HAZOP STUDY REPORT

HAZOP
STUDY

6|Page UNIVERSITY OF KARACHI

HAZOP STUDY REPORT

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HAZOP STUDY REPORT

8|Page UNIVERSITY OF KARACHI

HAZOP STUDY REPORT

Equipment Consequences of this Additional Action Required

reference Deviation What event can deviation on item of implication of this (recommendation)
and from cause this deviation equipment under sequences
operating operating consideration
condition condition

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

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 HAZOP STUDY REPORT

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

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 HAZOP STUDY REPORT

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 HAZOP STUDY REPORT

Equipment Consequences of this Additional Action Required

reference Deviation What event can deviation on item of implication of this (recommendation)
and from cause this deviation equipment under sequences
operating operating consideration
condition condition

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

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 HAZOP STUDY REPORT

 Ammonia loss

30. PCV-01 fails close  Insufficient  Incomplete

vaporization reaction in the
reactor
31. PIC-1 fails,  Insufficient  Incomplete
closing vaporization reaction in the
reactor

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

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 HAZOP STUDY REPORT

Less 42. Rupture  NH3 loss  NH3 Displaces  Alarming system

discharge line oxygen from should be installed
ground up
 Insufficient NH3 in
the reactor
43. Rupture line 101  NH3 loss  Insufficient NH3 in  Alarming system
the reactor should be installed
44. Tank rupture  NH3 loss  Insufficient NH3 in
the reactor
45. FCV-01 fails open  More heat is  Side reaction will
required in VE-01 occur in the reactor

46. FFC-1 fails,  More heat is  Side reaction will

opening FCV-01 required in VE-01 occur in the reactor

47. PCV-01 fails close  Vaporization seize  Incomplete

reaction in the
reactor
48. PIC-1 fails,  Vaporization seize  Incomplete
closing reaction in the
reactor
49. LCV-01 fails  Vaporization seize  Incomplete
closed reaction in the
reactor
50. LIC-1 fails,  Vaporization seize  Incomplete
closing LCV-01 reaction in the
reactor
51. NRV-01 fails  Vaporization seize  Incomplete
closed  reaction in the
reactor

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Temperature 52. LCV-01 fails close  Excessive  Side reaction will  Use temperature
More vaporization occur in the reactor Indicator

53. LIC-1 fails,  Excessive  Side reaction will  Use temperature

closing LCV-01 vaporization occur in the reactor Indicator

54. NRV-01 fails  Excessive  Side reaction will

closed vaporization occur in the reactor

55. FCV-01 fails close  Excessive  Reaction seize in

vaporization the reactor

56. FFC-1 fails,  Excessive  Reaction seize in

closing FCV-01 vaporization the reactor

57. PCV-01 fails open  Excessive  Side reaction will

vaporization occur in the reactor

58. PIC-1 fails,  Excessive  Side reaction will

opening vaporization occur in the reactor

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

61. LCV-01 fails open  less vaporization  Incomplete

occurs in VE-01 reaction in the
reactor
62. LIC-1 fails,  less vaporization  Incomplete
opening LCV-01 occurs in VE-01 reaction in the
reactor

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 HAZOP STUDY REPORT

Equipment Consequences of this Additional Action Required

reference Deviation What event can deviation on item of implication of this (recommendation)
and from cause this deviation equipment under sequences
operating operating consideration
condition condition

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

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 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

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 HAZOP STUDY REPORT

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 HAZOP STUDY REPORT

Equipment Consequences of this Additional Action Required

reference Deviation What event can deviation on item of implication of this (recommendation)
and from cause this deviation equipment under sequences
operating operating consideration
condition condition

Reactor Composition
RE-01
Other than 72. Wrong reagent  Another possible  Side reaction will  Use analyzer indicator
reaction occur in the reactor
 No reaction

As well as 73. Impurities in  Another possible  Side reaction will

reagent reaction occur in the reactor

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

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 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

82. FCV-01 fails open  Thermal Stress on  Side reaction will

catalyst bed occur in the reactor

83. FFC-1 fails,  Thermal Stress on  Side reaction will

opening FCV-01 catalyst bed occur in the reactor

Less 84. Rupture line 106  NH3 and O2 loss  Incomplete

reaction in the
reactor
 Side reaction will
occur in the reactor

85. FCV-01 fails close  Desired Reaction  Side reaction will

seize occur in the reactor

86. FFC-1 fails,  Desired Reaction  Side reaction will

closing FCV-01 seize occur in the reactor

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 HAZOP STUDY REPORT

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 HAZOP STUDY REPORT

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