on 2nd
42 To verify availability of compressor protection on loss of suction. Causes: 10.1.1 HOLD with VENDOR
1026 HAZOP worksheet. OPEN
Open

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Main HAZOP 05/14/2017 12:50:10

Item Recommendations (HAZOP) Place(s) Used ASSIGNED TO

Item Recommendations (HAZOP) Place(s) Used ASSIGNED TO

Item Recommendations (HAZOP) Place(s) Used ASSIGNED TO

24 To verify commisioning requirement with OUI on final pH Causes: 4.17.1, LLWT

25 To provide isolation at MOV-0063 and MOV-0064 to enable Causes: 4.20.1, LLWT

27 To incorporate low alarm at PIZA-1122/1222/1322 to alert operator Causes: 6.1.14 LLWT

30 To incorporate H and HH alarm at WIZA-1131/1231 to alert Causes: 6.1.18 LLWT

Item Recommendations (HAZOP) Place(s) Used ASSIGNED TO

Item Recommendations (HAZOP) Place(s) Used ASSIGNED TO

54 To incorporate FI-2012/PG-2012 in operator routine round checklist Causes: 8.1.9, LLWT

55 To change the flushing sequence of 4850-P-201/202/203 by Causes: 8.1.11, LLWT

Item Recommendations (HAZOP) Place(s) Used ASSIGNED TO

59 To provide appropriate facilities for pre-commisioning and Causes: 8.17.1, LLWT

60 To specify requirement of minimum level in 4850-T-201A/B prior to Causes: 8.17.2 LLWT

Item Recommendations (HAZOP) Place(s) Used ASSIGNED TO

67 To incorporate FI-3021/PG-3022 in operator routine round checklist Causes: 9.1.10, LLWT

68 To change the flushing sequence of 4850-P-301/302/303 by Causes: 9.1.12, LLWT

69 To incorporate FI-3021/PG-3022 in operator routine round checklist Causes: 9.1.14 LLWT

72 To specify requirement of minimum level in 4850-T-301 prior to Causes: 9.17.2 LLWT

76 To configure sequence of MOV-7101/7201 to be both fully open Causes: 10.1.1 LLWT

77 To incorporate FI-7016/PG-7012 in operator routine round checklist Causes: 10.1.2, LLWT

78 To change the flushing sequence of 4850-P-701A/B by stopping Causes: 10.1.4 LLWT

80 To install pressure transmitter upstream of PCV-7114/7214 and Causes: 10.1.6, LLWT

Item Recommendations (HAZOP) Place(s) Used ASSIGNED TO

81 To change the flushing sequence of 4850-P-702A/B by stopping Causes: 10.1.11 LLWT

83 To install pressure transmitter upstream of PCV-7314/7414 and Causes: 10.1.13, LLWT

85 To install check valves upstream of MOV-7111/7211 to provide Causes: 10.2.3 LLWT

87 To install check valves upstream of MOV-7311/7411 to provide Causes: 10.2.10, LLWT

Item Recommendations (HAZOP) Place(s) Used ASSIGNED TO

93 To prioritize 4850-P-701A/B and 4850-702A/B switchover over Causes: 10.19.1 LLWT

98 To configure sequence of MOV-6101/6201 to be both fully open Causes: 11.1.1 LLWT

99 To incorporate FI-6011/PG-6012 in operator routine round checklist Causes: 11.1.2, LLWT

Item Recommendations (HAZOP) Place(s) Used ASSIGNED TO

118 To install pressure transmitter upstream of PCV-1195/1295/1395 Causes: 12.1.9 LLWT

119 To install pressure transmitter upstream of PCV-1196/1296/1396 Causes: 12.1.11 LLWT

120 To interlock operation of 4850-P-108/109/110 with 4850-A-110- Causes: 12.1.14 LLWT

121 To install pressure transmitter upstream of PCV-1199/1299/1399 Causes: 12.1.15 LLWT

Item Recommendations (HAZOP) Place(s) Used ASSIGNED TO

131 To configure sequence of MOV-4101/4201/4301 to be both fully Causes: 14.1.1 LLWT

133 To change the flushing sequence of 4850-P-401/402/403 by Causes: 14.1.4 LLWT

134 To install pressure transmitter upstream of PCV-4114/4214/4314 Causes: 14.1.6 LLWT

LLWT confirms recommendation is implemented. P&ID - 1003 OK CLOSED

LLWT confirms recommendation is implemented. P&ID - 1005 to OK CLOSED

LLWT confirms recommendation is implemented. P&ID - 1008 OK CLOSED

LLWT confirms recommendation is implemented. P&ID - 1001 to OK. CLOSED

LLWT confirms recommendation is implemented. P&ID - 1003 OK CLOSED

LLWT confirms recommendation is implemented. P&ID - 1008 OK CLOSED

To prevent back flow in line it is recommended to use

Considering above limitations to installed check valve and

TEQ sent to PMC. To discuss. RAPID-P016B- PMC to follow up. CLOSED

LLWT confirms recommendation is implemented. P&ID - 1001 OK CLOSED

LLWT confirms recommendation is implemented. P&ID - 1005 OK CLOSED

LLWT confirms recommendation is implemented. P&ID - 1001 OK CLOSED

LLWT confirms recommendation is implemented. P&ID - 1002 OK CLOSED

LLWT confirms recommendation is implemented. P&ID - 1006 OK CLOSED

LLWT confirms recommendation is implemented. P&ID - 1002 OK CLOSED

2) Regarding manifold discharge pressure transmitter

LLWT confirms recommendation is to be implemented. Ok. To include in OPM. HOLD

LLWT confirms recommendation is implemented. P&ID - 1020 OK CLOSED

LLWT confirms recommendation is implemented. P&ID - 1033 OK CLOSED

LLWT confirms recommendation is implemented. P&ID - 1033 OK CLOSED

LLWT confirms recommendation is implemented. P&ID - 1033 OK CLOSED

LLWT confirms recommendation is implemented. P&ID - 1033 to OK. CLOSED