HAZOP STUDY

PROCESS SECTION DATE NODE NO

Furnace/burner used to heat up using fuel oil + air Heating oil to 250 C to supply to Distillation re boiler
FURNACE

100
PARAMETER Guide Words Deviation posssible causes possible consequences Safe Guard/Prote Action required/Recommendation ction PIC 1, PT-1, PI- High Alarm, 4, PI-5 High-high Alarm, Fuel gas control valve - fail close PI 3, PI 6 & FI Interlock shut off valve 3 Pressure Safety Valve to flare Fuel gas control valve - fail close PI 3, PI 6, FI 3 Interlock shut off valve & AT-1 Pressure Safety Valve to flare Piping/tube thermal shock and craking lead to leakage of continously high flame the heating oil to the furnace and get contact with the to the furnace. flame and resulting to high temperature in furnace cause cracking and Explosion fuel gas valve malfuction - more fuel gas into the furnace More fuel gas in the furnace, lead to high temperature in normal operation and may cause explosion during startup. Explosion at furnace stack or Fuel gas release to atmosphere in normal operation Flue gas control valve, High temperature of hot oil to reboiler, Distillation column PIC 1 malfaction - close experience high pressure that possible to crack and position explosion. Air supply to the furnace high flow & pressure

PRESSURE

MORE -

MORE - PRESSURE

Pressure Safety Valve to flare

FT 2 & PI 2

Flow Recordable Control Alarm (FRCA) link to fuel control sytem

PRESSURE

LESS -

LESS - PRESSURE

Less combustion The oil has not been heating up. The reboiler not reboil the (May caused by either PIC 1, PT-1, PIHC, the distillation flooding, liquid HC over flow to the Pressure Low Alarm less air pressure or less 4, PI-5 upper stream of distillation column. fuel gas) More fuel gas in the furnace, lead to explosion especially Less air pressure to during start-up or fuel gas release to atmosphere through FT 2 & PI 2 furnace for combustion stack due to low combustion Less fuel gas to the furnace Additional one parallel air compressor by automatic cut in.

The oil has not been heating up. The reboiler not reboil the FI 3, PI 3 & PI HC, the distillation flooding, liquid HC over flow to the 6 and bypass Flow Low alarm upper stream of distillation column. valve Piping/tube crack or burst due to overheating, mixture of oil burn and cause black smoke release High coke in furnace and piping, less heat transfer TI 8 TI 8 Automatic shut down heater on low air flow and/or low air/fuel ratio. Maintenance (cleaning) BCPS link to FT 1 and Low flow alarm

TEMPERATURE

MORE -

MORE TEMPERATURE

High flame in the furnace (high fuel and air) less hot oil flow to the tubing (less heat transfer )

Thermal craking to the furnace - fuel gas release can cause FT 1 a jet fire

TEMPERATURE

LESS -

LESS TEMPERATURE

No ignition and No flame in the furnace

High Fuel gas in the furnace - when it ignited it will exploded during start-up No heat transfer to Hot oil - No heating to reboiler of the distalltion column, if the Feed of the distillation is liquid, the distillation will flooding

pilot light

Temperature alarm low, additional one pilot light , automatic cut off the fuel and air supply Temperature alarm low, additional one pilot light , automatic cut off the fuel and air supply Air Flow Alarm Low and automatic shut down the fuel supply on low air flow and/or low air/fuel ratio. Fuel Flow Alarm Low and automatic shut down the air supply on low air flow and/or low air/fuel ratio. Automatic shut down the heater on low air flow and/or low air/fuel ratio.

pilot light

No air Flow

High Fuel gas in the furnace - when it ignited it will exploded No heat transfer to Hot oil - No heating to reboiler of the distalltion column, if the Feed of the distillation is liquid, the distillation will flooding

FT 2, PI 2

No fuel flow

FI 3

COMPOSITION

NOT CORRECT -

NOT CORRECT COMPOSITION

not corret stoikometri for perfect combustion High black smoke release to Atmosphere. of fuel gas Less heat transfer to the hot oil tubing/piping, less separation in distillation column, can lead to tower flooding,

OTHERS VALVE fuel gas valve un-adequate malfuction - cause maintenance of valve leakage to and instrument furnace. no pilot light un-adequate maintenance of valve and instrument explosion when fuel gas over filling in the furnace with out combustion, and operator tried to start up the plant.

PILOT LIGHT

explosion when main firing started. explosion when the enough pressure of fuel gas in the furnace Instrument malfunction - lead to false reading and indication and can lead to Explosion. Piping will crack Furnace will crack Explosion can happen if not following the SU and SD procedure.

Periodic Maintenance

MAINTENANCE SHUT DOWN & START UP

un adequate maintenance of Budget Control and unPiping and aware of the risk instrumentation Not follow Human Factor Procedure

HAZOP STUDY
PROCESS Section Date NODE NO

Furnace/burner used to heat up using fuel oil + air Heating oil

Air line supply to the furnace

200
PARAMETER FLOW MORE MORE - FLOW Guide Words Deviation

LESS -

LESS - FLOW

NO -

NO - FLOW

OTHERS THAN VALVE Valve malfuction

MAINTENANCE SHUT DOWN & START UP

Not follow Procedure

HAZOP STUDY
Air line supply to the furnace

er used to heat up using fuel oil + air Heating oil to 250 C to supply to Distillation re boiler

posssible causes

possible consequences

Safe Guard/Protection

the valve or control valve malfuction

air to fuel ratio not as per FT 2 stoikiometric, high presure in the furnace more gas rushing out to atm, PT 1, PI 4 & PI 5 PIC 1

piping leaking

air to fuel ratio not as per stoikiometric, more fuel coming out from the stack FT 2 & PI 2 can cause detonation/explosion more fuel gas in the furnace can cause explosion

piping leaking pump/compressor failure Piping blockage/valve malfuction

FT 2 & PI 2

un-edequate maintenance air supply to actuator block controller malfuction cost cutting

more flow or no flow of air to furnace equipment malfuction and error can occurred may lead to explosion Explosion can happen if not following the SU and SD procedure.

Human Factor

llation re boiler

action required/Recommendation

Air Flow Alarm Low and automatic shut down the fuel supply or heater on low air flow and/or low air/fuel ratio.

Periodic Piping inspection, Risk based inspection (RBI)

Air Flow Alarm Low and automatic shut down the fuel supply or heater on low air flow and/or low air/fuel ratio.

HAZOP STUDY
PROCESS section date study node

Furnace/burner used to heat up using fuel oil + air Heating

Fuel gas line supply to Furnace

300
PARAMETER Guide Words Deviation

NO

PRESSURE

MORE -

MORE - PRESSURE

LESS NO -

LESS - PRESSURE NO -PRESSURE

3 4

TEMPERATURE FLOW

MORE REVERSE -

MORE - TEMPERATURE REVERSE - FLOW

MORE -

MORE - FLOW

LESS NO OTHERS THAN VALVE

LESS - FLOW NO - FLOW

Valve malfuction

MAINTENANCE SHUT DOWN & START UP Not follow Procedure

HAZOP STUDY
Fuel gas line supply to Furnace

sed to heat up using fuel oil + air Heating oil to 250 C to supply to Distillation re boiler

posssible causes

possible consequences

Safe Guard/Protectio n PI 3 & PI 6

Fuel gas control valve malfunction

more fuel in the furnace, can cause explosion during start-up more air in the furnace, no enough heat to heat up hot oil to desired temperature.

piping leaking valve malfuction valve malfuction piping leaking external heating cause the gas expanded

PI 3 & PI 6

explosion when enter furnace.

TI 11

FI 3 Fuel gas control valve malfunction - fully open more fuel in the furnace, can cause explosion more air in the furnace, no enough heat to heat up hot oil to desired temperature. FI 3

piping leaking valve malfuction

un-edequate maintenance air supply to actuator block controller malfuction cost cutting Human Factor equipment malfuction and error can occurred may lead to explosion Explosion can happen if not following the SU and SD procedure. more flow or no flow to furnace

tillation re boiler

Action required/Recommendation Fuel Pressure Alarm High and automatic shut down the fuel supply or heater on low air low air/fuel ratio or high fuel supply

Fuel Perssure Alarm Low and automatic shut down heater if Alarm Low Low triggered.

Automatic shut down fuel gas supply and heater

Fuel control valve - Fail close Fuel Flow Alarm High and automatic shut down the fuel supply or heater on low air low air/fuel ratio or high fuel supply

Fuel Flow Alarm Low

HAZOP STUDY
PROCESS section date study node

Furnace/burner used to heat up using fuel oil + air Heati

Heating oil piping/tubing going to fur

400
PARAMETER PRESSURE Guide Words MORE Deviation MORE - PRESSURE

NO

1 LESS LESS - PRESSURE

NO -

NO -PRESSURE

TEMPERATURE

MORE -

MORE - TEMPERATURE

LESS -

LESS - TEMPERATURE

UN-EVEN TEMP

4 COMPOSITION 5 OTHERS THEN OTHERS THEN - COMPOSITION

FLOW

LESS -

LESS - FLOW

NO -

NO - FLOW

OTHERS THAN VALVE Valve malfuction

MAINTENANCE

SHUT DOWN & START UP

Not follow Procedure

HAZOP STUDY

p using fuel oil + air Heating oil to 250 C to supply to Distillation re boiler

oil piping/tubing going to furnace and out from furnace

posssible causes HC from reboiler leaking into heating oil tube

possible consequences Possible fie inside the tube and lead to explosion of tube and burst heating oil burn in furnace - black smoke , less heating oil to reboiler - column flooding with HC

Safe Guard/Protection

piping leaking - in the furnace

high combustion in furnace - distillation column high pressure and TI 1 ~ TI 10 (exclude TI 8) more fuel and air can cause explosion.

Low combustion in furnace column flooding with liquid HC

TI 1 ~ TI 10 (exclude TI 8)

coking in the tubing

piping craking and less flow to reboiler

TI 1 ~ TI 10 (exclude TI 8)

HC leaking to the heating oil, Reboiler crack, or tube cracking

Possible fire inside the tube and lead to explosion of tube and burst

High moisture content

tube hammmering

piping leaking to furnace

heating oil burn in furnace - black smoke ,

coking in tubing

column flooding with liquid HC

piping leaking

FT 1

pump failure

column flooding with liquid HC

Piping blockage/valve malfuction

un-edequate maintenance air supply to actuator block controller malfuction cost cutting equipment malfuction and error can occurred may lead to explosion Explosion can happen if not following the SU and SD procedure. more flow or no flow of to furnace, no heating reboiler

Human Factor

Action required/Recom mendation Indication of pressure at tube Indication of pressure at tube Indication of pressure at tube

Temperature High Alarm and automatic shut down the heater if Temperature Alarm High High Temperature Alarm Low and automatic shut down the heater if Temperature Alarm Low Low Temperature Alarm Low and automatic shut down the heater if Temperature Alarm Low Low Indication of composition at tube

Vaporiser instalation at heating oil prior to inlet to furnace Indication of flow at exit stream of furnace Online decoking peridically Indication of flow at exit stream of furnace Standby pump, automatically cut in if another fail to function Online decoking peridically