Final Hazop Nocl Dhds Sei

HAZOP STUDY REPORT
Samsung Engineering
Client
Nagarjuna Oil Corporation Ltd.
PROCESS
SO2331
S646-140-RT-00-04
Plant
DHU Unit (Unit -1400)
Dept.
Project
Document Number
OWNER
PMC
LICENSOR
FEED CONTRACTOR
:
:
:
:
0
Rev.
NAGARJUNA OIL CORPORATION LTD.

CB&I, LUMMUS
AXENS, IFP GROUP TECHNOLOGY
TECHNIP KT
06.12.10
Approved For Design
REV.
DATE
DESCRIPTION
PREPARED BY
CHECKED BY
APPROVED BY
PM
HAZOP STUDY REPORT
TECHNIP KT INDIA LTD.
Client
PROCESS
S646
Plant
Dept.
Project
Contents
1. Introduction ...4
1.1. Introduction 4
1.2. Objective.....4
2. Methodology..5
2.1. The HAZOP
HAZOP STUDY REPORT
S646-140-RT-00-04
Document Number
Rev.
...4
4
...4
..5
HAZOP STUDY REPORT
Client
PROCESS
S646
Plant
Dept.
Project
Executive Summary
M/S Nagarjuna oil Corporation Ltd (NOCL) intends to install as Diesel Hydrodesulphurization Unit, (DHU, Unit 1400) in its
Cuddalore Refinery Project. The unit will be located in Cuddalore, Tamil Nadu, India. The unit will be treating a
HAZOP STUDY REPORT
S646-140-RT-00-04
Document Number
Rev.
desulphurization Unit, (DHU, Unit 1400) in its

u, India. The unit will be treating a
HAZOP STUDY REPORT
Client
PROCESS
S646
Plant
Dept.
Project
1. Introduction
1.1 Introduction
M/S Nagarjuna oil Corporation Ltd (NOCL) intends to install as Diesel Hydrodesulphurization Unit, (DHU, Unit 1400) in its
Cuddalore Refinery Project. The unit will be located in Cuddalore, Tamil- Nadu, India. The unit will
HAZOP STUDY REPORT
S646-140-RT-00-04
Document Number
Rev.
desulphurization Unit, (DHU, Unit 1400) in its

du, India. The unit will
HAZOP STUDY REPORT
Client
PROCESS
S646
Plant
Dept.
Project
2. HAZOP METHODOLOGY
2.1
THE HAZOP PROCESS
HAZOP is a qualitative method that reviews plant design to identify design faults and omissions, potential hazards and
operating problems. This technique applies guide words to process parameters to create
HAZOP STUDY REPORT
S646-140-RT-00-04
Document Number
Rev.
aults and omissions, potential hazards and

ers to create
HAZOP STUDY REPORT
Client
PROCESS
S646
Plant
Dept.
Project
2.2
HAZOP ASSUMPTIONS
In Order to make HAZOP study more effective, complete and efficient following postulates were followed.
x
Wherever possible, causes will be identified in the Node under consideration.
x
Consequences
HAZOP STUDY REPORT
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Document Number
Rev.
following postulates were followed.

ration.
HAZOP STUDY REPORT
Client
PROCESS
S646
Plant
Dept.
Project
2.2.1 Node Selection

Appropriate section of the plant (called Node) will be selected to enable the HAZOP team to focus and clearly identify all the
design and operation issues.
The Nodes design intent will be defined.
When there are symmetrical syste
HAZOP STUDY REPORT
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Document Number
Rev.
HAZOP team to focus and clearly identify all the
HAZOP STUDY REPORT
Client
PROCESS
S646
Plant
Dept.
Project
2.3 GUIDEWORD APPLICABILITY
a) Causes
x All the potential causes of the deviation will be identified (by brainstorming).
x The credibility of each cause will be agreed upon.
x Only credible causes will be considered. Incredible or highly unlike
HAZOP STUDY REPORT
g).
S646-140-RT-00-04
Document Number
Rev.
GUIDE WORD
PARAMETER
NO
MORE
LESS
AS WELL
AS
PART OF
REVERSE
FLOW *
PRESSURE *
TEMPERATURE *
LEVEL
PHASE
COMPOSITION (SPECIFIC
COMPONENT)
OPERATION **
OTHER
THAN
y
y
n
n
y
y
y
* Normal Parameters
** Start-up / shutdown, isolation philosophy, different operating modes, maintenance access,
blow down, etc.
Not Used
Normally
Used
n
y
HAZOP STUDY REPORT
Client
PROCESS
S646
Plant
Dept.
Project
Most hazards will be protected against by a combination of hardware, instrumentation and / or operating practices.
Protection may be provided by a combination of the following:
x The intrinsic mechanical strength of the plant
x Process control respo
HAZOP STUDY REPORT
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Document Number
Rev.
mentation and / or operating practices.
HAZOP STUDY REPORT
Client
PROCESS
S646
Plant
Dept.
Project
2.4
HAZOP SOFTWARE
Specialized software is used to record the proceedings of the HAZOP study in the form of work sheets. The software used is
PHA-Pro-VIII from Dyadem international.
HAZOP STUDY REPORT
S646-140-RT-00-04
Document Number
Rev.
in the form of work sheets. The software used is
HAZOP STUDY REPORT
Client
PROCESS
S646
Plant
Dept.
Project
3. BASIS OF HAZOP STUDY

3.1 Nodes considered for Diesel Hydrodesulphurizing unit HAZOP study:
Refer to Annexure-III for Node details & Scanned copies of P&IDs used during HAZOP study.
HAZOP STUDY REPORT
dy:
OP study.
S646-140-RT-00-04
Document Number
Rev.
Node No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Node Description
Feed from B/L to Feed Surge Drum

Feed Surge Drum to Reactor Feed Heater
Reactor Feed Heater
Reactor Feed Heater Outlet to Reactor, Effluent Air Cooler, Trim Cooler Up to separator inlet
Wash Water System
Separator bottom to Sour water Flash Drum and B/L
Separator Drum to Stripper Inlet
Separator Overhead to Recycle gas compressor Inlet
Recycle Gas compressor to Mixing Point
Lean Amine from B/L to LP and HP Amine Absorber column
Rich Amine from HP Amine Absorber ,LP Amine Absorber bottom to B/L.
LP Amine Absorber system (LP Amine column KOD, Off Gas KOD) to B/L
Stripper bottom to Gas oil Air cooler, Coalescer and Salt Dryer to B/L
Stripper Overhead system
Makeup H2 Compressor system
Chemical Injection System
Fuel oil, Fuel gas and Heater Firing System
HP/MP Steam & MP BFW
Cooling water system
Portable/Service Water, LP Steam, Plant /Instrument Air and Nitrogen
Flare system
Amine drain system
Hydrocarbon drain system
Condensate Collection system
HAZOP STUDY REPORT
Client
PROCESS
S646
Plant
Dept.
Project
3.2 Documents referred for HAZOP study

Following is the list of documents referred during this study:
HAZOP STUDY REPORT
S646-140-RT-00-04
Document Number
Rev.
S.No.
Title
Document No.
Process Data Book
C450-1400-PB-REV0
Process flow diagram
CA-140-PR-11-0001 to 0006, Rev 0
Material Selection Diagram
CK-140-PR-19-0001 to 0003, Rev0
Plot Plan
CK-140-PI-16-0001,Rev1
Piping & instrumentation diagram

(Process)
CK-140-PR-15-0001 to 0027-Rev1
Piping & instrumentation diagram

(Utilities)
CK-140-PR-15-0030 to 0040,Rev1
CK-140-PR-15-0043 to 0044 ,Rev1
Equipment List
CK-140-PR-50-0001-Rev1
10
Flare load summary
CK-140-PR-50-0008-Rev1
11
Area Classification layout
CK-140-EL-12-0001-Rev 0
Process data sheet of equipments
13
Cause and effect Diagram
CK-140-PR-24-0001,Rev1
14
Safeguarding Memorandum
CK-140-PR-45-0001,Rev 1
12
HAZOP STUDY REPORT
Client
PROCESS
S646
Plant
Dept.
Project
3.3 HAZOP TEAM
The HAZOP was carried out from 13th July to 17th July 2009.A team of experienced engineers from Process,
Operations/Commissioning and Engineering were formed the list of participants is as below:
HAZOP Chairman: Mr. Madan Kumar Sinha, Techn
HAZOP STUDY REPORT
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Document Number
Rev.
enced engineers from Process,

nts is as below:
Technip KT India Ltd.
LCM
Full Time
Full Time
Mr.
Mr.
Part Time
Mr.
NOCL
Full Time
Mr.
HAZOP STUDY REPORT
Client
PROCESS
S646
Plant
Dept.
Project
4. RECOMMENDATIONS
The total number of recommendations adds to 67.The HAZOP recommendation can be classified into three categories for
engineering, monitoring and tracking action completion.
Soft- The software recommendation mainly includes alarms on vari
HAZOP STUDY REPORT
S646-140-RT-00-04
Document Number
Rev.
tion can be classified into three categories for
HAZOP STUDY REPORT
Client
PROCESS
S646
Plant
Dept.
Project
The recommendations of HAZOP study is listed below (For category wise list refer to Annexure I):
S.No
Recommendations
P&ID no
Responsibility
Provide High temperature alarm on

TI-107
Operating procedure should ensure
periodical checking of LG-506
CK-140-PR15-0001
CK-140-PR15-0002
DEC
Provide DCS indication from

FZ-448
Pump to be selected suitably to
provide safety margin for NPSH
requirements during detail
engineering
CK-140-PR15-0002
CK-140-PR15-0002
DEC
Provide low temp. alarm at

(TI-120) heater inlet
Provide low alarm at TI-122
&TI-223.
safe shutdown of the plant
CK-140-PR15-0004
CK-140-PR15-0004
DEC
Hydrocarbon skimmer for both HP

& LP amine absorber (C-001 and
C-003) to be routed to CBD instead
of amine drain
CK-140-PR15-0010, CK140-PR-150016
Cooling water sample analysis to

be considered during detail
engineering of OSBL system
2
3
5
6
7
10
11
12
13
14
Provide Low alarm for FC420.

periodical checking of PI-019.
DEC/NOCL
DEC
DEC
DEC/NOCL
DEC
PMC/NOCL
CK-140-PR15-0008
CK-140-PR15-0008
Operating procedure should ensure CK-140-PRperiodical checking of FI15-0006

458/459/460/461
Provide low alarm at FI-417.
CK-140-PR15-0006
Operating procedure should ensure CK-140-PRperiodical checking of LG-515
15-0006
DEC
DEC/NOCL
DEC/NOCL
DEC
DEC/NOCL
15

15-0021
DEC/NOCL
16
Provide low alarm at FC-416
DEC
CK-140-PR15-0007
HAZOP STUDY REPORT
S646-140-RT-00-04
Document Number
Rev.
st refer to Annexure I):
Status
To be incorporated by DEC
HAZOP STUDY REPORT
Client
PROCESS
S646
Plant
Dept.
Project
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Provide low alarm at TI-190
CK-140-PR15-0017
Provide High alarm on TICK-140-PR190.
15-0017
Operating procedure to include
CK-140-PRoperation of HS-822 to select FCV- 15-0012
423 to purge H2S to flare header
DEC
Provide open feed back alarm from

ZB 702 A
Operating procedure to monitor LG522 for HC carry over. When HC
level builds up it should be drained
to CBD by using Skim line.
CK-140-PR15-0007
CK-140-PR15-0010
DEC
UZ-720 should activate UZCK-140-PR710 to trip pump (P-003A/B)

15-0009
routing of off gas to flare header
when there is disturbance in lean
amine supply to C-003
DEC
Provide High alarm on TI170 at lean amine B.L

Provide additional LI with
HH alarm at C-001 bottom.
Provide LL alarm at LA-560
DEC
Operating procedure to ensure to

check LG 533
&LG-522 and drain out the
HC through Skim line.
LG-522&LG-533 to be transparent
to see the interface during upset
conditions.
CK-140-PR15-0009
CK-140-PR15-0010
CK-140-PR15-0016
CK-140-PR15-0010, CK140-PR-150016
CK-140-PR15-0010, CK140-PR-150016
CK-140-PR15-0010
DEC
DEC/NOCL
DEC/NOCL
DEC/NOCL
DEC
DEC
DEC/NOCL
DEC
The valve in HC Skimming line for

C-001 to be changed to Spring
loaded type.
15-0016
DEC
Periodical checking of interface in

LG-533.
DEC/NOCL
CK-140-PR15-0016
DEC/NOCL
32
Pressure transmitter with low alarm CK-140-PRto be provided at top of C-003.

15-0016
DEC
33
Provide NRV on line DA-017

Close to mixing point with
DA-012
DEC
CK-140-PR15-0016
HAZOP STUDY REPORT
S646-140-RT-00-04
Document Number
Rev.
HAZOP STUDY REPORT
Client
PROCESS
S646
Plant
Dept.
Project
Provide NRV on line P-806 close to CK-140-PRthe meeting point with line DA-012. 15-0016
DEC
Provide high alarm at TI185.

Include start permissive as a part of
safe guarding system for Pump P005A/B.
CK-140-PR15-0016
CK-140-PR15-0001
CK-140-PR15-0017
DEC
Provide high alarm for FC442.

Provide Pressure transmitter with
low alarm d/s V-019, before FCV442 on line P103.
draining of salt dryer at regular
intervals by checking LG-554.
CK-140-PR15-0022
CK-140-PR15-0022
DEC
CK-140-PR15-0022
DEC/NOCL
40
Provide low alarm at TI-192.
CK-140-PR15-0017
DEC
DEC/NOCL
41

draining of hydrocarbon from C-003
through skim line during failure of
EA-002
Provide power supply to EA002 fan motors from different
sources.
PID should contain a note that
signals from non running
compressor instruments shall not
be used for control and trip of the
running compressor.
DEC/NOCL
CK-140-PR15-0014&15
DEC/PMC
NRV to be provided at the junction

of H-162 and P-079 on line H-162.
CK-140-PR15-0021
DEC
Provide High alarm at TICK-140-PR176.

15-0013
periodical checking of Chemical
injection
pumps.
DEC
34
35
36
37
38
39
42
43
44
45
46
DEC
DEC
DEC/NOCL
47
48
Provide stop alarm in DCS for

chemical injection pumps.
NRV to be provided on lineCC-020
near B.L.
DEC
CK-140-PR15-0023
DEC
HAZOP STUDY REPORT
S646-140-RT-00-04
Document Number
Rev.
HAZOP STUDY REPORT
Client
PROCESS
S646
Plant
Dept.
Project
49

proper checking of levels in
chemical injection tanks.
50
Provide additional pressure

transmitter with low alarm in DCS.
CK-140-PR15-0026
DEC
Provide low alarm at PI-854

B.L.
CO, NOx Analyzer to be provided at
the stack.
Provide NRV on steam line to each
burner after shut down valve.
CK-140-PR15-0035
CK-140-PR15-0004
CK-140-PR15-0024
DEC
Provide high alarm at PI863.

Provided low alarm at TI832.
draining of hydrocarbon from V-025
periodically.
CK-140-PR15-0024
CK-140-PR15-0024
DEC
51
52
53
54
55
56
57
58
59
60
61
62
63
64
DEC/NOCL
DEC
DEC
DEC
DEC/NOCL
Standard operating procedure to be

made for decoking/dry out
operation.
Consider shutdown DS-001 when
KT-002 trips
Provide steam trap to take care this
situation during detail engineering.
DEC/NOCL
Provide low alarm at TCCK-140-PR239.

15-0030
Provide low alarm on PI-818
Hydraulic check should be carried
out during detail engineering based
on actual plan layout
DEC
Provide one additional LI on

CK-140-PRV-022
15-0044
Separate nitrogen connection to the
drum as well as separate vent to
flare line with lock open valve and
NRV to be provided.
DEC
DEC/NOCL
DEC
DEC
DEC
DEC
65
66
Provide one additional LI on

V-021
Operating procedure should
prevent draining of hot
CK-140-PR15-0040
DEC
DEC/NOCL
HAZOP STUDY REPORT
S646-140-RT-00-04
Document Number
Rev.
HAZOP STUDY REPORT
Client
PROCESS
S646
Plant
Dept.
Project
67
hydrocarbon in Hydrocarbon drain

drum.
Separate nitrogen connection to the
V-021 as well as separate vent to
flare line with lock open valve and
NRV to be provided.
DEC
HAZOP STUDY REPORT
S646-140-RT-00-04
Document Number
Rev.
S. No.
Recommendation
(A)
Hard
DEC
8.Hydrocarbon skimmer for both HP & LP amine absorber (C-001 and C-003) to be routed to CBD instead
of amine drain.
25.Provide additional LI with HH alarm at C-001 bottom.
28.LG-522&LG-533 to be transparent to see the interface during upset conditions.
DEC
29.The valve in HC Skimming line for C-001 to be changed to Spring loaded type.
DEC
33.Provide NRV on line DA-017 Close to mixing point with DA-012.
DEC
34.Provide NRV on line P-806 close to the meeting point with line DA-012.
DEC
35.Provide high alarm at TI-185.
DEC
42.Provide power supply to EA-002 fan motors from different sources.
DEC/NOCL
44.NRV to be provided at the junction of H-162 and P-079 on line H-162.
DEC
10
48.NRV to be provided on lineCC-020 near B.L.
DEC
11
50.Provide additional pressure transmitter with low alarm in DCS.
DEC
12
52.CO,NOx Analyzer to be provided at the stack.
DEC
13
53.Provide NRV on steam line to each burner after shut down valve.
DEC
14
59.Provide steam trap in MP Steam line to take care this situation during detail engineering.
DEC
15
63.Provide one additional LI on V-022.
DEC
16
64.Separate nitrogen connection to the drum as well as separate vent to flare line with lock open valve and DEC
NRV to be provided.
65.Provide one additional LI on V-021.
DEC
17
18
Responsibility
DEC
67.Separate nitrogen connection to the V-021 as well as separate vent to flare line with
lock open valve and NRV to be provided.
Soft
DEC
(B)
1
1.Provide High temperature alarm on TI-107.
DEC
3.Provide DCS indication from FZ-448.
DEC
4.Pump to be selected suitably to provide safety margin for NPSH requirements during detail engineering.
DEC
5.Provide low temp. alarm at (TI-120) heater inlet.
DEC
6.Provide low alarm at TI-122 &TI-223.
DEC
10.Provide Low alarm for FC-420.
DEC
13.Provide low alarm at FI-417.
DEC
P&ID No.
CK-140-PR-15-0010 & 16
CK-140-PR-15-0010
CK-140-PR-15-0010 & 16
CK-140-PR-15-0010
CK-140-PR-15-0016
CK-140-PR-15-0016
CK-140-PR-15-0016
CK-140-PR-15-0021
CK-140-PR-15-0023
CK-140-PR-15-0026
CK-140-PR-15-0004
CK-140-PR-15-0024
CK-140-PR-15-0030
CK-140-PR-15-0044
CK-140-PR-15-0044
CK-140-PR-15-0040
CK-140-PR-15-0040
CK-140-PR-15-0001
CK-140-PR-15-0002
CK-140-PR-15-0002
CK-140-PR-15-0004
CK-140-PR-15-0004
CK-140-PR-15-0008
CK-140-PR-15-0006
S. No.
Recommendation
Responsibility
8 16.Provide low alarm at FC-416.
DEC
9 17.Provide low alarm at TI-190.
DEC
10 18.Provide high alarm at TI-190.
DEC
11 20.Provide open feed back alarm from ZB 702 A.
DEC
12 24.Provide High alarm on TI-170 at lean amine B.L
DEC
13 26.Provide LL alarm at LA-560.
DEC
14 32.Pressure transmitter with low alarm to be provided at top of C-003.
DEC
15 36.Include start permissive as a part of safe guarding system for Pump P-005A/B.
DEC
16 37.Provide high alarm for FC-442.
DEC
17 38.Provide Pressure transmitter with low alarm d/s V-019, before FCV-442 on line P103.
DEC
18 40.Provide low alarm at TI-192.
DEC
19 43.PID should contain a note that signals from non running compressor instruments shall not be used for
control and trip of the running compressor.
DEC/PMC
20 45.Provide High alarm at TI-176.
DEC
21 47.Provide
DEC
stop alarm in DCS for chemical injection pumps.
22
51.Provide low alarm at PI-854 B.L.
DEC
23
54.Provide high alarm at PI-863.
DEC
24
55.Provided low alarm at TI-832.
DEC
25
60.Provide low alarm at TC-239.
DEC
26
61.Provide low alarm on PI-818
DEC
27
62.Hydraulic check should be carried out during detail engineering based on actual plan
layout.
DEC
P&ID No.
CK-140-PR-15-0007
CK-140-PR-15-0017
CK-140-PR-15-0017
CK-140-PR-15-0007
CK-140-PR-15-0009
CK-140-PR-15-0016
CK-140-PR-15-0016
CK-140-PR-15-0017
CK-140-PR-15-0022
CK-140-PR-15-0022
CK-140-PR-15-0017
CK-140-PR-15-0014&15
CK-140-PR-15-0013
CK-140-PR-15-0035
CK-140-PR-15-0024
CK-140-PR-15-0024
CK-140-PR-15-0030
CK-140-PR-15-0033
S. No.
Recommendation
Responsibility
(C )
Operating Instructions
2.Operating procedure should ensure periodical checking of LG-506.
DEC/NOCL
7.Operating procedure should ensure safe shutdown of the plant.
DEC/NOCL
9.Cooling water sample analysis to be considered during detail engineering of OSBL

system.
PMC/NOCL
11.Operating procedure should ensure periodical checking of PI-019.
DEC/NOCL
12.Operating procedure should ensure periodical checking of FI-458/459/460/461.
DEC/NOCL
14.Operating procedure should ensure periodical checking of LG-515
DEC/NOCL
15.Operating procedure should ensure periodical checking of LG-543
DEC/NOCL
19.Operating procedure to include operation of HS-822 to select FCV-423 to purge H2S

to flare header.
DEC/NOCL
21.Operating procedure to monitor LG-522 for HC carry over. When HC level builds up it should be drained
to CBD by using Skim line.
DEC/NOCL
10
22.UZ-720 should activate UZ-710 to trip pump (P-003A/B).
DEC
11
23.Operating procedure should ensure routing of off gas to flare header when there is
disturbance in lean amine supply to C-003.
DEC/NOCL
12
27.Operating procedure to ensure to check LG 533 &LG-522 and drain out the HC
through Skim line.
DEC/NOCL
13
30.Operating procedure should ensure periodical checking of LG-552.
DEC/NOCL
14
31.Periodical checking of interface in LG-533.
DEC/NOCL
15
39.Operating procedure should ensure draining of salt dryer at regular intervals by

checking LG-554.
DEC/NOCL
16
41.Operating procedure should ensure draining of hydrocarbon from C-003 through skim line during failure
of EA-002
DEC/NOCL
17
46.Operating procedure should ensure periodical checking of Chemical injection pumps.
DEC/NOCL
18
49.Operating procedure should ensure proper checking of levels in chemical injection

tanks.
DEC/NOCL
19
56.Operating procedure should ensure draining of hydrocarbon from V-025 periodically.
DEC/NOCL
20
57.Standard operating procedure to be made for decoking/dry out operation.
DEC/NOCL
21
58.Consider shutdown DS-001 when KT-002 trips.
DEC/NOCL
22
66.Operating procedure should prevent draining of hot hydrocarbon in Hydrocarbon

drain drum.
DEC/NOCL
P&ID No.
CK-140-PR-15-0002
CK-140-PR-15-0008
CK-140-PR-15-0006
CK-140-PR-15-0006
CK-140-PR-15-0021
CK-140-PR-15-0012
CK-140-PR-15-0010
CK-140-PR-15-0009
CK-140-PR-15-0010 & 16
CK-140-PR-15-0016
CK-140-PR-15-0016
CK-140-PR-15-0022
HAZOP WORKSHEET
Samsung Engineering India Pvt Ltd
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 01
Feed From B/L to Feed Surge Drum
DESIGN INTENTION
To Supply Gas Oil Feed from Unit B/L to Feed Surge Drum through Back Wash Filter.
DRAWINGS
CS-140-PR-15-001, CS-140-PR-15-002
EQUIPMENT
Feed Filter (140-F-001),Feed Surge Drum(140-V-001)
STREAM DETAILS
Gas Oil Feed from B/L to Feed Filter (F-001) and send to Feed Surge Drum (V-001)
AVAILABLE CONTROL
SCHEMES
None.
Nagarjuna Oil Corporation Ltd

Diesel hydro Desulphurization unit
Operating Parameters
SERVICE
Temperature(C)
Gas Oil Feed from B/L to Feed

Surge Drum
Pressure ( bar g)
Flow rate (Kg/hr)
63
3.4
120,083
Note:
Node
Deviation
Causes
Consequences
1. Feed from B/L to Feed Surge

Drum
Safeguards
1.Low Flow Alarm

(FQ447) at B/L.
1.U/S disturbance
1.Low level in FSD.
3.Automatic
backwash filter
system fails
2.High Flow
3.Low Pressure
1. Upstream
Disturbance
Remarks
1.1.1.1.3
1.Same as
safeguards for
cause 1
consequence 1
2.High Pressure drop in Feed

filter
2.High Alarm of PDI329 provided

1.1.2.2.2
1.Same as Cause-1
consequence1
1.Same as
safeguards for
cause 1
consequence 1
1.Feed Flow to FSD will

increase
.Liquid Overfilling can be
possible.
Responsibility
1.1.1.1.1
1.Same as Cause-1
consequence1
2.Choking of Back
wash Filter
(140-F-001).
Recommendations
2.Low level alarm

(LC501) provided at
1.1.1.1.2
FSD.
3.Low Low Level

Trip alarm (LZ504).
1.Low/No Flow
Ref. No.
1. High alarm (LC501) and High High

alarm (LI-503)
provided.
2. PSV-302A/B is
designed for liquid
overfilling case.
1. Same as Low/No
1.Refer Node-1 Deviation 1
flow
1.1.2.1.1
1.To be reviewed
during detail
engineering HAZOP
when vendor
information is
available.
1.1.3.1.1
1.2.1.1.1
1.2.1.1.2
1.3.1.1
1. System is
designed for
maximum U/S
pressure
1. U/S Disturbance
1. System may experience

higher than the operating
pressure
2. Choking of Feed
Filter(140-F001)
1.System is
1. System U/S feed filter may
designed for
experience higher than the
maximum U/S
operating pressure
pressure
1.U/S disturbance
1.System may experience

temperature higher than
design.
1.4.1.1.1
4.High Pressure
6.High Temperature
1.To be reviewed
during detail
engineering when
vendor information is
available
1.4.2.1.1
1.System is rated for

B/L
1.6.1.1.1
design temperature
1.Provide High temperature

alarm on
TI-107
DEC
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 01
Feed From B/L to Feed Surge Drum
DESIGN INTENTION
To Supply Gas Oil Feed from CDU directly to Feed Surge Drum through Back Wash Filter.
DRAWINGS
CS-140-PR-15-001 , CS-140-PR-15-002
EQUIPMENT
Feed Filter (140-F-001),Feed Surge Drum(140-V-001)
STREAM DETAILS
Gas Oil Feed from CDU to Feed Filter (F-001) and send to Feed Surge Drum (V-001)
AVAILABLE CONTROL
SCHEMES
None.

SERVICE
Temperature(C)
Gas Oil Feed from CDU to Feed

Surge Drum
Pressure ( bar g)
Flow rate (Kg/hr)
55
3.5
120,083
Note:
Node
1'. Feed from CDU to Feed

Surge Drum during start-up
operation
Deviation
Causes
1.U/S disturbance
Consequences
1.Low level in FSD.
Safeguards
1.Low level alarm

(LC501) provided at
1'.1.1.1.1
FSD.
2.Low Low Level

Trip alarm (LZ504).
1.Same as Cause-1
consequence1
2.Choking of Back
wash Filter
(140-F-001).
Ref. No.
1.Same as
safeguards for
cause 1
consequence 1
1'.1.1.1.2
1'.1.2.1.1
Recommendations
1.In addition to FQ-447B

provide low Flow Alarm.
Responsibility
Remarks
Node
Deviation
Causes
2.Choking of Back
wash Filter
(140-F-001).
3.Automatic
backwash filter
system fails
2.High Flow
3.Low Pressure
1. Upstream
Disturbance
Consequences
Safeguards
Ref. No.
2.High Pressure drop in Feed

filter
2.High Alarm of PDI1'.1.2.2.2

329 provided
1.Same as Cause-1
consequence1
1.Same as
safeguards for
cause 1
consequence 1
1.Feed Flow to FSD will

increase
.Liquid Overfilling can be
possible.
1. High alarm (LC501) and High High

alarm (LI-503)
provided.
2. PSV-302A/B is
designed for liquid
overfilling case.
1. Same as Low/No
1.Refer Node-1 Deviation 1
flow
1'.1.3.1.1
Recommendations
Responsibility
Remarks
1.To be reviewed
during detail
engineering HAZOP
when vendor
information is
available.
1'.2.1.1.1
1'.2.1.1.2
1'.3.1.1
1. System is
designed for
maximum U/S
pressure
1. U/S Disturbance
1. System may experience

higher than the operating
pressure
2. Choking of Feed
Filter(140-F001)
1.System is
1. System U/S feed filter may
designed for
experience higher than the
maximum U/S
operating pressure
pressure
1'.4.1.1.1
1.B/L design pressure

to be verified during
detail engineering
4.High Pressure
1'.4.2.1.1
1.To be reviewed
during detail
engineering when
vendor information is
available
Node
Deviation
6.High
Temperature
Causes
1.U/S disturbance
Consequences
1.System may experience

temperature higher than
design.
Safeguards
Ref. No.
1.System is rated for

B/L
1'.1.1.1.1
design temperature
Recommendations
Responsibility
1.Provide High temperature

alarm on
TI-107
DEC
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 02
Feed Surge Drum to Reactor Fired Heater Inlet
DESIGN INTENTION
To Preheat the Gas oil feed and H2 through exchanger train (E-001A/B/C/D) before further heating by reactor feed heater.
DRAWINGS
CS-140-PR-15-002, CS-140-PR-15-003, CS-140-PR-15-004
EQUIPMENT
Feed Surge Drum(140-V-001),Gas Oil Feed Pump(140-P-001),Reactor Feed Effluent

Exchanger
(140-E-001A/B/C/D)
Gas
Oil from
Feed Surge Drum (V-001) pumped to feed Effluent Exchanger train(E-
STREAM DETAILS
AVAILABLE CONTROL
SCHEMES
SERVICE

001A/B/C/D)
and then send to Reactor Feed Heater (H-001) Inlet
PC-330,LC-501,LC-505,FC-407A/B,FC-408,TC-119,LC-501.
Temperature(C)
Gas Oil Feed pump to

Mixing Point
Mixing Point to Feed/ Effluent
Exchanger Inlet
Feed/Effluent Exchanger to Fired
Heater Inlet
Pressure ( bar g)
Flow rate (Kg/hr)
63
91.3-101.0
120083
68.8
92.2-94.7
113540-121388
307.3-338.7
90.7-93.2
126850-127392
Note:
Node
2.Feed Surge Drum to Reactor
Feed Heater
Deviation
1.Low/No Flow
Causes
1.Tripping of Gas oil feed
pump(P-001A/B)
2.FC-408 malfunctions to close
2.
High Flow
Consequences
Ref.
Safeguards
1.Reaction section losses gas oil feed
1 FC- 408
provided with low
alarm.
2.High level in FSD(V-001)
2 FZ-448 provide
2.1.1.2.1
with LL alarm to trip
the fired heater
3.Possible overfilling of FSD V-001
1 High alarm LC501
2.1.1.3.1
2 HH alarm at LI503
2.1.1.3.2
3.1 PSV-302A/B is
designed for
overfilling case.
2.1.1.3.3
Recommendations
Responsibility
2.1.1.1.1
1.Same as cause 1 consequence1&2
1 FZ-448 provide
2.1.2.1.1
with LL alarm to trip
the fired heater
2.P-001A/B likely damage
2 Pump is
protected with
Min. flow bypass
2.1.2.2.2
2.1.3.1
3.LC-505 malfunctions to close
1.V-001 boot level will increase &

possibilities of water going with gas oil feed
4. FCV-407A/B malfunctions to
open
1. Same as cause 1 consequence

1&2
1. Same as cause 2.1.3.1.1

1 consequence
1&2
5. XZV-719 malfunctions to
close

1&2
1. Same as cause 2.1.5.1.1

1 consequence
1&2
1. FC-408 malfunctions to full

open
1. H2 to HC ratio will change and may

adversely affect the product quality
1 Low alarm LC501
2. Level in FSD may go down
2 LL Trip alarm LZ- 2.2.1.2.2

504 will activate
UZ-701
2.Operating procedure should

ensure periodical checking of
LG-506
DEC/NOCL
2. Operating procedure
should ensure periodical
checking of LG506
DEC/NOCL
2.2.1.1.1
3 Provide DCS
2.2.1.2.3
indication from FZ448.
2. LC-505 malfunctions to full
open(sour water)
1. Loss of Gas oil feed to close drain no

hazardous consequence
1. Water comes with Gas oil

feed
1. Process upset
1. High Level alarm 2.3.1.1.1

in LC- 505.
5. Reverse/Misdirected
Flow
1. P-001 trips
1. Back flow from high pressure side

(Reaction section)
1. UZ-719 will
activate & close
XZV-719.
6.
Low Pressure
1. PC 330 malfunctions to close 1. P-001A/B may cavitate

PCV 330A and open PCV330B
7.
High Pressure
1. PC 330 malfunctions to open 1. Over pressurizing of the FSD (VPCV 330A and close PCV001)
330B
1. PSV-302A/B
provided
2.7.1.1.1
2. P-001 trips
1. PSV-302A/B is
designed for liquid
overfilling case
2.7.2.1.1
3.
As well as
1. Liquid overfilling of FSD(V-001)

may occur
2.2.2.1
2.5.1.1.1
2.6.1.1
4. Pump to be selected
DEC
suitably to provide safety
margin for NPSH requirements
during detail engineering
Remarks
7.
Node
High Pressure
Deviation
Causes
3. FC-408 to close FCV-408
close
8. Less/Low
Temperature
Consequences
Safeguards
Ref.

may occur
1. PSV-302A/B is
designed for liquid
overfilling case
2. Pump discharge line up to FCV408 is subjected to high pressure
2. Pump (P2.7.3.2.2
001A/B) discharge
line is designed for
pump shutoff
pressure

may occur
1. PSV-302A/B is
designed for liquid
overfilling case
2. Pump discharge line up to XZV719 is subjected to high pressure
2. Pump (P2.7.4.2.2
001A/B) discharge
line is designed for
pump shutoff
pressure
2.8.1.1
2. FC-408 malfunctions to open 1. Likely low temp. at heater inlet, no major

FCV-408 fully
concern
2.8.2.1
9. High
Temperature
1. TC-119 malfunctions to close 1. No major concern

TCV-119
2.9.1.1
10.
1. FC-408 malfunctions to open 1. Refer High flow of this node

FCV-408
2.10.1.1
2. LC-505 malfunctions to open 1. Refer High flow of this node

LCV-505
2.10.2.1
3. LC-501 malfunctions to close 1. P-001A/B may cavitate

250 LCV-011A/B/C
11.
High Level
1. LZ-504 will
activate UZ701 which will trip
the pump
2.10.3.1.1
1. FC-408 malfunctions to close 1. Refer Low/No Flow of this node

FCV-408
2.11.1.1
close
1. Refer Low/No Flow of this node
2.11.2.1
3. LC-505 malfunctions to close 1. Refer Low/No Flow of this node

LCV-505
2.11.3.1
4. LCV-501 malfunctions to
open
250 LCV-011A/B/C fully
1. Overfilling of FSD (V-001)
1. HH Alarm LI503
2.11.4.1.1
2. PSV-302A/B is 2.11.4.1.2
designed for Liquid
overfilling case
12. Problem/Requirements
1. Tube leakage in (EE001A/B/C/D)
1. Possible contamination of product with

feed
Responsibility
2.7.4.1.1
1. TC-119 malfunctions to open 1. Low temp. at heater inlet may lead to

TCV-119
operational upsets
Less/Low Level
Recommendations
2.7.3.1.1
1. Analyzer AI-003 2.12.1.1.1

is provided on
product line
5. Provide low temp. alarm at DEC

(TI120) heater inlet
Remarks
Flow rate (Kg/hr)

120083
113540-121388
126850-127392
HAZOP WORKSHEET
PROJECT NO
: SO 2331
NODE NO: 03
Reactor Feed Heater
DESIGN INTENTION
To heat Gas Oil Feed +H2 mixture to Reactor inlet temperature.
DRAWINGS
CS-140-PR-15-0004
EQUIPMENT
Reactor Feed Heater (140-H-001)
STREAM DETAILS
After preheating from feed/effluent heat exchanger post heating is done in Fired Heater
AVAILABLE CONTROL SCHEMES
PC-899(For Detail see the Heater Firing P&ID for control system)
SERVICE
Temperature(C)
Fired Heater Outlet to
Hydrotreater Reactor Inlet
318.3-362.5
Note:
Node
3. Reactor Feed
Heater
Deviation
Causes
1.
Low/No Flow
1. U/S disturbance.
2.
High Flow
1. U/S disturbances
7. Low
Temperature
1. TC-124 malfunctions & less

firing in the heater
8. High
Temperature
1. TC-124 malfunctions and

over firing in heater
8. High
Temperature
Node
Deviation
1. TC-124 malfunctions and

over firing in heater
Causes
1. Heater tube leak
HAZOP WORKSHEET
Client
Project :
ost heating is done in Fired Heater

Pressure ( bar g)
86.4-88.9
Consequences
1. Possible overheating of heater tubes
leading to tube failure.
Safeguards
Ref.
1. TC-124 controls
the firing of heater
3.1.1.1.1
2. High alarm is
provided at TI-121 &
222(Skin temp.),TI122 &
223(COT)
3.1.1.1.2
3. TZ-123 HH temp.
will activate UZ-718
3.1.1.1.3
1. Refer high flow of node-2
Recommendations
3.2.1.1
1. Desired reactor temp. will not be

achieved leads to gas oil product quality
upsets.
1.Low alarm at TZ123 is provided.
1. Possible coke formation in heater tubes
1. TI-121,TI-122,TI3.8.1.1.1
222
&TI-223 provided with
high alarm
2.7.1.1.1
6. Provide low alarm at TI122 &TI223.
1. Possible coke formation in heater tubes
Consequences
Safeguards
Ref.
Recommendations
2. TZ-123 HH will
3.8.1.1.2
activate UZ-718 to trip
the heater
3. TI-101 &TI-102
provided with high
alarm
3.8.1.1.3
1. Fire box temp. high, possible heater

damage
1.High temp alarm at

TI101&TI-102
3.11.1.1.1
2. Fire box pressure high.
2. PC-899 high alarm

provided.PZ-900
provided with HH
alarm and activate
UZ-718 to trip the
heater
3.11.1.2.2
should ensure safe
shutdown of the plant

Flow rate (Kg/hr)
88.9
126850-127392
Responsibility
DEC
Remarks
Responsibility
DEC/NOCL
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 04
Reacted Feed Heater Outlet to Reactor ,Effluent air cooler, Trim Cooler up to Separator inlet
DESIGN INTENTION
1.
To hydro treat Gas Oil Feed in Reactor for desulphurisation, denitrogenation & aromatic saturation.
2.
To cool reactor effluent by exchangers, air cooler & trim cooler to separate converted H2S, NH3 from gas Oil in Separator drum.
3.
To maintain reactor temperature by Hydrogen Guarding.

DRAWINGS
CS-140-PR-15-0004, CS-140-PR-15-0005, CS-140-PR-15-0006, CS-140-PR-15-0007
EQUIPMENT
Reactor Feed Heater (140-H-001)
STREAM DETAILS
After post heating in Heater, Gas Oil is hydrotreated and passes through in feed effluent exchanger for heat transfer to cold feed and then send to air cooler and trim cooler for further cooling and finally to separator.
AVAILABLE CONTROL SCHEMESFC-412,FC-413,FC-414,FC-415,TC-124,TC-131,TC-137,TC-143,TC-151

SERVICE
Temperature(C)
Reactor to stripper feed
preheater , Feed effluent
exchanger at inlet of Air cooler
Air cooler to Separator
Pressure ( bar g)
Flow rate (Kg/hr)
185.5-397
80.2-83.4
45-65
78.8-.79.3
137867
144751
Note:
Node
Deviation
4. Reactor Feed Heater Outlet 1.

to Reactor, Effluent Air Cooler,
Trim Cooler Up to separator inlet
2.
Low/No Flow
High Flow
Causes
Consequences
Safeguards
Ref.
1. U/S disturbance
1. No hazardous consequences
2. FC-412 /413/414/415
malfunction to close
FCV412/413/414/415 (quench
H2)
1. Reactor bed temp. increases leading to

runaway situation
1. High temp.
4.1.1.1.1
alarms are provided
for each bed
1. U/S disturbance
1. Possible incomplete reaction resulting in

poor product quality
1. AI-003 is
4.2.1.1.1
provided on product
line
2. FC-412 /413/414/415
malfunction to fully open FCV
412/413/414/415
1. Reactor bed temp. decreases &

may lead to incomplete reaction
1. AI-003 is
4.2.2.1.1
provided on product
line
5.
Low Pressure
1. U/S disturbance
1. Incomplete reaction may lead to poor

product quality
1. Analyzer AI-003
is provided at
product line
6.
High Pressure
1. Disturbance in Hydrogen
recycle loop.
1. Likely pressurization of the system.
1. PC-358 provided 4.6.1.1.1

with high alarm.
2. PSV-307A/B
provided.
7. Low
Temperature
1. More quench Hydrogen flow

to reactor
1. Refer high flow of this node
8. High
Temperature
1. Low quench gas to reactor
1. Refer Low/No Flow of this node
Recommendations
Responsibility
4.1.1.1
4.5.1.1.1
4.6.1.1.2
4.7.1.1
1. High temp.
4.8.1.1.1
Alarms are provided
for each bed.
2. Low alarm at FC- 4.8.1.1.2

412/413/414/415.
2. EA-001 Fan motor trips
1. Pressure buildup due to less

condensation
1 High alarm at TI163
4.8.2.1.1
2. Higher hydrocarbons may condense in

HP Amine column (C-001) leading to foam
formation
2. PC-358 is
provided with high
alarm
4.8.2.2.2
3. PSV-307A/B is
provided
4.8.2.2.3
4. TI-167 high alarm 4.8.2.2.4

and TI-212 high
alarm is also
provided
5. Hydrocarbon
4.8.2.2.5
skimmer for both
HP & LP amine
absorber (C-001 and
C-003) is routed to
CBD instead of
amine drain.
3. Cooling water failure in EE003

1&2 of this node
1. Coking in reaction bed
1. High pressure drop in reactor bed
2. Vibration in Air cooler (EA001)

fans
1. Possible damage of EA-001 components 1. Vibration alarm 4.9.2.1.1

(VA001/002/003/004) is
provided
3. Tube leakage EE-003
1. Hydrocarbon may ingress in cooling

water
4.8.3.1
1. PDI with high

alarm provided for
each bed
4.9.1.1.1
4.9.3.1
9. Cooling water sample

analysis to be considered
during detail engineering
of OSBL system
PMC/NOCL
Remarks
Flow rate (Kg/hr)

137867
144751
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 05
Wash Water System
DESIGN INTENTION
Sour Water/MP BFW supply to Wash Water Drum(V-004)
DRAWINGS
CS-140-PR-15-0008, CS-140-PR-15-0021, CS-140-PR-15-0022
EQUIPMENT
Wash Water Drum(140-V-004) and Wash water pump(140-P-002A/B)
STREAM DETAILS
1.
To supply Stripper Sour Water/BFW/Recycle water to Wash water drum.
2.
To inject wash water in U/S of Reactor Effluent Air Cooler to dissolve ammonium salts.

AVAILABLE CONTROL SCHEMESFC-419,PC-368,LC-516,FC-451,FC-420,LC-542& LC-544

SERVICE
Temperature(C)
Sour Water/MP BFW supply to
Wash water Drum
Sour Water from Reflux
Drum
Pressure ( bar g)
65-128
45.0
Flow rate (Kg/hr)

5.0-24.0
5221-6212
6.4
3310
Note:
Node
5. Wash Water
System
Deviation
1.
Low/No Flow
Causes
1. U/S disturbance in unit 550.
Consequences
1. Level of (V-004) may go down
Ref.
Safeguards
1. BFW & Recycle 5.1.1.1.1

water is available
for make up.
2. Low alarm for FC- 5.1.1.1.2

420 is provided.
2. FC 420 malfunctions to close 1. Level of (V-004) may go down
FCV-420
1. BFW & Recycle 5.1.2.1.1

water is available
for make up
3. FC-451 malfunctions to close 1. Level of (V-004) may go down

FCV-451
1. Stripped sour
water and recycle
water is available
for makeup
5.1.3.1.1
4. LC-542 malfunction to close

LCV-542A
1. Stripped sour
water and BFW is
available for
makeup
5.1.4.1.1

LCV-544
1. Interface level of V-009 boot will

be high
1.1 LI-560A is
provided with
HH alarm
5.1.5.1.1
2. Water may carry over with diesel product. 1 SC-011is

provided.
5.1.5.2.1

FCV-420/451& LCV-542B
1. LZ-518 LL alarm 5.1.6.1.1

to trip wash water
pumps and activate
UZ-721to close
XZV-721
7. P-002A/B trips
1. Level of (V-004) may go high
1 LI-559 is provided 5.1.7.1.1

with
HH alarm
2. Back flow from reaction section
1. LC-516 is
provided with high
alarm
5.1.7.2.1
2. PSV-310A/B
designed for liquid
overfilling case
5.1.7.2.2
3. FZ-450 LL alarm 5.1.7.2.3

to close XZV-721
8. FC-419 malfunction to close 1. No wash water to EA-001, will increase

FCV-419
salt deposition
2. High level in V-004.
4. NRV is provided
at inlet of reactor
effluent air cooler
5.1.7.2.4
1.FZ-450 is
provided with
LL alarm
5.1.8.1.1
1. LI-559 is provided 5.1.8.2.1

with
HH alarm
2.LC-516 is
provided with high
alarm
9. XZV-721 malfunction to close 1. Same as cause 8,Consequence

1&2 above
5.1.8.2.2
5.1.9.1
Recommendations
Responsibility
Remarks
Node
Deviation
Causes
10. FC-455A/B malfunction to
full open FCV-455A/B
Consequences
1. Less wash water to EA-001, resulting salt 1 FZ-450 is

deposition in tubes.
provided with
LL alarm
2. FC-419
provided with low
alarm.
2.
High Flow
1. FC 420 malfunctions to open 1. Level of (V-004) may go high

FCV-420
2. FC-451 malfunctions to open 1. Same as Cause-1 consequence1 in the

FCV-451
same node.
4. LC-544 malfunction to open

LCV-544

FCV-420/451& LCV-542B
2. Boot level of V-008 may go down,HC

carry over to V-004 may lead to high
pressure
1. PC-368 provided
with high alarm.
5.2.3.2.1
1. Same as Cause
1, Consequence 1,
Safegaurds1&2.
5.2.4.1.1

pressure
1. PC-368 provided
with high alarm.
5.2.4.2.1
1. Same as Cause
1, Consequence 1,
Safegaurds2.
5.2.5.1.1

pressure
1. PC-368 provided
with high alarm.
5.2.5.2.1
2. PSV-310 A/B
provided.
5.2.5.2.2
1. LC-516 is
provided with low
alarm
5.2.6.1.1
2. LZ-518 provided
with low low alarm.
5.2.6.2.2
As well as
1. Contamination in Stripped
sour water.
5.
Low Pressure
1. PC-368 malfunctions to close 1. Pump may cavitate and wash water flow
PCV-368A and opens 368B
to EA-001 may be lost.
2. Nitrogen supply failure.
3. Low supply pressure of sour

water from unit 550
6.
High Pressure
12. Operation/Maintenance
1. Water washing of EA-001 may get

affected.
1. Pump may cavitate and wash water flow

to EA-001 may be lost.
1. BFW may enter into sour water line
1. PC-368 malfunctions to open 1. V-004 may experience high pressure.

PCV-368A and closes PCV368B.
1. Misdistribution of wash water

in air cooler tube bundles.
5.2.2.1
5.2.3.1.1
3.
1. Salt may deposit on air cooler tubes.
Remarks
5.2.1.1.2
1. Same as Cause
1,Consequence
1,Safegaurds 1&2
above
2. Likely low level in V-004.
Responsibility
5.1.10.1.2
6. FC-419 malfunction to open 1. More wash water to EA-001,EEFCV-419

001 (when in operation)no major concern.
Recommendations
5.1.10.1.1
1. LC-516 provided 5.2.1.1.1

with
High alarm.
2. LI-559 provided
with HH
alarm.

LCV-542A
Ref.
Safeguards
1.
Ensure
sampling
provision is
given in
Unit
550 during
detailing.
5.3.1.1
5.5.1.1
1. PC-368
provided with low
alarm.
5.5.2.1.1
2. PI-806 at B.L is
provided with low
alarm
5.5.2.1.2
11. Operating
procedure should
ensure periodical
checking of PI019.
DEC/NOCL
12. Operating
procedure should
ensure periodical
checking of FI458/459/460/461
DEC/NOCL
1. NRV is provided 5.5.3.1.1
1. PSV-310 A/B is
provided.
5.6.1.1.1
5.11.1.1
5.12
Flow rate (Kg/hr)

5221-6212
3310
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 06
Separator bottom to sour water flash Drum and B/L
DESIGN INTENTION
To separate the sour water from HC in Separator and send to B/L.
DRAWINGS
CS-140-PR-15-0006, CS-140-PR-15-0021
EQUIPMENT
Sour water Flash Drum(140-V-017)
STREAM DETAILS
Sour water from Separator (V-006) to Sour water flash drum (V-017) and then water will send to B/L and flash gas will be sent to LP Amine KOD(V-010)

AVAILABLE CONTROL SCHEMESLC-514.LC-556,LC542

SERVICE
Temperature(C)
Separator bottoms to
Sour water flash drum
Sour water flash drum to
Sour water B/L
Pressure ( bar g)
Flow rate (Kg/hr)
45
6.4-78.8
10085
45
4.0-6.4
10080
Note:
Node
6. Separator bottom to Sour
water Flash Drum and B/L
Deviation
1.
Low/No Flow
2.
6.
High Flow
High Pressure
Causes
Consequences
Safeguards
Ref.
1. LC-510 malfunctions to close 1. Boot level of V-006 may go high resulting 1. LI 512 is
LCV -510
in water carry over with gas oil product.
provided with
HH alarm.
6.1.1.1.1
2. LC-556 malfunctions to close 1. V-017 water side level may go high.

LCV-556
6.1.2.1.1
1.Low alarm at FI417 is provided..
Recommendations
Responsibility
3. LC-514 malfunctions to close 1. V-017 Hydrocarbon side level may go

LCV-514
high.
6.1.3.1

checking of LG515
DEC/NOCL
4. LC-542 malfunctions to close 1. V-008 boot level may go high, water may
LCV-542 B
go along with reflux/wild naphtha.
6.1.4.1

checking of LG543
DEC/NOCL

checking of LG515
DEC/NOCL
1. LC-510 malfunctions to
opens
LCV -510
1. Boot level of V-006 may go low resulting

in hydrocarbon carry over with Sour water.
1. LZ 513 is
provided with LL
alarm will activate
UZ-704 to close
XZV704.
6.2.1.1.1
opens
LCV-514
1. V-017 Hydrocarbon side level may go

low, flash gas may go to CBD.
1. CBD vessel is
connected to flare.
6.2.2.1.1
3. LC-556 malfunctions to open 1. V-017 water side level may go low and
LCV-556
HC may carry over with Sour water to B.L.
6.2.3.1
open
LCV-542 B
1. Boot level of V-008 may go low resulting

in hydrocarbon carry over with Sour water.
6.2.4.1
1. U/S Disturbance
1. System may experience higher than the

operating pressure
1. PSV-309A/B is
provided.
6.6.1.1.1
Remarks
1. Provision
for HC
carryover with
sour water to be
considered in
unit 550.

checking of LG543
DEC/NOCL
1. Provision
for HC
carryover with
sour water to be
considered in
unit 550.
Flow rate (Kg/hr)

10085
10080
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 07
Separator drum to stripper inlet
DESIGN INTENTION
To preheat Gas oil in exchanger trains and send to stripper for strip out to naphtha and lighter components.
DRAWINGS
CS-140-PR-15-0007, CS-140-PR-15-0017, CS-140-PR-15-0018
EQUIPMENT
Separator Drum(140-V-006),Stripper Feed / Bottom Exchanger(140-EE-006),Stripper

Preheater (140-V-002)
STREAM DETAILS
Gas oil is separated in separator(V-006) and send for further heating In Stripper feed/bottom (EE-006) and stripper preheater (EE-002A/B) then stripper

AVAILABLE CONTROL SCHEMESFC-416,TC-191

SERVICE
Temperature(C)
Separator bottom to stripper
Preheater inlet
stripper Preheater to
Stripper Inlet
Pressure ( bar g)
Flow rate (Kg/hr)
45-51
11.9-78.8
41810-119768
213-260
8.9-10.3
119768
Note:
Node
7. Separator Drum to Stripper
Inlet
Deviation
1.
Low/No Flow
Causes
close.
2. LC-507/FC-416 malfunctions
to close FCV-416.
Consequences
Safeguards
1. K.O.D V-007 is 7.1.1.2.1

provided.
1. Level of V-006 increases
1. When FC 416 7.1.2.1.1

malfuctions,LC
507 is available
with high alarm &
when LC 507
malfunctions FC
416 is available for
monitoring
16. Provide low alarm at

FC-416
DEC
1. PSV-930A/B
17. Provide low alarm at

TI-190
DEC
18. Provide High alarm

on TI-190.
DEC
1. Level of V-006 decreases and down

stream system will face high pressure
7.1.1.1.1
7.1.3.1.1
1. Mechanical
7.1.3.2.1
Limit stop
provided at TCV191A for minimum
flow to avoid total
blockage.
7.1.4.1
4. TC-191 malfunctions to open 1. No major concern

TCV-191A
to open FCV-416.
Responsibility
2. Liquid HC carryover in vapor line.
2. Low stripper inlet temperature possibly

leading to product off spec
High Flow
Recommendations
1. LC 507 high
alarm is provided.
3. TC-191 malfunctions to close 1. Pressure of system up to EE-002 may

TCV-191B
increase
2.
Ref.
1. Level of V-006 increases
1. LZ-509 is
provided with low
low alarm which
will activate UZ703 to trip XZV703.
7.2.1.1.1
2. PSV-319A/B is 7.2.1.1.2
designed for gas
blow case.
2. TC-191 malfunctions to open 1. No major concern

TCV-191B
3.
As well as
7.2.2.1
1. LC 510 malfunctions to close 1. V-006 boot level will increase, may lead
LCV-510
to water carry over with diesel.
1. LI-512 is
provided with
HH alarm.
7.3.1.1.1
7. Low
Temperature
1. Failure of heating medium in 1. Low stripper inlet temperature possibly

EE-006A/B/C/D
leading to product off spec
1. TC-191
provided with low
alarm.
7.7.1.1.1
8. High
Temperature
1. Malfunction of TCV-191 A
1. High inlet temperature in Stripper

C-002.
7.8.1.1
1. Tube leak in EE-006
1. Stripper bottom will ingress in unstab gas

oil. No hazardous consequence.
7.11.1.1
1. Reactor effluent may ingress in

Unstab gas oil leading to
1. PSV-319A/B is 7.11.2.1.1
provided for tube
rupture case.
7.12
Remarks
Flow rate (Kg/hr)

41810-119768
119768
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 08
Separator over head to Recycle gas compressor inlet
DESIGN INTENTION
1.
To remove H2S from separator overhead stream in HP Amine Absorber.
2.
To feed Recycle Gas to recycle gas Compressor.
DRAWINGS
EQUIPMENT
Separator (140-V-006),HP Absorber KOD(140-V-007), HP Amine absorber (140-C001),Recycle compressor KOD(140-V-005)
STREAM DETAILS
Separator (V-006) Overhead goes to KOD (V-007)and then HP Amine absorber column (C001) where H2S treated by lean amine solution and send to KOD of Recycle gas compressor (V-005)then finally recycle gas compressor (K-002)

AVAILABLE CONTROL SCHEMESLC-519,HC-826.LC-521,LC-524

SERVICE
Temperature(C)
Separator overhead to
HP amine absorber
HP Amine absorber to
Recycle gas compressor
Pressure ( bar g)
Flow rate (Kg/hr)
45
78.8
15891-18053
54
78.4
13337-15497
Note:
Node
8. Separator Overhead to
Recycle gas compressor Inlet
Deviation
1.
Low/No Flow
Causes
1. HCV-826 malfunction to full
open (No flow through to
column)
Consequences

LCV-524
Ref.
1. AI-001 is provided on
K-002 suction line
8.1.1.1.1
2. System pressure may increase due to

non removal of H2S
1. PC-358 is provided
with high alarm
8.1.1.2.1
2. PC-358/FC-423 malfunction 1. System pressure may go down possible

to open FCV-423(Less flow in
damage of compressor(K-002)
Recycle gas compressor Suction
line)

LCV-519
Safeguards
1. High H2S concentration in recycle gas

lead to off spec product
1. Level loses in V-007,stripper (C002)/(EE-006A/B/C/D) /(EE002)may subject to high pressure due to gas
blow by
1. Level loses in V-005, Gas blow by may

happen to C-003
2. PI-377B is provided
with low alarm
8.1.2.1.2
3. FI-429 is provided
with low alarm
8.1.2.1.3
1. PSV-319A/B is
designed for this gas
blow by case
8.1.3.1.1
2. PI-903 is provided
with high alarm.
8.1.3.1.2
with high alarm.
8.1.4.1.1
2. PSV-318A/B is
designed for this gas
blow by case.
8.1.4.1.2
8.2.1.1.1
High Flow
1. PC-358/FC-423 malfunction
to
Open FCV-423(Fuel gas line)
1. Fuel gas line may subjected to high

pressure.
1. PSV-941A/B is
designed for this case.
5.
Low Pressure
open.
1. System pressure may go down
1. PI-377B provided with 8.5.1.1.1

Low alarm
High Pressure
1. U/S Disturbance
1. Over pressurizing the system.
2. FI-429 provided with

Low alarm.
8.5.1.1.2
3. Compressor gets
tripped on PZ-378 LL
alarm.
8.5.1.1.3
2. PSV-307 A/B is
provided.
8.6.1.1.2
1. U/S disturbance
1. Heavier hydrocarbon carry over from

separator (V-006) to Hp Amine absorber(C001)
1. TI-167 and TI-212 is

provide with high alarm
8.8.1.1.1
10.

LCV-519
1. HC Liquid carry over to C-001
1. LC-521 is provided
with
High alarm.
8.10.1.1.1
2. LC-524 malfunctions to close 1. Liquid carry over with recycle gas to KLCV-524
002
1. LZ-526 provided with 8.10.2.1.1

HH alarm which will
activate UZ-705 to trip the
compressor.
1. Over pressurization of the

system due to some
emergencies
1. Emergency
8.11.1.1.1
depressurization
safeguarding system UZ702 is provided.
1. Possible loss of life and property.
Remarks
1.
Ensure
refinery fuel
gas
compositio
n has
considered
addition of
hydrogen
from this
unit during
detail
engineering
.
20. Provide open feed back

alarm from ZB 702 A
DEC
1. PC-358 provided with 8.6.1.1.1

high alarm.
8. High
Temperature
High Level
Responsibility
DEC/NOCL
1. PZ-378 LL alarm will 8.1.2.1.1

activate UZ-705 to trip the
compressor (K-002)
2.
6.
Recommendations
19. Operating procedure to
include operation of HS-822 to
select FCV-423 to purge H2S to
flare header
8.12

DEC/NOCL
monitor LG-522 for HC carry
over. When HC level builds up it
should be drained to CBD by
using Skim line.
15891-18053
13337-15497
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 09
Recycle gas compressor to mixing point
DESIGN INTENTION
To supply recycle gas from recycle gas compressor to Reaction section
DRAWINGS
CS-140-PR-15-0011, CS-140-PR-15-0003
EQUIPMENT
Recycle gas compressor (140-K-002)
STREAM DETAILS
H2 and lighter gases are recycled through RGC(K-002) to mixing point at the inlet of
Reactor feed/effluent exchanger

AVAILABLE CONTROL SCHEMESFC-427

SERVICE
Temperature(C)
Recycle gas compressor to
Mixing point
Pressure ( bar g)
Flow rate (Kg/hr)
75.7-79
92.5-95.2
4310-5022
Note:
Node
9. Recycle Gas compressor to
Mixing Point
Deviation
1.
Low/No Flow
Causes
1. K-002 trip
Consequences
1. No hydrogen supply to reactor.
Safeguards
1.1 UZ-705 will
activate
UZ-706
2. Gas oil may enter Compressor discharge 1. NRV is provided.

line
Ref.
Recommendations
Responsibility
Remarks
9.1.1.1.1
9.1.1.2.1
2. UZ-706 will activate 9.1.1.2.2

UZ719(back flow
protection system) to
close XZV-719
2. FC-427 malfunction to close

FCV-427(Antisurge line)
1. Possibly more hydrogen to Reactor

section.(NO major concern.)
9.1.2.1
3. Malfunctioning of XCV-715
(Antisurge line by supplier)
1. Possible damage of compressor.
9.1.3.1
4. FC-427 malfunction to open 1. Less Hydrogen to reactor/quench leading 1. FCFCV-427(Recycle gas and
to low product quality.
412/413/414/415 is
quench gas line)
provided with low
alarm.
High Flow
9.1.4.1.1
2. FZ-428 is
provided with
LL alarm
9.1.4.1.2
1. Anti surge valve

XCV715 provided.
9.1.5.1.1
1. To be
reviewed during
detail
engineering
when vendor
information is
available
1. FC-427 malfunction to open 1. Less Hydrogen to reactor/quench leading 1. FCFCV-427 (high flow in antisurge to low product quality.
412/413/414/415 is
line)
provided with low
alarm.
9.2.1.1.1
1. Low low
alarm of FZ428 to be verified
for this cause
during detailed
engineering.
5. U/S disturbance (Recycle

gas becomes less)
2.
1. This
antisurge is not
considered in
this HAZOP. To
be Considered in
Detail
engineering.
1. Possible surging of compressor.
2. FZ-428 is provided 9.2.1.1.2

with
LL alarm
Flow
2. K-002 trips
1. Make up hydrogen may back up in

recycle compressor discharge
6.
1. Malfunction of K-002
1. Possible over pressure causing damage

to the system
1. Malfunction of K-002
1. High discharge temperature may lead to

system damage
High Pressure
8. High
Temperature
1. Operational and safety

1. Possible hazard of life and property.
issues related to compressor (K002
& KT-002) and turbine system
1. NRV is provided.
9.4.2.1.1
9.6.1.1
1. To be
reviewed during
detail
engineering
when vendor
information is
available
1. TI-175 is provided
with high alarm.
9.8.1.1.1
2. TZ-174 with HH
alarm to activate UZ705
9.8.1.1.2
1. To be
reviewed during
detail
engineering
HAZOP when
vendor
information is
available.
9.11.1.1
1. To be
reviewed during
detail
engineering
HAZOP when
vendor
information is
available.
Flow rate (Kg/hr)

4310-5022
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
NODE NO: 10
Lean Amine from B/L to LP and HP amine absorber column
DESIGN INTENTION
Lean Amine supply to HP and LP amine absorber columns.
DRAWINGS
CS-140-PR-15-0009, CS-140-PR-15-0010, CS-140-PR-15-0016
EQUIPMENT
Lean Amine booster pumps(140-P-003A/B),HP Amine absorber column(140-C-001),LP Amine absorber columns(140-C-003)
STREAM DETAILS
Lean amine comes from B/L and goes to LP Amine absorber column (C-003) and pumped through amine Pump(P-003)to HP Amine absorber column
FC-434,FC-424
Project :
SERVICE
Temperature(C)
Lean Amine from B/L to LP Amine
absorber column
Lean Amine from B/L to HP Amine
absorber column
Pressure ( bar g)
50
9.5
50
9.5-86.5
Note:
Node
Deviation
10. Lean Amine from B/L to LP and HP 1.

Amine Absorber column
Low/No Flow
Causes
1. U/S disturbance
Consequences
1. P-003A/B may starve and get damaged
Safeguards
1. FC-424/434 provided
with low alarm
2. Less/No removal of H2S from recycle/ Off 1. PI-373 is provided with

gas
low alarm
2. P-003A/B trips(Lean Amine

to
C-001)
3. FC-434 malfunction to close

FCV-434(Lean Amine to C003)
3. AI-001 provide on
recycle gas line for
monitoring
10.1.1.2.3
4. AI-002 provided on off

gas drum outlet
10.1.1.2.4
10.1.2.1.1
2. back flow from HP Amine absorber to

lean amine pump(P003A/B)
1. FZ-443 provided with

LL alarm to activate UZ720(Lean amine to C001)
10.1.2.2.1
2. NRV is provided
10.1.2.2.2
1. AI-002 provided on off 10.2.3.1.1

gas drum outlet
1. Same as cause 4, consequences 1

;deviation (Less/No flow) in this node
6. FC-456A/B malfunction to full 1. Less removal of H2S from recycle gas

open FCV-456A/B(Low flow of
Lean amine to C-001)
2.
High Flow
1. FC-434 malfunction to open

FCV-434(Lean Amine to C003)

DEC/NOCL
should ensure routing of off gas
to flare header when there is
disturbance in lean amine
supply to C-003
22. UZ-720 should activate

DEC
UZ-710 to trip pump (P-003A/B)
10.2.4.1.2
1. AI-001 provide on
monitoring
10.2.6.1.1
2. FC-424 provided with

Low alarm
10.2.6.1.2
1. C-003 level increases, possible column

overfilling
1. LC-532 is provided with 10.2.1.1.1

high alarm
2. Possible column (C-003)flooding
1. LA-560 is provided with 10.2.1.2.1

HH alarm
2. FC-424 malfunctions to open 1. C-001 level increases, possible column

FCV-424(Lean Amine to Coverfilling
001)
2. U/S disturbance
10.2.4.1.1
10.2.5.1
2. PDI-392 is provided
with high alarm
Flow

DEC/NOCL
should ensure routing of off gas
to flare header when there is
disturbance in lean amine
supply to C-003
10.1.1.2.2

LL
alarm to activate UZ720(Lean amine to C001)
Responsibility
10.1.1.2.1
1. Less/No removal of H2S from recycle gas 1. AI-001 provide on

monitoring
1. Less/No removal of H2S from Off gas
Recommendations
DEC

LL alarm to activate UZ720(Lean amine to C001)
4. FC-424 malfunctions to close 1. Less/No removal of H2S from recycle gas 1. AI-001 provide on
FCV-424(Lean Amine to Crecycle gas line for
001)
monitoring
close(Lean Amine to C-001)
Ref.
10.1.1.1.1
10.2.1.2.2

high alarm
2. Possible column (C-001)flooding
1. PDI-372 is provide with

high alarm
1. Off/Fuel gas may back to OSBL

through lean amine line from C003
1. NRV is provided in the 10.4.2.1.1

line
10.2.2.21.1

DEC
Remarks
Node
Deviation
6.
High Pressure
7. Low
Temperature
Causes
Consequences
Safeguards
Ref.
1. FC-424 malfunctions to close 1. System up to FCV-424 from PFCV-424(Lean Amine to C003 may get pressurized
001)
1. System is designed for 10.6.1.1.1

shut off pressure of the
pump P-003.
close(Lean Amine to C-001)
1. System up to XZV-720 from P003 may get pressurized
1. System is designed for 10.6.2.1.1

shut off pressure of the
pump P-003.
1. U/S disturbance
1. HC may condense in amine solution

leading to foaming
1. TI-171 is provided with 10.7.1.1.1

low alarm(for C-001), TI186 is provided with low
alarm(for C-003)
2. TDI-213 is provided
with low alarm(for C001),TDI-214 is provided
with low alarm(for C-003)
Recommendations
Responsibility

ensure to check LG 533 &LG522 and drain out the HC
through Skim line.
DEC/NOCL
24. Provide High alarm on TI170 at lean amine B.L
DEC
10.7.1.1.2
3. LG-522 & LG-533 are

10.7.1.1.3
transparent type to see the
interface during upset
conditions.
4. The valve in HC
10.7.1.1.4
Skimming line for C-001 is
Spring loaded type.
8. High
Temperature
1. U/S disturbance
1. Poor removal of H2S from

Recycle gas/Off gas
1. AI-001/AI-002 is
provided for monitoring
10.8.1.1.1
Remarks
Flow rate (Kg/hr)

17649-18370
57857
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 11
Rich Amine from HP Amine absorber system to LP amine absorber bottom to B/L
DESIGN INTENTION
To supply Rich amine from HP amine absorber column to LP amine absorber column
DRAWINGS
CS-140-PR-15-0011, CS-140-PR-15-0016
EQUIPMENT
HP Amine absorber column (140-C-001), LP Amine absorber column (140-C-003)
STREAM DETAILS
Rich amine from HP Amine absorber column(C-001) bottom to LP Amine absorber column(C-003)

AVAILABLE CONTROL SCHEMESLC-521

SERVICE
Temperature(C)
Rich amine from HP
amine absorber column to LP
Amine absorber column
Pressure ( bar g)
Flow rate (Kg/hr)
56-57
6.2-78.6
60413
Note:
Node
11. Rich Amine from HP Amine
Absorber ,LP Amine Absorber
bottom to B/L.
Deviation
1.
2.
Less/No flow
High Flow
Flow
Causes
Consequences
Safeguards
Ref.
11.1.1.1
1. LC-521 Malfunctions to
Close LCV-521
1. Level of C-001 may go high.
2. XZV-709 Malfunctions to
close
with
High alarm.
11.1.2.1.1
3. LC-532 Malfunctions to
Close
LCV-532
1. LA-560 is provided
with
HH alarm.
11.1.3.1.1
1. LC-521 Malfunctions to open 1. Level of C-001 may go down.

LCV-521
1. LZ-523 LL alarm
will activate UZ-709.
11.2.1.1.1
2. LC-532 Malfunctions to open 1. Level of C-003 may go down.

LCV-532
1. Low low alarm at LA- 11.2.2.1.1

560 is provided.
1. Reverse flow of Rich amine

from B.L to C-003 bottom.
1. NRV is provided at
B.L
11.4.1.1.1
with high alarm.
11.4.1.1.2
3. LA-560 is provided
with high alarm.
11.4.1.1.3
1. Level in C-003 may go high
Recommendations
25. Provide additional LI
with HH
alarm at C-001 bottom.
Responsibility
DEC
Remarks
Flow rate (Kg/hr)

60413
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 12
LP Amine absorber system (LP Amine Column KOD, Off gas KOD) to B/L
DESIGN INTENTION
To Supply Off /Fuel gases from reflux drum to B/L Unit-350
DRAWINGS
CS-140-PR-15-0021, CS-140-PR-15-0016
EQUIPMENT
Stripper Reflux Drum (140-V-008),LP Amine KOD(140-V-010), LP Amine Absorber Column

(140-C-003), Off gas KOD (140-V-018) ,Sour water flash Drum(140-V-017)
STREAM DETAILS
Flash gas from flash drum(V-017)and off gases from Reflux drum (V-008) is collected to KOD of LP Amine absorber column (C-010) where it is treated with amine solution and send to B/L or Fuel gas header
AVAILABLE CONTROL SCHEMESPC-394,LC-551

SERVICE
Temperature(C)
Off gases from reflux drum to
KOD of LP Amine absorber
Off gases/Fuel gases LP
amine KOD to B/L
Pressure ( bar g)
Flow rate (Kg/hr)
45.0
6.4
1172-1371
45.0
2.6 - 6.3
512-741
Note:
Node
Deviation
12. LP Amine Absorber system 1.

(LP Amine column KOD, Off Gas
KOD) to B/L
2.
Less/No flow
High Flow
Causes
Consequences
1. PC-394 malfunctions to close 1. System will be pressurized

PCV-394A/B.
1. PI-903 is provide with

high alarm at C-002
overhead
12.1.1.2.1
3. Improper flashing of HC in V-017 leading

to HC carryover with
Sour water.
1. AI-003 is provided
12.1.1.3.1
2. PI-903 is provide with

high alarm at C-002
overhead
12.1.1.3.2
8. High
Temperature
Recommendations
Responsibility
2. LC-551 malfunctions to close 1. V-018 level will increase & Liquid may
LCV-551 when required.
carryover with off gas/fuel gas
12.1.2.1

checking of LG552
DEC/NOCL
3. LC-530 malfunctions to close 1. V-010 level will increase & Liquid may
carryover with off gas to C- 003 leads to
foaming in C-003.
12.1.3.1
31. Periodical checking of

interface in
LG-533.
DEC/NOCL
4. U/S disturbance in C-002
12.1.4.1
1. No major consequence for this node
1. PC-394 malfunctions to open 1. Column level in C-003 will increase.

PCV-394A/B.
3. System pressure may go down
High Pressure
Ref.
2. Pressurization may lead to off spec

product gas oil
2. Less removal of H2S from off gas
6.
Safeguards
1. PSV-318A/B is provided 12.1.1.1.1

high alarm.
1. LA-560 is provided with 12.2.1.2.1
HH alarm.
2. H2S analyzer (AI-002)

in the product line
indicates off-spec off gas
12.2.1.2.2
1. AI-002 is provided for

monitoring.
12.2.1.3.1
2. Pressure transmitter
PT-999 is provided with
low alarm at top of C003.
12.2.1.3.2
2. LC-551 malfunctions to open 1. Rich Amine may backup to V-018

1. NRV is provided on line 12.2.2.1.1

DA-017 close to mixing
point with DA-012.
3. LC-530 malfunctions to open 1. System will face low pressure.

1. Pressure transmitter
PT-999 is provided with
low alarm at top of C003.
2. Choking of Packed Bed in C- 1. High Pressure drop in Column leading to

003
Improper H2S removal.
1. PDI-392 provided with 12.6.2.1.1

high alarm.
1. U/S disturbance
1. Heavier HC condenses in C-003
12.2.3.1.1
2. PSV-318A/B is
provided.
12.6.2.1.2
1. TI-208 at V-008 top is

provided with high alarm.
12.8.1.1.1
2. TI-184 on inlet of C003 is provided with high

alarm.
12.8.1.1.2
35. Provide high alarm at TI- DEC

185.
Remarks
Flow rate (Kg/hr)

1172-1371
512-741
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 13
Stripper bottom to Gas oil air cooler , Coalescer and salt dryer to B/L
DESIGN INTENTION
To supply Hydro treated gas oil from Stripper Bottom to B/L.
DRAWINGS
EQUIPMENT
Stripper(140-C-002),Stripper bottoms pump(140-P-005),Stripper feed/bottom exchanger(140-EE-006),Gas oil air cooler (140-EA-003),Gas oil trim cooler (140-EE-007), Coalescer (140-V-009),Salt dryer (140-V-019)
STREAM DETAILS
Stripper bottoms is cooled in Stripper feed bottoms exchanger, Gas oil air cooler and Gas oil trim cooler. Then it is passed to coalescer and salt dryer to remove moisture. Then it is sent to B.L.
AVAILABLE CONTROL SCHEMESFC-442,LC-535,LC-544

SERVICE
Temperature(C)
Stripper bottoms to feed bottom
exchanger, Gas Oil Air cooler,
Trim cooler
Gas oil From Coalescer to B.L.
Pressure ( bar g)
Flow rate (Kg/hr)
65-252.1
7.3-11.8
115553
40.0
5.0-7.3
115214
Note:
Node
Deviation
13. Stripper bottom to Gas oil Air 1.

cooler, Coalescer and Salt Dryer
to B/L
Less/No flow
Causes
1. P-005A/B trips.
Consequences
1. C-002 level will increase
2. System pressure at pump P-005 d/s will

come down
Safeguards
1. LC-535 provided with
high alarm
Ref.
Recommendations
Responsibility
13.1.1.1.1
1. LZ-537 is provided with 13.1.1.2.1

HH alarm & activates UZ717 to isolate MP Steam
toC-002
2.Pressure transmitter PT- 13.1.1.2.2

444 is provided with low
alarm downstream of V019, before FCV-442 on
line P-103.
to close FCV-442.
to close FCV-454(Start-up
recirculation line).
1. System will face P-005 shut off pressure
1. System is designed for

pump shut off pressure.
2. Level will increase in column C002.
1. Same as safeguards 1, 13.1.2.2.1

2 for cause 1 in this
node.
High Flow
13.1.3.1

1&2 of deviation less/no flow in this node.
4. MOV -004 in closed condition 1. Pump will run dry if it is started.
1.Start permissive is
13.1.4.1.1
included as a part of safe
guarding system for Pump
P-005A/B.
5. Choking of coalescer in V009
1.PDI-914 provided with

High alarm.
6. Choking of salt dryer in V019
1. PDI-923 Provided with 13.1.6.1.1

High alarm
7. FC-436 malfunctions to close 1. Product quality upset (Flash point ,sulfur

FCV-436
content of Gas oil)
2.
13.1.2.1.1
13.1.5.1.1
1. SC-012 is provided at 13.1.7.1.1

pump discharge P-005
2. AI-003 is provided for

monitoring
13.1.7.1.2
13.1.8.1.1
close
1. Same as cause 7 deviation less/no flow

in this node
1. FC-436 provided with

low alarm.
to open FCV-442.
1. Level of C-002 may go down.
1. LZ-538 is provided with 13.2.1.1.1

LL alarm to activate UZ712.
13.2.1.2.1
2. Product quality may get affected due to

less residence time in V009/V-019 respectively.
to open FCV-454(Start-up
recirculation line).
1. Level of C-002 may go down.
1. LZ-538 is provided
with
LL alarm to activate UZ712.
13.2.2.1.1
3. FC-436 malfunctions to
open
FCV-436
1. V-008 boot level may increase.
with high alarm.
13.2.3.1.1
Flow
1. P-005 A/B trips
1. Gas oil may backup from storage
1. NRV provided in
Rundown line at B.L.
13.4.1.1.1
5.
1. U/S disturbance
1. P-005 capacity reduces and level in

column will rise.
1. LZ-537 HH will
activate
UZ-717 to close XZV717 on M.P steam line.
13.5.1.1.1
1. EA-003 trips
1. Likely Poor performance of V009/V-019
1. High alarm provided

at TI-203.
13.8.1.1.1

at TI-204.
13.8.2.1.1
Low Pressure
8. High
Temperature
37. Provide high alarm for

FC-442.
DEC
Remarks
8. High
Temperature
Node
Deviation
Causes
3. Cooling medium failure in
EE-006
Consequences
Safeguards
13.8.3.1.1

at TI-204.
13.8.3.1.2
13.11.1.1
1. Not Draining of salt dryer
1. Water may carry over with diesel product.
2. Loss of salt in salt dryer
1. Water may carry over with diesel product. 1. SC-011 is provided for 13.11.2.1.1
sampling
3. Leakage through Seal in P005A/B
1. Possible fire
Recommendations
Responsibility
1. P&ID -0017
rev 1, to be
corrected
accordingly
13.11.3.1.2
13.11.4.1
1. Stripper bottom will ingress in cooling

water line
5. Vibration in Air cooler (EA003) fans
1. Possible damage of EA-003 components 1. VA-008A/B is provided 13.11.5.1.1

with high alarm
13.12
Remarks

DEC/NOCL
should ensure draining of
salt dryer at regular intervals
by checking LG554.
1. Pump is provided with 13.11.3.1.1

double mechanical seal
2. HZ-850 is provided at
safe distance to activate
UZ-712.
Ref.

at TI-203.

during detail engineering of
OSBL system
PMC/NOCL
Flow rate (Kg/hr)

115553
115214
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 14
Stripped overhead system
DESIGN INTENTION
To Supply Wild Naphtha to B/L.
DRAWINGS
CS-140-PR-15-0017, CS-140-PR-15-0020, CS-140-PR-15-0021
EQUIPMENT
Stripper Air Condenser(140-EA-002), Stripper Trim Condenser(140-EE-005),Stripper

Reflux Drum(140-V-008), Stripper Reflux Drum(140-V-008),Stripper Reflux Pumps(140-P004A/B)
Stripper Overhead is condensed and sent to B.L for storage. A part is sent back to column as reflux.
STREAM DETAILS

AVAILABLE CONTROL SCHEMESLC-542,FC-439,FC-441,LC-540

SERVICE
Temperature(C)
Stripper Reflux
Wild Naphtha to Storage
.
Pressure ( bar g)
Flow rate (Kg/hr)
45
45
9.5-11.5
6.0-11
9105
2956
Note:
Node
14. Stripper Overhead system
Deviation
1.
Low/No Flow
Causes
1. U/S disturbance(stripping
steam failure/Low feed inlet
temperature to C-002)
Consequences
1. Product quality may get affected
(Gas oil) due to poor stripping.
Safeguards
2. SC-011 is provided
2. P-004A/B trips(reflux)
Ref. No.
Recommendations
Responsibility
1. AI-003 is provided on 14.1.1.1.1

product line
1. V-008 level may go high
11 LC-540 is provided
with high alarm.
2. C-002 overhead pressure &

temp. may increase.
1.2 FC-439/441 is
provided with low alarm
14.1.2.1.1
2.1 PI-903 is provided

with high alarm.
2.2 PSV-319A/B is
designed for reflux failure
case
3. FC 439 malfunctions to close 1. Same as cause 2 consequence
FCV-439
1&2 of deviation less/no flow in this node.
2.
High Flow
4. FC 441 malfunctions to close 1. V-008 level may go high

FCV-441
with high alarm.

LCV-540B/FCV-441
1. FC-441 is provided
with low alarm.
1. V-008 level may go high
1. FC 439 malfunctions to open 1. Column overhead temperature may come 1.1 SC-011 is provided
FCV-439
down which lead to gas oil product off
for sampling
spec(Flash point)
Low alarm at TI-192 is
provided.
2. V-008 level may come down
2.1 LC-540 is provided

with low alarm.
2. FC 441 malfunctions to open 1. V-008 level may go down

FCV-441
with low alarm.

LCV-540B/FCV-441
1. V-008 level may go down
1. FC-441/FC-439 is
provided with Low alarm
2. Pump will loose suction.
2. Refer safeguards 2.1,

2.2 for cause 2, deviation
low/no flow in this node.
1. Reverse flow may occur from unit

160/200.
1. NRV is provided at
B.L.
Flow
1. P-004 A/B trips
5.
1. D/S disturbance(PCV-394A/B 1. Carry over of diesel in stripper overhead. 2.1 LC-540 is provided
full open)
heavies in wild naphtha to unit -160/200.No
with high alarm
hazardous consequences
Low Pressure
2. P-004 discharge pressure will come down 2.2 FC-439 and FCleading to increase of level in V-008.
441are provided with low
alarm
8. High
Temperature
2. EA-002 trips
1. Heavier hydrocarbon carryover with Off

gas to upset C-003
1.1FI-438 is provide with

high alarm
2. Level of V-008 may come down which

leads to reflux failure,
2.1PI-903 is provided with

high alarm.

hydrocarbon from C-003
through skim line during
failure of EA-002
DEC/NOCL
Remarks
8. High
Temperature
Node
Deviation
2. EA-002 trips
Causes
2. Level of V-008 may come down which

leads to reflux failure,
Consequences
Safeguards
Ref. No.
Recommendations
Responsibility
2.2PSV-319A/B is
designed for reflux failure
case
2.3TI-208 is provided with
high alarm
Power supply to EA-002
fan motors from different
sources is provided.

1&2 above.
1. Stripper over head will ingress in cooling

water line
2. Vibration in Air cooler (EA002) fans
1. Possible damage of EA-002 components 1. VA-005/006 is

provided with high alarm

during detail
engineering of OSBL
system
PMC/NOCL
Remarks
Flow rate (Kg/hr)

9105
2956
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 15
Makeup H2 Compressor System
DESIGN INTENTION
To make up Hydrogen supply to make-up Compressor.
DRAWINGS
CS-140-PR-15-0013, CS-140-PR-15-0014, CS-140-PR-15-0015
EQUIPMENT
Make Up Gas Compressor K.O.Drum (140-V-002), Make-up Compressor (140-K-001A/B), Make-up Compressor Inter stage Cooler (140-EE-008A/B), Make-Up Compressor Interstage K.O. Drum (140-V-003A/B).
STREAM DETAILS
Make up hydrogen comes from B.L. to K.O.Drum to remove any liquid content and compressed to 95 barg

SERVICE
Temperature(C)
Hydrogen from B.L.
.
Pressure ( bar g)
Flow rate (Kg/hr)
45
20
2457
Note:
Node
15. Makeup H2
Compressor system
Deviation
1.
Low/No Flow
Causes
1. U/S disturbance
Consequences
Safeguards
1. Less/No hydrogen make up to reaction

section
1.1 FI-432 is provided

with low alarm.
2. Suction pressure of compressor may go

down
2.1 PC-383 is provided

with low alarm
Ref.
Recommendations
Responsibility
Remarks
2.2 PZ-385/PZ-956 LL
alarm will activate UZ707 to trip K-001A/B
Note-13 is provided in
P&ID stating that signals
from non running
compressor instruments
shall not be used for
control and trip of the
running compressor.
2. K-001A/B trips
1. No hydrogen make up to reaction section 1. Standby compressor

is available.
3. XZV-707 Malfunction to close 1. No hydrogen make up to reaction section 1.1 PC-974 is provided
with high alarm
2. Compressor discharge may experience

high pressure.
2.1 Spill back line is

provided.
2.2 FI-432 is provided
with low alarm
4. FC-431/PC-383/PC-974
malfunctions to open FCV431(Makeup line)
1. Less hydrogen make up to reaction

section
with low alarm
5. FC-431/PC-383 /PC-974
malfunctions to close FCV431(Spill back line)
1. System pressure may go high
with high alarm
2. PSV-316/317 is
provided.
2.
High Flow
Flow
6. PC-922 malfunction to close

PCV-922(hydrogen to Unit2500)
1. No major concern as this line is

NNF.
7. PC-922 malfunction to open

PCV-922(Make up line)
1. System d/s PCV-922 may experience

high pressure.
1. FC-431/PC-383/PC-974
malfunctions to close FCV431(Makeup line)
1. Refer cause 5, Low/No flow in this node.
2. FC-431/PC-383 /PC-974
malfunctions to open FCV431(Spill back line)
3. PC-922 malfunction to open

PCV-922(hydrogen to Unit2500)
4. PC-922 malfunction to close

PCV-922(Make up line)
1. K-001A/B trips.
1. Recycle gas may backflow in the system
2. U/S disturbance at Unit

1500(start up line to V-008)
1. Off gas may back up in the system
1. PSV-952A/B is
provided.
1. NRV is provided in
make up hydrogen line to
Recycle gas.
2. UZ-707 will close
XZV- 707
NRV is provided at the
junction of H-162 and P079 on line H-162.
1. Compressor
safeguards and
system should be
Hazoped when the
vendor information
is available during
detailed
engineering.
Node
Deviation
5.
Low Pressure
Causes
2. Compressor malfunctioning
Consequences
1. Less makeup hydrogen flow to
Reaction section
Safeguards
Ref.
Recommendations
Responsibility
1. PI-036/037 is
provided with low alarm
Remarks
1. To be
reviewed during
detail engineering
HAZOP when
vendor information
is available.
2. PZ-385A/956A is
provided with LL alarm to
activate UZ-707.
3. Note-13 is provided in
from non running
running compressor.
6.
High Pressure
8. High
Temperature
2. Cooling water failure for EE008A/B
1. V-003A/B pressure may go high
1. PI-036/037 is
provided with high alarm.
1. Cooling water failure in EE008A/B
1. Compressor may get damage
1. TI-229/230provided
with high alarm.
2. TI-180/182 is
provided with High alarm.
3. TZ-181/183 HH alarm
from non running
running compressor.
2. Compressor (K-001A/B)
malfunctions
1. TI-231/233 is
provided with High alarm
2. TI-180/182 is
Will activate UZ-707.
from non running
running compressor.
with
HH alarm
2. TI-231/233 is
3. TI-180/182 is
1. Hydrogen to B.L will go at High

temperature, possible damage in d/s
with high alarm
5. U/S disturbance
1. TI-231/233 is
2. TI-180/182 is
10.
High Level
1. U/S disturbance
1. Compressor may get damage due to

carryover of liquid.
1. LI-527/562/565 is
2. LZ-529/561/564 HH
alarm will activate UZ707 to trip compressor.
1. Consider CW
failure in EE-009
during detail
engineering of Unit2500.
45. Provide High alarm at

TI-176.
DEC
Node
Deviation
Causes
Consequences
Safeguards
Ref.
Recommendations
Responsibility
Remarks
from non running
running compressor.
1. Tube leak in EE004/008A/008B/009
1. Hydrogen may ingress in cooling water.

No major concern for
small leak. For major leak system will loose
hydrogen and compressor suction pressure
may go down.
with low alarm
1.
Hydrogen
ingress in Cooling
water should be
considered during
detail engineering
of cooling water
system.
Flow rate (Kg/hr)

2457
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 16
Chemical Injection package
DESIGN INTENTION
Chemical injection to prevent Corrosion/undesirable upsets in process.
DRAWINGS
CS-140-PR-15-0023, CS-140-PR-15-0025
EQUIPMENT
Antifoaming Agent /Anti Oxidant /Sulfiding Agent/Anti foulant /Corrosion Inhibitor injection
System
STREAM DETAILS
Antifoaming Agent /Anti Oxidant /Sulfiding Agent/Anti foulant /Corrosion Inhibitor injection
System


SERVICE
Temperature(C)
Sulfiding Agent
Antifoulant
Corrosion Inhibitor Antifoaming
Anti Oxidant
Pressure ( bar g)
Flow rate (Kg/hr)
Ambient
Ambient
Ambient
Ambient
Ambient
1.5-7.5
0.0-4.0
0-10.8
0-11/12
0-7.5
1600
14.0
1.6
0.34/0.11
6.0
Note:
Node
16. Chemical Injection System
Deviation
1.
Low/No Flow
Causes
1. P-007A trips( during
sulfidation)
Consequences
1. Discharge pressure will go down.
Delaying in sulfiding process.
Safeguards
Ref.
Recommendations
Responsibility
Remarks
1. Sulfiding process is
attended activity, LG549 is provided for
monitoring.
2. Stop alarm in DCS is

provided for chemical
injection pumps.
2. P-008A trips

Reactor circuit may get fouled.
1. LG-550 is provided for

monitoring.

checking of Chemical
injection pumps.
DEC/NOCL

injection pumps.
DEC/NOCL

injection pumps.
DEC/NOCL

injection pumps.
DEC/NOCL

injection pumps.
3. P-011A trips

Corrosion in stripper overhead circuit.

monitoring.

injection pumps.
4. P-010A trips

Possible Foaming in C-001/003

monitoring.

injection pumps.
5. P-012A/B

Possible gum formation in product

monitoring.

injection pumps.
2.
High Flow
Flow
6. Nitrogen failure

Possible detoriation of chemicals due to air
ingress.
1. DEC should
ensure the
requirement of
nitrogen
blanketing during
detail
engineering.(local
environmental
regulations)
1. High stroke in P-007A
1. Possible damage/reduced life of reactor

catalyst.
1. Sulfiding process is a
attended activity.
1. Reverse flow from unit 400
1. possible contamination
NRV is provided on line CC020 near B.L.
2. Reverse flow from P-001

suction line.
1. Reactor circuit may get fouled.
1.1 NRV is provided on the

line
1. Draining of
the OSBL line to
be reviewed
during detail
engineering of
Unit 400.
2. Delay in sulfiding process(during sulfiding 2.1 NRV is provided on the

operation)
line
3. Reverse flow from C-002
overhead.
1. Stripper overhead backflows.
1. NRV is provided on the

line
4. Reverse flow P-003 Suction

line/C-003
1. Lean amine backflows

line
1. Ensure in
detail engineering
that mixing point
of antifoam agent
is close to P003A/B suction.
Node
Deviation
Causes
Consequences
Safeguards
5. Reverse flow of gas oil

product to P-012A
1. Gas oil backflows to anti oxidant drum.

line.
1. PSV304/305/971/932/322
6.
High Pressure
1. D/S disturbance
1. less/no flow of chemicals
9.
Low Level
1. low level in tanks
1. Pump will run dry.
Ref.
Recommendations

should ensure proper
checking of levels in
chemical injection tanks.
Responsibility
DEC/NOCL
Remarks
Flow rate (Kg/hr)

1600
14.0
1.6
0.34/0.11
6.0
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 17
Fuel oil, Fuel gas and Heater Firing system.
DESIGN INTENTION
To Supply fuel gas/fuel oil to reactor fire heater.
DRAWINGS
CS-140-PR-15-0024, CS-140-PR-15-0026
EQUIPMENT
Hydro treating reactor feed Heater (140-H-001)
STREAM DETAILS
Heater is Dual fired

AVAILABLE CONTROL SCHEMESPC-802,PC-823,UC-001

SERVICE
Temperature(C)
Fuel Gas
Fuel Oil
Pressure ( bar g)
Flow rate (Kg/hr)
25
180
3.5
11
416
615
Note:
Node
17. Fuel oil, Fuel gas and
Heater Firing System
Deviation
1.
Low/No Flow
Causes
1. PC -802 malfunctions to
close
PCV-802(fuel gas line)
Consequences
Safeguards
1. Loss of firing of fuel gas may lead to

process upset
1. Fuel oil is provided as

alternate fuel to provide
adequate firing from
UC-001.
2. Fuel gas pressure may come down.
2. PZ-821 is low low alarm to

activate UZ-718.
2. XZV-718A/C malfunctions to
close(fuel gas line)
1. Same as Cause 1 above.
3. XZV-718E/F malfunctions to
close(pilot gas line)
1. Pilot flame will loss
1. Pilot flame scanner (BZS001/002/003) is provided
2. PZ-823 is provided with low

low alarm to
activate UZ-718.
4. PC-823 malfunctions to close 1. Loss of firing of fuel oil may lead to
PCV-823A(Fuel oil line)
process upset
2. Fuel oil pressure may come down.
5. XZV-718N malfunctions to
close(Fuel oil line)
1. Same as Cause 4 above.
6. PDC-826 malfunctions to
close
PCV-826
1. Loss of fuel oil flame

2. Fuel oil spillage in heater leading to
burner tip choking.
1. Fuel gas is provided as

alternate fuel to provide
adequate firing from
UC-001.
2. PZ-858 is provided with low

low alarm to
activate UZ-718.
1. PDZ-860 is provided with

low low alarm to activate UZ718.
3. Steam pressure may come down

7. U/S disturbance in fuel gas
1. Refer cause 1,Consequence 1
Low alarm is provided at PI-854

B.L .
8.
1. Refer cause 4,Consequence 1
Addtional pressure transmitter

with low alarm in DCS is
provided.
9. U/S disturbance in atomizing 1. Refer cause 6, Consequence 1

Steam line
1. PI-808 is provided with low

alarm.
10. Strainer choking.
1. PDI -827 is provided with

high alarm(Fuel gas line)
U/S disturbance in fuel oil
1. Possible loss of fuel may lead to flame

failure.
2. PDI-857 is provided with

high alarm(Fuel oil line)
3. All strainers are provided

with spare for change over.
11. PC-899/HCV-830
malfunctions to close.
1. Box pressure will increase.
1.1 PZ-900 is provided with HH

alarm to activate to trip UZ-718.
2. Less air flow may lead to incomplete

combustion.
2.1 AI-004 provided for

monitoring.
3. Box temperature likely to increase
3.1 (3.1)TI-102 is provided with

high alarm.
O2/CO analyzer (For
combustion control), Two
Pollution Monitoring Nozzles for
monitoring purpose are
provided.
12. 180-FA-001C/D Choking
1. Unit 1800 may get disturbed.
1. PDI-010 is provided with

high alarm
2. Spare Flame arrestor is
provided.
2.
High Flow
1. PC-823 malfunctions to open 1. Possible Improper atomization may lead

PCV-823A(Fuel oil line)
to flame loss.
1.1 (PDZ-860 with LL alarm will

activate UZ-718.
Ref.
Recommendations
Responsibility
Remarks
2.
Node
High Flow
Deviation
1. PC-823 malfunctions to open

PCV-823A(Fuel
oil line)
Causes
Consequences
2. Spillage at burner tip leading to burner
choking.
Safeguards
Ref.
Recommendations
Responsibility
Remarks
3.1 PZ-858 with HH alarm will

activate UZ-718.
3. Fuel oil pressure will increase and it may

back flow in steam line
NRV is provided on steam line
to each burner after shut down
valve.
2. PC -802 malfunctions to
open
PCV-802(fuel gas line)
1. Flame lifting may occur, leading to higher 1. TI-121/122 is provided with

Tube metal temperature.
high alarm
2. Fuel gas line operating pressure will
increase
3. PDC-826 malfunctions to
open
PCV-826
4. PC-899/HCV-830
malfunctions to open.
2. PZ-821 HH alarm will

activate UZ-718 to trip heater.
1. Flame lifting may occur, leading to higher 1. TI-121/122 is provided with

Tube metal temperature.
high alarm
2. Steam line operating pressure will
increase
2. High alarm at PI-863 is

provided.
1. Fuel efficiency may decrease.
1. Oxygen analyzer AI-004 is

provided for monitoring
2. Draft will be increased, no major concern. 2. PI-048 is provided for

monitoring.
5.
Low Pressure
7. Low
Temperature
3. U/S disturbance (off gas

from
LPG Merox)
1. Flame may propagate back to line
1. Flame Arrester 180-FA001 is provided.
1. U/S disturbance (fuel gas

line)
1. Carryover of condensate with

1. Steam tracing is provided
fuel gas line leading to choking of the burner d/s V-025
2. U/S disturbance (fuel oil line) 1. Improper atomization may lead to sooty
flame(incomplete combustion)

provided.
3. Steam tracing failure in fuel

oil line.
1. Improper atomization may lead to sooty

flame(incomplete combustion)

provided.
8. High
Temperature
1. U/S disturbance (Fuel oil

supply)
1. Vapor lock of burner may occur.
10.
1. High level in V-025
1. Liquid may carry over with fuel gas
High Level
1. It is
assumed that
Fuel oil is
homogenous
mixture.
1. LI-807 is provided with

High alarm
2. LZ-810 HH alarm will
activate UZ-718.
1. Heavies in fuel gas
1. Improper firing and possible burner

choking.
1. V-025 is provided
2. Low/No flow of M.P

steam(during decoking/dry out
operation)
1. Hot spot may appear
1. FI-409A is provided with low

alarm
2. TI-121/222 is provided with
high temp.alarm
56. Operating procedure DEC/NOCL

hydrocarbon from V-025
periodically.
57. Standard operating DEC/NOCL

procedure to be made for
decoking/dry out
operation.
Flow rate (Kg/hr)

416
615
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 18
HP/MP Steam & MP BFW
DESIGN INTENTION
To supply HP steam ,MP steam and MP BFW
DRAWINGS
CS-140-PR-15-0030, CS-140-PR-15-0024, CS-140-PR-15-0004, CS-140-PR-15-0012, CS-140-PR-15-0011, CS-140-PR-15-0017

EQUIPMENT
Hydrotreater Reactor Feed Heater (140-H-001),Start-Up Ejector (140-J-001),Recycle

Compressor Steam Turbine (140-KT-01),MP Steam Desuperheater (140-DS-001)
STREAM DETAILS
HP steam, MP Steam and MP BFW will be supplied from B/L to Unit. HP steam will be send to RGC Turbine from where it converts to MP steam and some amount send to Stripper column and rest is send to the return header of MP
steam via desuperheater.
AVAILABLE CONTROL SCHEMESSCV-002,TCV-239

SERVICE
Temperature(C)
HP STEAM
MP STEAM
MP BFW
Pressure ( bar g)
388
184
128
Flow rate (Kg/hr)

53.5
10
24
27437
1500
7687
Note:
Node
18. HP/MP Steam
& MP BFW
Deviation
1.
Low/No Flow
Causes
1. U/S disturbance (HP Steam
Failure)
2. 1. U/S disturbance (MP Steam

Failure)
3.
U/S disturbance (MP BFW Failure)
Consequences
Safeguards
1. KT-002 trips
with low alarm.
2. MP steam go back to stripper from main

header via DS-001
1. Shutdown of DS-001
is considered when
KT-002 trips
1. No supply of atomization of fuel oil in

Fired heater
with low alarm
2. No supply of MP steam for decoking

when required
with low alarm.
1. MP steam temp. Will be high.
4. TC-239 malfunctions to close

TCV-239
1. Same as cause 3 consequence1 above.
Ref.
Recommendations
Responsibility
Remarks
1. To be
reviewed during
detail engineering
HAZOP when
vendor
information is
available.
2.
High Flow
1. TC-239 malfunctions to open

TCV-239
1. BFW may enter MP steam line header

leading to hammering.
1. Steam trap is
provided.
5.
Low Pressure
1. U/S disturbance (HP Steam

Failure)
1. KT-002 may get tripped
with low alarm.
2. Shutdown of DS-001
is considered when
KT-002 trips
2. 1. U/S disturbance (MP Steam

Failure)
1. Atomization of fuel oil in Fired heater may 1.1 FI-804 is provided

get affected.
with low alarm
1.2 High alarm at PI863 is provided.
2. No supply of MP steam for decoking
when required
3.
6.
High Pressure
U/S disturbance (MP BFW Failure)
2.1 PI-808 is provided

with low alarm.
1. MP steam temp. will be high.
1. To be
reviewed during
detail engineering
HAZOP when
vendor
information is
available.
1. U/S disturbance (HP Steam high

header pressure)
1. KT-002 may get tripped
with high alarm.
2. 1. U/S disturbance (MP Steam high

header pressure )
1. Atomization of fuel oil in Fired heater may 1. FI-804 is provided

get affected. Refer cause 3, Consequence 1 with high alarm
of deviation high flow of node 17.
1. To be
reviewed during
detail engineering
HAZOP when
vendor
information is
available.
with high alarm.
3. U/S disturbance (MP BFW

high pressure)
1. No major concern
1. To be
reviewed during
detail engineering
HAZOP when
vendor
information is
available.
27437
1500
7687
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 19
Cooling Water
DESIGN INTENTION
Cooling water supply to exchangers
DRAWINGS
CS-140-PR-15-0032
EQUIPMENT
Reactor Effluent trim cooler(140-EE-003),Hydrogen cooler(140-EE-009), Hydrogen makeup kick back cooler(140-EE-004), Make up compressor interstage cooler (140-EE-008A/B),
Stripper trim condenser(140-EE-005),Gas oil trim cooler(140-EE-007)

STREAM DETAILS
Cooling water is supplied to all cooling water exchangers from B/L and similarly cooling water return from all exchangers to header
AVAILABLE CONTROL SCHEMESPC-330,LC-501,LC-505,FC-407A/B,FC-408,TC-119,FCV-436

SERVICE
Temperature(C)
Cooling water supply
Cooling water return
Pressure ( bar g)
Flow rate (Kg/hr)
33
44
4
3
688411
688411
Note:
Node
19. Cooling water system
Deviation
1.
Low/No Flow
8. High
Temperature
Causes
Consequences
Safeguards
1. U/S disturbance
1. Cooling water exchangers will be starved 1. PI-816 is provided

with low alarm
1. U/S disturbance
1. Desired cooling of process stream is not

achieved in water cooled exchangers
1.1 High temp. alarm on

process outlet side is
provided on all critical
cooling water
exchangers
2. Expected high return temperature of

cooling water
2.1 TI-818 is provided

with high alarm
1. Insufficient cooling in some exchangers
Hydraulic Check is
carried out based on
actual plant layout.
1. Possibilities of cooling water

misdistribution
Ref.
Recommendations
Responsibility
Remarks
1. Operation to
ensure proper
distribution of
cooling water
during startup
Flow rate (Kg/hr)

688411
688411
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 20
Portable/Service Water, LP Steam, Plant /Instrument Air and Nitrogen
DESIGN INTENTION
To supply Portable/Service Water, LP Steam, Plant /Instrument Air and Nitrogen
DRAWINGS
CS-140-PR-15-0031, CS-140-PR-15-0033, CS-140-PR-15-0034

EQUIPMENT
STREAM DETAILS
Portable/Service Water, LP Steam, Plant /Instrument Air and Nitrogen will be supplied from
B/L to Hose station.
AVAILABLE CONTROL SCHEMESPC-330,LC-501,LC-505,FC-407A/B,FC-408,TC-119,FCV-436

SERVICE
Temperature(C)
LP steam
Service water
Potable water
Plant air
Instrument air
Nitrogen
Pressure ( bar g)
152
Amb.
Amb.
Amb.
Amb.
Amb
Flow rate (Kg/hr)

4
3
3
4.9
6.1
8
2818
1000(1)
1000(1)
518
215
430(2)
Note:1- Confirmed by DEC

2. Flow rate is based on startup and shutdown requirement
Node
20. Portable/Service Water, LP
Steam,
Plant/Instrument Air
and Nitrogen
Deviation
1.
Low/No Flow
Causes
Consequences
1. U/S disturbance(Potable
water)
1. Water is not available at eye wash

fountain and for drinking
2. U/S disturbance(Service
water)
1. All hose stations will run dry. No major

concern.
3. U/S disturbance(Plant Air)
1. Plant air will not be available at hose

stations. No major concern.
Safeguards
Ref.
Recommendations
Responsibility
Remarks
Low alarm on PI-818

is provided.
2. Plant air is not available for decoking of

heater when required. No major concern.
4. U/S disturbance(Instrument 1. Instrument air pressure will come down

Air)
leading to unit shut down
5. U/S disturbance(Nitrogen)
6.
6.
High Pressure
1. No/low pressure of nitrogen for blanketing 1. PI-806 is provided

and purging, may lead to hazards
with low alarm.
U/S disturbance(LP Steam) 1. No/Low flow in header will result in low

pressure of snuffing/purging steam available
when required
1. U/S Disturbance(LP steam)
with low alarm.

operating pressure
with low alarm.
with high alarm.
1.
Safeguards
to be
reviewed
during
detail
engineering
when
complete
information
is available
Flow rate (Kg/hr)

2818
1000(1)
1000(1)
518
215
430(2)
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 21
Flare System
DESIGN INTENTION
To vent PSV discharge gases to main flare header
DRAWINGS
CS-140-PR-15-0037, CS-140-PR-15-0038
EQUIPMENT
Flare K.O drum(140-V-023), Flare K.O drum pump(140-P-015A/B)
STREAM DETAILS
PSV discharge collected in Flare K.O drum (140-V-023) where liquid and gaseous phase is separated .Liquid HC is sent to slop header through flare K.O. drum pump (140-P-015A/B) and gaseous HC is sent to main flare header for burning.

SERVICE
Temperature(C)
Flare Gas From Flare
KOD to Flare header
Flare KOD/CBD Pump to
Slops Tank
Flare system
1.
9.
Low/No Flow
Low Level
Flow rate (Kg/hr)

0.25
45
57
5.5
57
Note:1- Confirmed by DEC

2. Flow rate is based on startup and shutdown requirement
Node
Deviation
21.
Pressure ( bar g)
45
Causes
Consequences
Safeguards
1. U/S disturbance(No flow of

fuel gas to flare header)
1. Possible air ingress in flare header
2. LS-806 malfunctions to trip

P015A/B
1. V-023 level may increase leading to liquid 1. LI-805 provided with

overloading in flare header and downstream high alarm.
system.
1. LS-806 malfunctions ,not

stopping the pump-015A/B.
1. Pump will run dry.
Ref.
Recommendations
Responsibility
Remarks
Low alarm at PI-854

(located at B.L.) is
provided.
1. LI-805 is provided with

low alarm.
1. Review of
US-731 to be
done during
detail
engineering.
Flow rate (Kg/hr)

45
57
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 22
Amine System
DESIGN INTENTION
To collect drained Amine
DRAWINGS
CS-140-PR-15-0043, CS-140-PR-15-0044
EQUIPMENT
Amine drain drum (140-V-022), Amine drain drum pump (140-P-014A/B)
STREAM DETAILS
Amine effluent collected in Amine drain drum (140-V-022) where liquid and gaseous phase is separated .Liquid HC is sent to ARU Unit through amine drain pump( 140-P-014A/B) and gaseous HC is sent to flare header for burning.

SERVICE
Temperature(C)
Pressure ( bar g)
57
Amine
Flow rate (Kg/hr)
0.25
27634
Note:
Node
22. Amine drain system
Deviation
1.
Low/No Flow
Causes
Consequences
Safeguards
1. LS-801 malfunctions, not

starting P-014A
1. Level of V-022 will increase
LI on V-022 is
provided.
Flow
1. P-014A trips
1. Rich Amine may backup to V022 from ARU
1. NRV is provided
at pump discharge.
9. Low Level

stopping the pump-014A
1. Pump may run dry
LI on V-022 is
provided.
1. Purging of V-022 with nitrogen 1. May lead to hazard affecting plant

personnel and property.
Separate nitrogen
connection to the
drum as well as
separate vent to flare
line with lock open
valve and NRV is
provided.
Ref.
Recommendations
Responsibility
Remarks
1. Review of US-733 to
be done during detail
engineering.
Flow rate (Kg/hr)
27634
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 23
Hydrocarbon drain system
DESIGN INTENTION
To collect drained hydrocarbon from different equipments
DRAWINGS
CS-140-PR-15-0039, CS-140-PR-15-0040
EQUIPMENT
Hydrocarbon drain drum (140-V-021), Closed drain drum pumps (140-P-013A/B)
STREAM DETAILS
HC effluent collected in HC drain drum 140-V-021 where liquid and gaseous phase is separated .Liquid HC is sent to SLOP through closed drain pump 140-013A/B and gaseous HC is sent to flare header for burning.

SERVICE
Temperature(C)
Hydrocarbon
Pressure ( bar g)
40
Flow rate (Kg/hr)

0.25
7500
Note:
Node
23. Hydrocarbon drain system
Deviation
1.
Low/No Flow
Causes
Consequences
Safeguards
1. LS-802 malfunctions, not

starting P-013A
1. Level of V-021 will increase
LI on V-021 is
provided.
Flow
1. P-013A trips
1. HC may backup to V-021 from slops

header
1. NRV is provided
at pump discharge.
8. High
Temperature
1. Draining hot HC material

design temperature
with high alarm
9.

stopping the pump-013A
1. Pump may run dry
LI on V-021 is
provided.
1. Purging of V-021with
nitrogen
1. May lead to hazard affecting plant

personnel and property.
Separate nitrogen
connection to the
drum as well as
separate vent to flare
line with lock open
valve and NRV is
provided.
Low Level
Ref.
Recommendations
Responsibility
Remarks
1. Review of US-732 to
be done during detail
engineering.

should prevent draining of hot
hydrocarbon in Hydrocarbon
drain drum.
DEC/NOCL
Flow rate (Kg/hr)

7500
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 24
Condensate collection system
DESIGN INTENTION
To collect condensate from different traps
DRAWINGS
CS-140-PR-15-0041

EQUIPMENT
STREAM DETAILS
Condensate from steam traps is collected in LP/MP/HP headers & drained to ND after cooling

SERVICE
Temperature(C)
Flow rate (Kg/hr)
Pressure ( bar g)
1030
Condensate (Water) in LP/MP
condensate header
Condensate (Water) in HP
condensate header
102
0.1
102
0.1
350
Note:
Node
24. Condensate Collection
system
Deviation
Causes
Consequences
Safeguards
Ref.
Recommendations
Responsibility
Remarks
Flow rate (Kg/hr)

1030
350

Final Hazop Nocl Dhds Sei

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HAZOP STUDY REPORT

Nagarjuna Oil Corporation Ltd.

DHU Unit (Unit -1400)

NAGARJUNA OIL CORPORATION LTD.

Approved For Design

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Nagarjuna Oil Corporation Ltd.

DHU Unit (Unit -1400)

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Nagarjuna Oil Corporation Ltd.

DHU Unit (Unit -1400)

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desulphurization Unit, (DHU, Unit 1400) in its

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Nagarjuna Oil Corporation Ltd.

DHU Unit (Unit -1400)

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desulphurization Unit, (DHU, Unit 1400) in its

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Nagarjuna Oil Corporation Ltd.

DHU Unit (Unit -1400)

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aults and omissions, potential hazards and

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DHU Unit (Unit -1400)

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following postulates were followed.

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2.2.1 Node Selection

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HAZOP team to focus and clearly identify all the

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DHU Unit (Unit -1400)

2.3 GUIDEWORD APPLICABILITY

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mentation and / or operating practices.

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in the form of work sheets. The software used is

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