Table for HAZOP Studies
St ID: 0419022037
Study node: Ammonia solution feed line to the DAP reactor
Parameter Guide word Possible causes
(deviation)
Flow No 1. Flow control valve A fail close
2. Sensor or flow indicator
failure
3. Plugging of line
4. Leakage or rupture in line
5. No feed material in the
ammonia solution storage
tank
High 1. Flow control valve A fail open
2. Sensor or flow indicator
failure
Possible consequences Existing safeguards
1. Possible accumulation
of unreacted
phosphoric acid into the
reactor if valve C is
closed
2. Unreacted phosphoric
acid carried over to the
DAP storage tank and
lead to corrosion
1. Possible accumulation
of unreacted ammonia
inside the reactor if
valve C is closed and
phase change due to
any increase in
temperature and
pressure leading to
explosion
2. Unreacted ammonia
carried over to the DAP
storage tank and
release into the
enclosed work area
Name: Mysha Momtaz
Required actions/
recommendations
1. Flow indicator and 1. No flow alarm
controller 2. Redundant flow control system
3. Independent and uninterrupted
power supply for control
system
4. Periodic maintenance and
inspection for valve A
1. Flow indicator and 1. High flow alarm
controller 2. Redundant flow control system
2. Pressure safety 3. Independent and uninterrupted
valve on the power supply for control
storage tank and system
reactor 4. Periodic maintenance and
3. Ammonia detectors inspection for valve A
and alarms 5. Flow control valve fail close
 Low 1. Partial failure of flow control
valve A or control valve
stiction
2. Plugging of line
3. Leakage or rupture in the line
4. Shortage of feed material in
the ammonia solution storage
tank
5. Operator sets ammonia
solution flow rate too low
1. Possible accumulation 1. Flow indicator and 1. Low flow alarm
of unreacted controller 2. Redundant flow control system
phosphoric acid into the 3. Independent and uninterrupted
reactor if valve C is power supply for control
closed system
2. Formation of an off- 4. Periodic maintenance and
specification product inspection for valve A
due to the abundance
of phosphoric acid in
the reactor
3. Unreacted phosphoric
acid carried over to the
DAP storage tank and
lead to corrosion

Temperature High 1. No adequate insulation 1. Phase change of
around the pipeline ammonia and possible
2. Unusual rise in ambient explosion due to
temperature increase in pressure
2. High energy release due
to high reaction rate at
high temperature
leading to explosion
Low 1. Unusual fall in ambient 1. No significant
temperature consequence
1. Pressure safety 1. Adequate insulation around the
valve on the pipeline
reactor and storage 2. Temperature Indicator in the
tank pipeline
3. High temperature alarm
4. Ammonia solution cooling
system
Pressure High 1. Temperature rise of ammonia 1. Possible explosion of 1. Pressure safety 1. Adequate insulation around the
solution reactor valve on the pipeline
reactor and storage 2. Temperature Indicator in the
tank pipeline
3. High temperature alarm
4. Ammonia solution cooling
system
Low 1. Plugging of line 1. Decrease in reaction 1. Ammonia detectors 1. Regular inspection and
rate and possible and alarms maintenance of pipeline
accumulation of condition
unreacted ammonia
inside the reactor
carried over to the
storage tank and
enclosed work area