BYCO 

PETROLEUM PAKISTAN LIMITED
HAZOP STUDY
CHECK LIST
BPPL‐ADV‐CL‐01
Issue Date:

Description: BOILER HAZOP Study
Node: 4. Condensate from Flash Vessel (FV‐01) to Condensate Tank (CT‐01) through Preheater (PH‐01)
P&ID No: 6162‐B01‐063‐007
Line No:  8" CR‐1209‐0111‐25H
Process Parameters Keyword Causes Consequences Safeguard

Flash Vessel Low Level Alarm LT- 1200

LCV‐1200 on flash vessel opens abnormaly.  Low level in flash vessel.
available. High level alarm available on
High Level in Condensate tank.
condensate tank.
High Low level in flash vessel.
Flash Vessel Low Level Alarm LT- 1200
Low DMW outlet temperature; loss of
Preheater  PH‐01 bypass valve open available. High level alarm available on
steam in LP/HP deaerator.
condensate tank.

Low level in flash vessel. Flash Vessel Low Level Alarm LT- 1200
Steam along with condensate comes in Flash Vessel High Level in Condensate tank. Feed available. High level alarm available on
Water temperature rises. condensate tank.

Condensate tank temperature low and TT-1200 available. High level alarm
Preheater PH‐01 tube leakage takes place
level will rise available on condensate tank.

Low level in condensate tank; condensate

pump trip with logic I-1201
Hot condensate exposure can burn Pre-alarms on flash vessel/condensate
Flash vessel's 8" condensate outlet line 
Low working men. tank level.
Flow immediate flange leak
Low DMW temperature at outlet of Operator's vigilance
preheater; causing steam loss in
deaerator.
Low level in condensate tank; condensate
pump trip with logic I-1201
Hot condensate exposure can burn
Control Valves 1200,1201 may malfunction working men. do
Low DMW temperature at outlet of
preheater; causing steam loss in
deaerator.
Condensate supply failure do do
Low level in condensate tank; condensate
Pre-alarms on flash vessel level.
pump trip with logic I-1201.
Operator's vigilance.
Low DMW temperature at outlet of
Interlock I-1201 for condensate pumps
Preheater PH‐01 manual inlet valve close preheater, resulting loss of steam in HP
No tripping is available in case of CT-01 low
deaerator.
level
High level in flash vessel, causing
inadequate LP steam separation.

High PRV‐1200,1201 may malfunction Flash Vessel FV-01 over pressurization PSV-504 available on flash vessel

Pressure

Steam with condensate is coming in FV‐01 Flash Vessel FV-01 over pressurization PSV-504 available on flash vessel

Low PSV pop up NA

High Steam with condensate is coming in FV‐01 DW higher temperature TT‐1200 available

No/Low flow of Demin Water do do
Temperature
Low NA NA NA
 
   
Level alarms on Flash vessel are
Low level in flash vessel.
available.
High  LCV-1200 malfunctioned. High level in condensate tank.
Level transmitter with LG are available.

 
Level Low level in condensate tank will trip pump
through logic I-1201.
Low Preheater PH-01 outlet flange leak Low level in HP deaerator. Operator's monitoring as per SOP.
Hot condensate exposure can burn
working men. may travel to boiler resulting
Contaminates
in foaming in steam drum
Contaminates High  RFO Heaters leakages may take place  Heater Tube Choking may lead to lower Lab testing of water sample
DW temperature.
 
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Recommendations

Drain valve and over flow line on

condensate tank to be checked. Level
gauge/transmitter also to be checked.
Drain valve and over flow line on
condensate tank to be checked. Level
gauge/transmitter also to be checked.

Drain valve and over flow line on

condensate tank to be checked. Level
gauge/transmitter also to be checked.

SOPM to be followed.
Maintenance/Inspection plans to be
followed.

Operator intervention as per SOP.

Scheduled PM of control valves to be

followed

Operatioon SOP to be followed

Fail Safe Mode of LCV-1200 to be

checked with vendor.
Operator's intervention as per SOP

Routine Maintenance plan to be followed

Up-stream steam traps to be checked as

per routine maintenance schedule

NA

Operator Intervention
do

NA

Drain valve and over flow line on

condensate tank to be checked. Level
gauge/transmitter also to be checked.

Operator's monitoring as per SOP.