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HAZOP STUDY
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UNIVERSITY OF KARACHI
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UNIVERSITY OF KARACHI
1. NH3 storage empty 2. LCV-01 fails closed 3. NRV-01 fails closed 4. Line 100 plugs 5. Line 101 plugs 6. LIC-1 fails, closing LCV-01 More 7. LCV-01 fails open
Pump cavitates Deadhead pump Deadhead pump Pump cavitates Deadhead pump Deadhead pump
Damage to pump Damage to pump Damage to pump Damage to pump Damage to pump Damage to pump
Use level alarm in NH3 Storage Use by pass manual valve system at LCV-01 Use Flow Indicator Use flow Indicator Use by pass manual valve system
Upset in vaporizer
Liquid level increases Pressure increases Liquid level increases Pressure increases
Upset in vaporizer
Use by pass manual valve system Use drain valve before pump Use by pass manual valve system
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Pressure More 9. LCV-01 fails closed 10. NRV-01 fails closed 11. LIC-1 fails, closing LCV-01 12. Line 101 plugs Deadhead pump Deadhead pump Deadhead pump Deadhead pump Liquid level increases Liquid level increases Pump cavitates Pump cavitates Damage to pump Damage to pump Damage to pump Damage to pump Use by pass manual valve system Use pressure Indicator Use by pass manual valve system Use pressure Indicator
Less
13. LCV-01 fails open 14. LIC-1 fails, opening LCV-01 15. NH3 storage empty 16. Line 100 plugs
Upset in vaporizer Use by pass manual valve system Upset in vaporizer Use by pass manual valve system Damage to pump Damage to pump Use level alarm in NH3 Storage
Temperature More 17. LCV-01 fails closed 18. NRV-01 fails closed 19. LIC-1 fails, closing LCV-01 20. Line 101 plugs Deadhead pump Deadhead pump Deadhead pump Deadhead pump Damage to pump Use temperature Indicator Damage to pump Use temperature Indicator Damage to pump Use temperature Indicator Damage to pump
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Heat/steam loss Heat/steam loss Heat loss/steam loss Excessive vaporization Heat loss/steam loss Excessive vaporization Heat/steam loss Heat/steam loss Heat/steam loss Heat loss/steam loss Heat loss/steam loss
Excessive vaporization
Excessive vaporization Use by pass manual Side reaction will valve system occur in the reactor Ammonia loss Use by pass manual Side reaction will valve system occur in the reactor Ammonia loss Excessive vaporization Excessive vaporization Excessive vaporization Use by pass manual Side reaction will valve system occur in the reactor Ammonia loss Use by pass manual Side reaction will valve system occur in the reactor UNIVERSITY OF KARACHI
24. PIC-1 fails opening PCV-01 25. LCV-01 fails closed 26. NRV-01 fails closed 27. LIC-1 fails, closing LCV-01 28. FCV-01 fails open
Ammonia loss 30. PCV-01 fails close Insufficient vaporization Insufficient vaporization Vaporizer Overflow Vaporizer Overflow Vaporizer Overflow Vaporizer Overflow Incomplete reaction in the reactor Incomplete reaction in the reactor Reaction seize Reaction seize Insufficient vaporization Insufficient vaporization Use by pass manual valve system Use by pass manual valve system
More
32. FCV-01 fails close 33. FFC-1 fails, closing FCV-01 34. LCV-01 fails open 35. LIC-1 fails, opening LCV-01
36. LCV-01 fails open 37. LIC-1 fails, opening LCV-01 38. FCV-01 fails close 39. FFC-1 fails, closing FCV-01 40. PCV-01 fails open 41. PIC-1 fails, opening
Tank rupture Tank rupture Tank rupture Tank rupture Tank rupture Tank rupture Use safety valve in VE01 Use safety valve in VE01 Use pressure Indicator
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Less
NH3 loss
43. Rupture line 101 44. Tank rupture 45. FCV-01 fails open
NH3 loss NH3 loss More heat is required in VE-01 More heat is required in VE-01 Vaporization seize Vaporization seize Vaporization seize Vaporization seize Vaporization seize
NH3 Displaces Alarming system oxygen from should be installed ground up Insufficient NH3 in the reactor Insufficient NH3 in Alarming system should be installed the reactor Insufficient NH3 in the reactor Side reaction will occur in the reactor Side reaction will occur in the reactor Incomplete reaction in the reactor Incomplete reaction in the reactor Incomplete reaction in the reactor Incomplete reaction in the reactor Incomplete reaction in the reactor
48. PIC-1 fails, closing 49. LCV-01 fails closed 50. LIC-1 fails, closing LCV-01 51. NRV-01 fails closed
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Temperature 52. LCV-01 fails close More 53. LIC-1 fails, closing LCV-01 54. NRV-01 fails closed 55. FCV-01 fails close
Excessive vaporization Excessive vaporization Excessive vaporization Excessive vaporization Excessive vaporization Excessive vaporization Excessive vaporization No vaporization occurs in VE-01 No vaporization occurs in VE-01 less vaporization occurs in VE-01 less vaporization occurs in VE-01
Side reaction will occur in the reactor Side reaction will occur in the reactor Side reaction will occur in the reactor Reaction seize in the reactor Reaction seize in the reactor Side reaction will occur in the reactor Side reaction will occur in the reactor Reaction seize Reaction seize Incomplete reaction in the reactor Incomplete reaction in the reactor
58. PIC-1 fails, opening Less 59. PCV-01 fails close 60. PIC-1 fails, closing 61. LCV-01 fails open
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63. Piece of filter material (i.e. cloth) breaks free 64. Filter saturated
Damage to compressor Damage to compressor Damage to compressor Insufficient air for reaction in the reactor Insufficient air for reaction in the reactor Damage to compressor Side reaction may occur in the reactor Damage to compressor Side reaction may occur in the reactor Damage to compressor Potential to corrodes
Another filter should be installed as standby Another filter should be installed as standby
Less
67. Filter saturated Load increases on the compressor 68. Atmosphere humidity increases
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Pressure More
69. Piece of filter material (i.e. cloth) breaks free 70. Line 106 chock
Damage to compressor Surge the compressor Damage to compressor Insufficient air for reaction in the reactor Blow off valve should be installed
Performance decreases
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Side reaction will Use analyzer indicator occur in the reactor Side reaction will occur in the reactor
As well as
Pressure More
Stress on catalyst bed Stress on catalyst bed NH3 and O2 loss NO and NO2 loss NH3 and O2 will not enter in the reactor NH3 and O2 will not enter in the reactor
Less
77. Rupture line 107 78. FCV-01 fails close 79. FFC-1 fails, closing FCV-01 20 | P a g e
Insufficient ratio of NH3 and O2 in the reactor Damage the catalyst bed Reaction seize Reaction seize
UNIVERSITY OF KARACHI
Temperature More 80. PCV-01 fails open Thermal Stress on catalyst bed Thermal Stress on catalyst bed Thermal Stress on catalyst bed Thermal Stress on catalyst bed NH3 and O2 loss Side reaction will occur in the reactor Side reaction will occur in the reactor Side reaction will occur in the reactor Side reaction will occur in the reactor Incomplete reaction in the reactor Side reaction will occur in the reactor Side reaction will occur in the reactor Side reaction will occur in the reactor There must be inter cooling system in the reactor
Less
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