4.1.1 HAZOP Worksheet-Ammonia Unit-Raw - India Project

中国五环工程有限公司
WUHUAN ENGINEERING CO., LTD.

地址: 中国武汉市东湖新技术开发区民族大道1019号(430223)Address: 1019 Minzu Road, Wuhan 430223, PR China
Website: www.cwcec.com Tel: +86-27-81926149 Fax: +86-27-81928302
HAZOP Worksheet
Node: 1. Syn Gas feed to Syn gas compressor
Node Intention: 1. To receive Syn Gas from OSBL, compress it to the required specification and supply to ammonia converter
Drawing No: 17269-060000-CP25-62-D111, Rev 2A+; 17269-060000-CP25-62-D112, Rev 2A+; 17269-060000-CP25-62-D113, Rev 2A+
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Recommendation Comment
Deviation Cause Consequence L S RR Safeguards L S RR nsibilit
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1. No/Less Flow 1.1. Upstream upset, syn 1.1.1. Loss of suction C 3 M 1. Anti surge provision D 3 M 1. Provide PAL- Wuhua
gas supply failure and surging, is available to 1004 at the inlet n
feed to the damage of syn prevent surging, of suction of syn
compressor gas compressor further damages gas
compressor(103
J)
2. PAL-1073 is
available to alert the
operator at the
Inlet of Hg guard
bed.
1.1.2. Downstream C 2 M 1. PAL-1073 is D2 L
process operation available to alert the
upset leads to loss operator
of Ammonia
production
[Revalidated]
1.2. Exhaustion of 1.2.1. Slipage of mercury 1. Routine sampling Discussion
mercury gaurd leads to damage done related to
bed(end of lifecycle) of NH3 converter provision
catalyst of Hg on
line
analyzer at
the inlet of
Hg guard
bed as per

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PDIL
comments
EPC wants
to remove
the bed. (
design
issue)
1.2.2. High dP across 1. PDAH-1105A
the bed available
1.3. Choking of demister 1.3.1. Loss of suction 1. PAH-1073 is
pad 06150-D and surging, available
damage of syn 2. Anti surge provision Discussion
gas compressor is available to design
prevent surging, issues or
further damages other
pressure
protection
reqd.
comments
PDIL
1.3.2. Downstream 1. Downstream unit
process operation has inherent
upset leads to loss safeguards to take
of Ammonia the process into
production safe state.
1.3.3. Overpressurization 1. PAH-1073 is Design
of suction KOD available issue,
and upstream discussion

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point. PDIL
comments.
1.4. Malfunction of PIC- 1.4.1. Loss of suction( C 3 M 1. Anti surge provision D 3 M 3. Provide PAL on Wuhua
1004 to open PV- low suction pr) to is available to PT-1006 in DCS n
1004 when not syn gas prevent surging,
required compressor and further damages
surging, possible
damage of syn
gas compressor.
1.4.2. Downstream C 3 M 1. Down stream unit D 3 M 3. Provide PAL on Wuhua
process operation has inherent PT-1006 in DCS n
1.5. Choking of SP-STR- 1.5.1. Loss of suction( E 3 L 1. PDAH- F 3 L Normal run
103J1/103J2/103J3 low suction 8105/8132/8133 case is
at the suction of syn pressure) and provided considered
gas compressor in all surging, damage for RR
stages of syn gas 2. Anti surge valve F 3 L
compressor status open/close
indication is
available in DCS
1.5.2. Downstream 1. Down stream unit 4. Provide PAL on Wuhua
process operation has inherent PT-1045 in DCS n
[Revalidated]

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1.6. Inadvertent opening 1.6.1. Downstream 1. Down stream unit 4. Provide PAL on Wuhua
FV-1007 (first stage process operation has inherent PT-1045 in DCS n
anti surge)(holds upset leads to loss safeguards to take
good for other anti of Ammonia the process into
surges) production safe state.
[Revalidated]
1.6.2. Loss of suction to C 3 M 1. Anti surge provision D 3 M 4. Provide PAL on Wuhua
the subsequent is available to PT-1045 in DCS n
stages. Surging prevent damage of
and damage of the compressor.
syn gas
compressor
1.7. Inadvertent closure of 1.7.1. Loss of suction to 1. Valve status
XV-1103 at the the second stage indication is
second stage suction suction, possible available
surging and
damage of the
compressor.
1.7.2. Downstream 1. Valve status
process operation indication is
upset leads to loss available
of Ammonia 2. Air bottle is available 5. Review the
production to cater for 2 requirement of
strokes(refer Note 2 air bottle with 3
in P&ID) strokes action
as
recommended
by Licenser

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3. Downstream has
inherent safeguards
to take the process
into safe state
1.7.3. Loss of suction to E 3 L 1. Anti surge provision
the subsequent is available in each
stages. Surging stage to protect the
and damage of compressor
syn gas 2. PAH-1004 is
compressor available to alert the
operator
3. PIC-1004 is
available to
modulate and
control the pressure
1.8. Inadvertent opening 1.8.1. Possible surging 1. Anti surge provision 4. Provide PAL on Wuhua
of HIC- of 3rd stage is available in each PT-1045 in DCS n
1019(operation error) compressor and stage to protect the
damage. Loss of compressor
syn gas
&refrigerant gas to
flare.
1.8.2. Downstream 1. Downstream has 4. Provide PAL on Wuhua
process operation inherent safeguards PT-1045 in DCS n
upset leads to loss to take the process 6. Provide all the Wuhua
of Ammonia into safe state process n
production parameters
indication to

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DCS also in
parallel with the
indication to anti
surge control
system
1.9. Trip of syn gas 1.9.1. High back 1. Anti surge provision
compressor pressure in the is available in each
U/S section and stage to protect the
possible compressor
rupture/damage of 2. PAH-1004 is
piping and available to alert the
equipment. operator
3. PIC-1004 is
available to
modulate and
4. PRV-116C1 is
provided at 1st
stage discharge
5. PRV-150D provided
at suction KOD
1.9.2. Downstream 1. Downstream has 4. Provide PAL on Wuhua
process operation inherent safeguards PT-1045 in DCS n
upset leads to loss to take the process
of Ammonia into safe state
production
2. More/ High Flow 2.1. Malfunction of PIC- 2.1.1. High pressure in 1. PAL-1073 is
1006 at the suction of synthesis loop available

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compressor to leading to process 2. PRV-103J at
increase the speed of operation upset at compressor
turbine the downstream discharge
2.1.2. Low suction 1. Anti surge provision 1. Provide PAL- Wuhua
pressure and is available in each 1004 at the inlet n
possible surging of stage to protect the of suction of syn
the machine compressor gas
compressor(103
J)
2.1.3. Possible 1. Redundant
overspeed of the overspeed trip
turbine and electronic relay is
damage available to protect
the machine
3. Reverse Flow 3.1. Trip of 103J syn gas 3.1.1. Possible damage 1. NRV is provided at
compressor, possible of dry gas seal in the discharge of
reverse flow from the compressor compressor
converter loop 2. Bidirectional type
dry gas seal
provided
3. Anti surge provision
is available in each
stage to protect the
compressor
4. Mis-directed flow 4.1. No credible cause 4.1.1. 1.
5. High Tempeature 5.1. Failure of chilled 5.1.1. High suction 1. TAH-1691 is
water supply to temperature at the available at outlet of

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06150-C first stage suction 6150-D Suction
leads high temp in KOD
all stages and 2. TAH- 7. Provide/Ensure Wuhua
Inefficient 9390/9391/9392 are TAH is provided n
operation of the available at 103J in in all the 3
compressor each stage transmitters of
discharge all the stages
5.2. Cooling water failure 5.2.1. Inefficient 1. TAH- 7. Provide/Ensure Wuhua KBR
for the inter coolers operation of the 9390/9391/9392 are TAH is provided n accepted
compressor available at 103J in in all the 3 the MOC in
each stage transmitters of intercooler
discharge all the stages design as
intended
by
wuhuan.
To be
updated in
the
operation
philosophy
and
process
description
documents
.
2. TAHH-
9390/9391/9392 is
provided with 2oo3
voting logic to trip

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the compressor
5.2.2. Possible damage 1. To be
of tube bundle in discussed
the cooler when outside the
exposed to high workshop
temp gas. for the
design
intent of
tube
bundle
6. Low 6.1. No credible cause 6.1.1. 1.
Temperature envisaged
7. High Pressure 7.1. Refer flow deviation 7.1.1. 1.
above
8. Low Pressure 8.1. Refer More/high flow 8.1.1. 1.
deviation
8.2. Malfunction of PIC- 8.2.1. Possible surging 1. Anti surge provision 4. Provide PAL on Wuhua
1006 to reduce the of compressor and is available in each PT-1045 in DCS n
speed of turbine damage stage to protect the
compressor
9. High Level 9.1. Possible liquid 9.1.1. Possible liquid 1. LAH-1008 provided
carryover from 147-D caryyover to
2. LAHH-1008 is
compressor and
provided with 2oo3
damage
the syngas
compressor
10. Low Level 10.1. No credible cause 10.1.1. 1.

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11. Composition 11.1. Upstream upset and 11.1.1. Change in 1. 8. Provide AAH- Wuhua
change possible upset of N2 molucular wt. 1001 and AAL- n
purity, H2, Ar leads to the anti 1001 analyzer
surge opening alarm for H2/N2
and downstream ratio and
process provide AAH-
operation upset 1001C for Ar
11.1.2. Upset in H2/ N2 1. 9. Provide PAH- Wuhua
ratio and loss of 1045 on PT- n
Ammonia 1045 in DCS
production
11.1.3. Loss of pressure 1. 4. Provide PAL on Wuhua
and low PT-1045 in DCS n
temperature in
the converter
leads to loss of
ammonia
production
12. Other 12.1. 12.1.1. 1.
13. Maintenance- 13.1. 13.1.1. 1. To be
Accessbility closed
during
model
review
14. Maintenance- 14.1. No issues 14.1.1. 1. Based on
Positive envisaged(Refer Wuhuan
isolation/drains/ comments) confirmatio
vent n vide

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letter no
L144 this
point is
closed
15. Startup/shutdo 15.1. No issues 15.1.1. 1.
wn/comissionin envisaged as KBR
g O&M philosophy is
available for
commissioning,
startup /shut down
activities including
catalyst decanting
and charging in the
respective vessel.
15.2. Operator 15.2.1. Potential facility 1. Commissioning
training(unskilled hazard support is available
operation)
16. Safety system 16.1. Leakage (e.x 16.1.1. Potential Fire 1. F&G system is
flanges), Flashing of hazard if ignition provided
gas/liquid, source is 2. Eye washers and
available safety showers are
Potential provided in the area.
personnel injury
16.2. Noise pollution 16.2.1. Potential 1. Noise level in the

personnel injury - compressor area is
Hearing impact within the threshold
limit value (normal

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decibel)
17. Sampling 17.1. No issues 17.1.1. 1.

envisaged
18. High corrosion 18.1. NA 18.1.1. 1.
19. Relief or 19.1. No issues 19.1.1. 1.
blowdown envisaged
20. Power 20.1. Loss of power 20.1.1. Total ammonia 1. Emergency
facility shutdown generators are
leads to loss of available for
ammonia essential system
production
21. Instrument air 21.1. Instrument Air 21.1.1. Process shut 1. Process leads to fail
failure failure down safe position as per
the confirguration
22. Cooling water 22.1. Refer high 22.1.1. 1.
temperature
deviation of this
node
23. Chilled water 23.1. Refer high 23.1.1. 1.
temperature
deviation of this
node
24. Nitrogen 24.1. N2 supply failure 24.1.1. Scenario is not 1.
envisaged
24.1.2. Maintenance 1.
operation

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delayed for want
of purging.
25. Tube rupture 25.1. Cooling 25.1.1. Overpressurizati 1. PRVs(150C and 10. Ensure
water/chilled water on of cooling 116C) are available PRVs(150C
exchanger tube leak water system and 116C) are
and chilled water sized for tube
system and rupture case
possible rupture
of tubes
Node: 2. Syn gas converter, effluent & HP/LP steam generation

Node Intention: 1. To produce NH3 & generate HP/LP steam from the converter effluent
Drawing No: 17269-060000-CP25-62-D114, Rev 2A+; 17269-060000-CP25-62-D114A, Rev 2A+; 17269-060000-CP25-62-D115, Rev 2A+;
17269-060000-CP25-64-D101, Rev 2A+
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1. No/Less Flow of 1.1. syn gas compressor 1.1.1. Loss of ammonia 1. Compressor running 4. Provide PAL on Wuhua
syn gas to trips production status indication PT-1045 in DCS n
ammonia available
converter 105-D 1.1.2. High skin 1. 11. Provide all Wuhua
temperature on skin n
converter 105-D temperature
measurement
with high
alarm TAH-
1395 A-Z

17269-060000-CP25-64-D101, Rev 2A+
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1.1.3. Loss of HP steam 1. FAL-1033 available
generation to to alert the operator
OSBL, process 2. PAL-1036 available
operation upset to alert the operator
3. TAL-1550 available
to alert the operator
1.1.4. Loss of LP steam 1. PAL-7614 available
generation leads
2. LAL-7405 available
to process
operation upset in
deaerator area.
1.2. Inadvertent closure 1.2.1. High back 1. Anti surge provision
HV-1101 at the inlet pressure to is available in each
of 121-C(Operation compressor and stage to protect the
error) possible surging compressor
and damage of the
machine
1.2.2. Process operation 1. D/s unit has inherent 4. Provide PAL on Wuhua
upset in safeguard to take PT-1045 in DCS n
downstream unit. the process into
Loss of NH3 safe state
production
1.2.3. High skin 1. 11. Provide all Wuhua
temperature on skin n
converter 105-D temperature
measurement
with high

17269-060000-CP25-64-D101, Rev 2A+
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alarm TAH-
1395 A-Z
1.3. Inadvertent closure 1.3.1. High back 1. Anti surge provision
HV-1044(Operation pressure to is available in each
error) compressor and stage to protect the
possible surging compressor
1.3.2. Process upset and 1. Compressor running 4. Provide PAL on Wuhua
loss of ammonia status indication PT-1045 in DCS n
production available 12. Provide FAL- Wuhua
1105 n
1.3.3. High skin 1. HV-1044 butterfly 11. Provide all Wuhua
temperature on valve has provision skin n
converter 105-D of disc cut to allow temperature
flow upto measurement
69000kg/hr with high
alarm TAH-
1395 A-Z
1.4. Inadvertent closure 1.4.1. High back 1. Valve status 13. Update the Wuhua
HV-1046(Operation pressure to indication is P&ID for the n
error) compressor and available. Position position

17269-060000-CP25-64-D101, Rev 2A+
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possible surging transmitter is transmitter for
provided the HV-1046
14. Provide Wuhua
discripency n
alarm for HV-
1046
2. Anti surge provision
is available in each
stage to protect the
compressor
1.4.2. Process upset and 1. Compressor running 4. Provide PAL on Wuhua
loss of ammonia status indication PT-1045 in DCS n
production available 12. Provide FAL- Wuhua
1105 n
1.5. Inadvertent closure 1.5.1. Increase in 1st 1. TAH-1383/1384
HV-1025 if bed temperature available
open(Operation error) and process
operation upset
1.6. Inadvertent closure 1.6.1. Possible damage 1. FAL-1257 available
HCV-1047 if of heater coil
2. FALL-1257 available
open(Operation error)
to trip the heater
3. TSH-1396 available
4. TSHH-1396
available to trip the
heater

17269-060000-CP25-64-D101, Rev 2A+
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5. TAH-1047 available
1.6.2. Startup operation 1.
delayed
1.7. Inadvertent closure 1.7.1. Normally closed 1.
HIC-1034(Operation valve
error). Not available
when required
1.8. Inadvertent closure 1.8.1. High back 1. Anti surge provision 9. Provide PAH- Wuhua
HIC-1033(Operation pressure to is available in each 1045 on PT- n
error) at 06121-C compressor and stage to protect the 1045 in DCS
outlet. converter loop and compressor
possible surging
1.8.2. Loss of ammonia 1. Compressor running 4. Provide PAL on Wuhua
production status indication PT-1045 in DCS n
available
1.9. Inadvertent closure 1.9.1. Normally closed 1.
HIC-1032(Operation valve
error)
1.10. Inadvertent opening 1.10.1. Refer to no/low 1.

17269-060000-CP25-64-D101, Rev 2A+
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of HV-1019 flow deviation of
(operation error) at node 1(cause
the 103-J discharge 1.8)
2. No/Less Flow 2.1. BFW supply failure 2.1.1. Over heating of 1. FSL-1020 is
BFW to steam from deareator area 123-C1/C2 available to start the
generation standby BFW pump
system 2. LAL-1223A/B/C
available
3. LAL-1001A/B
available
4. LSLL-
123A/B/C(2oo3)
ammonia unit
6. FAL-1033 available
2.1.2. Over heating of 1. TAH-1371 available
140-C1/C2
2. Condensate from
112J/JA is available
4. LAL-7405/7406
available

17269-060000-CP25-64-D101, Rev 2A+
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2.1.3. Loss of steam HP 1. FAL-1033 available
production to alert the operator
2. PAL-1036 available
2.1.4. Process operation 1.
upset leads to
ammonia
production
2.2. LV-1001 stuck in 2.2.1. Low level in steam 1. FSL-1020 is
close position on drum 141-D available
BFW line 2. LAL-1223A/B/C
available
3. LAL-1001 A or B
available(standby
one)
4. LSLL-
123A/B/C(2oo3)
ammonia unit

17269-060000-CP25-64-D101, Rev 2A+
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upset leads to loss
ammonia
production
2.2.4. Over heating of 1. FSL-1020 is
123-C1/C2 available to start the
standby BFW pump
2. LAL-1223A/B/C
available
3. LAL-1001A/B
available
4. LSLL-
123A/B/C(2oo3)
ammonia unit
2.3. Inadvertent closure 2.3.1. Low level in steam 1. FSL-1020 is
TV-1371A drum 141-D available
2. LAL-1223A/B/C
available

17269-060000-CP25-64-D101, Rev 2A+
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3. LAL-1001A/B
available
4. LSLL-
123A/B/C(2oo3)
ammonia unit
upset leads to loss
ammonia
production
2.3.4. Over heating of 1. FSL-1020 is
123-C1/C2 available to start the
standby BFW pump
2. LAL-1223A/B/C
available
3. LAL-1001A/B
available
4. LSLL-
123A/B/C(2oo3)

17269-060000-CP25-64-D101, Rev 2A+
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ammonia unit
2.4. Inadvertent closure 2.4.1. Process operation 1.
TV-1371B upset leads to loss
ammonia
production
2.5. Inadvertent closure 2.5.1. Over heating of 1. TAH-1371 available
LIC-7406(LP steam ) 140-C1/C2
2. Condensate from
2.5.2. Loss of LP steam 1. PAL-7614 available
production.
Process operation
upset on deareater
side
3. No/Less Flow of 3.1. Inadvertent closure of 3.1.1. High back 1. Valve status
steam to OSBL MOV-1007(operation pressure on the indication is
error) steam drum and available in DCS
possible damage 2. Steam drum and
of equipment and associated lines are

17269-060000-CP25-64-D101, Rev 2A+
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rupture of steam designed for high
lines. shutoff pressure.
3. PAH-1036 available
5. PV-1036 available
to vent the steam
6. PRV-141D1/D2
available
3.1.2. Process operation 1. D/s unit has inherent
upset in d/s units safeguard to take
leads to loss the process into
ammonia safe state
production
3.2. Inadvertent closure of 3.2.1. High back 1. PAH-1036 available
MOV-9502(operation pressure on the
error) in the field steam drum and
possible damage
of equipment and 3. PV-1036 available
rupture of steam to vent the steam
lines. 4. PRV-141D1/D2
available
3.3. Inadvertent opening 3.3.1. Loss of HP steam 1. PAL 1036 is
of PV-1036 when not to atmosphere, available in drum.
required process operation 2. FAH 1033 is
upset in NH3 unit available.

17269-060000-CP25-64-D101, Rev 2A+
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and loss of 3. TAL 1556 is
Ammonia available
Production.
4. Valve status
indication is
available in DCS
3.3.2. Low level in 140 D 1. LAL1223A/B/C are
available.
2. LALL 1223 ABC is
available with 2003
the syn unit
3.4. Malfunction of PIC- 3.4.1. Loss of HP steam 1. FAH 1033 is
1036 to open full PV to atmosphere, available.
1036 process operation 2. TAL 1556 is
upset in NH3 unit available
and loss of
3. Valve status
Ammonia
indication is
Production.
available in DCS
3.4.2. Low level in 140 D 1. LAL1223A/B/C are
available.
2. LALL 1223 ABC is
available with 2003
the syn unit
4. No/less of LP 4.1. LV-1129 stuck in 4.1.1. High level in 186D 1. LAL-1129 is 17. Provide FAL-
steam to LP close position and potential available available 1826 on FT-

17269-060000-CP25-64-D101, Rev 2A+
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header carryover of 1826
condensate to LP
header
4.2. Inadvertent closure of 4.2.1. High pressure on 1. PAH-7614 is
PV 7614 at the outlet 140C1/C2 leads to available
of 140C2. possible damage 2. PRV-140C is
of vessel available
140C1/C2
4.2.2. Loss of steam to 1. Refer node 5
deaerator system
leads to possible
corrosion in BFW
system (slow
process)
4.3. PT-7614 malfunctions 4.3.1. High pressure on 1. PRV-140C is
to close PV-7614 140C1/C2 leads to available
possible damage 2. TAH-1420 available
of vessel
140C1/C2
5. No/less flow of 5.1. LT-7406 malfunction 5.1.1. Loss of level 1. High back pressure 16. Provide PAH-
BFW to 140C2 to close(refer 140C2 leads to to LP BFW pump 6095 at PT-
previous deviation) upset in LP steam 6095 at the
production and at discharge of
the consumer end LP BFW pump
2. FAL-6106 is
available

17269-060000-CP25-64-D101, Rev 2A+
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6. High/More Flow 6.1. Malfunctions of 6.1.1. High level on 1. LAH-1001A/B are
of BFW to steam cascade loop on steam drum and available
drum steam drum BFW line possible carryover 2. LAH-1223A/B/C are
leads to full open LV- of BFW to HP available
1001 steam header and
hammering
6.2. TV-1371A 6.2.1. No significant
malfunction to open consequence
full
6.3. TV-1371B 6.3.1. Process operation 1. TAH-1371 available
malfunction to open upset in Ammonia
full unit.
7. More/high flow of 7.1. PIC 7614 7.1.1. Low pressure and 1. TAL-7112 is
LP steam malfunctions to open low temperature of available
full PV 7614 140C1/C2
7.1.2. Process operstion 1. Synthisis unit has
upset in ammonia inherent safegaurd
synthsis unit to take the process
into safe state
7.1.3. Increase in LP 1. Refer node 6
header pressure
7.2. PV 7614 stuck in 7.2.1. Low pressure and 1. TAL-7112 is
open position low temperature of available
140C1/C2 2. PAL-7614 available
7.2.2. Process operstion 1. Synthisis unit has

17269-060000-CP25-64-D101, Rev 2A+
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upset in ammonia inherent safegaurd
synthsis unit to take the process
into safe state
8. More/High flow 8.1. Inadvertent/malfuncti 8.1.1. High level in 1. LAH 7406/7405 is
BFW to 140C2 on of 140C2 and available
LT 7406 to open LV- possible BFW
7406 full carry over to LP
steam line,
possible
hammering and
damage of LP
steam line.
8.1.2. Low temp on LP 1. TAL 7112 is
steam ,process available
operation upset.
8.1.3. Low pr LP steam 1. PAL 7614 is
process operation available
upset
9. Reverse Flow 9.1. PT-1036 malfunction 9.1.1. Reverse flow of 1. NRV is provided
to open full PV-1036 HP steam from
OSBL to steam
drum/silencer
[Revalidated]
10. Mis-directed 10.1. LT-7405 10.1.1. high level on 1. LAH-7406 is
flow malfunctions to 140C2(water available
open when not diverted to 2. LIC-7406 is

17269-060000-CP25-64-D101, Rev 2A+
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required 140C2 from available to
ISBL) leads to modulate and close
possible the valve
carryover to LP
steam header
and hammering
11. High 11.1. Refer flow deviation 11.1.1. 1.
Tempeature
12. Low 12.1. Refer flow deviation 12.1.1. 1.
Temperature
13. HIgh Pressure 13.1. Refer flow deviation 13.1.1. 1.
14. Low Pressure 14.1. Refer flow deviation 14.1.1. 1.
15. High Level 15.1. Refer flow deviation
15.2. High level in steam

drum 141D.(Refer to
flow deviation)
15.3. Uncontrolled drain 15.3.1. High level in 186 1. LIC /LV 1129 is
from steam drum D available to
thro series of BDV vessel and modulate and
to LP steam Blow possible carry control the level
down drum 186D over of
condensate into
LP steam line,
hammering and

17269-060000-CP25-64-D101, Rev 2A+
Respo
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damage.
15.4. LIC malfunction to 15.4.1. High level in 186

close LV 1129 D
vessel and
possible carry
over of
condensate into
LP steam line,
hammering and
damage.
16. Low Level 16.1. Low level in steam

drum 141D.(refer
flow deviation.)
16.2. LIC 1129 16.2.1. Low level in
malfunction to open 186D and no
LV 1129 full. significant
consequences
16.3. LV 1129 stuck in 16.3.1. Low level in
open position 186D and no
significant
consequences
17. Composition 17.1. Possibility of high 17.1.1. Possible 1. Conductivity online
change conductivity in BFW deposition of analyzer AAH-
scale on turbine 1050/1051/1006
blades and high available at steam

17269-060000-CP25-64-D101, Rev 2A+
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vibration drum
18. Other
19. Maintenance- 19.1. Refer node 1
Accessbility
20. Maintenance- 20.1. Refer node 1
Positive
isolation/drains/
vent
21. Startup/shutdo 21.1. Refer node 1
wn/comissionin
g 21.2. Operator 21.2.1. Potential facility 1. Commissioning
training(unskilled hazard support is available
operation)
22. Safety system 22.1. Seal failure on LP 22.1.1. Flashing of BFW 1. PPE is available
BFW pump water, potential
2. Double mechanical
104JA/JB/JC personnel injury.
seal is provided.
22.2. Seal failure on LP
BFW pump 150J/JA.
22.3. Leakage (e.x
flanges), Flashing of
gas/liquid.(Refer to
node 1)
23. Sampling 23.1. Refer Node 1


17269-060000-CP25-64-D101, Rev 2A+
Respo
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24. High corrosion 24.1. Refer composition
chnage above
25. Relief or 25.1. No issues.
blowdown
26. Power failure 26.1. Refer Node 1
27. Instrument air 27.1. Refer Node 1
failure
28. Cooling water 28.1. CW supply failure to 28.1.1. Damage of pump
LP/HP BFW pump seal
seals
28.2. Cooling water
supply failure 191C
29. Chilled water 29.1. NA
30. Nitrogen 30.1. Refer node 1
31. Tube rupture 31.1. Tube rupture in 31.1.1. Over 1. PAH 7614 is
140C1/C2 pressurization available
and Possible 2. PRV 140 is
rupture of LP available
steam line.
31.2. Tube leak at 191C 31.2.1. Over 1. PRV 191C is
pressureization available at the HW
of cooling water header
header and
possible damage
31.3. Tube rupture of 31.3.1. Possible 1. Conductivity online

17269-060000-CP25-64-D101, Rev 2A+
Respo
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123C1/C2 contamination of analyzer AAH-
BFW with syn 1050/1051/1006
gas and available at steam
overpressurizatio drum
n of steam drum 2. PRV-141D1/D2 are
available
3. PAH-1036 is
available
4. PV-1036 is available
to modulate and to
release the steam to
vent header
31.4. Tube rupture of 31.4.1. Process 1. Tube Design intent 18. Provide AAL-
121C operation upset is taken care of 1022D(Ammo
in Ammonia unit. nia)
Node: 3. NH3 Refrigerant loop

Node Intention: 1. To refrigerate ammonia and supply the liquid ammonia to Urea Plant/Storage
Drawing No: 17269-060000-CP25-62-D116A, Rev 2A+; 17269-060000-CP25-62-D114, Rev 2A+; 17269-060000-CP25-62-D117, Rev 2A+;
17269-060000-CP25-62-D118, Rev 2A+; 17269-060000-CP25-62-D118A, Rev 2A+; 17269-060000-CP25-62-D119, Rev 2A+
Respo
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1. No/Less Flow 1.1. Syn gas compressor 1.1.1. Refrigeration loop 1. Anti surge provision
103 J trips upset, possible is available in each

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surge of 105J and stage to protect the
loss of NH3 compressor 105J
production 2. Inherent safegaurd
is available in NH3
loop to take the
process into safe
state
1.2. Refrigeration 1.2.1. Process upset in 1. Inherent safegaurd
compressor 105J synthsis loop, is available in NH3
trips referigeration loop, loop to take the
shutdown of 103J process into safe
and loss of NH3 state
production
1.2.2. High pressure in 1. PAH-1009 is
unitized chiller available
120C 2. PRV-120CF1/2/3/4
are available
1.3. Malfunction of FT to 1.3.1. Unitized chiller 1.
close FV 1059 103J operation upset
3rd stage out let to
(recycle) to 124C
1.4. FV 1059 stuck in

close position (
mechanical failure)

Respo
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1.5. Inadvertent closure of
HV 1033/1101
(operation
error).(Refer node 2)
1.6. Inadvertent closure of 1.6.1. High level in 1. LAH-1214A/B/C is

LV 1022 NH3 liquid to 120CF4 leads to available
120CF3 from potential liquid 2. LAHH-1214A/B/C is
120CF4. NH3 carryover to avialable to trip 105J
compressor (2oo3 voting logic)
suction and
damage
1.6.2. Low level in 1. Anti surge provision
120CF3 leads to is available in each
low suction stage to protect the
pressure on 3rd compressor 105J
stage of 105J, 2. LAL-1022 is
possible surging available
and damage
1.6.3. Low level in 1. LAL-1022 is
120CF3 leads to available
possible process 2. Inherent safeguard
upset and loss of is available in NH3
NH3 production syn loop to take the
process into safe
state
1.7. Malfunction of LT- 1.7.1. High level in 1. LAH-1214A/B/C is

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1022 NH3 liquid to 120CF4 leads to available
close LV-1022 potential liquid 2. LAHH-1214A/B/C is
120CF3 from NH3 carryover to avialable to trip 105J
120CF4. compressor (2oo3 voting logic)
suction and
damage
stage of 105J,
possible surging
and damage
1.7.3. Low level in 1. Inherent safeguard
120CF3 leads to is available in NH3
possible process syn loop to take the
upset and loss of process into safe
NH3 production state
1.8. Inadvertent closure of 1.8.1. High level in 1. LAH-1215A/B/C is
LV 1023 to 120CF2 120CF3 leads to available
from 120CF3. potential liquid 2. LAHH-1215A/B/C is
NH3 carryover to avialable to trip 105J
suction and
damage

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pressure on 2nd compressor 105J
and damage
possible process 2. Inherent safeguard
upset and loss of is available in NH3
NH3 production syn loop to take the
process into safe
state
120CF3 from 120CF3 NH3 carryover to available to trip 105J
suction and
damage
stage of 105J,
possible surging
and damage

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1.10. Inadvertent closure 1.10.1. High level in 1. LAH-1216A/B/C is
of LV 1024 to 120CF2 leads to available
120CF1 from potential liquid 2. LAHH-1216A/B/C is
120CF2. NH3 carryover to avialable to trip 105J
suction and
damage
and damage
possible process
upset and loss of
NH3 production
120CF1 from NH3 carryover to available to trip 105J

Respo
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120CF2 compressor (2oo3 voting logic)
suction and
damage
1.11.2. Low level in 1. Anti-surge provision
stage of 105J,
possible surging
and damage
1.12. Inadvertent closure 1.12.1. High level in 1. LAH-1013 is
of LV 1013 at the 146D leads to available
NH3 separator 146 liquid carryover 2. LAH-1218A/B/C is
D boot outlet to NH3 to 120-C thereby available
let down drum to compressor
147D. 103J(syn gas 3. LAHH-1218A/B/C
available to trip
compressor)
103J(2oo3 voting
logic)
1.12.2. Low level on 1. LAL-1011 is 19. Provide LAL &
147-D leads to available LAH-1012 on
upset in redundant
refrigeration loop transmitter LT-

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1012
1.13. Malfunction of LT 1.13.1. High level in 1. LAH-1218A/B/C is
1013 at the NH3 146D leads to available
separator 146 D liquid carryover 2. LAHH-1218A/B/C
boot outlet to close to 120-C thereby available to trip
LV-1013 NH3 let to compressor 103J(2oo3 voting
down drum 147D. 103J(syn gas logic)
compressor)
1.13.2. Low level on 1. LAL-1011 is 19. Provide LAL &
147-D leads to available LAH-1012 on
upset in redundant
refrigeration loop transmitter LT-
1012
1.14. LV 1012A stuck in 1.14.1. High level in 1. Refer node 1
close position 147D leads to
2. LAH-1011 is 19. Provide LAL &
mechanical failure. liquid carryover
available LAH-1012 on
Towards 120CF1 to 150D
redundant
from 147D(when
transmitter LT-
cold NH3 loop in
1012
operation)
1.14.2. Low level in 120- 1. LAL-1217A/B/C is
CF1 leads to available
possible 2. LALL-1217A/B/C is
cavitation of 124 available to trip
J/JA(cold NH3 124J/JA(2oo3 voting
pump) logic)
3. Min flow line SP-

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ARV-124J/JA
1.14.3. Possible surging 1. Anti-surge provision
in 1st stage of is available in each
105J stage to protect the
compressor 105J
1.15. Inadvertent closure 1.15.1. High level in 1. Refer node 1
of LV 1012B at the 147D leads to
2. LAH-1011 is 19. Provide LAL &
inlet of refrigerant liquid carryover
receiver 149D to 150D
redundant
vessel
transmitter LT-
1012
1.15.2. Low level in 1. LAL-1015A is
149D leads to available
process upset in 2. Min flow line SP-
refrigerant loop ARV-113J/JA
and possible
3. LALL-1615 is
cavitiation of 113
J/JA(warm NH3
pump 113J/JA
pump)
1.16. Inadvertent closure 1.16.1. Loss of NH3 to 1. 20. Provide TAH-
of HV 1026 flare 1404 on TT-
(Operation error) at 1404
the inlet of 149 D
refrigerant receiver
vent condenser.
1.17. Inadvertent closure 1.17.1. High level in 1. LAH-1015A/1615
of LV-1021 to 149D leads to are available

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120CF4 from 149D. liquid carryover
to flare header
pressure on 4th compressor 105J
stage of 105J,
possible surging
and damage
1.18. Inadvertent closure 1.18.1. High temperature 1. TAH-1428 is
of TV 1067 to 149D of warm NH3 available
vessel. product
1.19. Choking of suction 1.19.1. Possible surging 1. Anti surge provision
strainer SP-STR- and damage to is available in each
105J1/J2/J3/J4 at 105J stage to protect the
the each stage of compressor 105J
105J ref 2. PDAH-
compressor. ( Holds 8108/8109/8110/811
good for other 1 are available
stages of ref
compressor 105J)
1.20. Choking of demister 1.20.1. Not a credible
pad at the gas outlet scenario as NH3
Unitized chiller of is a clean gas
120CF1/CF2/CF3/C
F4 to the respective
stages of the Ref

Respo
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compressor 105J.
1.21. Inadvertent closure 1.21.1. High back 1. Anti surge provision 21. Provide PAH-
of MOV 9501at the pressure to is available in each 1085 at PT-
4th stage out let of compressor and stage to protect the 1085 in DCS
Ref compressor possible surging compressor 105J
105J and damage of 2. PSV-105J is
the machine available
1.22. Inadvertent opening 1.22.1. Increase in 120C 1. TAH-1080 is
of Anti surge valve pressure leads to available at CF1
FV 1009/1010/1011 high temperature outlet to 146D
& 1012 to the to 146D, high
respective stages of NH3 recycle to
105J. synthesis loop
leads to low
conversion and
loss of NH3
production
1.23. Failure of warm NH3 1.23.1. High level in 1. Standby pump is
pumps 113J/JA to 149D leads to available
urea plant. liquid carryover 2. Pump running status
to flare header indication is
available
1.24. Inadvertent closure 1.24.1. Refer to cause
of LV 1015B at the 1.22
discharge of 1.24.2. High back 1. Min flow line SP-
113J/JA. pressure to the ARV-113J/JA
pump

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1.25. Failure of cold NH3 1.25.1. High level on 1. LAH-1217A/B/C are
product pumps 120CF1 leads to available
124J/JA to possible liquid 2. LAHH-1217A/B/C
storage(during cold carryover to 1st are available to trip
NH3 operation) stage of the
refrigerant compressor(2oo3
compressor and voting logic)
damage of
3. FAL-1061 is
machine
available at pump
discharge
4. Pump running status
indication is
available
1.26. Inadvertent closure 1.26.1. High level on 1. LAH-1217A/B/C are
of LV 1015A at the 120CF1 leads to available
discharge of possible liquid 2. LAHH-1217A/B/C
124J/JA. carryover to 1st are available to trip
stage of the
refrigerant compressor(2oo3
compressor voting logic)
3. FAL-1061 is
available at pump
discharge
indication is
available

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1.26.2. High back 1. Min flow line SP-
pressure to the ARV-124J/JA
pump
1.27. Inadvertent closure 1.27.1. Possible 1. Routine sampling
of FV 1090 at the corrosion in NH3 done
steam condensate storage
line to cold NH3 tank(slow
pump discharge process)
1.28. Stuck in open 1.28.1. Loss of NH3 to 1. 22. Provide FAH-
position of PV 1109 flare 1057 on FT-
at 149 D outlet. 1057
1.28.2. Low pressure in 1. 23. Provide PAL-
149D 1085 at 105J
discharge in
DCS
1.29. Stuck in open 1.29.1. Loss of NH3 to 1. PAL-1092 is
position of PV flare available
1108B at the outlet 1.29.2. Loss of purge
of 147-D to NH3 gas to 150D. No
flare header significant
consequences
1.29.3. Loss of NH3 to
149D. Refer
cause 1.14
above
1.30. Stuck in open 1.30.1. More purge gas

Respo
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position of PV to 150D. No
1108A at the outlet significant
of 147-D to suction consequences
KOD 150-D. 1.30.2. Loss of NH3 to
149D. Refer
cause 1.14
above
2. More/ High Flow 2.1. Malfunction of LT 2.1.1. High level in 1. LAH-1215A/B/C is
1022 to open full LV 120CF3 leads to available
1022 NH3 liquid to potential liquid 2. LAHH-1215A/B/C is
120CF3 from 120CF4 NH3 carryover to available to trip 105J
suction and
damage
pressure on 4th compressor 105J
stage of 105J,
possible surging
and damage
1023 to 120CF2 from potential liquid 2. LAHH-1216A/B/C is
120CF3. NH3 carryover to available to trip 105J
suction and

Respo
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damage
stage of 105J,
possible surging
and damage
1024 to 120CF1 from potential liquid 2. LAHH-1217A/B/C is
120CF2. NH3 carryover to available to trip 105J
suction and
damage
stage of 105J,
possible surging
and damage
2.4. Malfunction of LT 2.4.1. Low level in 146D 1. LAL-1218A/B/C are
1013 to open full LV available
1013 at the NH3 2.4.2. Possible gas 1. PAH-1108 is
separator 146 D boot blowby scenario to available
outlet to NH3 let 147D, 2. PRV-147D1/D2 is

Respo
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down drum 147D. overpressurization available
in 147D
2.5. Malfunction of LT 2.5.1. High level in 1. Refer low flow
1012 to open full LV 120CF1 leads to deviation
1012A stuck in open potential liquid
position mechanical NH3 carryover to
failure. Towards compressor
120CF1 from 147D suction and
damage
2.5.2. Low level in 147D 1. LAL-1011 is 19. Provide LAL &
redundant
transmitter LT-
1012
2.6. Malfunction of LT 2.6.1. High level in 149D 1. Refer low flow
1012 to open full LV leads to liquid deviation
1012B at the inlet of carryover to flare
refrigerant header
condenser149D 2.6.2. Low level in 147D 1. LAL-1011 is 19. Provide LAL &
vessel. available LAH-1012 on
Malfunction of LT redundant
1021 to open full LV- transmitter LT-
1021 to 120CF4 from 1012
149D.
2.7. Malfunction of TIC 2.7.1. Low temperature
1067 to open full TV of warm NH3. No
1067 to 149D vessel. significant

Respo
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consequences
2.8. Inadvertent start of 2.8.1. No significant
standby warm NH3 consequence
pumps 113J/JA to
urea plant along with
main pump.
2.9. Stuck in open position 2.9.1. No significant
of LV 1015B at the consequence
discharge of 113J/JA
/
Malfunction of LT
1015 to open full of
LV 1015 B
2.10. Inadvertent/Malfunct 2.10.1. No significant
ion start of standby consequence
cold NH3 product
pumps 124J/JA to
storage along with
Main pump.
2.11. Stuck in open 2.11.1. No significant
position of LV consequence
1015A at the
discharge of
124J/JA.
Malfunction of LT
1015 to open full LV
1015A

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2.12. Malfunction of FT 2.12.1. No significant
1090 to FV 1090 at consequence
the steam
condensate line to --
----
3. Reverse Flow 3.1. No issues envisaged 3.1.1. 1.
4. Mis-directed flow 4.1. No issues envisaged 4.1.1. 1.
5. High 5.1. Failure of CWS to 5.1.1. Over 1. PAH-1109 is
Temperature 127C refrigerant pressurization in available
condenser. 149D 2. PV-1109 is available
to modulate and
3. PRV-149D is
available
4. PRV-105J is
available
5.1.2. Low level in 149-D 1. Refer flow deviation
5.1.3. High temperature 1. 24. Provide TAH-
at 127C outlet 1401
6. Low 6.1. No credible cause 6.1.1. 1.
Temperature
7. High Pressure 7.1. Refer flow deviation 7.1.1. 1.
8. Low Pressure 8.1. Refer flow deviation 8.1.1. 1.

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9. High Level 9.1. Refer flow deviation 9.1.1. 1.
10. Low Level 10.1. Refer flow deviation 10.1.1. 1.
11. Composition 11.1. No issues
change envisaged
12. Other 12.1. Refer node 1
Maintenance
Accessibility
wn/commissioni
13.2. Training of operator 13.2.1. Potential facility 1. Commissioning
ng
hazard support is available
13.3. Long shutdown on 13.3.1. Potential thermal 1. Thermal relief valve 34. Replace
turnaround expansion and PRV-128C is thermal relief
possible rupture available valve tag no to
of tubes TRV instead of
PRV
13.4. Long shutdown on 13.4.1. Potential thermal 1. Thermal relief valve 34. Replace
turnaround expansion and PRV-127C is thermal relief
possible rupture available valve tag no to
of tubes TRV instead of
PRV
14. Positive 14.1. Refer node 1
isolation, drain,
vent etc.
15. Safety system 15.1. Seal failure warm


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NH3 pump
15.2. Seal failure of cold
NH3 pump
16. Sampling 16.1. No issues
envisaged
17. Utility- 17.1. Refer node 1
Instrument air
failure
18. Utility-power 18.1. Refer node 1
failure
19. Utility CW 19.1. Refer tube rupture
failure deviaton
20. Chill water 20.1. NA

failure
21. N2 failure 21.1. Refer node 1
22. Tube rupture. 22.1. Possible 127C tube 22.1.1. Slow process 1. PAH-1109 is
rupture choking of tubes available
because of high
pH due to
precipitation of
phosphate leads
to loss of heat
duty and high

Respo
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pressure on
149D
22.2. Possible outer tube 22.2.1. Overpressurizati 1. PAH-1009 is
rupture of 120C on of 120CF and available
possible damage 2. PRV-120CF1/2/3/4
are available
22.3. Possible tube 22.3.1. Slow process
rupture of 128C choking of tubes
because of high
pH due to
precipitation of
phosphate leads
to loss of heat
duty and high
pressure on
149D
Node: 4. Ammonia Liquid Storage and Transportation.

Node Intention: 1. Storage and transportation. (Flare, loading/unloading, and refergeration package will be done after receipt of all
vendor documents related to HAZOP). NH3 heater HAZOP on hold
Drawing No: 17269-400100-CP25-01, Rev 2A+; 17269-400100-CP25-02, Rev 2A+; 17269-400100-CP25-03, Rev 2A+; 17269-400100-
CP25-04, Rev 2A+; 17269-400100-CP25-05, Rev 2A+; 17269-400100-CP25-06, Rev 2A+; 17269-400200-CP25-01, Rev 2A+; 17269-
400400-CP25-01, Rev 2A+
Respo
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400400-CP25-01, Rev 2A+
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1. No/Less Flow of 1.1. Failure of cold NH3 1.1.1. No significant
NH3 from NH3 pump 124J/JA consequences.
unit to storage Standby pump is
tank 40T101A/B available
1.2. LV-1015A stuck in 1.2.1. High back 1. Pump is designed
close position(during pressure to the for high shutoff
cold operation) pump and possible pressure
damage of the 2. Pump SP-ARV-
pump. 124J/JA is available
to protect the pump
3. FAL-1061 is
available
1.3. Malfunction of LIC- 1.3.1. High back 1. Pump is designed
1024B to close LV- pressure to the for high shutoff
1015A(during cold pump and possible pressure
operation) damage of the 2. Pump SP-ARV-
pump. 124J/JA is available
to protect the pump
3. FAL-1061 is
available
1.4. Inadvertent closure 1.4.1. High back 1. Pump is designed
XV-1001/1021 pressure to the for high shutoff
pump and possible pressure
damage of the 2. Valve status

400400-CP25-01, Rev 2A+
Respo
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pump. indication is
available
3. Pump SP-ARV-
to protect the pump
4. FAL-1061 is
available
1.4.2. Possible low level 1. LAL-1001A/B/C,
in T-101A/B when LAL-1021A/B/C are
NH3 transfer available
pump P-101A/B, 2. LAL-1001D, LAL-
loading pump P- 1021D are available
102 are in
operation
1.4.3. Possible cavitation 1. LAL-1001A/B/C,
of the transfer LAL-1021A/B/C are
pump P-101A/B, available
loading pump P- 2. LAL-1001D, LAL-
102 1021D are available
3. LALL-1001A/B/C,
LALL-1021A/B/C
are available(2oo3
voting logic)
2. No/less flow of 2.1. Failure of transfer P- 2.1.1. High level in T- 1. LAH-1001A/B/C,

400400-CP25-01, Rev 2A+
Respo
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NH3 from 101A/B, P-102 101A/B leads to LAH-1021A/B/C are
Storage tank to loading pump NH3 carryover to available
loading/ urea compressor 2. LAH-1001D, LAH-
plant suction and 1021D are available
damage
3. LAHH-1001A/B/C,
LAHH-1021A/B/C
are available(2oo3
voting logic)
2.1.2. Upset in loading 1. Standby pump is
operation and loss available
of revenue
[Revalidated]
2.1.3. Low/no flow at 1. TIC-1010 is To be
discharge pump available to discuss
header leads to modulate and during
high temperature control the vendor
of heater outlet temperature through package
and upset in LP steam HAZOP
loading area/Urea 2. TAH-1013 is
available
3. TAH-1010 is
available
4. TAHH-1013 is 33. Convert
available TAHH-1013 to

400400-CP25-01, Rev 2A+
Respo
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2oo3 voting
logic
2.2. Choking of suction 2.2.1. Possible cavitation 1. PDAH-1055A/B/C
strainer of the transfer are available
pump P-101A/B,
loading pump P-
102 and damage
2.3. Inadvertent closure 2.3.1. High level in T- 1. LAH-1001A/B/C,
XV-1002/1022 at the 101A/B leads to LAH-1021A/B/C are
outlet of tank NH3 carryover to available
compressor 2. LAH-1001D, LAH-
suction and 1021D are available
damage
3. LAHH-1001A/B/C,
LAHH-1021A/B/C
are available(2oo3
voting logic)
2.3.2. Possible cavitation 1. PDAH-1055A/B/C
of the transfer are available
pump P-101A/B,
loading pump P-
102 and damage
2.4. Inadvertent closure of 2.4.1. High back 1. SP-40110A/B/C are 31. Provide PAH To be
XV-1005/1006 at NH3 pressure to the available on PT-1046 at discuss
loading area pump, the outlet of during
overpressurization NH3 heater vendor

400400-CP25-01, Rev 2A+
Respo
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y
downstream of 40E0101 package
equipment and HAZOP
damage 2. Design
intent to be
proved for
downstrea
m
equipment
and
pipings
3. No/less flow of 3.1. TIC-1010 3.1.1. Low temperature 1. TAL-1013 is To be
LP steam to NH3 malafunction to close of heater outlet available discuss
E-0101 TV-1010 during
vendor
package
HAZOP
2. TALL-1013 is 32. Convert TALL-
available 1013 to 2oo3
voting logic
4. More/ High Flow 4.1. LV-1015A stuck in 4.1.1. High level in T- 1. LAH-1001A/B/C,
of NH3 from NH3 open position(during 101A/B leads to LAH-1021A/B/C are
unit to storage cold operation) NH3 carryover to available
tank 40T101A/B compressor 2. LAH-1001D, LAH-
damage
3. LAHH-1001A/B/C,

400400-CP25-01, Rev 2A+
Respo
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y
LAHH-1021A/B/C
are available(2oo3
voting logic)
4. FAH 1061 is
available.
4.2. Malfunction of LIC- 4.2.1. High level in T- 1. LAH-1001A/B/C,
1024B to open LV- 101A/B leads to LAH-1021A/B/C are
1015A(during cold NH3 carryover to available
operation) compressor 2. LAH-1001D, LAH-
damage
3. LAHH-1001A/B/C,
LAHH-1021A/B/C
are available(2oo3
voting logic)
4. FAH 1061 is
available.
5. More flow of NH3 5.1. Inadvertent startup of 5.1.1. Low level in T- 1. LAL-1001A/B/C,
from Storage standby pump with 101A/B leads to LAL-1021A/B/C are
tank to loading/ main pump(operation possible cavitation available
urea plant error) 2. LAL-1001D, LAL-
1021D are available
3. LALL-1001A/B/C,
LALL-1021A/B/C
are available(2oo3

400400-CP25-01, Rev 2A+
Respo
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y
voting logic)
5.1.2. High flow at 1. TAL-1013 is To be
discharge pump available discuss
header leads to during
low temperature of vendor
heater outlet and package
upset in loading HAZOP
area/Urea 2. TAL-1010 is
available
3. TALL-1013 is 32. Convert TALL-
available 1013 to 2oo3
voting logic
6. More flow of LP 6.1. TIC-1010 6.1.1. High temperature 1. TAH-1013 is To be
steam to NH3 E- malafunction to open at the heater outlet available discuss
0101 full TV-1010 during
vendor
package
HAZOP
2. TAHH-1013 is 33. Convert
available TAHH-1013 to
2oo3 voting
logic
6.1.2. Condensate pot D- 1. Design intent is
0101 is subjected taken care of
to high

400400-CP25-01, Rev 2A+
Respo
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y
temperature
7. Reverse Flow 7.1. No issues envisaged
8. Mis-directed flow 8.1. No issues envisaged
9. High Tempeature 9.1. Refer no/less flow
10. Low 10.1. Refer More/high
Temperature flow deviation
11. High Pressure 11.1. Refer flow deviation
12. Low Pressure 12.1. XV-1004/1024 12.1.1. Low pressure 1. BV40103A/B,
stuck in close and possible BV40123A/B are
position, not vacuum and available to prevent
available when damage of the the vacuum and
required tank damage of the tank
2. PSL-1002A/B/C,
PSL-1022A/B/C are
available
3. PSL-1002D/E/F,
PSL-1022D/E/F are
available
4. PSLL-1002A/B/C,
PSLL-1022A/B/C
are available only
for alarm for this
scenario

400400-CP25-01, Rev 2A+
Respo
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y
12.2. Inadvertent opening 12.2.1. Low pressure 1. BV40103A/B,
of XV-1003/1023 and possible BV40123A/B are
vacuum and available to prevent
damage of the the vacuum and
tank damage of the tank
2. PSL-1002A/B/C,
PSL-1022A/B/C are
available
3. PSL-1002D/E/F,
PSL-1022D/E/F are
available
4. PSLL-1002A/B/C,
PSLL-1022A/B/C
are available
12.3. Excess pump out 12.3.1. Low pressure 1. BV40103A/B,
and possible BV40123A/B are
vacuum and available to prevent
damage of the the vacuum and
tank damage of the tank
2. PSL-1002A/B/C,
PSL-1022A/B/C are
available
3. PSL-1002D/E/F,
PSL-1022D/E/F are

400400-CP25-01, Rev 2A+
Respo
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y
available
4. PSLL-1002A/B/C,
PSLL-1022A/B/C
are available
12.3.2. Refer flow
deviation above
13.2. Inadvertent closure 13.2.1. high level and 1. To be
LV-1011 possible liquid discuss
carryover to during
heater and LP vendor
steam line package
HAZOP
14. Low Level 14.1. Refer flow deviation
14.2. Inadvertent full 14.2.1. Low level and 1. TAH-1010 is To be
opening of LV-1011 possible gas available discuss
blowby scenario during
vendor
package
HAZOP
15. Composition 15.1. No issues
change envisaged
Maintenance

400400-CP25-01, Rev 2A+
Respo
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y
Accessibility
isolation,drain,v
ent etc.
18. Safety system 18.1. Leakage in tank 18.1.1. Potential 1.

personnel injury,
environment and
asset loss
19. Sampling
20. Utility-
Instrument air
failure
21. Utility-power
failure
22. Utility CW
failure
23. Chill water

failure
24. N2 failure

400400-CP25-01, Rev 2A+
Respo
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y
25. Tube rupture. 25.1. 25.1.1. 1. To be
discuss
during
vendor
package
HAZOP
Node: 5. DM water,
Deaerator system & HP/LP BFW pumps
Node Intention: 1. To supply BFW to steam generators
Drawing No: 17269-060000-TE25-64-D106, Rev 2A+; 17269-060000-TE25-64-D106A, Rev 2A+; 17269-060000-TE25-64-D106B, Rev
2A+; 17269-060000-TE25-64-D109, Rev 2A+
Respo
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y
1. No/Less Flow 1.1. FT 1056 malfunctions 1.1.1. Loss of make up 1. FAL 1056 is
to close FV1056 on to deaerator, low available.
DM water make up to level leads to 2. LAL 1030 is
Deaerator cavitation of the available
101U/inadvertent BFW pumps and
3. LALL 1123 A/B/C
closure of FV-1056 damage.
are available with
on DM water makeup
2003 voting logic.
Dearerator
4. SP-ARV-104JA/B/C
Node: 5. DM water,
2A+; 17269-060000-TE25-64-D109, Rev 2A+
Respo
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y
are available
5. SP-ARV-150J/JA is
available
1.1.2. Loss of BFW 1. Refer Node 2.
make up to steam
2. Routine monitoring
drum in Ammonia
done.
unit, process
operation upset (
Refer Node 2 )
1.1.3. High back 1. Pump designed for

pressure to the shut off pressure.
DM water pump 2. FV-5007 minimum
and damage. flow valve available.
1.2. Inadvertent closure of 1.2.1. Low level in DM 1. LAL 5002 is
HV-5001 (operation water storage tank available
error) at the DM water and possible 2. LALL 5002 is
inlet to storage tank cavitation of the available to trip the
199-T pump and pump.
damage.
3. Valve open close
status indication is
available in DCS.
1.3. Failure of DM water 1.3.1. Low level in 1. Stand by pump is
pump199J/JA deaerator and available.
possible cavitation 2. LAL 1030 is
Node: 5. DM water,
2A+; 17269-060000-TE25-64-D109, Rev 2A+
Respo
s s
y
of the BFW pump. available.
3. FAL-5007 is
available
1.4. Failure BFW from 1.4.1. Low level in 1. SP-ARV-104JA/B/C
facility any one to Deaerator leads to are available
deaerator 101U cavitation of BFW 2. LAL 1030 is
pumps and available
damage.
3. LALL 1123 A/B/C
are available with
2oo3 voting logic.
1.5. Malfunction of PT 1.5.1. Loss of dearation 1. PAL 1031 is 25. Change PI-
1031 to close PV and possible available to alert the 1743 to PT-
1031, LP steam to ingress of O2 in operator. 1743 and
deaerator BFW system leads provide PAL-
to high corrosion 1743
in the long run and 2. Routine monitoring
damage. is done.
3. O2 scavenger
Chemical injection is
available.
1.5.2. Low pr. In 1. PAL 1031 is 25. Change PI-
Deaerator vessel available. 1743 to PT-
and possible 1743 and
vacuum. provide PAL-
1743
Node: 5. DM water,
2A+; 17269-060000-TE25-64-D109, Rev 2A+
Respo
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y
2. Vessel is designed
for full vacuum.
1.6. Failure of 104 1.6.1. Upset in steam 1. Refer Node 2
JA/JB/JC BFW pump. generation unit
2. Standby pump is
Leads to process
available
operation upset in
NH3 unit. (Refer
Node 2)
1.6.2. High level in 1. LAH 1030 is
deaerator possible available.
flashing of hot 2. LIC 1031 is
water over the available to
vent, potential modulate to drain
personnel injury. the vessel and
control the level.
3. PPE is available.
1.7. Choking of suction 1.7.1. High level in 1. LAH 1030 is
strainer SP-STR- deaerator available.
104J1/J2/J3 2. LAH-1031 is
available
3. PDAH 8117/18/20
are available to alert
the operator.
4. LIC-1031 is
available to
Node: 5. DM water,
2A+; 17269-060000-TE25-64-D109, Rev 2A+
Respo
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y
modulate to drain
the vessel and
control the level.
5. PAL-1095 is
available at
discharge of HP
BFW pump
6. FAL-1020 is
available to
autostart the
standby pump
1.8. Stuck in close 1.8.1. High back 1. Pump design intent
position ( mech pressure to the taken care of,
failure) LV1001 at the pump and possible designed for shut off
discharge of BFW damage of the pressure.
Pumps ( inlet to pump. 2. Pump is provided 15. Provide PAH Wuhua
123C2) on Steam with minimum flow on PT 1095. n
drum cascade valve
loop./malfunction of
1.8.2. Refer node 2
cascade loop to close
LV 1001
1.9. Inadvertent closure of 1.9.1. High level in 1. LAH 1030 is

LV 1031 to drain deaerator available
vessel from 101U
1.10. Failure of O2 1.10.1. High corrosion in 1. Routine sampling
Node: 5. DM water,
2A+; 17269-060000-TE25-64-D109, Rev 2A+
Respo
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y
scavenger injection the long run and done at deaerator.
pumps 106LJ/JA possible damage 2. Standby pump is
of the BFW available.
system.
indication is
available
1.11. Failure of LP BFW
pump 150J/JA
1.12. Choking of pump
150J/JA suction
strainer
1.13. Failure of LV-7406
to 140C1/C2(Refer
node 2)
2. More/ High Flow 2.1. Inadvertent open of 2.1.1. High level in 1. LAH 1030 is
FV-1056 on DM water deaerator ,flashing available
make up to Deaerator of Hot water thro’ 2. LIC 1031 is
101U full. the vent and loss available to
of DM water modulate to drain
through’ drain LV the vessel and
1031. control the level.
2.2. Refer low flow
deviation for loss of
LP steam.
2.3. Inadvertent to open 2.3.1. Possible over 1. PAH 1031 is 26. Change PI- Wuhua
Node: 5. DM water,
2A+; 17269-060000-TE25-64-D109, Rev 2A+
Respo
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y
full PV 1031, LP pressurization of available 1743 to PT- n
steam to deaerator the vessel and 1743 and
damage. provide PAH-
1743
2. PRV 101U is
available.
2.4. Possible startup of 2.4.1. High discharge 1. Pump running status 15. Provide PAH Wuhua
stand by pump 104 pressure to the indication is on PT 1095. n
JA/JB/JC BFW pump pump available
along with Main pump 2. SP-ARV-104JA/B/C
autostart are available
2.5. Inadvertent opening 2.5.1. Process operation
of LV1001 at the upset in Ammonia
discharge of BFW unit.
Pumps ( inlet to 2.5.2. Low level in 1. LAL1030 is
123C2) on Steam deaerator available.
drum ./malfunction of
cascade loop to open 2. LSLL 1123 is
available with 2oo3
LV 1001 full
the pumps.
2.5.3. Refer node 2 for

141D
2.6. Malfunction of LV 2.6.1. Loss of O2 1. LAL 1030 is
1031 to drain vessel scavenger available
Node: 5. DM water,
2A+; 17269-060000-TE25-64-D109, Rev 2A+
Respo
s s
y
from 101U chemical .No 2. LSLL 1123 is
significant available with 2oo3
consequence. voting logic to trip
the pumps.
2.7. Inadvertent startup of 2.7.1. Loss of O2 1. LAL 1030 is

the standby O2 scavenger available
Scavenger pump chemical .No 2. LSLL 1123 is
along with main significant available with 2oo3
pump. consequence. voting logic to trip
the pumps.
2.8. Inadvertent startup of 2.8.1. High discharge 1. LV-7406 is available 16. Provide PAH-
standby LP BFW pressure to the to modulate and 6095 at PT-
pump 150J/JA on pump control level 6095 at the
autostart of LAL-7405 discharge of
LP BFW pump
2. LAH-7406 is
available
3. SP-ARV-150J/JA is
available
3. Reverse Flow 3.1. No issues envisaged
4. Mis-directed flow 4.1. No issues envisaged
5. High Tempeature 5.1. CW failure to pump 5.1.1. Possible seal
Node: 5. DM water,
2A+; 17269-060000-TE25-64-D109, Rev 2A+
Respo
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y
seal failure and
[Revalidated] damage
5.2. More flow of LP 5.2.1. No significant
steam to deaerator consequences
6. Low 6.1. Failure of LP steam to 6.1.1. Refer flow
Temperature deaerator deviation
7. High Pressure 7.1. Refer flow deviation.
8. Low Pressure 8.1. Refer flow deviation.
9. High Level 9.1. Refer flow deviation.
10. Low Level 10.1. Refer flow deviation.
11. Composition 11.1. DM water system 11.1.1. Upset in boiler
change upset and supply of operation in
Off spec DM water. OSBL
11.1.2. High conductivity 1. AAH 1005 is
in the BFW water available to alert the
and upset in the operator at the DM
operation of water inlet of
steam turbines deaerator.
12. Other 12.1. Refer Node 1
Maintenance
Accessibility
13. Positive 13.1. Refer Node 1
isolation,drain,v
ent etc.
Node: 5. DM water,
2A+; 17269-060000-TE25-64-D109, Rev 2A+
Respo
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y
14. Safety system 14.1. Seal failure 14.1.1. Loss of BFW to 1. Pump is provided
atmosphere with double
mechanical seal??
[Revalidated]
15. Sampling 15.1. Refer Node1
16. High corrosion 16.1. Refer flow deviation.
16.2. Failure of corrosion 16.2.1. Possible damage 1. Stand by pump is
inhibitor pump 107-L of piping and available.
J/JA equipment in
long run
17. Relief or 17.1. Refer Node 1
blowdown
18. Utility- 18.1. Refer Node 1
Instrument air
failure
19. Utility-power 19.1. Refer Node 1
failure
20. Utility CW 20.1. Failure of CW to the 20.1.1. Casing High 1. TAH 1556 is
failure pump casing. temperature and available at the
possible damage BFW pump
of the pump discharge.

Node: 5. DM water,
2A+; 17269-060000-TE25-64-D109, Rev 2A+
Respo
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y
failure
22. N2 failure 22.1. Refer Node 1
23. Tube rupture. 23.1. Tube leak at 123C2 23.1.1. Over 1. PAH-1036 is
pressurization of available
the steam drum 2. PRV-141D1/D2 are
141D and available
damage.
23.1.2. Process
operation upset
in NH3 unit.
Node: 6. HP/MP/LP steam distribution.

Node Intention: 1. HP/MP/LP steam distribution.
Drawing No: 17269-060000-TE25-64-D102, Rev 2A+; 17269-060000-TE25-64-D103, Rev 2A+; 17269-060000-TE25-64-D104, Rev 2A+
Respo
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y
1. No/less flow of 1.1. Supply failure from 1.1.1. Low pressure on 1. Vendor
HP steam to HP OSBL. HP steam leads to justification
header from HP turbine trip is required
OSBL. for impact
of turbine
damage

Respo
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y
1.1.2. Syn gas 1. Refer node 1 & 2
compressor trips
and possible
process operation
upset in synthisis
unit , loss of NH3
production
1.2. Upset in NH3 unit 1.2.1. Low pressure on 1. PAL is available 27. Update the
loss of steam HP steam leads to P&ID with tag
production. HP turbine trip nos
2. PALL is available 27. Update the
P&ID with tag
nos
compressor trips
and possible
process operation
upset in synthisis
unit , loss of NH3
production
1.3. Inadvertent closure of 1.3.1. Low pressure on 1. PAL is available 27. Update the
MOV-1001 at the B/L. HP steam leads to P&ID with tag
HP turbine trip nos
P&ID with tag
nos
compressor trips

Respo
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y
and possible
process operation
upset in synthisis
unit , loss of NH3
production
1.4. PIC 1024 malfunction 1.4.1. Low pressure on 1. PAL is available 27. Update the
to open PV 1024 HP steam leads to P&ID with tag
when not required. HP turbine trip nos
P&ID with tag
nos
compressor trips
and possible
process operation
upset in synthisis
unit , loss of NH3
production
1.5. Trip of HP turbine 1.5.1. Syn gas 1. Refer node 1 & 2
103JT compressor trips
and possible
process operation
upset in synthisis
unit , loss of NH3
production
1.6. Inadvertent closure of 1.6.1. Increase in HP 1. PV-1024 is available
PV 1018 MP steam header pressure to vent the HP
let down valve. header

Respo
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y
2. PAH-1018B is
available
3. PRV-101B1/2 is
available
1.6.2. Decrease in MP 1. PIC-1015 is 28. Provide PAL-
steam header available to 1014(on mid of
pressure modulate the header PT-1013,
pressure through 1014, 1015)
PV-1015
1.7. Inadvertent closure of 1.7.1. Increase in HP 1. PV-1024 is available
HV 1028 MP steam header pressure to vent the HP
let down valve when header
required 2. PAH-1018B is
available
3. PRV-101B1/2 is
available
4. PV-1018 let down is
available
1.8. Inadvertent closure of 1.8.1. High temperature 1. TAH-1554 is
BFW quench valves leads to upset in available
TV-1020/1021 (BFW MP steam turbine, 2. TAH-9551 is
from 104J/JA) when possible available
required towards the damage(refrigerati
3. TAHH-9585A/B/C
HP/MP let down on compressor
station turbine) available to trip the
turbine(2oo3 voting
logic)

Respo
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y
4. Valve hand wheel
provision is
available for both
TV-1020/1021
2. No/Less flow of 2.1. Failure HP steam 2.1.1. Refrigeration 1. HV-1028/PV-1018 28. Provide PAL-
MP steam to MP turbine, extraction compressor 105JT are available 1014(on mid of
steam header steam fails trips (No supply of PT-1013,
MP steam to 1014, 1015)
105JT) 2. Turbine running
status indication
available
2.1.2. MP steam export 1. 28. Provide PAL-
to OSBL upset 1014(on mid of
PT-1013,
1014, 1015)
2.2. Failure PV 1018 /HV
1028 let down
stations. (HP -MP let
down stations.)(refer
No/less flow of HP
steam to HP header
from OSBL.
deviation)
2.3. PIC-1014 2.3.1. Loss of MP steam 1. 28. Provide PAL-
malfunctions to open to atm 1014(on mid of
PV-1014. PT-1013,
1014, 1015)
2.3.2. Refrigeration 1. PIC-1018 is

Respo
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y
compressor 105JT available to
trips (No supply of modulate the header
MP steam to pressure through
105JT) PV-1018
2.3.3. MP steam export 1. 28. Provide PAL-
to OSBL upset 1014(on mid of
PT-1013,
1014, 1015)
3. No/less flow of 3.1. Supply failure from 3.1.1. High temperature 1. TAH-1555 is
BFW from deaerator area/failure on LP steam available
150J/JA LP BFW of Pump 150J/JA. header
pump. 3.1.2. Low pressure on 1. PAL-1017 is
LP header leads to available
process operation 2. TAL-1555 is
upset available
3.2. Inadvertent closure of 3.2.1. High temperature 1. TAH-1555 is
TV 1023 at BFW line on LP steam available
(quench) header
4. No/less flow of 4.1. Inadvertent closure of 4.1.1. No significant
LP steam to PV-1016 when consequences
header. required
4.2. Malfunction of PIC 4.2.1. No significant
1016 to PV 1016 to consequences
close
4.3. Inadvertent closure of 4.3.1. Overpressurization 1. 29. Reveiw the
manual I/V at the of 186D requirment of
outlet of 186D manual

Respo
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y
(operation error -fail isolation vavle
to line up during start at the outlet of
up) 186D
overhead. If
required
provide PRV
5. No/less flow LP 5.1. Inadvertent closure of 5.1.1. No significant
steam to urea PV 1017A LP steam consequences
plant to urea plant.
5.2. PIC 1017 5.2.1. No significant
malfunctions to open consequences
PV 1017B towards
atmosphere.
6. More/High flow of 6.1. PIC malfunctions to 6.1.1. Increase in MP 1. PAH-1014 is
MP steam open PV 1018 header pressure available
HP/MP steam let 2. PIC-1014 is
down valve., full available to
modulate and
3. PRV-MS1/MS2
6.1.2. Decrease in HP 1. PAL-1018 is
steam header available
pressure
compressor trips
and possible
process operation

Respo
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y
upset in synthisis
unit , loss of NH3
production
7. More/High flow of 7.1. Malfunction of PIC 7.1.1. Low pressure at 1. 28. Provide PAL-
MP steam to 1015 to open PV MP header 1014(on mid of
urea plant 1015 full towards PT-1013,
urea plant. 1014, 1015)
7.1.2. Low pressure in 1. Vendor
105JT and trips justification
is required
for impact
of turbine
damage
8. More flow of LP 8.1. Inadvertent opening 8.1.1. High pressure in 1. PRV-LS is available 30. Provide PT
steam to header of PV-1016 when not LP header with high and
required Low alarm on
LP steam
header
8.1.2. Low pressure at 1. 28. Provide PAL-
MP header 1014(on mid of
PT-1013,
1014, 1015)
8.2. Malfunction of PIC 8.2.1. High pressure in 1. PRV-LS is available 30. Provide PT
1016 to PV 1016 to LP header with high and
open Low alarm on
LP steam
header
8.2.2. Low pressure at 1. 28. Provide PAL-

Respo
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y
MP header 1014(on mid of
PT-1013,
1014, 1015)
9. More flow of LP 9.1. Inadvertent opening 9.1.1. Low pressure in 1. 30. Provide PT
steam to urea of PV-1017A when LP steam header with high and
plant not required Low alarm on
LP steam
header
10. More flow of 10.1. Inadvertent opening 10.1.1. BFW carryover in 1. Scenario to
BFW from of TV 1023 at BFW LP steam header be
150J/JA LP line (quench) and to discussed
BFW pump. OSBL(urea plant) during urea
plant
HAZOP
workshop
10.1.2. Low temperature 1. TAL-1555 is
in LP steam available
header
11. More flow of 11.1. Inadvertent opening 11.1.1. BFW carryover in
BFW from of TV-1020/1021 MP steam
104JA/B/C HP header and
BFW pump. possible upset in
operation of
105JT
11.1.2. BFW carryover in 1. Scenario to
MP steam be
header and to discussed
OSBL(urea plant) during urea

Respo
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y
plant
HAZOP
workshop
11.1.3. Low temperature 1. TAL-1554 is
in MP steam available
header
12. Reverse Flow 12.1. No issues
envisaged
13. Mis-directed 13.1. No issues
flow envisaged
14. HIgh 14.1. Refer flow deviation
Tempeature
15. Low 15.1. Refer flow deviation
Temperature
16. HIgh Pressure 16.1. Refer flow deviation
17. Low Pressure 17.1. Refer flow deviation
18. High Level 18.1. NA
19. Low Level 19.1. NA
20. Composition 20.1. NA
change
Maintenance
Accessibility
isolation,drain,v

Respo
s s
y
ent etc.
23. Safety system 23.1. No credible cause
24. Sampling 24.1. No credible cause

25. Utility- 25.1. No credible cause
Instrument air
failure
26. Utility-power 26.1. No credible cause
failure
27. Utility CW 27.1. No credible cause
failure
28. Chill water 28.1. No credible cause

failure
29. N2 failure 29.1. No credible cause
30. Tube rupture. 30.1. No credible cause
Node: 7. 103-JT HP steam Turbine,surface condenser & accessories.

Node Intention: 1. HP steam turbine, prime mover of sys gas compressor
Drawing No: 17269-060000-TE25-64-D105, Rev 2A+; 17269-060000-TE25-64-D105A, Rev 2A+; 17269-060000-TE25-64-D107, Rev 2A+;
17269-060000-CP25-65-D101E, Rev 2A+; 17269-060000-CP25-65-D101F, Rev 2A+
Respo
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y
1. No/Less Flow 1.1. U/S upset less supply 1.1.1. Low speed of 1.
HP steam to of HP steam to 103JT turbine
103JT HP steam 1.1.2. Trip of Syn gas 1. Compressor
turbine compressor and antisurge provision
Process operation is available
upset ,loss of NH3 2. NH3 loop has
Production. inherent safeguard
to take the process
into safe state.
1.2. In advertant closure 1.2.1. Loss of HP steam 1. HP steam turbine
of XV-9305/XV-9313 to turbine trips leads to syn
compressor trips
1.2.2. Process operation 1. Inherent safegaurd
synthesis loop is available to take
upset and loss of synthesis process
NH3 production loop to fail safe
system
1.3. Choking of 1.3.1. Loss of HP steam 1. HP steam turbine
Strainer/Filter U/s of to turbine trips
XV 9305/9313. 1.3.2. Process operation 1. Inherent safegaurd
system
1.4. Inadvertent closure of 1.4.1. Low speed of
SV 9307 at the inlet turbine
of HP steam turbine. 1.4.2. High back 1. PAH-9351 is
pressure in HP available
steam line 2. PAHH-9385 is
turbine(2oo3 voting

Respo
s s
y
logic)
3. PRV-101B1/2 is
available
4. HV-1028 is available
to let down HP
steam to MP steam
header
1.5. Malfunction of PT- 1.5.1. Low pressure on
1024 to open PV- HP steam line and
1024 when not reduce the speed
required of turbine(hold
point)
1018 to open PV- HP steam line and
required on the of turbine(hold
HP/MP let down point)
station 1.6.2. Refer node 6
2. No/less flow of 2.1. PT-9314 malfunction 2.1.1. Loss of vacuum in 1. PAH-9399 is
LP sealing steam to close PCV-9314 turbine leads to available
to turbine trip turbine and 2. PAHH-9334 is
compressor available(2oo3)
3. No/less flow of 3.1. Failure of pumps 3.1.1. Damage of turbine 1. LAH-9332 is To be
Surface 112J/112JA due to condensate available to start the discussed
condenser carryover to standby pump outside the
condensate turbine workshop

Respo
s s
y
pump to OSBL for the
turbine
damage
2. LAHH-9333 is
available(2oo3
voting logic)
3.1.2. High level in 1. PAH-9399 is
surface condenser available
leads to possible 2. PAHH-9334 is
loss of vacuum available(2oo3)
3.2. Choking of suction 3.2.1. High level in 1. PAH-9399 is
strainer of pumps surface condenser available
112J/JA leads to possible 2. PAHH-9334 is
3. LAH-9332 is
available to start the
standby pump
4. 2. LAHH-9333 is
available(2oo3
voting logic)
3.3. Inadvertent opening 3.3.1. High level in 1. PAH-9399 is
of FCV 9385 min flow surface condenser available
back to hot well. leads to possible 2. PAHH-9334 is
3. LAH-9332 is

Respo
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y
standby pump
4. LAHH-9333 is
available(2oo3
voting logic)
3.4. Inadvertent closure of 3.4.1. High level in 1. PAH-9399 is
LCV-9535 surface condenser available
condensate to OSBL. leads to possible 2. PAHH-9334 is
3. LAH-9332 is
available
4. LAHH-9333 is
available(2oo3
voting logic)
4. No/less flow of 4.1. Failure of motive 4.1.1. Loss of vacuum 1. PAH-9399 is
MP steam to steam to ejector ist available
inter/after and 2nd stage 2. PAH-9332 is
condenser ejectors available
06103-
3. PAHH-9334 is
JCC1/JCC2
available(2oo3)
4. PRV-9335 is
available
5. No/Less flow CW 5.1. Failure CW supply to 5.1.1. Loss of vacuum 1. PAH-9399 is
to ejector ejector condenser. available
condenser 2. PAH-9332 is
available

Respo
s s
y
3. PAHH-9334 is
available(2oo3)
4. PRV-9335 is
available
6. No/less flow of 6.1. CW supply failure to 6.1.1. Loss of vacuum 1. PAH-9399 is
CW surface Surface condenser available
available
3. PAHH-9334 is
available(2oo3)
4. PRV-9335 is
available
7. No/less of MP 7.1. Inadvertent opening 7.1.1. No significant
steam extraction of FCV-9309 consequence
from HP turbine
8. More/ High Flow 8.1. Inadvertent opening 8.1.1. Overpressurization 1. PSV-9370 is
Of LP steam of PCV-9314 full of steam sealing available
sealing system system and
possible damage
of seal
9. More/high flow of 9.1. Inadvertent start up 9.1.1. Low level on 1. Min recycle valve
Hot well stand by condensate surface condenser FCV-9385 is
condensate to pump along with main leads to possible available
offsite. pump. cavitation of pump 2. LALL-9332 is
and damage available to stop
both the pump

Respo
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y
indication is
available
9.2. Inadvertent opening 9.2.1. Low level on 1. Min recycle valve
of LCV 9535 full. surface condenser FCV-9385 is
Towards Offsite. leads to possible available
cavitation of pump 2. LALL-9332 is
both the pump
3. LAL-9332 is
available
10. More/High flow 10.1. Possible excess HP 10.1.1. Possible high 1. Redundant over
of HP steam to steam to Turbine speed of the speed trip electronic
turbine turbine relay is available to
protect the machine
2. SV-9307 is available
to control the speed
10.1.2. Upset in syn loop
,process
operation upset
and loss of NH3
production
10.2. SV-9307 opens full 10.2.1. Possible high 1. Redundant
speed of the overspeed trip
turbine electronic relay is
available to protect

Respo
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y
the machine
11. More flow of 11.1. Inadvertent closure 11.1.1. Over 1. Refer node 6
MP steam of FCV-9309 pressurization of
extraction from MP steam
HP turbine header
12. Reverse Flow 12.1. When HP turbine 12.1.1. Possible reverse
trips flow on MP
extraction line
from the MP
header and
overspeed
flow envisaged
14. High 14.1. CW supply failure to 14.1.1. Refer no/less
Temperature Surface condenser flow deviation
14.2. High temperature of 14.2.1. High temperature 1. TAH-9351 is
steam from OSBL of steam and available
possible damage 2. TAHH-9385 is
of turbine available with 2oo3
voting logic
15. Low 15.1. Low temperature of 15.1.1. Low temperature 1. TAL-9351 is
Temperature steam from OSBL of steam and available
possible damage 2. UAL-9351 is
of turbine due to available
condensation
3. USLL-9385 is
available with 2oo3

Respo
s s
y
voting logic
17.2. Loss of steam HP 17.2.1. HP turbine trips
steam pressure
20. Composition 20.1. CW Tube rupture in 20.1.1. High 1. AAH-1019 is
change the Surface conductivity carry available
condenser over in 2. Routine sampling
exchanger condensate done
possible upset in
offsite facility
operation.
20.2. Possible high silica 20.2.1. Scale formation 1. AAH-1019 is
content in HP steam (slow available
process)/possible 2. Routine sampling
upset in done
efficiency of
turbine
Maintenance
Accessibility
isolation,drain,v

Respo
s s
y
ent etc.
23. Safety system 23.1. No issues

envisaged
envisaged
25. Utility-
Instrument air
failure
26. Utility-power
failure
27. Utility CW 27.1. Refer composition
failure change deviation
Refer ejector
condenser
deviation.
failure
30. Tube rupture. 30.1. Refer composition

change deviation.
Node: 8. 105-JT MP steam Turbine, surface condenser & accessories.

Node Intention: 1. MP steam turbine, prime mover of refrigeration compressor( tag no to be change)
Drawing No:
Respo
s s
y
1. No/Less Flow 1.1. U/S upset less supply 1.1.1. Low speed of
MP steam to of MP steam to 105JT turbine
105JT MP steam 1.1.2. Trip of 1. Compressor ant
turbine Refrigeration surge provision is
compressor and available
Process operation
upset ,loss of NH3
Production.
1.2. In advertant closure 1.2.1. Loss of MP steam 1. MP steam turbine
of XV-9505 to turbine trips
1.2.2. Process operation 1. Inherent safeguard
system
1.3. Choking of 1.3.1. Loss of HP steam 1. HP steam turbine
Strainer/Filter U/s of to turbine trips
XV 9505 1.3.2. Process operation 1. Inherent safeguard
system
1.4. Inadvertent closure of 1.4.1. Low speed of
SV 9307 at the inlet turbine
of HP steam turbine. 1.4.2. High back 1. PAH-9351 is
pressure in HP available
steam line 2. PAHH-9385 is

Drawing No:
Respo
s s
y
turbine(2oo3 voting
logic)
3. PRV-101B1/2 is
available
4. HV-1028 is available
to let down HP
steam to MP steam
header
1014 to open PV- MP steam line and
required of turbine(hold
point)
1016 to open PV- MP steam line and
required on the MP to of turbine(hold
LP let down station point)
1.6.2. Refer node 6
1.7. Malfunction of PT- 1.7.1. No significant
1015 to full open PV- consequences
1015 when not
required
2. No/less flow of 2.1. PT-9314 malfunction 2.1.1. Loss of vacuum in 1. PAH-9399 is
LP sealing steam to close PCV-9314 turbine leads to available
to turbine trip turbine and 2. PAHH-9334 is
compressor available(2oo3)

Drawing No:
Respo
s s
y
3. No/less flow of 3.1. Failure of pumps 3.1.1. Damage of turbine 1. LAH-9332 is To be
Surface 118J/118JA due to condensate available to start the discussed
condenser carryover to standby pump outside the
condensate turbine workshop
pump to OSBL for the
turbine
damage
2. LAHH-9333 is
available(2oo3
voting logic)
3.1.2. High level in 1. PAH-9399 is
surface condenser available
leads to possible 2. PAHH-9334 is
3.2. Choking of suction 3.2.1. High level in 1. PAH-9399 is
strainer of pumps surface condenser available
112J/JA leads to possible 2. PAHH-9334 is
3. LAH-9332 is
standby pump
4. 2. LAHH-9333 is
available(2oo3
voting logic)
3.3. Inadvertent opening 3.3.1. High level in 1. PAH-9399 is
of FCV 9385 min flow surface condenser available
back to hot well. leads to possible 2. PAHH-9334 is

Drawing No:
Respo
s s
y
3. LAH-9332 is
standby pump
4. LAHH-9333 is
available(2oo3
voting logic)
3.4. Inadvertent closure of 3.4.1. High level in 1. PAH-9399 is
LCV-9535 surface condenser available
condensate to OSBL. leads to possible 2. PAHH-9334 is
3. LAH-9332 is
available
4. LAHH-9333 is
available(2oo3
voting logic)
4. No/less flow of 4.1. Failure of motive 4.1.1. Loss of vacuum 1. PAH-9399 is
MP steam to steam to ejector ist available
inter/after and 2nd stage 2. PAH-9332 is
condenser ejectors available
06103-
3. PAHH-9334 is
JCC1/JCC2
available(2oo3)
4. PRV-9335 is
available
5. No/Less flow CW 5.1. Failure CW supply to 5.1.1. Loss of vacuum 1. PAH-9399 is
to ejector ejector condenser. available

Drawing No:
Respo
s s
y
available
3. PAHH-9334 is
available(2oo3)
4. PRV-9335 is
available
6. No/less flow of 6.1. CW supply failure to 6.1.1. Loss of vacuum 1. PAH-9399 is
CW surface Surface condenser available
available
3. PAHH-9334 is
available(2oo3)
4. PRV-9335 is
available
7. No/less of MP 7.1. Inadvertent opening 7.1.1. No significant
steam extraction of FCV-9309 consequence
from HP turbine
8. More/ High Flow 8.1. Inadvertent opening 8.1.1. Overpressurization 1. PSV-9370 is
Of LP steam of PCV-9314 full of steam sealing available
sealing system system and
possible damage
of seal
8.2. Malfunction of PT-
1015 to close PV-
1015
9. More/high flow of 9.1. Inadvertent start up 9.1.1. Low level on 1. Min recycle valve

Drawing No:
Respo
s s
y
Hot well stand by condensate surface condenser FCV-9385 is
condensate to pump along with main leads to possible available
offsite. pump. cavitation of pump 2. LALL-9332 is
both the pump
indication is
available
9.2. Inadvertent opening 9.2.1. Low level on 1. Min recycle valve
of LCV 9535 full. surface condenser FCV-9385 is
Towards Offsite. leads to possible available
cavitation of pump 2. LALL-9332 is
both the pump
3. LAL-9332 is
available
10. More/High flow 10.1. Possible excess HP 10.1.1. Possible high 1. Redundant over
of HP steam to steam to Turbine speed of the speed trip electronic
turbine turbine relay is available to
protect the machine
2. SV-9307 is available
to control the speed
10.1.2. Upset in syn loop
,process
operation upset
and loss of NH3
production

Drawing No:
Respo
s s
y
10.2. SV-9307 opens full 10.2.1. Possible high 1. Redundant over
speed of the speed trip electronic
turbine relay is available to
protect the machine
10.3. Malfunction of PT- 10.3.1. High 1. SV-9507 is available
1015 to close PV- backpressure to to control the speed
1015 MP header and 2. PV-1014 is available
upset in to vent the MP
refrigerant steam
compressor
operation 3. PAHH-9585 is
turbine(2oo3 voting
logic)
4. PRV-MS1/MS2 are
available
11. More flow of 11.1. Inadvertent closure 11.1.1. Overpressurizati 1. Refer node 6
MP steam of FCV-9309 on of MP steam
extraction from header
HP turbine
12. Reverse Flow 12.1. No credible cause
flow envisaged
14. High 14.1. CW supply failure to 14.1.1. Refer no/less
Temperature Surface condenser flow deviation
15. Low 15.1. No credible cause
Temperature

Drawing No:
Respo
s s
y
17.2. Malfunction of PV- 17.2.1. Refer no/less
1014 opens flow deviation
20. Composition 20.1. CW Tube rupture in 20.1.1. High 1. AAH-4019 is
change the Surface conductivity carry available
condenser over in 2. Routine sampling
exchanger condensate done
possible upset in
offsite facility
operation.
20.2. Possible high silica 20.2.1. Scale formation 1. AAH-4019 is
content in MP steam (slow available
process)/possible 2. Routine sampling
upset in done
efficiency of
turbine
Maintenance
Accessibility
isolation,drain,v
ent etc.

Drawing No:
Respo
s s
y
23. Safety system 23.1. No issues
envisaged
envisaged
25. Utility-
Instrument air
failure
26. Utility-power
failure
27. Utility CW 27.1. Refer composition
failure change deviation
Refer ejector
condenser
deviation.
failure
30. Tube rupture. 30.1. Refer composition

change deviation.
Node: 9. 103 J & JT LO and control oil system.

Node Intention: 1. To supply lube oil and control oil to 103 J & JT
Drawing No:
Respo
s s
y
1. No/Less FlowLO 1.1. Failure of LO pumps 1.1.1. High vibration and
to Turbine and 103JL/JLA possible damage
Compressor of the machines
103JT/J 1.2. Malfunction of PCV 1.2.1. Low LO pressure
9324 to open when to the main LO
not required. header, and
damage.
1.2.2. High vibration and
damage of the
machines.
1.3. Choking LO main 1.3.1. Low LO pressure
filter 103JLL1A/B to main LO
header------
1.4. Inadvertent closure of 1.4.1. Low LO
TV9306 when not temperature and
required. Low pr to the main
LO header-------
1.5. Malfunction to close 1.5.1. Loss of LO to the
PCV 9359. machines, high
vibration and
damage of the
machines
1.6. Malfunction of 9305 in 1.6.1. Trip of HP turbine
control oil line to and process
close. operation upset in
syn gas unit and
loss of NH3
production.
2. More/ High Flow 2.1. Inadvertent start up of 2.1.1. Over
standby pump with pressurization of
main LO pump (Auto the LO header and

Drawing No:
Respo
s s
y
mechanism failure) possible damage
of the machine.
2.1.2. Oil whip and
possible damage
of the bearings
leads to high
vibration of the
machine and
damage.
3. Reverse Flow
4. Mis-directed flow
5. HIgh Tempeature 5.1. Failure of CW to LO 5.1.1. High LO
coolers. temperature leads
to Bearing High
temperature and
damage.
5.1.2. High vibration and
damage of the
machines.
6. Low 6.1. Refer flow deviation
Temperature
6.2. Cut in off switch
failure in LO console
heater
7. HIgh Pressure 7.1. Refer flow deviation

Drawing No:
Respo
s s
y
9. High Level 9.1. Loss of oil in the 9.1.1. Low LO console
system level leads to
cavitation of the Lo
pumps and
damage
10. Low Level 10.1. Loss of oil in the 10.1.1. Low LO console
system level leads to
cavitation of the
Lo pumps and
damage
11. Composition 11.1. Failure of Centrifuge 11.1.1. Possible slip of
change system moisture and
dusts into LO
system leads to
malfunction of
the control
system.
12. Other 12.1. Refer Node 1
Maintenance
Accessibility
isolation,drain,v
ent etc.

wn/commissioni
ng
15. Safety system

Drawing No:
Respo
s s
y
16. Sampling 16.1. Refer to node 1

17. Utility-
Instrument air
failure
18. Utility-power 18.1. Refer to node 1 18.1.1. 1. Emergency power
failure supply to barring
motor and LO
pump???
19. Utility CW
failure
20. Chill water

failure
21. N2 failure
22. Tube rupture. 22.1. Tube leak In LO

cooler
Node: 10. 105 JT& J LO and control oil system

Drawing No:
Respo
s s
y

Drawing No:
Respo
s s
y
1. No/Less Flow
2. More/ High Flow
3. Reverse Flow
5. HIgh Tempeature
6. Low
Temperature
7. HIgh Pressure
8. Low Pressure
9. High Level
10. Low Level
11. Composition
change
12. Other
Maintenance
Accessibility
13. Positive
isolation,drain,v
ent etc.
14. Safety system
15. Sampling

Drawing No:
Respo
s s
y
16. Utility-
Instrument air
failure
17. Utility-power
failure
18. Utility CW
failure
19. Chill water

failure
20. N2 failure
21. Tube rupture.
Node: 11. 103 J seal gas system including seal gas treatment.
Node Intention: 1. To supply seal gas to 103 J
Drawing No:
Respo
s s
y
1. No/Less Flow
2. More/ High Flow
3. Reverse Flow
Drawing No:
Respo
s s
y
5. High Tempeature
6. Low
Temperature
7. High Pressure
8. Low Pressure
9. High Level
10. Low Level
11. Composition
change
12. Other
13. Maintenance-
Accessbility
14. Maintenance-
Positive
isolation/drains/
vent
15. Startup/shutdo
wn/comissionin
g
16. Fire
17. Sampling
18. High corrosion
Drawing No:
Respo
s s
y
19. Relief or
blowdown
20. Power
21. Instrument air
failure
22. Cooling water
23. Chilled water
24. Nitrogen
25. Tube rupture
Drawing No:
Respo
s s
y
1. No/Less Flow
2. More/ High Flow
3. Reverse Flow
5. High Tempeature
Drawing No:
Respo
s s
y
6. Low
Temperature
7. High Pressure
8. Low Pressure
9. High Level
10. Low Level
11. Composition
change
12. Other
13. Maintenance-
Accessbility
14. Maintenance-
Positive
isolation/drains/
vent
15. Startup/shutdo
wn/comissionin
g
16. Fire
17. Sampling
18. High corrosion
19. Relief or
blowdown
Drawing No:
Respo
s s
y
20. Power
21. Instrument air
failure
22. Cooling water
23. Chilled water
24. Nitrogen
25. Tube rupture
Node: 13. Utility System

Node Intention: 1. Nitrogen, Cooiling water, chilled water pakcage, Instrument air, chemical injection system
Drawing No:
Respo
s s
y
1. No/Less Flow
2. More/ High Flow
3. Reverse Flow
5. High Tempeature
6. Low
Temperature

Drawing No:
Respo
s s
y
7. High Pressure
8. Low Pressure
9. High Level
10. Low Level
11. Composition
change
12. Other
13. Maintenance-
Accessbility
14. Maintenance-
Positive
isolation/drains/
vent
15. Startup/shutdo
wn/comissionin
g
16. Fire
17. Sampling
18. High corrosion
19. Relief or
blowdown
20. Power
21. Instrument air

Drawing No:
Respo
s s
y
failure
22. Cooling water
23. Chilled water
24. Nitrogen
25. Tube rupture
Node: 14. Ammonia Flare Knock Out Drum

Node Intention: 1. To receive flare gas from the facility, seperate the liquid and supply ammonia dry gas to flare. Flare package at the
OSBL not in Wuhuan's scope. No HAZOP is required for this KOD drum.
Drawing No:
Respo
s s
y
1. No/Less Flow
2. More/ High Flow
3. Reverse Flow
5. High Tempeature
6. Low
Temperature
7. High Pressure
8. Low Pressure

Drawing No:
Respo
s s
y
9. High Level
10. Low Level
11. Composition
change
12. Other
13. Maintenance-
Accessbility
14. Maintenance-
Positive
isolation/drains/
vent
15. Startup/shutdo
wn/comissionin
g
16. Fire
17. Sampling
18. High corrosion
19. Relief or
blowdown
20. Power
21. Instrument air
failure

Drawing No:
Respo
s s
y
22. Cooling water
23. Chilled water
24. Nitrogen
25. Tube rupture

4.1.1 HAZOP Worksheet-Ammonia Unit-Raw - India Project

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4.1.1 HAZOP Worksheet-Ammonia Unit-Raw - India Project

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中 国 五 环 工 程 有 限 公 司

WUHUAN ENGINEERING CO., LTD.

Node: 1. Syn Gas feed to Syn gas compressor

Node: 1. Syn Gas feed to Syn gas compressor

Node: 1. Syn Gas feed to Syn gas compressor

Node: 1. Syn Gas feed to Syn gas compressor

Node: 1. Syn Gas feed to Syn gas compressor

Node: 1. Syn Gas feed to Syn gas compressor

Node: 1. Syn Gas feed to Syn gas compressor

Node: 1. Syn Gas feed to Syn gas compressor

Node: 1. Syn Gas feed to Syn gas compressor

Node: 1. Syn Gas feed to Syn gas compressor

16.2. Noise pollution 16.2.1. Potential 1. Noise level in the

Node: 1. Syn Gas feed to Syn gas compressor

17. Sampling 17.1. No issues 17.1.1. 1.

Node: 1. Syn Gas feed to Syn gas compressor

Node: 2. Syn gas converter, effluent & HP/LP steam generation

Node: 2. Syn gas converter, effluent & HP/LP steam generation

Node: 2. Syn gas converter, effluent & HP/LP steam generation

Node: 2. Syn gas converter, effluent & HP/LP steam generation

Node: 2. Syn gas converter, effluent & HP/LP steam generation

Node: 2. Syn gas converter, effluent & HP/LP steam generation

Node: 2. Syn gas converter, effluent & HP/LP steam generation

Node: 2. Syn gas converter, effluent & HP/LP steam generation

Node: 2. Syn gas converter, effluent & HP/LP steam generation

Node: 2. Syn gas converter, effluent & HP/LP steam generation

Node: 2. Syn gas converter, effluent & HP/LP steam generation

Node: 2. Syn gas converter, effluent & HP/LP steam generation

Node: 2. Syn gas converter, effluent & HP/LP steam generation

Node: 2. Syn gas converter, effluent & HP/LP steam generation

Node: 2. Syn gas converter, effluent & HP/LP steam generation

Node: 2. Syn gas converter, effluent & HP/LP steam generation

14. Low Pressure 14.1. Refer flow deviation 14.1.1. 1.

15. High Level 15.1. Refer flow deviation

15.2. High level in steam

Node: 2. Syn gas converter, effluent & HP/LP steam generation

15.4. LIC malfunction to 15.4.1. High level in 186

16. Low Level 16.1. Low level in steam

Node: 2. Syn gas converter, effluent & HP/LP steam generation

23. Sampling 23.1. Refer Node 1

Node: 2. Syn gas converter, effluent & HP/LP steam generation

Node: 2. Syn gas converter, effluent & HP/LP steam generation

Node: 3. NH3 Refrigerant loop

Node: 3. NH3 Refrigerant loop

1.4. FV 1059 stuck in

Node: 3. NH3 Refrigerant loop

1.6. Inadvertent closure of 1.6.1. High level in 1. LAH-1214A/B/C is

Node: 3. NH3 Refrigerant loop

Node: 3. NH3 Refrigerant loop

Node: 3. NH3 Refrigerant loop

Node: 3. NH3 Refrigerant loop

Node: 3. NH3 Refrigerant loop

Node: 3. NH3 Refrigerant loop

Node: 3. NH3 Refrigerant loop

Node: 3. NH3 Refrigerant loop

Node: 3. NH3 Refrigerant loop

Node: 3. NH3 Refrigerant loop

Node: 3. NH3 Refrigerant loop

Node: 3. NH3 Refrigerant loop

Node: 3. NH3 Refrigerant loop

Node: 3. NH3 Refrigerant loop

Node: 3. NH3 Refrigerant loop

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