Action Items

Printed: July 17, 2010, 2:48 PM

Company:
Location:
Facility:
PHA Method: HAZOP
PHA Type: Initial

Process:

File Description:

Date:

Process Description:

Chemicals:

Purpose:

Scope:

Objectives:

Project Notes:

Filters: No Filter Applied

PHAWorks by Primatech Inc.

 Action Items

Company: Page: 1 of 9
Facility:

Session: (1) 7/15/2010 Revision:

Node: (1) LPG Treatment: Untreated LPG from B/L through caustic contactors to B/L as treated LPG
Intention: The coker LPG received from DCU will be washed with 12% caustic in caustic wash contactor to remove the balance H2S content. Then it is routed to 1st and 2nd stage
CFC caustic wash contactor through filters FD 34001 A/B where it comes in contact with circulating caustic solution. Both caustic and LPG flow cocurrently through the film
contactor. At the outlet, both the phases are seperated and LPG exists from the top of the vessel to the inlet of the 2nd stage contactor. Similar cocurrent contact with
circulating caustic solution takes place in the 2nd stage contactor. Treated LPG passes through a coalescer in the same vessel to remove any caustic solution. Treated
caustic from 2nd stage is cooled in the LPG cooler EA 34001 and routed to storage under back pressure controller after being routed through a sand filter. Provision
available to divert LPG to offspec storage. LPG, CFC unit bypass line joins the LPG rundown line to offspec storage at B/L.
Drawings: 6782-EPCC3-TO-PDD-DW-30-340-1111, 6782-EPCC3-TO-PDD-DW-30-340-1112, 6782-EPCC3-TO-PDD-DW-30-340-
1113, 6782-EPCC3-TO-PDD-DW-30-340-1116.
Parameter: Flow
GW DEVIATION CAUSES CONSEQUENCES SAFEGUARDS RECOMMENDATIONS BY
No/Less 1. No/Less Flow of 1.3. Plugging of LPG filter 1.3.2. Upstream piping and 1.3.2.1. Piping, equipment Review the design pressure (31.5 PMC/
LPG FD 34001 A/B. equipment may be subjected and instruments in unit 340 kg/cm2 g) of equipment and lines in TOYO/
to LPG pump shutoff are designed to 31.5 the LPG product line (Unit 340) in Licensor
pressure. (PSV 001 A/B kg/cm2g. view of the LPG product pump GA
provided in the prewash 33433 A/B shut-off pressure of 33
column DA 34001, however, kg/cm2 g. Normal discharge
the safety valve is not pressure of LPG product pump is
suitable for blocked outlet about 27 kg/cm2 g. The design
case and is not a safeguard pressure of the equipment in LPG
for this scenario.) system of DCU may be taken into
account.

1.5. Plugging of sand filter 1.5.1. Flow of LPG through 1.5.1.1. FAL 001 provided in Review the need for PDAH across TOYO
FD 34003 the vessel may be restricted. the LPG line at the inlet of sand filter FD 34007.
the unit.

1.5.1.2. FAL 012 provided

downstream of filter.

1.5.1.3. FAL 051 provided

downstream of sand filter.

1.5.1.4. Block and bypass

arrangement for filter
provided to facilitate online
replacement of coalescing
medium

1.6. PIC 052 malfunctions
and closes PV 052 in the
LPG line to B/L.
PHAWorks by Primatech Inc.
1.6.1. Entire coker LPG 1.6.1.1. FAL 001 provided in Review the design pressure (31.5 PMC/
treating unit and LPG the LPG line at the inlet of kg/cm2 g) of equipment and lines in TOYO/
section of DCU may be the unit. the LPG product line (Unit 340) in Licensor
subjected to LPG product... view of the LPG product pump...
 Action Items

Company: Page: 2 of 9
Facility:

GW DEVIATION CAUSES CONSEQUENCES SAFEGUARDS RECOMMENDATIONS BY

No/Less 1. No/Less Flow of 1.6. PIC 052 malfunctions ...pump GA 33433 A/B
(cont.) LPG (cont.) and closes PV 052 in the shutoff pressure. Caustic
LPG line to B/L. (cont.) circulation may be stopped or
reduced due to increased
differential pressure
requirement. (PSV 001 A/B
provided in the prewash
column DA 34001, however,
the safety valve is not
suitable for blocked outlet
case and is not a safeguard
for this scenario.) No flow of
LPG to storage.
1.6.1.2. FAL 012 provided ...GA 33433 A/B shut-off pressure
downstream of filter. of 33 kg/cm2 g. Normal discharge
pressure of LPG product pump is
1.6.1.3. FAL 051 provided about 27 kg/cm2 g. The design
downstream of sand filter. pressure of the equipment in LPG
system of DCU may be taken into
1.6.1.4. PAH 002 provided in account.
LPG line at the inlet of unit
340.
1.6.1.5. Piping, equipment
and instruments in unit 340
are designed to 31.5
kg/cm2g.

Session: (1) 7/15/2010 Revision:

Node: (1) LPG Treatment: Untreated LPG from B/L through caustic contactors to B/L as treated LPG
Intention: The coker LPG received from DCU will be washed with 12% caustic in caustic wash contactor to remove the balance H2S content. Then it is routed to 1st and 2nd stage
CFC caustic wash contactor through filters FD 34001 A/B where it comes in contact with circulating caustic solution. Both caustic and LPG flow cocurrently through the film
contactor. At the outlet, both the phases are seperated and LPG exists from the top of the vessel to the inlet of the 2nd stage contactor. Similar cocurrent contact with
circulating caustic solution takes place in the 2nd stage contactor. Treated LPG passes through a coalescer in the same vessel to remove any caustic solution. Treated
caustic from 2nd stage is cooled in the LPG cooler EA 34001 and routed to storage under back pressure controller after being routed through a sand filter. Provision
available to divert LPG to offspec storage. LPG, CFC unit bypass line joins the LPG rundown line to offspec storage at B/L.
Drawings: 6782-EPCC3-TO-PDD-DW-30-340-1111, 6782-EPCC3-TO-PDD-DW-30-340-1112, 6782-EPCC3-TO-PDD-DW-30-340-
1113, 6782-EPCC3-TO-PDD-DW-30-340-1116.
Parameter: Pressure
GW DEVIATION CAUSES CONSEQUENCES SAFEGUARDS RECOMMENDATIONS BY
More 5. Higher Pressure 5.5. External fire on LPG 5.5.1. Overpressure and Provide suitable measures to PMC/TO
cooler EA 34001 potential failure. protect LPG cooler against YO
overpressure due to external fire.

PHAWorks by Primatech Inc.

 Action Items

Company: Page: 3 of 9
Facility:

Session: (1) 7/15/2010 Revision:

Node: (1) LPG Treatment: Untreated LPG from B/L through caustic contactors to B/L as treated LPG
Intention: The coker LPG received from DCU will be washed with 12% caustic in caustic wash contactor to remove the balance H2S content. Then it is routed to 1st and 2nd stage
CFC caustic wash contactor through filters FD 34001 A/B where it comes in contact with circulating caustic solution. Both caustic and LPG flow cocurrently through the film
contactor. At the outlet, both the phases are seperated and LPG exists from the top of the vessel to the inlet of the 2nd stage contactor. Similar cocurrent contact with
circulating caustic solution takes place in the 2nd stage contactor. Treated LPG passes through a coalescer in the same vessel to remove any caustic solution. Treated
caustic from 2nd stage is cooled in the LPG cooler EA 34001 and routed to storage under back pressure controller after being routed through a sand filter. Provision
available to divert LPG to offspec storage. LPG, CFC unit bypass line joins the LPG rundown line to offspec storage at B/L.
Drawings: 6782-EPCC3-TO-PDD-DW-30-340-1111, 6782-EPCC3-TO-PDD-DW-30-340-1112, 6782-EPCC3-TO-PDD-DW-30-340-
1113, 6782-EPCC3-TO-PDD-DW-30-340-1116.
Parameter: Temperature
GW DEVIATION CAUSES CONSEQUENCES SAFEGUARDS RECOMMENDATIONS BY
Less 6. Lower 6.1. Release of liquid LPG 6.1.1. Flare header may be Review the need for making the PMC/TO
Temperature into flare line (e.g passing of subjected to low temperature flare header in unit 340 suitable for YO
safety valve, depressurising handling liquid LPG in case of
of cooler, etc.) leakage across safety valves or
during depressurization

6.2. Equipment 6.2.1. Equipment may be 6.2.1.1. MDMT of caustic Examine if MDMT of -27 oC is PMC
depressurization for subjected to low temperature wash column, caustic wash suitable for LPG being produced in
maintenance. contactors and sand filters is DCU.
-27 oC.
Review the MDMT of LPG filters FD PMC
34001 A/B to make it suitable for
LPG depressurization.

Session: (1) 7/15/2010 Revision:

Node: (1) LPG Treatment: Untreated LPG from B/L through caustic contactors to B/L as treated LPG
Intention: The coker LPG received from DCU will be washed with 12% caustic in caustic wash contactor to remove the balance H2S content. Then it is routed to 1st and 2nd stage
CFC caustic wash contactor through filters FD 34001 A/B where it comes in contact with circulating caustic solution. Both caustic and LPG flow cocurrently through the film
contactor. At the outlet, both the phases are seperated and LPG exists from the top of the vessel to the inlet of the 2nd stage contactor. Similar cocurrent contact with
circulating caustic solution takes place in the 2nd stage contactor. Treated LPG passes through a coalescer in the same vessel to remove any caustic solution. Treated
caustic from 2nd stage is cooled in the LPG cooler EA 34001 and routed to storage under back pressure controller after being routed through a sand filter. Provision
available to divert LPG to offspec storage. LPG, CFC unit bypass line joins the LPG rundown line to offspec storage at B/L.
Drawings: 6782-EPCC3-TO-PDD-DW-30-340-1111, 6782-EPCC3-TO-PDD-DW-30-340-1112, 6782-EPCC3-TO-PDD-DW-30-340-
1113, 6782-EPCC3-TO-PDD-DW-30-340-1116.
Parameter: Level
GW DEVIATION CAUSES CONSEQUENCES SAFEGUARDS RECOMMENDATIONS BY
Less 8. Lower Level 8.1. Sand filter FD 34003 8.1.1. Possible release of 8.1.1.1. Drain valve is in view Ensure that water draining facility TOYO
drain valve left open. LPG to atmosphere of LG. from sand filter conforms to the
(regulating valve is shown configuration of valves in line with
connected to open drain) relevant OISD standard.

Normal draining of water from sand TOYO

fliter should be to a closed system...
PHAWorks by Primatech Inc.
 Action Items

Company: Page: 4 of 9
Facility:

GW DEVIATION CAUSES CONSEQUENCES SAFEGUARDS RECOMMENDATIONS BY

Less 8. Lower Level 8.1. Sand filter FD 34003 8.1.1. Possible release of 8.1.1.1. Drain valve is in view ...(CCBD) with blind position
(cont.) (cont.) drain valve left open. (cont.) LPG to atmosphere of LG. (cont.) indicated as "open".
(regulating valve is shown
connected to open drain)
(cont.)

Session: (1) 7/15/2010 Revision:

Node: (1) LPG Treatment: Untreated LPG from B/L through caustic contactors to B/L as treated LPG
Intention: The coker LPG received from DCU will be washed with 12% caustic in caustic wash contactor to remove the balance H2S content. Then it is routed to 1st and 2nd stage
CFC caustic wash contactor through filters FD 34001 A/B where it comes in contact with circulating caustic solution. Both caustic and LPG flow cocurrently through the film
contactor. At the outlet, both the phases are seperated and LPG exists from the top of the vessel to the inlet of the 2nd stage contactor. Similar cocurrent contact with
circulating caustic solution takes place in the 2nd stage contactor. Treated LPG passes through a coalescer in the same vessel to remove any caustic solution. Treated
caustic from 2nd stage is cooled in the LPG cooler EA 34001 and routed to storage under back pressure controller after being routed through a sand filter. Provision
available to divert LPG to offspec storage. LPG, CFC unit bypass line joins the LPG rundown line to offspec storage at B/L.
Drawings: 6782-EPCC3-TO-PDD-DW-30-340-1111, 6782-EPCC3-TO-PDD-DW-30-340-1112, 6782-EPCC3-TO-PDD-DW-30-340-
1113, 6782-EPCC3-TO-PDD-DW-30-340-1116.
Parameter: Others
GW DEVIATION CAUSES CONSEQUENCES SAFEGUARDS RECOMMENDATIONS BY
Other 10. Other Than 10.1. Tube leak in LPG 10.1.1. Potential 10.1.1.1. LPG cooler is Consider upgrading the design PMC/TO
Than Others cooler EA 34001. overpressurization in the designed to 10/13 rules and pressure of cooling water inlet and YO
cooling water side. no overpressurization of this outlet line upto the isolation valves,
equipment is foreseen. to that of cooler EA 34001 tube
(However, the inlet and outlet side.
piping do not confrom to this
10/13 rule.)

PHAWorks by Primatech Inc.

 Action Items

Company: Page: 5 of 9
Facility:

Session: (1) 7/15/2010 Revision:

Node: (2) LPG Treatment:Caustic Solution circulation from CFC 2nd stage to inlet of Regenerator
Intention: Caustic separated in the 2nd stage CFC will be routed to 1st stage CFC through interstage caustic circulation pumps GA-34003 A/B under level control. The spent caustic
generated in 1st stage CFC flows to regenerator column DA 34002 under level control after preheating in caustic heater EA 34002 (by LP steam). Proprietory Catalyst is
added intermittently to the feed spent caustic stream to regenerator column DA 34002.
Drawings: 6782-EPCC3-TO-PDD-DW-30-340-1112, 6782-EPCC3-TO-PDD-DW-30-340-1113, 6782-EPCC3-TO-PDD-DW-30-340-
1114.
Parameter: Flow
GW DEVIATION CAUSES CONSEQUENCES SAFEGUARDS RECOMMENDATIONS BY
More 12. More Flow of 12.2. LIC 011 malfunctions 12.2.1. Loss of interface level 12.2.1.1. LALL 012 (2 o o 3) Ensure that the configuration of PMC
circulating caustic and opens LV 011 in the in 1st stage wash contactor. provided in the 1st stage LALL 012 trip system is reliable
outlet line from 1st stage Possible LPG breakthrough wash seperator which will enough to prevent
contactor. to regeneration column. activate Interlock (I-2) and overpressurization of regeneration
Potential overpressurization. close UV 011. column due to LV 011 failing in
open position. Also, presence of
12.2.1.2. PSV 031 A/B excessive HC in the regenerator
provided on regenerator may be hazardous.
column.

12.2.1.3. PAH 031 provided

on regenerator column.

Session: (1) 7/15/2010 Revision:

Node: (2) LPG Treatment:Caustic Solution circulation from CFC 2nd stage to inlet of Regenerator
Intention: Caustic separated in the 2nd stage CFC will be routed to 1st stage CFC through interstage caustic circulation pumps GA-34003 A/B under level control. The spent caustic
generated in 1st stage CFC flows to regenerator column DA 34002 under level control after preheating in caustic heater EA 34002 (by LP steam). Proprietory Catalyst is
added intermittently to the feed spent caustic stream to regenerator column DA 34002.
Drawings: 6782-EPCC3-TO-PDD-DW-30-340-1112, 6782-EPCC3-TO-PDD-DW-30-340-1113, 6782-EPCC3-TO-PDD-DW-30-340-
1114.
Parameter: Temperature
GW DEVIATION CAUSES CONSEQUENCES SAFEGUARDS RECOMMENDATIONS BY
More 17. Higher 17.1. TIC 031 malfunctions 17.1.1. Ineffective 17.1.1.1. FAH 032 provided Consider provision of TAH on TI TOYO
Temperature and opens TV 031 in the LP regeneration and catalyst in the steam line to the inlet 034 in the caustic inlet to
steam line to caustic heater. activity may reduce leading to of caustic heater. regenerator.
Offspec LPG.

PHAWorks by Primatech Inc.

 Action Items

Company: Page: 6 of 9
Facility:

Session: (1) 7/15/2010 Revision:

Node: (2) LPG Treatment:Caustic Solution circulation from CFC 2nd stage to inlet of Regenerator
Intention: Caustic separated in the 2nd stage CFC will be routed to 1st stage CFC through interstage caustic circulation pumps GA-34003 A/B under level control. The spent caustic
generated in 1st stage CFC flows to regenerator column DA 34002 under level control after preheating in caustic heater EA 34002 (by LP steam). Proprietory Catalyst is
added intermittently to the feed spent caustic stream to regenerator column DA 34002.
Drawings: 6782-EPCC3-TO-PDD-DW-30-340-1112, 6782-EPCC3-TO-PDD-DW-30-340-1113, 6782-EPCC3-TO-PDD-DW-30-340-
1114.
Parameter: Others
GW DEVIATION CAUSES CONSEQUENCES SAFEGUARDS RECOMMENDATIONS BY
Other 20. Other Than 20.2. Heat loss from 20.2.1. Regeneration process 20.2.1.1. Sample point SC-4- Consider insulation (IH) on caustic TOYO
Than Others regeneration column due to will be adversely afected. 011 provided in the LPG run heater outlet line & Regeneration
lack of insulation. down line. column to conserve heat to ensure
proper regeneration reaction.

PHAWorks by Primatech Inc.

 Action Items

Company: Page: 7 of 9
Facility:

Session: (1) 7/15/2010 Revision:

Node: (6) LPG Treatment:Naptha from B/L to solvent wash contactor and then to B/L
Intention: Naphtha is used as a solvent for removing DSO from regeneration column to B/L . Naphtha is received at B/L at about 5 kg/cm2g and boosted to about 9 kg/cm2g. This
Naphtha is routed to CFC solvent wash contactor under differential pressure control. The naphtha containing DSO is seperated in wash seperator where it forms the upper
layer. This is pumped by solvent circulation pump and routed to B/L through sand filter under flow control. A portion of the pump discharge is recirculated back to the
contactor under flow control. It was decided to record observations and findings under the general guide words "Others"
Drawings: 6782-EPCC3-TO-PDD-DW-30-340-1115, 6782-EPCC3-TO-PDD-DW-30-340-1116, 6782-EPCC3-TO-PDD-DW-30-340-
1118.
Parameter: Others
GW DEVIATION CAUSES CONSEQUENCES SAFEGUARDS RECOMMENDATIONS BY
Other 24. Other Than 24.1. FIC 052 in the solvent 24.1.1. CFC solvent wash 24.1.1.1. PDIC 041 between Examine the design pressure 9 PMC
Than Others + DSO line to B/L contactor, sand filter and regeneration column and kg/cm2g of CFC wash contactor DC
malfunctions and closes FV associated piping may be CFC solvent wash contactor 34002 in view of the shutoff
052 (FC type). subjected to shutoff pressure will close PDV 041 in the pressure of fresh solvent pump GA
of fresh solvent pump GA Naphtha inlet line. 34006 A/B being 20.3 kg/cm2g.
34006 A/B. This may cause Provide measures as required.
the design pressure of the 24.1.1.2. FAL 043 provided in
vessel to be exceeded. (PSV the naphtha inlet line to CFC
041 A/B provided on CFC solvent contactor.
solvent wash contactor.
However, this is not suitable
for this scenario.)

PHAWorks by Primatech Inc.

 Action Items

Company: Page: 8 of 9
Facility:

Session: (2) 7/16/2010 Revision:

Node: (7) Caustic storage and pumping system
Intention: 20% caustic is received in FB 34001, where it is diluted to about 12% normally with DM water. The circulation facility with jet eductor is provided for this purpose. Sampling
facility provided to monitor the quality. Metering pump provided to inject this 12% caustic to process as and when required. Tank is provided with overflow line connected to
CCBD. Tank is located in a curbed area to contain the spillage if any. Similarly, tank FB 34002 is provided to receive 20% caustic. This caustic is supplied to process by
metering pump continuously. No dilution of this caustic is foreseen. Overflow line is provided, connected to CCBD. Provision is also available to supply 20% caustic to DCU
naphtha wash section for supplying makeup caustic as and when required through 20% fresh caustic pumps GA 34007 A/B. It was decided to record observations and
findings under the general guide words "Others"
Drawings: 6782-EPCC3-TO-PDD-DW-30-340-1111 Rev 2; 6782-EPCC3-TO-PDD-DW-30-340-1115 Rev 2; 6782-EPCC3-TO-PDD-DW-30-340-1117 Rev 2
Parameter: Others
GW DEVIATION CAUSES CONSEQUENCES SAFEGUARDS RECOMMENDATIONS BY
Other 25. Other Than 25.1. DM water pump trips 25.1.1. Possible reverse flow Consider provision of NRV in the TOYO
Than Others while receiving in the tank of caustic into the DM water DM water inlet line to tank FB
FB 34001. line. 34001.

25.2. Overflow line
connected to CCBD with
hydraulic seal and siphon
breaking valve.
25.2.1. With the siphon Review the hydraulic seal provision TOYO/P
breaking valve remaining in with siphon breaker in the overflow MC
open position, HC vapour line from caustic tanks. The
from CCBD may escape to objective is to ensure that seal is
atmosphere or air may enter always maintained and no vapour
the system. If the siphon from CCBD can escape through
breaking valve is removed or siphon breaking valve.
closed, the hydraulic seal in
the overflow line cannot be
assured. This may cause
vapour from CCBD entering
the tank.

25.3. Metering pump GA 25.3.1. Possible reverse flow 25.3.1.1. Injection of caustic Provide check valve in the caustic TOYO
34004 A/B trips while of LPG into the fresh castic as a make up is operator injection line to caustic prewash
supplying to caustic tanks FB 34001/ FB attended operation. column to prevent reverse flow of
prewash column DA 34001. 34002. LPG into the tank.

Operating manual should highlight TOYO

the hazard associated with possible
reverse flow of LPG into the caustic
tanks and stress for following the
correct procedure and monitoring
the system during charging.

25.4. Caustic circulation
pump GA 34002 A/B trips
while supplying to caustic
prewash column DA 34001.
PHAWorks by Primatech Inc.
25.4.1. Possible reverse flow 25.4.1.1. This facility is used Provide check valve in the TOYO
of LPG into the CFC solvent during startup and is normally regenerated caustic line (CL-
wash contactor. Potential operator attended. 3400121) to caustic prewash
overpressure. column to prevent reverse flow of...
 Action Items

Company: Page: 9 of 9
Facility:

GW DEVIATION CAUSES CONSEQUENCES SAFEGUARDS RECOMMENDATIONS BY

Other 25. Other Than 25.4. Caustic circulation 25.4.1. Possible reverse flow 25.4.1.1. This facility is used ...LPG into the tank
Than Others (cont.) pump GA 34002 A/B trips of LPG into the CFC solvent during startup and is normally
(cont.) while supplying to caustic wash contactor. Potential operator attended. (cont.) Operating manual should highlight TOYO
prewash column DA 34001. overpressure. (cont.) the hazard associated with possible
(cont.) reverse flow of LPG into the caustic
tanks and stress for following the
correct procedure and monitoring
the system during charging.

25.5. Improper lining of 25.5.1. Possible gravitation 25.5.1.1. Operating Consider provision of check valve TOYO
caustic receipt from OSBL from one tank to other procedures in the caustic inlet line to each of
(Both tank inlet valves left causing operational problem the tank.
open) and overflow

25.6. Improper lining of
caustic receipt from OSBL
(Interconnecting valve
between outlet line of both
tanks open)
25.6.1. Possible gravitation 25.6.1.1. Operating Provide spectacle blind in the TOYO
from one tank to other procedures interconnecting line (CL-3400330)
causing operational problem for both the tanks.
and overflow

PHAWorks by Primatech Inc.

 Action Items - Index

Node 1: LPG Treatment: Untreated LPG from B/L through caustic contactors to B/L as treated LPG 1
Parameter: Flow 1
Parameter: Pressure 2
Parameter: Temperature 3
Parameter: Level 3
Parameter: Others 4
Node 2: LPG Treatment:Caustic Solution circulation from CFC 2nd stage to inlet of Regenerator 5
Parameter: Flow 5
Parameter: Temperature 5
Parameter: Others 6
Node 6: LPG Treatment:Naptha from B/L to solvent wash contactor and then to B/L 7
Parameter: Others 7
Node 7: Caustic storage and pumping system 8
Parameter: Others 8

PHAWorks by Primatech Inc.