HAZOP Worksheet

Date & Session:

System:
Node Number:

Node Description:
Drawings:

Intent:

Deviation

1. No Flow
2. Higher Flow
2. Higher Flow

3. Lower Flow
 4. Reverse Flow

Temperature 5. Higher Temperature

Pressure 6. Higher Pressure
Pressure 6. Higher Pressure

Viscosity 7. Greater viscosity

 8. Higher Level

Level

9. Lower Level
Tuesday, March 24, 2020
Supercritical Water Gasification (SCWG) of Corn Cob Waste
1
Absorber Tower (T-101) and the streams going directly in and out of
the absorber (ABSFEED, DEPGFD, CLEANH2, RICHOUT).
1

To remove CO2 from products of SCWG reaction for high purity H2.

Cause

Pipe rupture at DEPGFD due to possbility of pressure surge from P-

102 / P-103 failure / breakdown.

Pipe rupture at ABSFEED due to possibility of pressure surge from K-

101 compressor.
P-102 and/ or P-103 break down.

Insufficient cooling water in reactor effluent coolers E102 to E105,

increased temperature in D-101.

Leakage in the nozzles of D-101 and drop in pressure.

Overheating of stream in E-109 and increased temperature in D-
102.

Leakage in the nozzles of D-102 and drop in pressure.

DEPG-P has no flow due to clogging in purge pipe with char

resulting in full recycle of DEPG-REC.

Pipe leakage along DEPGFD.

Pipe leakage along ABSFEED.

Pump head produced by P-103 is insufficient to drive recycle flow
due to too much pressure loss along the pipe and hydraulic issue,
hence back flow of DEPGFD to T-101

Insufficient cooling utility in E-102 to E-105 or insuffient piping

insulation

Insufficient piping insulation along G101OUT to D101FEED

Excessive heating utility in E-109, E-111, E-112

Fouling of E-106/E-107 resulting in lower heat transfer efficiency

and hence less cooling effect from utility streams.
Insufficient cooling utility in E-106 and/or E-107,

Plugging of ABSFEED pipe from char deposition due to incomplete

removal of char by cyclones C-101 and C-102.

Insufficient cooling utility in E-102 to E-105.

Excessive heating utility in E-109, E-111, E-112.

Insufficient cooling utility in E-106 and/or E-107.

Line RICHOUT gets plugged due to char deposition due to

incomplete removal of char in cyclones C-101 and C-102

Too much cooling in E-106 and/or E-107

Line RICHOUT gets plugged due to char deposition due to
incomplete removal of char in cyclones C-101 and C-102.

Throttle valve V-102 gets plugged due to char deposition due to

incomplete removal of char in cyclones C-101 and C-102.

Increase in DEPGFRES due to P-102 pump motor malfunction.

Leakage in bottom nozzle of T-101.

 Consequence Freq Sev Risk Safeguards

Loss of containment of DEPG. Prolonged

contact with DEPG may cause skin
irritation. Prolonged and excessive
inhalation of DEPG can cause adverse
effects.
Shrapnel from ruptured pipes can injure
workers.
Accumulation of flammable DEPG.

3 5 15 (H) -

Loss of containment of flammable gases 1.1-a

H2, CH4, CO. Potential to combust CH4
1.1-b
and H2 if near spark source. With CO2
c. Reciprocating
under high pressure, contact with it can
compressor was
cause rapid suffocation. Shrapnels from
used, so compressor
explosion of pipes can injure workers.
surge unlikley

3 5 15 (H)
No liquid feed to T-101, no cooling of
vapour entering T-101. Potential
flammability hazard from hot surface
ignition and increasing temperature of T-
101 such that it reaches Hydrogen ignition
temperature.

f. T-101 operating at
2 5 10(M) room temperature

Increases vapour-liquid separation in D-

101, resulting in higher vapour flow of
ABSFEED.
Pressure in T-101 buildup.
Higher pressure in gas outlet pipe
CLEANH2 which can result in pipe rupture.

Loss of containment of flammable gases

H2. Potential to combust H2 if near spark
source. Shrapnels from explosion of pipes
can injure workers.

a. T-101 operating
pressure is 1.1 times
3 5 15 (H) of design pressure.

Same as above.

1.2-a
1.2-b
3 5 15 (H)
Increased vapour-liquid separation in D-
102, resulting in higher vapour flow of
F1RECYCL and ABSFEED.
Pressure in T-101 buildup.
Higher pressure in gas outlet pipe
CLEANH2 which can result in pipe rupture.

Loss of containment of flammable gases

H2. Potential to combust H2 if near spark
source. Shrapnels from explosion of pipes
can injure workers.

1.2-a
1.2-b
3 5 15 (H)

Same as above.

1.2-a
1.2-b
3 5 15 (H)

Higher liquid flow in T-101.

Pressure in T-101 buildup.
Higher pressure in gas outlet pipe 1.1-d
CLEANH2 which can result in pipe rupture. 1.2-a
1.2-b
4 5 20 (H)

Loss of containment of DEPG. Prolonged

contact with DEPG may cause skin
irritation. Prolonged and excessive
inhalation of DEPG can cause adverse
effects.
Accumulation of flammable DEPG. 1.1-a_x000D_
1.1-b_x000D_
3 4 12 (M) 1.1-d

Loss of containment of flammable gases

H2, CH4, CO. Potential to combust CH4
and H2 if near spark source. With CO2
under high pressure, contact with it can
cause rapid suffocation.
1.1-a_x000D_
1.1-b_x000D_
3 4 12 (M) 1.1-d
Too little liquid feed to T-101, less cooling
of vapour entering T-101. Potential
flammability hazard from hot surface
ignition and increasing temperature of T-
101 such that it reaches Hydrogen ignition
temperature.

2 5 10(M) 1.1.f

Higher temperature in D-101, resulting in

higher separation efficiency in D-101.
Higher vapour flow in T-101, resulting in
pressure buildup in T-101. a. Material used to
Higher temperature of gas ABSFEED into build T-101 is SS316,
T-101, resulting in overheating of T-101. T- which can withstand
101 could lose its material strength and temperatures up to
result in higher susceptibility to material 800degC.
damage and corrosion. 1.2-a
Higher pressure in gas outlet pipe 1.2-b
CLEANH2 which can result in pipe rupture. 3 5 15 (H) 1.2-c

1.2-a
1.2-b
Same as above. 3 5 15 (H) 1.2-c

Higher temperature of gas ABSFEED into

T-101, resulting in overheating of T-101.
Pressure buildup in T-101. T-101 could
lose its material strength and result in
higher susceptibility to material damage 1.2-a
and corrosion. 1.2-b
Higher pressure in gas outlet pipe 1.5-a
CLEANH2 which can result in pipe rupture. 3 5 15 (H)

1.2-a
1.2-b
1.5-a
same as below 3 5 15 (H)
Higher temperature of DEPGFD into T-101,
resulting in overheating of T-101. Pressure
buildup in T-101.
T-101 could lose its material strength and
result in higher susceptibility to material 1.2-a
damage and corrosion. 1.2-b
Higher pressure in gas outlet pipes 1.5-a
CLEANH2 which can result in pipe rupture. 3 5 15 (H)

Same vapour flow rate but through a

smaller cross-sectional area, resulting in
higher pressure in ABSFEED pipe which
can result in pipe rupture.

Loss of containment of flammable gases

H2, CH4, CO. Potential to combust CH4
and H2 if near spark source. With CO2
under high pressure, contact with it can
cause rapid suffocation. Shrapnels from 1.1-a
explosion of pipes can injure workers. 1.1-b
1.1-d
4 5 20(H) 1.1-e

Higher temperature in D-101, resulting in

higher separation efficiency in D-101.
Higher vapour flow in T-101, resulting in
pressure buildup in T-101. a. Material used to
Higher temperature of gas ABSFEED into build T-101 is SS316,
T-101, resulting in overheating of T-101. T- which can withstand
101 could lose its material strength and temperatures up to
result in higher susceptibility to material 800degC.
damage and corrosion. 1.2-a
Higher pressure in gas outlet pipe 1.2-b
CLEANH2 which can result in pipe rupture. 3 5 15 (H) 1.2-c

Higher temperature of gas ABSFEED into

T-101, resulting in overheating of T-101.
Pressure buildup in T-101. T-101 could
lose its material strength and result in
higher susceptibility to material damage 1.2-a
and corrosion. 1.2-b
Higher pressure in gas outlet pipe 1.5-a
CLEANH2 which can result in pipe rupture. 3 5 15 (H) 1.5-c
Higher temperature of DEPGFD into T-101,
resulting in overheating of T-101. Pressure
buildup in T-101.
T-101 could lose its material strength and
result in higher susceptibility to material 1.2-a
damage and corrosion. 1.2-b
Higher pressure in gas outlet pipes 1.5-a
CLEANH2 which can result in pipe rupture. 3 5 15 (H) 1.5-e

Liquid accumulation at bottom of tower.

Pressure buildup in T-101, backflow occurs 1.2-a
in DEPGFD and ABSFEED. 1.2-b
Accumulation of flammable DEPG also 1.2-j
poses a fire hazard. 4 5 20 (H) 1.6-a

Higher viscosity of DEPG results in

pumping, mixing and mass transfer issues.

Potential plugging of DEPGFD and

RICHOUT pipes, resulting in pressure
buildup in pipes and possible explosion.

Loss of containment of DEPG. Prolonged

contact with DEPG may cause skin
irritation. Prolonged and excessive
inhalation of DEPG can cause adverse
effects.
Shrapnel from ruptured pipes can injure
workers. 1.1-a
Accumulation of flammable DEPG. 3 5 15 (H) 1.1-b
Liquid accumulation at bottom of tower.
Pressure buildup in T-101, backflow occurs 1.2-a
in DEPGFD and ABSFEED. 1.2-b
Accumulation of flammable DEPG also 1.2-j
poses a fire hazard. 4 5 20 (H) 1.6-a

1.2-a
1.2-b
1.2-j
1.6-a
1.8-b
Same as above. 4 5 20 (H) 1.8-c

1.1-g
1.2-a
1.2-b
1.8-b
Same as above. 4 5 20 (H) 1.8-c

Pressure decay in T-101

Loss of containment of flammable
material in T-101 such as H2 and DEPG.
a. Thickness of T-101
Prolonged contact with DEPG may cause has accounted for
skin irritation. Prolonged and excessive any material defects
inhalation of DEPG can cause adverse (0 severity for ASM)
effects. 3 5 15 (H) 1.1-a
 Unmitigated Risk Recommendations

a. Wear PPE to protect workers from skin

irritation and flammable materials.
b. Install sturdy pipe casing (eg. steel casing
pipes) along DEPGFD.
c. Install pressure control loop to maintain
pressure along DEPGFD by controlling the P-
102 and P-103 flowrate using control valve.

15 (H)

d. Annual, semi-annual and/or quarterly

maintenance inspection on piping.
e. Install pressure control loop to maintain
pressure along ABSFEED by changing the flow
rate of the discharge line connected to
ABSFEED.

5 (M)
 g. Install spare pumps in parrallel.

5(M)

b. Install appropriately sized pressure relief

valve at T-101.
c. Install temperature control loop to maintain
D-101 temperature by changing E-102 to E-105
utility streams' flow rate using control valves.

10 (M)

d. Install vessel leak detectors and alarms at

the nozzles of D-101.
e. Annual, semi-annual and/or quarterly
5 (M) maintenance checks on D-101.
 f. Install temperature control loop to maintain
D-102 temperature by changing E-109 utility
stream flow rate using control valves.
5 (M)

g. Install vessel leak detectors and alarms at

the nozzles of D-102.
h. Annual, semi-annual and/or quarterly
5 (M) maintenance inspections on D-102.

i. Install flowrate control loop to maintain

flowrate along DEPG-REC by changing the
flowrate along DEPGFRES using control valve.
j. Use appropriate chemical solvents during
5 (M) maintenance to remove char deposition.

3 (L)

3 (L)
5(M) b. Install check valve at the outlet of P-103

3 (L)

b. Install piping insulator along G101OUT to

4(L) D101FEED.

c. Install ____ control loop to maintain

temperature of T-101 by changing E-109, E-111
and E-112 utility streams' flowrate using
4 (L) control valves.

d. Annual, semi-annual and/or quarterly

4 (L) maintenance inspections on E-106/E-107.
 e. Install ____ control loop to maintain
temperature of T-101 by controlling E-106
and/or E-107 utility streams' flowrates using
4 (L) control valves.

a. Collect sampling of char conc in the cyclone

discharge regularly.
(add sampling point in P&ID), can use as
4 (L) safeguard for other relevant cause below)

3 (L)

3 (L)
3 (L)

4 (L)

a. Install temperature control loop to maintain

temperature of DEPGFD by changing E-106
and/or E-107 utility streams' flowrates using
5 (M) control valves.
 b. Add spillover line at bottom of T-101 to drain
excess liquid to organic waste storage
c. Install high level alarm with level indicator
below the spill over line (95% of the spillover
4 (L) line).

2(L)

d. Install ___ control loop to maintain liquid

level in the 2nd tray of T-101 by changing the
flow rate of DEPGFRES using control valve.

4(L)

b. Install vessel leak detectors and alarms at

the bottom nozzle of T-101.
c. Bund wall surrounding T-101 to contain any
overwhelming leakage and a drainage system
to organic waste storage.
d. Annual, semi-annual and/or quarterly
maintenance inspections on T-101.
5 (M)
 Comments

https://www.researchgate.net/publication/291411920_Comparison_of_SelexolTM_and_RectisolR_Technologies_in_an_In

http://www.sjgov.org/commdev/cgi-bin/cdyn.exe/handouts-mtnhouse_EIR_Appendix_K_Pipeline_R?grp=handouts-mtnh
http://www.desware.net/Sample-Chapters/D09/E6-165-07-00.pdf

Template for writing control loops:

install ___ control loop to maintain CV by
changing MV using ___

Also consider feed DEPG pump (P-102) or recycle

DEPG pump (P-103) breakdown as cause, conseq:
flooding-->liq accum in
SS316 info -> https://askzn.co.za/stainless-
steel/tech-grade-316.htm
SS316 info -> https://askzn.co.za/stainless-
steel/tech-grade-316.htm
https://www.ncbi.nlm.nih.gov/pmc/articles/PMC5551143/ http://www.ipcbee.com/vol24/

reference for change in viscosity of DEPG with

temperature:
https://www.sciencedirect.com/science/article/pii
/B9780128015667000087 https://bre.com/PDF/A-Compar
https://suw.biblos.pk.
edu.pl/downloadReso
urce&mId=502589
http://www.ipcbee.com/vol24/67-ICBEC2011-C20031.pdf

https://bre.com/PDF/A-Comparison-of-Physical-Solvents-for-Acid-Gas-Removal-REVISED.pdf
latest flow diagram 23/3/20
Take Note, Turbine will be placed along PRFLOUTT