What lflchecklist 8-1

CHAPTER 8

What IflChecklist

What If
Preparation
Assemble drawings.
Assign nodes.
Prepare checklist.

Assemble Team
Explain process.

Commence Analysis
Add additional checklist items at the end of review of individual nodes.

Proceed on Same Basis as HAZOP

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 What IflChecklist 8 -2

Advantages and Pitfalls

Advantages

Interesting for participants.

Usually very productive with experienced team.
Versatile: No litniting formats or constraints.

Pitfalls

May not cover all cases.

Very dependent on experience of team members.
Dependent on obtaining/creating/using good cl~ecklists.

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What IfIChecklist 8-3

Checklist
Available checklists, other data and your own experience may be used to create Checklists.
Failing that, or in addition, you can use the following to assist with the preparation:

1. What does the equipment actually do? In what ways can the equipment actually
fail?

2. What are the major hazards associated with the material being handled by the
equipment?

3. What potential interactions between upstream or downstream equipment or

conditions could lead to problems?

4. Could an external event give problems?

5. Could supporting utility failure(s) give problems?

6. Could environmental conditions give problems, e.g., low temperatures?

7. Could individual component failures, e.g., control valves, level switches, give
problems?

8. Any problems with start-up or shut down?

9. Any problems maintaining equipment or individual components?

10. Sparing philosophy, equipment reliability?

11. Instrumentation & control system failures: what will happen?

12. Are there adequate protective systems? If so, how about redundancy?

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 What lflchecklist 8 -4

13. Have you considered:

Power failure?
Iilstruinent air failure?
Cooling water failure?
Steam failure'?
Have effects of all of these been considered in relation to flare system
sizing?

14. Do system components, e.g., contr"o1valves, fail safe?

15. Have you considered:

Equipment isolation?
Drainage?
Venting?
Blinding?
Emergency interlocks?

16. Have you considered any special operations, e.g., yreszrlfiding, on-site cata1j)st
loading/unloading, on-site regeneratiorz, etc. ?

17. Have you looked at coininon problems, such as:

High pressurellow pressure interfaces?

Possibility of reverse flow?
Chances of seal ruptures?
Equipment plugging?
Gas breakthrough on level control failure?
Bypasses being left open around control valves?
Tube ruptures in furnaces and heat exchangers?
Water hammerltwo phase flow damaging lines?
Stress corrosion cracking e.g., stainless steel in presence of chlorides?

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What IflChecklist 8-5

Checklist Applied to a Furnace Oil Heater

1. The Functionality of the Furnace Oil Heater

Furnace heats the oil and vaporizes it

Uses natural gas to heat oil
Controls the flow of oil
Containment of oil in tubes
Controls the temperature of oil
Maintains negative pressure in the furnace
Controls combustion air through grating
Controls natural gas pressure
Pilot flame ensures combustion

The following are some general what if questions for the Furnace Oil Heater:

a. What if heating is lost?

b. What if the oil gets over heated?
c. What if there is a disruption in the natural gas supply?
d. What if the flow of oil is too low?
e. What if the flow of oil is too high?
f. What if the tubes containing the oil, ruptures?
g. What if the temperature of the oil is too high?
h. What if the temperature of the oil is too low?
i. What if there is too little combustion air?
j. What if there is too much combustion air?
k. What if the gas pressure is too low?
1. What if the gas pressure is too high?
m. What if the pilot is extinguished?
n. What if the Pilot doesn't initiate the flame?

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2. Major Hazards

a. What if the tube containing the oil ruptures?

b. What if there is insufficient purging? (fire box explosion a possibility)

3. Flam~nableRelease (Upstream /Down stream conditions)

a. What if the tubes containing the oil rupture?

b. What if there is insufficient purging?
c. Is there a firewall protection?

4. Control

a. Is the temperature of coil adequately controlled'?

b. Is the Firebox pressure controlled /regulated?

5. Worst eventlworst Credible Scenarios

a. What are the mitigation steps taken to reduce the effects of fire box explosion?
b. What are the mitigation steps taken to reduce the effects of tube rupture?
c. What are the mitigation steps taken to reduce the effects of vapor cloud
explosion?

6. Supporting Utilities

a. Is the co~nbustionair regulated?

b. Is the natural gas supply continuous? Chances of interruption?

7 . Process Side

a. Is the temperature in the process area monitored and maintained at acceptable

level?

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What IfIChecklist 8-7

8. Individual Component Failures

a. Are there any controls to regulateldetect high pressure on tube side? Are they fail
safe?
b. Could heater be source of ignition for the vapor cloud release of flammable?

a. Are the CVs or controllers open?

b. Are there extra temperature monitors to detect temperature fluctuations during
emergency shut down?
c. Is the cooling water system linked to the emergency shutdown?

10. Are there sufficient monitorslalarm switches to detect:

a. local tube overheating

b. high firebox pressure
c. loss/escape of pilot flame

1 1. Emergency Shut Down

a. Will furnace trip on, on power failure?

b. Will furnace trip on, on loss of instrument air? Are controls fail safe if the
instrument air is disrupted?
c. Will the furnace trip on, on loss of process/utility flows?
d. Will furnace trip on, on loss of steam?

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 What lfichecklist 8-8

a. Are flow control valves fail safe on loss of actuating medium (e.g., instrument air
failure)?

b. Is the PSV sized to take the vaporization load?

c. Is the heater located upwindldown wind?

d. Has an integrity check been made of the burner?

e. If relief valve could plug or coke up, is a purge stream (e.g., steam) included?

f. Have decoking provisions been reviewed?

g. Are there emergency shut off valves?

h. Are coil drains provided?

i. Is there adequate venting in place?

j. Are there spectacle blinds provided at all process inlets and outlets?

k. If process flow is lost will burner shut down?

1. Are there adequate highllow pressure alarms on fuel gas & pilot gas provided?

m. What if reverse flow into the firebox occurs in the event of tube failure?

n. Are emergency shutoff valves installed on fuel lines?

o. If burner tip is plugged, could atomizing stream cause higher pressure than fuel?

p. Are emergency shut down valves separate from control valves?

q. What if bypasses are left open around control valves?

r. What mitigation steps are taken to reduce the effects of tube rupture in the
furnace?

s. Are valve closure times low enough to prevent water hammer?

t. Are piping materials suitable for maximum possible operating temperatures?

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What IfIChecklist 8-9

What If Example
Figure 8-1: P&ID of Ammonia Refrigeration Unit

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 What lflchecklist 8-10

Figure 8-2: Process Flow Diagram

PROCESS FLOW SKETCH FOR ANIIYDROISS AMMONIA REFRlGERATlON UNIT
XYZ Cald Storape Cornoration

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What IfIChecklist 8-1 1

Table 8-1: Thermodynamic Properties of Saturated Ammonia by Temperature

M 80.19 1.112 R M S.284 20.04 (LO73 847.3 0.0387 1.0746 38.00 0.39%
60 107.6 1.120 0.02587 &R1 81.28 2818.1 848.4 03814 18888 38.W O m
m 128.8 1.118 0.02634 2.812 4X.M 608.8 MIS 08848 1.0482 98.00 0.4325
80 1638 1.188 0.02683 1.868 M.08 4S8.7 56e.8 0.1041 1.0283 37.48 OH16
90 180.8 1.147 O.OPmt 1.881 66.66 488.6 664.1 0.12110 18188 35.W 0.6018

m& I 1 1 0~?668 I . . . . . 1 1
1 I
1857 ..... (886) 0 .... ..... ..... 14.6 ......
'Dttrhom~dS~CirCOL(IYn142 B w Te:- 32F.
(smThe (igutes m pclraattuui~swen calcu*tsd tm empirical equsths givsa in BWP Df S~lndardsScienMc ppan IDS.
313 sad 316 ad -dm
abtsinsd b l srtmpobtk k q w d lha nass caacsd In the ergshlatsl wwk.

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 What lflchecklist 8-12

Table 8-2: Worksheet for What If Analysis Example

,_ _^ _^_^ - ---- -
Subsystems: 1.1. Rec k;:::
Type: Vessel I dr

- --- -- --- -- - -- * - - -
- i *a

k
Operating ConditionsIParameters: 138 psig, 76°F
*:%eK~%f&W=%$&b*b,
SXb ?tYb> "&%L&WL%%&W\B~B%&
AS&?
%
i
$ m W ~ w ~ @ qP ~
$ a ~~ & ~ & +A@&*VL
?k ~ % s W% 6 5' 9%

What If Responsibilitie
S

, -- -- - -
I . Overfilling? Anna D

Nigel W

2. Level too Geoff B

low?

3. Pressure Steve L
exceeds design
specifications?

Anna D

4. Level gauge Nigel W

(LG- I0 1)
breaks?
5. Level
transmitter
(LT-101) fails?
&
&
=
--

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 What IfIChecklist 8-13

Subsystems: 1.2. Accumulator V-002 Drawing: ARU-A 1

r
Type: Vessel
Operating ConditionsIParameters: 35 psig, 2 1.7"F I 1

into condenser

do not result in
I

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 What lflchecklist 8-14

( "" _ " -_---- - - - - - - - * " - - - - -

What If Causes Consequences Risk Safeguards j Recommendations Responsibilitie
Matrix S
- J

S / L RR
, -- ""-" -.-- - - - -
' i ,3--
"

2. Level too 2.1. LV-20 1 or 2.1. 1" 2.1. Level 3. Acc~uinulator / Geoff B
low? controller LC- Accumulator G a ~ ~ g e / should be large
20 1 tends to einpty (LG- 102) I enough to ensure the
malfunctioning fill1 contents of the
j receiver.
2.2. Damage to 1 16. Level Alann Low Geoff B
Piimp 1 (LAL- 201)
I

3. Pressure 3.1. Fire case 3.1. Release of 3.1. High 14. Ensure fire Steve L
exceeds design ammonia point vent monitors and
specifications? through relief 1
extinguishers are
system ; nearby
3.2. Some fire
hazard in
vicinity 15. Locate relief valve Anna D
1 vents in a safe
3.3. Hazard to ! location.
personnel in
vicinity
4. Level gauge 4. I. Physical
(LG- impact from
4.1. Hazard to
personnel in
4. I. None 1 6. Provide annor
plated level gauges
Nigel W

102)breaks? wrench vicin~ty

-- ---- *- - /_ -- I_ - -^__

5. Low 5.1. 5.1. Steel can 5.1. None 8. Check need for Geoff B
temperature Depressuring to shatter if ' Charpee Tested
embrittlement? atmosphere on ~mpactedby Carbon Steel
pressure let wrench I
--- - - -- * I
down during
5.2. Hazard to I
inaintenance i
personnel in
. . . I
r " -
6. Toxic or 6. I. Release 6.1. Hazard to 6.1. None i 9. Self contalned Nigel W
hazardous from joints or personnel in 1 breathing apparatus
" - -
' service? flanges during vicinity
- *

maintenance
1 10. Biiddy system Nigel W
' 1 1. Develop Anna D
/1 operational
procedures
" " -
1

7. Vortex on 7. I . Low l i q ~ ~ i d7.1. Loss of 7. I . Level 12. Install Vortex Roy S

liquid level in V-002 perforinance Gauge j breaker
' discharge? (LG-102) ' 16. Level Alann Low Geoff B
(LAL- 20 1 )
322iW J~$-E*&~&(-=
~ k + t + 5 '>MI% r? ti zT&T%..& a ,lwm .J<h

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 What IfIChecklist 8-15

Table 8-3: Recommendations Report for a What If Analysis Example

Recommendation Drawing
Is
Establish operational procedures for inventory control of ammonia ARU-A 1
Design to ensure that inventories of ammonia in receiver and accumulator plus piping are ARU-A 1
compatible and do not result in flooding.
(Accumulator should be large enough to ensure the full contents of the receiver. I MU-A 1
4. 1 Ensure fire monitors and extinguishers are nearby I ARU-A 1
Locate relief valve vents in a safe location.
Provide armor plated level gauges IARu-A 1
No action required.

' 8. /Check need for Charpee Tested Carbon Steel

Self contained breathing apparatus
Buddy system ARU-A 1
' 11. 1 Develop operational procedures
Install Vortex breaker IARu-AI --

Install high-limit stops on all control valves: TV-301, 302, FV 30 1,302 ARU-
A1
Operating procedure for setting temperature controls TIC-301, 302

Install High Level Alarm V-002 ARU-

IAl
Level Alarm Low (LAL- 20 1) ARU -
A1

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 SUGGESTED READING (URLs current at time of publication)
"Guidelines for Hazard Evaluation Procedures" by AIChE, CCPS, 2'Id edition, 1992 plus
"Guidelines for Hazard Evaluation Procedures" by AIChE, CCPS, 1st edition, 1985
www.aiche.or~!pubcat/~eac1tl.as~~'!Act=C~&C~ate.~ory=S~ct3&Mi1i=20
"Use 'What i f method for process hazard analysis" by L.Zoller, J.P.Esping, Hydrocarbon
Processing, January 1993, pages 132-B to 1 32-G
www.hvdl~ocurbonprocessing.com/co~itents
'pub1 ications::'hpi

"Speed Your Hazard Analysis with the Focused What If?" by L.Goodman, Chemical
Engineering Progress, July 1996, pages 75 to 79
www.cepniagazinc.org/
"Process Safety Review Checklist", University of Florida, (Website)
t l~caltli/~~rocess
I~tt~:!lpie.cl~e.ii~l.ed~1/g~1i~1~~~s;~f checklist.html
"Process Hazards Analysis" by I.Sutton, published by SWISutton & Associates, 2002
prlia.slltml
ht tp://www.swbooks.cc~~n~!L~ooks/bool

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