Hazop

HAZOP STUDY REPORT
Client
Nagarjuna Oil Corporation Ltd.
PROCESS
SO2331
CS-140-PR-47-0001
Plant
DHU Unit (Unit -1400)
Dept.
Project
Document Number
OWNER
PMC
LICENSOR
EPC CONTRACTOR
:
:
:
:
0
Rev.
NAGARJUNA OIL CORPORATION LTD.

CB&I, LUMMUS
AXENS, IFP GROUP TECHNOLOGY
SAMSUNG ENGINEERING INDIA PVT. LTD.
HAZOP Study Report

For
Diesel Hydrodesulphurization Unit

Unit 1400
17.12.10
Issued for Design
PDA
KA
GCM
REV.
DATE
DESCRIPTION
PREPARED BY
CHECKED BY
APPROVED BY
RS
PM
HAZOP STUDY REPORT
Client
PROCESS
SO2331
CS-140-PR-47-0001
Plant
Dept.
Project
Document Number
Rev.
Contents
1. Introduction. 3
2. Executive Summary....4
3. Unit Description....5
4. Objective of Study...5
5. HAZOP Methodology & Techniques..6
6. HAZOP Assumptions..8
7. Basis of HAZOP Study..12
8. Documents Referred for HAZOP study...14
9. HAZOP Team ..16
10. Recommendations.18
Annexure I: Node details & HAZOP P&IDs( 60 sheets )

Annexure II: Recommendations( 15 sheets )
Annexure III: HAZOP Worksheets( 104 sheets )
Annexure IV: Attendance( 2 sheets )
Page 2 of 136
HAZOP STUDY REPORT
Client
PROCESS
SO2331
CS-140-PR-47-0001
Plant
Dept.
Project
Document Number
Rev.
1. Introduction
The Hazard and operability study (HAZOP) has been carried out for Diesel Hydrodesulphurization unit
(DHU-Unit 1400), which forms part of Cuddalore Refinery project at Cuddalore,Tamil-Nadu. The HAZOP
proceeding was conducted at Samsung Engg. India Pvt. Ltd. w.e. f. 06/12/10 to 14/12/10.
The HAZOP study team consists of representative from the SEI, PMC, Licensor, NOCL and was lead by
an independent Chairman, HAZOP study was conducted by a multi discipline group.
The action points that have emerged from the study are presented in the action list appended at the end
of this report. Each action item is subjected to a number. A given action item may pertain to more than
one points. However priority categorization shall be done based on SIL study.
Page 3 of 136
HAZOP STUDY REPORT
Client
PROCESS
SO2331
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Plant
Dept.
Project
Document Number
Rev.
2. Executive Summary
A total 31 nodes are identified for analysis resulting to- no. of action points. These nodes have been
described in outline enclosed in the report. Report is based on the HAZOP study conducted in presence
of concerned department officers/PMC/Licensors/NOCL representatives. All recommendations are listed
& annexed in the reports. Some of the information which were not available (seal system of hydrogen
compressor BHEL, backwashing system of filters etc.) needs to be identified & P&IDs shall be upgraded
accordingly.
Page 4 of 136
HAZOP STUDY REPORT

Client
Nagarjuna Oil
Corporation Ltd.
PROCESS
SO2331
CS-140-PR-47-0001
Plant
Dept.
Project
Document Number
Rev.
3. Unit Description
The unit consists of the following sections:
Reaction
Recycle Gas Loop
Stripper and LP Absorber
- Reaction Section
The feed consists of SRHD, LVGO, LCGO, and LCO streams supplied from battery limits. The
gas oil blend flows to the back wash Feed Filter,A4 140-F-001, before entering theFeed Surge
Drum, 140-V-001. The feed drum is nitrogen blanketed and the drum pressureis under level
controlled using a split range control scheme. The oil feed is pumped to the reactor circuit on
flow control using the Gas Oil Feed Pump, 140-P-001 A/B. The feed drum level is controlled by
supplying excess DHU feed from storage. The level controller is sent to storage, Unit 2500,
outside battery limits.
Make-up hydrogen is supplied at 20 bar g, to the Make-up Gas Compressor K.O. Drum 140-V002, and then is compressed by the Hydrogen Make-up Compressor 140-K-001 A/B. The
make-up compressor has two stages and the interstage gas cooling is done with cooling water
in the Make-Up Compressor Interstage Cooler, 140-EE-008 A/B. The makeup gas flowrate to
the reaction section is controlled by means of a compressor spillback to the Make-up Gas
Compressor K.O. Drum, 140-V-002. The spill back is cooled by the Hydrogen Make-Up Kick
Back Cooler, 140-EE-004. A line is provided on the Make-up
Gas Compressor discharge to send Hydrogen to bullet storage. Before being sent to storage
outside battery limits the hydrogen is cooled in the Hydrogen Cooler, 140-EE-009.
The make-up and recycle gas streams are combined with the feed, and the total feed
mixture is heated up against the reactor effluent in the Reactor Feed / Effluent Exchanger,
140-EE-001 A/B/C/D. A bypass of all the shells is provided on the gas oil feed line to
facilitate the Hydrotreater Reactor Feed Heater, 140-H-001, operation at minimum
turndown. The preheated oil and hydrogen mixture is heated to the reactor inlet
temperature in the Hydrotreater Reactor Feed Heater, 140-H-001.
The Hydrotreater Reactor, 140-R-001, contains five catalytic beds. Recycle hydrogen is
used as the quench gas, for maintaining the desired WABT in each of the catalytic bed.
The top layer of the first catalytic bed in the reactor operates at a lower temperature, and
this bed saturates the feed olefins and diolefins. The inlet temperature to the Reactor is
adjusted so that the required inlet temperature is obtained for the subsequent HDS catalyst
in the same catalytic bed. The effluent from the first catalytic bed is quenched to control
the inlet temperature of the second catalytic bed. In the remaining four catalytic beds, the
targeted average WABT is about the same to complete the remaining reactions. The
quench gas is supplied on flow control, reset by the catalytic bed inlet temperature.
The reactor effluent is cooled by preheating the stripper feed in the Stripper Feed
Preheater, 140-EE-002, then by preheating the oil/hydrogen feed in the Feed/Effluent
Exchanger, 140-EE-001 A/B/C/D. Wash water is injected into the reactor effluent at the
outlet of the final Feed/Effluent Exchangers shell, in order to prevent any deposit of
ammonium salts. The wash water is a mixture of recycled water from the Stripper Reflux
Drum, 140-V-008, and the Coalescer, 140-V-009, plus make-up stripped sour water from
battery limits. Additional water injection facilities are provided for the last two shells, tube
side, of the Feed/Effluent Exchanger to wash out any salt deposits. This injection is
normally intermittent and usually not required. The wash water is pumped by the Wash
Water Pump, 140-P-002 A/B, from the Wash Water Drum, 140-V-004, on flow control to
the reactor effluent upstream of the Reactor Effluent Air Cooler, 140-EA-001, to avoid
ammonium salt deposit and the risk of corrosion. The Wash Water Drum, 140-V-004 is
nitrogen blanketed and the drum pressure is under level controlled using a split range
control scheme.
The Reactor Effluent then is cooled in the Reactor Effluent Air Cooler, 140-EA-001, and
the Reactor Effluent Trim Cooler, 140-EE-003. The reactor effluent is collected in the
Page out
5 of of
136the Separator Drum consists of the
Separator Drum, 140-V-006. The vapor phase
recycle and quench gas circulated by the recycle compressor. The Separator Drum is
used as the quench gas, for maintaining the desired WABT in each of the catalytic bed.
The top layer of the first catalytic bed in the reactor operates at a lower temperature, and
this bed saturates the feed olefins and diolefins. The inlet temperature to the Reactor is
adjusted so that the required inlet temperature is obtained for the subsequent HDS catalyst
in the same catalytic bed. The effluent from the first catalytic bed is quenched to control
the inlet temperature of the second catalytic bed. In the remaining four catalytic beds, the
HAZOP
REPORT
targeted average WABT is about the same to complete
theSTUDY
remaining
reactions. The
quench gas is supplied on flow control, reset by the catalytic bed inlet temperature.
The reactor effluent is cooled by preheating the stripper feed in the Stripper Feed
Client
Nagarjuna Oil
SO2331
0
Preheater, 140-EE-002,
then by PROCESS
preheating the oil/hydrogen
feedCS-140-PR-47-0001
in the Feed/Effluent
Corporation Ltd.
Exchanger, 140-EE-001 A/B/C/D. Wash water is injected into the reactor effluent at the
Plant
Unit (Unit -1400) Dept.
Document Number
outlet of the finalDHU
Feed/Effluent
Exchangers shell,Project
in order to prevent
any deposit Rev.
of
ammonium salts. The wash water is a mixture of recycled water from the Stripper Reflux
Drum, 140-V-008, and the Coalescer, 140-V-009, plus make-up stripped sour water from
battery limits. Additional water injection facilities are provided for the last two shells, tube
side, of the Feed/Effluent Exchanger to wash out any salt deposits. This injection is
normally intermittent and usually not required. The wash water is pumped by the Wash
Water Pump, 140-P-002 A/B, from the Wash Water Drum, 140-V-004, on flow control to
the reactor effluent upstream of the Reactor Effluent Air Cooler, 140-EA-001, to avoid
ammonium salt deposit and the risk of corrosion. The Wash Water Drum, 140-V-004 is
nitrogen blanketed and the drum pressure is under level controlled using a split range
control scheme.
The Reactor Effluent then is cooled in the Reactor Effluent Air Cooler, 140-EA-001, and
the Reactor Effluent Trim Cooler, 140-EE-003. The reactor effluent is collected in the
Separator Drum, 140-V-006. The vapor phase out of the Separator Drum consists of the
recycle and quench gas circulated by the recycle compressor. The Separator Drum is
equipped with a water boot, and adequate residence time is provided for obtaining a good
separation of the liquid and sour water streams. Sour water is separated from the
hydrocarbon liquid phase on HC/water interface level control from the settling zone of the
separator. Then the sour water is routed to the Sour Water Flash Drum, 140-V-017, before
being sent to FCC Sour Water Unit, Unit 550 outside battery limits. The hydrocarbon
liquid flows on level control to the stripping section. The separator also contains a
coalescing pad close to the feed inlet nozzle. In addition to coalescing the small water
droplets, the coalescing pad helps to streamline the HC/H2O flow in the settling zone.
- Recycle Gas Section
The recycle hydrogen stream leaving the Separator Drum, 140-V-006, is routed to the HP
Amine Absorber, 140-C-001 for HsS removal, through the HP Amine Absorber KO Drum,
140-V-007. The lean amine is a 40 wt% MDEA solution, supplied on flow control to the
HP Amine Absorber using the Lean Amine Booster Pump, 140-P-003 A/B. The rich amine
from the HP absorber bottoms is sent to the LP Amine Absorber, 140-C-003, on level
control, for flashing off the dissolved light ends.
The recycle gas leaving the HP Amine Absorber is routed to the Recycle Compressor, 140K-002, through the Recycle Compressor K.O. Drum, 140-V-005. There is a provision to
remove a small amount of the sweetened gas stream leaving the HP absorber on flow
control as a high pressure purge, to provide added flexibility during operation. However,
the unit is designed based on no purge gas flow, and hence normally there is no high
pressure purge gas leaving the unit. The recycle compressor is driven by a back-pressure
type steam turbine, 140-KT-002.
The reactor circuit pressure is controlled at the Separator Drum, 140-V-006. The pressure
is controlled through a hand switch sending a signal adjusting either the make-up hydrogen
supply to the reactor circuit or/and the HP purge gas.
The Recycle Compressor discharge is split into recycle gas and quench gas streams. The
recycle gas is combined with the make-up hydrogen and the gas oil feed. Then, the total
feed enters the reaction circuit.
- Stripper Section
The Stripper, 140-C-002, fractionates the diesel product and the wild naphtha from the
reactor effluent liquid stream supplied from the Separator Drum, 140-V-006.
Liquid Feed from the Separator is first preheated by heat exchange with the stripper
bottoms in the Stripper Feed/Bottoms Exchanger, 140-EE-006 A/B/C/D, followed by the
final heating with the reactor effluent in the Stripper Preheater, 140-EE-002. The stripper
feed temperature is controlled by varying the feed flow through the Stripper Feed
Preheater and the exchanger bypass streams.
The hot feed enters the Stripper onto the 22nd tray (counting from the bottom). The feed is
stripped of H2S and light ends from the diesel product using MP steam, which is
superheated to 237C. The MP Steam comes from the Recycle Compressor Steam
Page 6 of 136
Turbine, 140-KT-002.
The Stripper overhead vapor is condensed in an air cooled condenser, 140-EA-002, and the
supply to the reactor circuit or/and the HP purge gas.

The Recycle Compressor discharge is split into recycle gas and quench gas streams. The
recycle gas is combined with the make-up hydrogen and the gas oil feed. Then, the total
feed enters the reaction circuit.
- Stripper Section
The Stripper, 140-C-002, fractionates the diesel product
the wildREPORT
naphtha from the
HAZOPand
STUDY
reactor effluent liquid stream supplied from the Separator Drum, 140-V-006.
Liquid Feed from the Separator is first preheated by heat exchange with the stripper
bottoms in the Stripper
Exchanger,
140-EE-006 A/B/C/D,
followed 0by the
Client
Nagarjuna Feed/Bottoms
Oil
PROCESS
SO2331
CS-140-PR-47-0001
Ltd. effluent in the Stripper Preheater, 140-EE-002. The stripper
final heating withCorporation
the reactor
Plant
DHU
(Unit -1400)by
Dept.
Project
Document
Number
feed temperature
is Unit
controlled
varying the feed
flow through the
Stripper
FeedRev.
Preheater and the exchanger bypass streams.
The hot feed enters the Stripper onto the 22nd tray (counting from the bottom). The feed is
stripped of H2S and light ends from the diesel product using MP steam, which is
superheated to 237C. The MP Steam comes from the Recycle Compressor Steam
Turbine, 140-KT-002.
The Stripper overhead vapor is condensed in an air cooled condenser, 140-EA-002, and the
trim condenser, 140-EE-005. The sour off-gas product from the Stripper Reflux Drum,
140-V-008, is sent to the LP Amine Absorber K.O. Drum, 140-V-010, where it is mixed
with any Flash Gas coming out of the Sour Water Flash Drum, 140-V-017. Then the sour
off-gas is sent to the LP Amine Absorber, 140-C-003, where it is contacted with lean
amine from battery limits. In the LP Absorber, H2S is removed from the offgas, which then
flows to the Off Gas K.O Drum, 140-V-018 before being directed to battery limits.
The stripper circuit pressure is controlled by the pressure controller located on the LP
Amine Absorber overhead, downstream of the Off Gas K.O. Drum, 140-V-018. The LP
Amine absorber is operated at a high enough pressure to route the sweet off-gas product to
either Unit 350 or to fuel gas. High pressure rich amine from the HP Amine Absorber is let
down to LP Amine Absorber, and the combined rich amine is sent from the LP Amine
Absorber under level control to the Amine Regeneration Unit. The water condensate
containing dissolved H2S and traces of NH3 is removed from the
Stripper Reflux Drum waterboot on interface level control. This sour water is recycled to
the Wash Water Drum, 140-V-004, for water injection upstream of the Reactor Effluent
Air cooler, 140-EA-001. The stripper reflux is returned to the tower on flow control, and
the Wild Naphtha overhead product is sent to the battery limits on flow control, reset by
the reflux drum level. The wild naphtha product is normally sent to Unit 200, with
provisions for routing to Unit 160.
The stripped diesel product is pumped by the Stripper Bottoms Pump, 140-P-005 A/B, to
the battery limits on level control of the stripper bottoms. Heat is recovered from the diesel
product by preheating the stripper feed in the Stripper Feed/Bottom Exchanger, 140-EE006 A/B/C/D, and the Stripper Preheater, 140-EE-002. The diesel product is further cooled
in the Gas Oil Air Cooler, 140-EA-003 and Gas Oil Trim Cooler, 140-EE-007. The
dissolved water in the diesel product settles out as free water as the product stream is
cooled. The entrained water is first taken out in the Product Coalescer, 140-V-009. The
Product Coalescer, 140-V-009 water is recycled under interface level control to the Wash
Water Drum, 140-V-004 to be used as Wash Water. Water is further removed from the
diesel product to meet water specification in the Salt Dryer, 140-V-019 before being
routed to the storage, Unit 2500, outside battery limits.
Page 7 of 136
HAZOP STUDY REPORT

Client
Nagarjuna Oil
Corporation Ltd.
PROCESS
SO2331
CS-140-PR-47-0001
Plant
Dept.
Project
Document Number
Rev.
Page 8 of 136
HAZOP STUDY REPORT
Client
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CS-140-PR-47-0001
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Project
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Rev.
4.Objective of study
The objective of HAZOP study was to identify the potential hazard and the operability problem by
systematic review of the Diesel hydrodesulphurization unit and to identify the action items to alleviate
such problems. The objective of the HAZOP study in nutshell is
- To provide process safety information
- Finding out of different HAZARD during plant operation
- To establishing safe operating procedure.
- To maintain safe work practice.
Page 9 of 136
HAZOP STUDY REPORT
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Document Number
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5. HAZOP Methodology & Technique

5.1 Methodology
HAZOP studies are undertaken by application of formal, systematic and critical approach to examine the
process the process engineering intentions of process design. The potential of hazard is thus assessed,
and the chances of malfunction of individual equipment and its consequences for the whole system are
identified.
Identical equipment and associated system are subjected to a generic approach including where two or
more system operate in partial.
5.2 Technique
The HAZOP study involve a rigorous and systematic examination of all known deviations from normal
operating condition using a series of guidewords and covering every parameter of system under review.
Deviation (ie-guideword+chosen parameter) are identified by application of standard list guide words.
The guide words are used were: No,More,Less,Reverse other than etc.
The following parameters relevant to the system under review were considered:
Flow, temperature, Pressure, Level, Composition, Others.
5.3 Intention:
The intention defines how the system is expected to operate at the nodes. It thus provides a point of
reference for developing deviations.
5.4 Deviation:
These are departures from the design intention that are discovered by systematically applying the
guidewords to each parameter at each node (e.g. HIGH + TEMPERATURE = HIGH TEMPERATURE). It
is not unusual to have more than one deviation from the application of a same guideword. For example,
"MORE FLOW" could mean either that there is a higher FLOWRATE, or more quantity is flowed.
5.5 Causes:
These are the reasons why deviations may occur. Not all possible deviations are meaningful and tehh
HAZOP team identified meaningful deviations with credible causes. These causes can be equipment
failures, human errors or external (e.g. loss of power).
5.6 Consequences:
These are the results of the deviations should they occur (e.g. release of toxic materials). Note that the
consequences of a deviation offten differ for each cause of the deviation.
5.7 Actions/Recommendations
These are either suggested actions to prevent the consequences of a deviation, or a need to obtain
further information before the particular deviation can be properly assessed. The HAZOP study is
intended to identify problems, not necessarily solve them where a solution is not obvious, a potentila
problem existes and recommends that someone review it for potential solutions.
5.8 Recording:
Records are documented through "recording by exception", i.e. to only record the deviations that cause
particular hazards or operating problems. If no deviations are discovered "N.A" /"NOW NEW CAUSE"
may be recorded against that node. In this way the amount of documentation can be kept at a
reasonable level.
5.9 Undertaking the study:
From the description of the HAZOP study it is clear that a study team will consider part of a process
design for a number of Deviation and Guidewords. Thus, a study meeting will follwo through a series of
steps repeatedly. The sequence of action for the HAZOP can be represented as given below. These are
Page 10 the
of 136
seven steps, whichare repeated, many times during
HAZOP.
problem existes and recommends that someone review it for potential solutions.
HAZOP STUDY REPORT

5.8 Recording:
Records Nagarjuna
are documented
through "recording by exception",
to only record
the deviations that cause
0
Client
Oil Corporation Ltd.
PROCESS i.e. SO2331
CS-140-PR-47-0001
particular
hazards
or
operating
problems.
If
no
deviations
are
discovered
"N.A"
/"NOW
NEW
CAUSE"
Plant
Dept.
Project
Document Number
Rev.
may be recorded against that node. In this way the amount of documentation can be kept at a
reasonable level.
5.9 Undertaking the study:
From the description of the HAZOP study it is clear that a study team will consider part of a process
design for a number of Deviation and Guidewords. Thus, a study meeting will follwo through a series of
steps repeatedly. The sequence of action for the HAZOP can be represented as given below. These are
seven steps, whichare repeated, many times during the HAZOP.
a) Apply the guideword
b) Develop a deviation
c) Examine possible causes
d) Examine consequences
e) Consider hazards or operatability problems
f) Decide upon action
g) Make a record of the discussion and decision
A full record of the HAZOP study was made on worksheets and these are presented in the Appendices
(Refer Annexure-III)..
HAZOP has been done on Excel work sheets.
Page 11 of 136
HAZOP STUDY REPORT
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6. HAZOP ASSUMPTIONS
The following assumptions have been considered during HAZOP study:
- Mechanical protection device (PSV,TSV etc.) is expected to work.
- No quantitative analysis will be done during HAZOP session.
- Single check valve is adequate unless reverse flow may cause pressure exceeding the test pressure.
- No design work will be done.
The following have not been considered:
- Simultaneous occurrence of two unrelated incidents.
- Operator negligence.
- Simultaneous failure of more than one independent protection device.
- Natural calamity (flood earth quake etc.)
- Objects falling from sky.
- Sabotage.
Page 12 of 136
HAZOP STUDY REPORT
Client
PROCESS
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CS-140-PR-47-0001
Plant
Dept.
Project
Document Number
Rev.
GUIDE WORD
PARAMETER
NO
MORE LESS AS WELL AS
PART
OF
REVERSE
OTHER
THAN
FLOW *
PRESSURE *
TEMPERATURE *
LEVEL
PHASE
COMPOSITION (SPECIFIC
COMPONENT)
OPERATION **
Page 13 of 136
HAZOP STUDY REPORT
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* Normal Parameters
** Start-up / shutdown, isolation philosophy, different
operating modes, maintenance access, blow down, etc.
Not Used
Normally Used
HAZOP STUDY REPORT
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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 response
Page 15 of 136
HAZOP STUDY REPORT
TECHNIP KT INDIA LTD.
Client
PROCESS
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Plant
Dept.
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Document Number
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7. BASIS OF HAZOP STUDY

Nodes considered for Diesel Hydrodesulphurizing unit HAZOP study:
Refer to Annexure-I for Node details & Scanned copies of P&IDs used during HAZOP study.
Page 16 of 136
HAZOP STUDY REPORT
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8 Documents referred for HAZOP study

Following is the list of documents referred during this study:
S.No.
Title
Process Data Book
Process flow diagram
3
4
Document No.
C450-1400-PB-REV0
CA-140-PR-11-0001 to 0006
Material Selection Diagram
CS-140-PR-19-0001 to 0003
Plot Plan
CS-140-PI-16-0001,Rev1
Piping & instrumentation diagram

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

(Utilities)
CS-140-PR-15-0030 to 0041
CS-140-PR-15-0043 to 0044
6
7
Equipment List
CS-140-PR-50-0001
Flare load summary
CS-140-PR-50-0008
Area Classification layout
CS-140-EL-12-0001
10
Process data sheet of equipments
11
Cause and effect Diagram
CS-140-PR-24-0001
12
Safeguarding Memorandum
CS-140-PR-45-0001
13
Vendor P&IDs
Refer Annexure 1
Page 17 of 136
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HAZOP STUDY REPORT
Client
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CS-140-PR-47-0001
Plant
Dept.
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Document Number
Rev.
9. HAZOP TEAM
The HAZOP was carried out from 6th Dec. to 14th Dec.2010. A team of experienced engineers from Process, Operations/Commissioning and
Engineering were formed the list of participants is as below:
HAZOP Chairman: Mr. Gour Chandra Mitra.
SAMSUNG ENGG. INDIA
PVT. LTD.
PMC
NOCL
Licensor
Vendors
Mr. P. K. Gupta-Part
Mr. V. K. Bansal-Part
Mrs. Ketaki Adhikaray
Mr. K. Y. Nam-Part
Mr. Pawan K. Sharma-Part
Mrs. A. Chamundeswari-Part
Mr. Riji P. day
Mr. R. Manna-Part
Mr. Arun Goel-Part
Mr. Pradeep Amale
Mr. Ambrish Bajpai-Part
Mr. Amiya Ray
Mr. Ankur Agarwal-Part
Mr. Mayank Gupta
Mr. Y. K. Joshi
Mr. R. Y. Bloem-Part
Mr. S. Ravishankar
Mr. Bhaskar Das
Mr. Rajashekhran-Part
Mr. Raj Kumar-Part
Mr. Sebastian-Part
Mr. Aravindan-Part
Mr. Stephane Chapot
BHEL
Mr.Krishnan-Part
NEA
Mr. Yogesh Kohil-Part
Mr. Subramanium-Part
Detailed attendence list is attached as Annexure-V)
Page 19 of 136
HAZOP STUDY REPORT
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Plant
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Document Number
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10. RECOMMENDATIONS
The total number of recommendations are 147. (Attached as Annexure II)
Page 20 of 136
Annexure I
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
25
26
27
28
29
30
31
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
Makeup H2 Compressor-Lube oil System
Makeup H2 Compressor- Closed cooling water System
Makeup H2 Compressor- Distance piece/packing purge
Recycle Compressor- Lube oil
Recycle Compressor- Seal Gas ( Vendor is expected to revise the seal gas system
P&ID,Accordingly no HAZOP was done.
Recycle Compressor- Steam & drain
Recycle Compressor- cooling water System ( No HAZOP was done. The same need to be
carried out later with the vendor).
Page 21 of 136
HAZOP STUDY REPORT
Client
PROCESS
SO2331
CS-140-PR-47-0001
Plant
Dept.
Project
Document Number
Rev.
The recommendations of HAZOP study are listed below:

(Annexure II)
S.No
Recommendations
P&ID no
Responsibility
CS-140-PR-15-0001
Provide low alarm for PC-343.
Design case for overpressure in

filter is to be reviewed.
High temperature alarm to be

provided on TI-107 and TI-343.
CS-140-PR-15-0001
SEI
LCO,LCGO flow rate indications to

be duplicated in DHU graphics.
CS-140-PR-15-0001
PMC/SEI
Feed stream ratio indication with

alarm to be repeated in DHU
graphics.
CS-140-PR-15-0001
PMC/SEI
Provide TDI (TI-129 and TC-124)on

the first bed with high alarm set at
differential temp. of 30 C.
Ensure proper thermal expansion in

Mechanical design is considered in
case of depressurization temp. of
405 C for all shells.
Operating manual/SOP should

ensure periodical checking of LG506
Manual isolation valves

downstream of FCV-407A/B,to be
LO.
10
Operating procedure should ensure

periodical checking of LG-506.
11
CS-140-PR-15-0001,
CS-140-PR-15-0002,
CS-140-ME-E-03800002
SEI
Vendor/SEI
PMC/SEI
CS-140-PR-15-0002,
CS-140-PR-15-0003,
CS-140-PR-15-0004
SEI
CS-140-PR-15-0002
SEI/NOCL
CS-140-PR-15-0002
SEI
CS-140-PR-15-0002
SEI/NOCL
Provision of local temp. gauge to be

provided for ascertaining the
temperature before taking the
sample.
CS-140-PR-15-0002,
CS-140-PR-15-0003,
CS-140-PR-15-0004
SEI/NOCL
12

temp. of sampling fluid below 80 C.
CS-140-PR-15-0002,
CS-140-PR-15-0003,
CS-140-PR-15-0004
SEI/NOCL
13
Provide low pressure alarm at PC358 at 140-V-006 gas outlet.
CS-140-PR-15-0007
SEI
Page 22 of 136
Status
HAZOP STUDY REPORT
Client
PROCESS
SO2331
CS-140-PR-47-0001
Plant
Dept.
Project
Document Number
Rev.

(Annexure II)
S.No
Recommendations
P&ID no
Responsibility
14

safe shutdown of the plant.
CS-140-PR-15-0004,
CS-140-PR-15-0006
15
All pump motor trip alarms to be

provided in DCS.
CS-140-PR-15-0003,
CS-140-PR-15-0005,
CS-140-PR-15-0006,
CS-140-PR-15-0007,
CS-140-PR-15-0017
SEI
16
Maintenance schedule for vibration

checking is to be strictly followed on
regular basis.
CS-140-PR-15-0006
NOCL
17
Manual isolation valves

downstream of FCV-455A/B,to be
LO.
CS-140-PR-15-0008
SEI
18
Confirm gas break through LCV542A case is considered for PSV310A/B
19
Provide additional control scheme

on V-008 boot with LT (Low low
level signal), new shutdown valve
on recycle water line from V-008 to
avoid gas break through.
20
Review the impact of vapor break

through/liquid HC in unit 550.
21
Provide low alarm for LI-560A at V009 boot
22

periodical checking of PI369A/B at pump suction..
23
24
Provide high temp. Alarm at TI210.
Operating procedure to ensure

Increase of injection water flow rate
and/or plant capacity to be
decreased. To be further checked
for the feasibility of this operation.
SEI/NOCL
CS-140-PR-15-0008, CS140-PR-15-0021
CS-140-PR-15-0021
SEI
SEI/ PMC/ NOCL/

Axens
CS-140-PR-15-0003, CS140-PR-15-0006, CS-140PR-15-0008, CS-140-PR15-0021, CS-140-PR-150022, CS-140-PR-15-0030,

CS-140-PR-15-0037
NOCL
CS-140-PR-15-0022
SEI/NOCL
CS-140-PR-15-0008
SEI/NOCL
CS-140-PR-15-0008
Axens/SEI
CS-140-PR-15-0003, CS140-PR-15-0006, CS-140PR-15-0008, CS-140-PR15-0021, CS-140-PR-150022, CS-140-PR-15-0030,

CS-140-PR-15-0037
Page 23 of 136
Axens/SEI
Status
HAZOP STUDY REPORT
Client
PROCESS
SO2331
CS-140-PR-47-0001
Plant
Dept.
Project
Document Number
Rev.

(Annexure II)
S.No
Recommendations
25

periodical checking of FI458/459/460/461
26
check working of P-002A/B,when

operating only on BFW(128 C)
27
P&ID no
Responsibility
CS-140-PR-15-0006
SEI/NOCL
CS-140-PR-15-0008
SEI
Operating procedure should

ensure periodical checking of LG515
CS-140-PR-15-0006,
CS-140-PR-15-0007
SEI/NOCL
28
Ensure LG-515 facing with LCV-514

bypass valve
CS-140-PR-15-0006
SEI
29
Consider FC-416 low alarm is set

below turndown flow.
CS-140-PR-15-0007
SEI / AXENS
CS-140-PR-15-0008
SEI / AXENS
CS-140-PR-15-0007, CS140-PR-15-0017, CS-140PR-15-0018
SEI/NOCL
30
Consider installation of limiting

temp. controller (TI-120) in heater
inlet.
31
SOP to address lining of quench

gas in the bottom bed which will
help in reducing the reactor outlet
temp. minimizing the disturbance.
32
Check the impact on the inlet piping

and equipments due to increased
inlet temp. to EE-001A/B/C/D and
reactor effluent air cooler EA-001
CS-140-PR-15-0003,
CS-140-PR-15-0006
SEI
33

gas oil air cooler EA-003.
CS-140-PR-15-0018,
CS-140-PR-15-0019
SEI
34
Provide DCS PI with high alarm

upstream of EE-006A/B/C/D.
CS-140-PR-15-0018
SEI
35
Provide high alarm at analyzer AI003.
CS-140-PR-15-0022
SEI
Page 24 of 136
Status
HAZOP STUDY REPORT
Client
PROCESS
SO2331
CS-140-PR-47-0001
Plant
Dept.
Project
Document Number
Rev.

(Annexure II)
S.No
Recommendations
P&ID no
Responsibility
36
Provide high temp. alarm TI-192.
CS-140-PR-15-0017
SEI
37
Consider converting TI-192 to TC

and put reflux on TC/FC cascade.
CS-140-PR-15-0017
Axens/PMC/SEI
38
Check the system integrity

upstream of TCV-191A/B during
gas break through.
CS-140-PR-15-0017
SEI
39

reactor effluent air cooler EA-001
CS-140-PR-15-0017
SEI
40

gas oil air cooler EA-003.
CS-140-PR-15-0017
SEI
41
Check if downstream product tank

can be pressurized due to tube
rupture.
CS-140-PR-15-0018
SEI
42
Consider increase in operating

pressure of product.
43
Check the overpressurization of

system and confirm that PSVs are
sized for this case.
44
Operating procedure to include

operation of HS-822 to select FCV423 to purge H2S to flare header
CS-140-PR-15-0007,
CS-140-PR-15-0009,
CS-140-PR-15-0010,
CS-140-PR-15-0012
45
low low suction pressure

compressor trip PZ-378 is not
required as per process reason and
to be deleted.
CS-140-PR-15-0011
CS-140-PR-15-0018,
CS-140-PR-15-0022
CS-140-PR-15-0017
Page 25 of 136
SEI
SEI
SEI/NOCL
SEI
Status
HAZOP STUDY REPORT
Client
PROCESS
SO2331
CS-140-PR-47-0001
Plant
Dept.
Project
Document Number
Rev.

(Annexure II)
S.No
Recommendations
P&ID no
Responsibility
46
Operating instruction to include

feed cut-off if system pressure is
below 80% of the normal pressure.
CS-140-PR-15-0007
AXENS
47
BHEL to confirm if low low suction

pressure trip is required for
machine protection.
CS-140-PR-15-0007
BHEL
48
Ensure refinery fuel gas

composition has considered
addition of hydrogen from this unit.
CS-140-PR-15-0007
NOCL
49
Flow indication of hydrogen to fuel

gas unit is to be repeated in fuel
gas unit.
CS-140-PR-15-0012
NOCL
50
Move high alarm from PC-394 to

PI-999.
CS-140-PR-15-0012
SEI
51
Provide high alarm on PDI-688.
CS-140-PR-15-0011
SEI
52
BHEL recommends the closing of

MOVs with a time delay while rpm
is reduced to 500.
CS-140-PR-15-0011
BHEL/ PMC/ SEI/

NOCL/ Axens
53
System to be reviewed for required

protection, when potential liquid
carryover tocompressor as there is
a time delay in closer of suction
MOV.
CS-140-PR-15-0011
BHEL/ PMC/ SEI/

NOCL/ Axens
54
Check the feasibility of Nitrogen

startup operation for refractory
dryout feed heaterresulting in
Possible high suction temp. leading
to high discharge temp. (higher
than current design).
CS-140-PR-15-0007,
CS-140-PR-15-0009,
CS-140-PR-15-0010, CS140-PR-15-0012
SEI
55
Operating procedure to monitor LG522 for HC carry over. When HC

level builds up it should be drained
to CBD by using Skim line.
CS-140-PR-15-0010
Page 26 of 136
SEI/NOCL
Status
HAZOP STUDY REPORT
Client
PROCESS
SO2331
CS-140-PR-47-0001
Plant
Dept.
Project
Document Number
Rev.

(Annexure II)
S.No
Recommendations
Confirm that the max. allowable trip

temp. (while running in nitrogen
service) & all trip set points for
machine safeguards for startup
nitrogen case are not different from
the normal operating case.
P&ID no
Responsibility
CS-140-PR-15-0011,
CS-140-PR-15-0012
BHEL
57
If set points are different separate

modes of operation to be
programmed in DCS and in
safeguarding system.
CS-140-PR-15-0011,
CS-140-PR-15-0012
BHEL
58
Operating procedure to include

operation of HS-822 to select FCV423 to purge H2S to flare header.
CS-140-PR-15-0012
59
Considering full flow through FCV427, verify low-low flow alarm on

FZ-428.
CS-140-PR-15-0003,
CS-140-PR-15-0005,
CS-140-PR-15-0006,
CS-140-PR-15-0011
SEI
CS-140-PR-15-0009,
CS-140-PR-15-0010,
CS-140-PR-15-0016
SEI
56
60
61
For low flow alarm FC-424 and low

low trip FZ-443,trip values are
presently given as per process
point of view, which needs to be
verified based on pump vendor min
flow requirement. So UZ-720
should also activate UZ-710 to trip
pump (P-003A/B)-logic to be
implemented Consider clubbing of
UZ-710 & UZ-720).

routing of off gas to flare header
when there is disturbance in lean
amine supply to C-003
62
Provide high alarm at AI-002.
63
Check unit 350 design for possible

increase of H2S in feed gas from
DHU.
CS-140-PR-15-0009
SEI/NOCL
SEI/NOCL
CS-140-PR-15-0016
SEI
CS-140-PR-15-0016
NOCL/PMC
Page 27 of 136
Status
HAZOP STUDY REPORT
Client
PROCESS
SO2331
CS-140-PR-47-0001
Plant
Dept.
Project
Document Number
Rev.

(Annexure II)
S.No
64
65
66
67
Recommendations
UZ-720 should activate UZ-710 to

trip pump (P-003A/B)
Provide low alarm at TI-170.
Ensure the provision of Hot

insulation on the lean amine line
coming from ARU (Outside DHU
B/L).
Provide High alarm on TI-170 at
lean amine B.L
P&ID no
Responsibility
CS-140-PR-15-0009
SEI
CS-140-PR-15-0009
SEI
CS-140-PR-15-0009
PMC/NOCL
CS-140-PR-15-0009
SEI
68
SOP to address regular sampling of

recycle gas for CO/CO2.
CS-140-PR-15-0009
69
LG-522A/B (Magnetic type) are to

be provided with high high alarm
with switch.
CS-140-PR-15-0010,
CS-140-PR-15-0016
SEI
70
Ensure this gas breakthrough case

has been considered in design of
safety valve in ARU (Receiving
flash drum vessel).
CS-140-PR-15-0009
PMC/NOCL
71
LG-552 to be converted to Mag.

Type with provision of high level
alarm with switch.
CS-140-PR-15-0021,
CS-140-PR-15-0016,
CS-140-PR-15-0006
SEI
72
Periodical checking of interface in

LG-533A/B/C/D.
CS-140-PR-15-0016
73
Keep the spectacle blind located in

startup recirculation line in open
position to maintain unit under
circulation during upset without
loosing much time.
CS-140-PR-15-0017,
CS-140-PR-15-0018,
CS-140-PR-15-0019,
CS-140-PR-15-0022
SEI
74
FC-436 should be force closed

when UZ-717 is activated.
CS-140-PR-15-0017
SEI
Page 28 of 136
SEI/NOCL
SEI/NOCL
Status
HAZOP STUDY REPORT
Client
PROCESS
SO2331
CS-140-PR-47-0001
Plant
Dept.
Project
Document Number
Rev.

(Annexure II)
S.No
Recommendations
P&ID no
Responsibility
Provide high alarm for FC-442.
CS-140-PR-15-0022
SEI
76
Provide independent DCS low low

alarm from LZ-537
CS-140-PR-15-0022
SEI
77
Possibility of dissolution of salt in

gas oil product is to be confirmed.
CS-140-PR-15-0022
Vendor/SEI
78

draining of salt dryer at regular
intervals by checking LG554.
CS-140-PR-15-0022
SEI/NOCL
79
Regular top up
procedures/schedules to be
mentioned in SOP.
CS-140-PR-15-0022
SEI/NOCL
80
P&ID is to be updated for

maintenance /Top up
discharge/bypassing salt dryer
procedure.
CS-140-PR-15-0022
Vendor/SEI
81
Confirm that hydrocarbon detectors

are provided in cooling tower area.
CS-140-PR-15-0019
NOCL
82
TBC from vendor regarding the

requirement of min. flow to avoid
churning.
CS-140-PR-15-0017,
CS-140-PR-15-0020,
CS-140-PR-15-0021,
CS-140-PR-15-0023
SEI
83
Consider providing independent

level transmitters with high alarm
and delete the high alarm from LC540
CS-140-PR-15-0021
SEI
CS-140-PR-15-0021
SEI
CS-140-PR-15-0021
SEI
75
84
85
Consider Providing independent

Consider Providing independent

Page 29 of 136
Status
HAZOP STUDY REPORT
Client
PROCESS
SO2331
CS-140-PR-47-0001
Plant
Dept.
Project
Document Number
Rev.

(Annexure II)
S.No
Recommendations
P&ID no
Responsibility
86
Provide high temp alarm on TI-192
CS-140-PR-15-0017
SEI
87

CS-140-PR-15-0020
NOCL
88
SOP to ensure that the proper

dosing rate is maintained and
confirmed with proper lineup.
CS-140-PR-15-0023
89
Provide low alarm at PI-358A on

separator drum.
CS-140-PR-15-0007
SEI
90
Check the time required to startup

spare compressor .
CS-140-PR-15-0014,
CS-140-PR-15-0015
SEI/NOCL
91
PT with high alarm is to be provided

instead of PI-953.
CS-140-PR-15-0013
SEI
92
Low pressure alarm at PC-358 is to

be provided on V-006.
CS-140-PR-15-0007
SEI
93
Confirm that the suction system

can either withstand with the high
suction pressure and PSV is
designed for the same.
CS-140-PR-15-0013
SEI
94
HydroCOM vendor to clarify for the

consequences of sudden loading
and how tp prevent tripping of
compressor and implement solution
to provide the same.
CS-140-PR-15-0013,
CS-140-PR-15-0014,
SEI/NEA
95
Consider forced PCV-922 close

when compressor trips.
CS-140-PR-15-0013,
CS-140-PR-15-0014,
SEI
96

CS-140-PR-15-0013,
CS-140-PR-15-0014,
NOCL
Page 30 of 136
SEI/NOCL
Status
HAZOP STUDY REPORT
Client
PROCESS
SO2331
CS-140-PR-47-0001
Plant
Dept.
Project
Document Number
Rev.

(Annexure II)
S.No
Recommendations
P&ID no
Responsibility
97
Provide High alarm at TI-176.
CS-140-PR-15-0013,
SEI
98
Provide High high level

compressor trip for 2nd stage
suction vessel
CS-140-PR-15-0013,
CS-140-PR-15-0014,
NEA
99

CS-140-PR-15-0013,
CS-140-PR-15-0014,
NOCL
100
Provide low point drain valve at the

shell side outlet of EE-009 and
SOP to ensure checking of leakage
of cooling water after any
maintenance.
CS-140-PR-15-0013,
CS-140-PR-15-0014,
SEI
101
Inspection opening of 2nd stage

suction vessel shall be located
closer to the vanepack for
inspection purpose.
CS-140-PR-15-0013,
CS-140-PR-15-0014,
NEA/SEI
102
Venting/purge facility to flare at EE009 outlet is to be provided near

B/L.
CS-140-PR-15-0013
SEI
103
PI-304 to be provided with low

pressure alarm.
CS-140-PR-15-0023,
CS-140-PR-15-0025
SEI
104
Ensure that blockage of carbon

canister is not possible.
CS-140-PR-15-0023,
CS-140-PR-15-0025
NOCL
105
Provide additional flushing oil return

taping upstream of XZV-718 M for
flushing.
CS-140-PR-15-0024,
CS-140-PR-15-0026
SEI
CS-140-PR-15-0004
SEI
CS-140-PR-15-0004
SEI
106
107
Damper open/close indications are

provided (P&ID is to be updated
accordingly).
Startup and shut down overrides for
damper control to be included in
P&ID note.
Page 31 of 136
Status
HAZOP STUDY REPORT
Client
PROCESS
SO2331
CS-140-PR-47-0001
Plant
Dept.
Project
Document Number
Rev.

(Annexure II)
S.No
Recommendations
P&ID no
Responsibility
108
Low oxygen alarm at AI-004 is to

be provided
CS-140-PR-15-0004
SEI
109
Ensure that upstream system is

properly monitored to avoid any
vaporization.
CS-140-PR-15-0024,
CS-140-PR-15-0026
NOCL
110
MP steam for soot blower tapping

to be downstream of FI-409.(P&ID
to be updated).
CS-140-PR-15-0004
SEI
111
HH pressure trip PZ-678A/B/C

requirement is to be reviewed from
vendor in view of turbine back
pressure.
CS-140-PR-15-0030
BHEL/SEI
112
Line from Desuperheater

downstream upto steam trap is to
be designed for two phase flow.
CS-140-PR-15-0030
SEI
113
Vendor to provide min. temp. of

steam acceptable at turbine inlet,
irrespective of min. operating temp.
specified in B/L condition.
CS-140-PR-15-0030
BHEL
114
TI-627 is to be provided with low

temp. alarm in DCS.
CS-140-PR-15-0011
SEI
115
SOP to ensure checking of leakage

of cooling water after any
maintenance.
CS-140-PR-15-0032
SEI/NOCL
116

CS-140-PR-15-0032
NOCL
117
Provide 3" jumpover connection line

(with valve and spec. blind)
between cooling water supply and
return headers near dead end.
Jumpover will be used for initial
passivation during commissioning.
CS-140-PR-15-0032
SEI
Page 32 of 136
Status
HAZOP STUDY REPORT
Client
PROCESS
SO2331
CS-140-PR-47-0001
Plant
Dept.
Project
Document Number
Rev.

(Annexure II)
S.No
Recommendations
P&ID no
Responsibility
118
Ensure different connections are

available for air and nitrogen hose
stations to avoid wrong
connections.
CS-140-PR-15-0031,
CS-140-PR-15-0033,
CS-140-PR-15-0034
SEI
119
SOP to ensure Manual intervention

of HS-908
CS-140-PR-15-0037,
CS-140-PR-15-0038
SEI/NOCL
120
Provide high high alarm at LI-800
CS-140-PR-15-0044
SEI
121
Provide low low alarm at LI-801
CS-140-PR-15-0044
SEI
122
Provide high high alarm at LI-902
CS-140-PR-15-0040
SEI
123
Provide NRV in the flare KOD

pump discharge line no. P803 near
to tie in point to slop header.
CS-140-PR-15-0038
SEI
124
Operating procedure should

prevent draining of hot hydrocarbon
in Hydrocarbon drain drum.
CS-140-PR-15-0040
SEI / NOCL
125
Provide low low alarm at LI-902
CS-140-PR-15-0040
SEI
126
Provide differential pressure gauge

across the suction strainer.
CS-140-PR-D-06600002
NEA
127
Consider PSV set point change to

8.7 barg as per project philosophy.
900001-1-05 (NEA P&ID)
NEA
128
Trip of aux. pump with time delay is

to be ensured when compressor is
tripped (refer vendor cause and
effect diagram).
900001-1-05 (NEA P&ID)
NEA
Page 33 of 136
Status
HAZOP STUDY REPORT
Client
PROCESS
SO2331
CS-140-PR-47-0001
Plant
Dept.
Project
Document Number
Rev.

(Annexure II)
S.No
Recommendations
P&ID no
Responsibility
129
Manual sampling arrangement is to

be provided.
900001-1-05 (NEA P&ID)
NEA
130
Provide possible leakage quantity

to process gas and specification,
including all impurities in the oil
used for cylinder lubrication.Axens
will confirm the acceptance.
900001-1-05 (NEA P&ID)
NEA / AXENS
131
Vendor operation manual should

mention bypass operation.
CS-140-PR-D-06600006
NEA
132
Vendor operating manual should

mention closing of manual isolation
valve located in pump minimum
circulation line in case both
compressors are in operation
during changeover.
900001-1-09 (NEA P&ID)
NEA
133
Gate valve in min circulation line to

be changed to globe valve.
900001-1-09 (NEA P&ID)
NEA
134
Vendor to recheck requirement of

low temp alarmTI-932 and
compressor start permissive (refer
vendor cause & effect page 4).
900001-1-09 (NEA P&ID)
NEA
135
Gas dew point to be confirmed.
900001-1-09 (NEA P&ID)
NEA
136
Suitable makeup water connection

to cooling water tank is to be
provided.
900001-1-09 (NEA P&ID)
NEA
137
Cooling water tank vent should be

provided at safe location.
900001-1-09 (NEA P&ID)
NEA
138
PCV-902/903 set points to be

reviewed in view of max. flare back
pressure of 2 barg (during general
power failure).
CS-140-PR-D-06600003
NEA / SEI
Page 34 of 136
Status
HAZOP STUDY REPORT
Client
PROCESS
SO2331
CS-140-PR-47-0001
Plant
Dept.
Project
Document Number
Rev.

(Annexure II)
S.No
Recommendations
P&ID no
Responsibility
139
Isolation valve in vent line to flare

is to be LO.
900001-1-06 (NEA P&ID)
NEA
140
PSV discharge and Goose neck

provided on distance piece, to be
routed to safe location.
900001-1-06 (NEA P&ID)
NEA
141
Drain line from packing drain pot to

be routed to CBD
900001-1-06 (NEA P&ID)
NEA / SEI
CS-140-PR-15-0011,
CS-140-PR-15-0030,
1-336-00-33049(BHEL)
BHEL/SEI
CS-140-PR-15-0011,
CS-140-PR-15-0030,
1-336-00-33049(BHEL)
BHEL/SEI
1-336-00-33049(BHEL
P&ID)
BHEL/SEI
145
Standby PSV requirement for PSV691 is to be checked as per project

standards (considering PSV-691
failure).
1-336-00-33049(BHEL
P&ID)
BHEL/SEI
146
All condensate collections having

temp<70 C will be routed to ND
system and others having temp.>
70 C will be routed to condensate
collection system.
1-336-00-33049(BHEL
P&ID)
BHEL/SEI/NOCL
147
SOP to ensure mentioning of gland

steam condenser isolation and
steam is to be vented out through
local vent.
1-336-00-33049(BHEL
P&ID)
BHEL/SEI/NOCL
142
143
144
All drains to be properly routed.
All condensate collections having

temp<70 C will be routed to ND
system and others having temp.>
70 C will be routed to condensate
collection system.
BHEL confirmed that PCV-691 is

fail to close.
Page 35 of 136
Status
HAZOP WORKSHEET
(Annexure-III)
Samsung Engineering India Pvt Ltd
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 01
Gas oil feed From B/L to Feed Surge Drum, including gas oil feed from CDU
DESIGN INTENTION
To Supply Gas Oil Feeds from Unit B/L to Feed Surge Drum through Back Wash Filter.
DRAWINGS
CS-140-PR-15-001, CS-140-PR-15-002,CS-140-ME-E-03800002
EQUIPMENT
Feed Filter (140-F-001), Feed Surge Drum(140-V-001)
STREAM DETAILS
Gas Oil Feed from B/L (including feed from CDU) to Feed Filter (F-001) and send to Feed Surge Drum (V-001)
AVAILABLE CONTROL
SCHEMES
PC-343
Nagarjuna Oil Corporation Ltd

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

Surge Drum
Pressure ( bar g)
Flow rate (Kg/hr)
63 / 120
3.4/15.5
120,083
Note:
Node
Deviation
1. Feed from B/L to Feed Surge

Drum
1.Low/No Flow
Causes
1.U/S disturbance in
Gas Oil Feed from
storage.
Consequences
1.Low level in FSD likely

leading to No level causing
damage to pump accessories.
Safeguards
Ref. No.
Recommendations
1.Low level alarm

(LC501) provided at
1.1.1.1.1
FSD.
2.Low Low Level

Trip alarm (LZ504).
1.1.1.1.2
3. Feed from CDU is

available through
1.1.1.1.3
PCV-343.
2.U/S disturbance in 1.Low level in FSD likely
Gas Oil Feed from leading to No level causing
CDU
damage to pump accessories.
1.Low level alarm

(LC501) provided at
1.1.2.1.1
FSD.
2.Low Low Level

Trip alarm (LZ504).
1.1.2.1.2
3. Feed from
1.1.2.1.3
storage is available.
3.Choking of Back
wash Filter
(140-F-001).
2.High Pressure drop in Feed

filter
1.Refer safeguards
1.1.1.1.1, 1.1.1.1.2
and 1.1.1.1.3
1.1.3.2.1
2.High Alarm of PDI329 provided

1.1.3.2.2
Page 36 of 136
Responsibility
Remarks
1.Low/No Flow
HAZOP WORKSHEET
(Annexure-III)
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 01
DESIGN INTENTION
DRAWINGS
CS-140-PR-15-001, CS-140-PR-15-002,CS-140-ME-E-03800002
EQUIPMENT
STREAM DETAILS
AVAILABLE CONTROL
SCHEMES
PC-343

SERVICE
Temperature (C)
3.Choking of Back
2.High Pressure drop in Feed
wash Filter
filter
(140-F-001).
63 / 120

Surge Drum
Pressure ( bar g)
Flow rate (Kg/hr)
3.4/15.5
120,083
Note:
Node
Deviation
Causes
Consequences
Safeguards
3-Automatic
backwash facility is
available.
4.Automatic
backwash filter
system fails.
1. Refer Cause-1
consequence-1
5. Low/No flow of
backwash fluid to
filter.
1.No adequate backwash

leading to more frequent
backwash cycle.
1.PDI-310 is
provided. Also PDI329 with high alarm
is provided.
Ref. No.
Recommendations
1. High flow from

upstream.
1.Feed Flow to FSD will

increase
.Liquid Overfilling can be
possible.
Remarks
1.1.3.2.3
Details to discussed
separately in vendor
package HAZOP.
1.1.4.1.1
1.PDI-329 with high

alarm is provided.
Currently there is no
control of backwash
fluid. This can result in
intermittent high peak
flow rate from the
stripper through the
coalescer and the salt
dryer leading to loss of
product quality and
plant stability. This has
to be discussed with
filter vendor for
reduction in backwash
flow.
1.1.5.1.1
2.High Flow
Responsibility
1. High alarm (LC501) and

independent High
High alarm (LI-503)
provided.
1.2.1.1.1
Page 37 of 136
HAZOP WORKSHEET
(Annexure-III)
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 01
DESIGN INTENTION
DRAWINGS
CS-140-PR-15-001, CS-140-PR-15-002,CS-140-ME-E-03800002
EQUIPMENT
STREAM DETAILS
AVAILABLE CONTROL
SCHEMES
PC-343

SERVICE
Temperature (C)

Surge Drum
Flow rate (Kg/hr)
63 / 120
2.High Flow
Note:
Node
Pressure ( bar g)
Deviation
1. High flow from

upstream.
Causes
3.4/15.5
Consequences
Safeguards
2. PSV-302A/B is
designed for liquid
overfilling case.
Ref. No.
Recommendations
1.2.1.1.2
1.2.2.1.1
2.PC-343 failure
leading to PCV-343
fully open.
3.LC-501
malfunctions.

increase
possible.

increase
possible.
1.Refer safeguard
1.2.1.1.1 and
1.2.1.1.2
1.2.3.1.1
1.3
3. Reverse flow
4.Low Pressure
1. PC-343
malfunctions and
closes PCV-343
1.Same as Low/No flow.
1.4.1.1.1
2.ow supply pressure

1.Same as Low/No flow.
from CDU.
1.High supply
pressure from CDU.
120,083

increase
possible.
1. System may experience

higher than the operating
pressure
1.4.2.1.
1. System is
designed for
maximum U/S
pressure.
1.Provide low alarm for PCSEI

343.
1.5.1.1.1
5.High Pressure
Page 38 of 136
Responsibility
Remarks
HAZOP WORKSHEET
(Annexure-III)
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 01
DESIGN INTENTION
DRAWINGS
CS-140-PR-15-001, CS-140-PR-15-002,CS-140-ME-E-03800002
EQUIPMENT
STREAM DETAILS
AVAILABLE CONTROL
SCHEMES
PC-343

SERVICE
Temperature (C)

Surge Drum
Pressure ( bar g)
Flow rate (Kg/hr)
63 / 120
3.4/15.5
120,083
Note:
Node
Deviation
Causes
Consequences
Safeguards
Ref. No.
Recommendations
Responsibility
Remarks
5.High Pressure
2.External fire.
6.High Temperature
1.U/S disturbance
1.Potential overpressure in
filter.
1.Interface(LT-505) in FSD
may get affected due to high
temperature
1..5.2.1
1.System is rated for

B/L
1.6.1.1.1
design temperature
No significant cause
1.7
8. High Level
Not applicable
1.8
9 Low level
Not applicable
1.9
10.Composition
1. Composition
change due to mixing
of different feed
streams in upstream
unit.
2..Design case for

overpressure is to be
reviewed.
3.High temperature alarm

to be provided on TI-107
and TI-343.
Vendor/SEI
SEI
7.Low Temperature
1. Higher exothermic
conditions in reaction section
due to more cracked feed.
1.Regular sampling
1.10.1.1.1
2. Lower product Cetane due

to high LCO content in feed.
4. LCO, LCGO flow rate

indications to be duplicated
in DHU graphics.
5. Ratio indication with
alarm to be repeated in
DHU graphics.
6. Provide TDI (TI-129 and
TC-124)on the first bed with
high alarm set at differential
temp. of 30 C.
11.Others
1. Not applicable
1.11.1
Page 39 of 136
PMC/SEI
Determine cause of
overpressure.
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
STREAM DETAILS
AVAILABLE CONTROL
SCHEMES
(V-001)
pumped to feed Effluent
PC-330,LC-501,LC-505,FC-407A/B,FC-408,TC-119,LC-501.
Exchanger train (E001A/B/C/D) and then send to
Reactor Feed Heater (H-001)
Inlet
SERVICE
(C)

Temperature
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)
63/120
91.3-101.0/127
120083
68.8/120
92.2-94.7/108
113540-121388
307.3-338.7/365
90.7-93.2/106.5
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)
Consequences
Safeguards
Ref. No.
1.Reaction section losses gas oil feed
1 FC- 408 provided

with low alarm.
2.1.1.1.1
2.High level in FSD(V-001)
1. FZ-448 provide with

LL alarm to trip the
fired heater
2.1.1.2.1
3.Possible overfilling of FSD V-001
1 High alarm LC-501
2.1.1.3.1
2 HH alarm at LI-503
2.1.1.3.2
Recommendations
Responsibility
7. Ensure proper thermal

expansion in Mechanical
design is considered in case of
depressurization temp. of 405
C for all shells.
SEI
3.1 PSV-302A/B is
2.1.1.3.3
designed for overfilling
case.
2.FC-408 malfunctions to close
1. Refer 2.1.1.1.1 and 2.1.1.2.1
1 FZ-448 provide with

LL alarm to trip the
fired heater
2.1.2.1.1
2.P-001A/B likely damage
1. Pump is protected
with
Min. flow bypass
2.1.2.2.1
3.LC-505 malfunctions to close
1.V-001 water/oil interface may get disturbed 1.Small quantity of

2.1.3.1.1
& possibilities of water going with gas oil
water is not desirable
feed.
but acceptable as the
same will be vaporized
at operating conditions.
Water is not allowed at
reactor inlet.
8.Operating manual/SOP
should ensure periodical
checking of LG-506
4. FCV-407A/B malfunctions to
open
1. Refer 2.1.1.1.1 and 2.1.1.2.1
9. Manual isolation valves

downstream of FCV-407A/B,to
be LO.
2.1.4.1.1
Page 40 of 136
SEI/NOCL
SEI
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 02

Fired Heater Inlet
DESIGN INTENTION
DRAWINGS
CS-140-PR-15-002, CS-140-PR-15-003, CS-140-PR-15-004
EQUIPMENT

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

Temperature

Mixing Point
Exchanger Inlet
Heater Inlet
Pressure ( bar g)
Flow rate (Kg/hr)
63/120
91.3-101.0/127
120083
68.8/120
92.2-94.7/108
113540-121388
307.3-338.7/365
90.7-93.2/106.5
126850-127392
Note:
Node
Deviation
2.
3.
High Flow
As well as
4. Reverse/Misdirected
Flow
Causes
Consequences
Safeguards
Ref. No.
5. XZV-719 malfunctions to
close
1. Refer 2.1.1.1.1 and 2.1.1.2.1
1. FC-408 malfunctions to full

open
1. H2 to HC ratio will change and may

adversely affect the product quality
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 in

LC- 505.
2.3.1.1.1
1. P-001 trips
1. Back flow from high pressure side

(Reaction section) ,leading to
overpressurization of FSD.
1. UZ-719 will activate

& close XZV-719.
2.4.1.1.1
1.High flow alarm is

available at FI-448.
2.2.1.1.1
2.2.2.1
5.
Low Pressure
1. PC 330 malfunctions
to open PCV-330B
6.
High Pressure
1. PC 330 malfunctions to open 1. Over pressurizing of the FSD (VPCV 330A and close PCV-330B 001)
2. Likely loss of feed to FSD.
1. PSV-302A/B
provided
2. Refer 1.1.1.1.1
2.6.1.1.1
2. P-001 trips
1. PSV-302A/B is
designed for liquid
overfilling case
2.6.2.1.1
1. Liquid overfilling of FSD(V-001)

may occur
3. FC-408 malfunctions to close 1. Refer 2.1.1.1.1 and 2.1.1.2.1

FCV-408.
Responsibility
2.1.5.1.1
2.Two Check valve

2.4.1.1.2
available. One at pump
discharge and double
check valves at
upstream of 140-EE001.
1. P-001A/B may cavitate
Recommendations
1. Safety margin of 2.3 2.5.1.1.1

m is available in
NPSHr even at low
FSD pressure.
2.6.3.1.1
Page 41 of 136
10. Operating procedure

checking of LG-506.
SEI/NOCL
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 02

Fired Heater Inlet
DESIGN INTENTION
DRAWINGS
CS-140-PR-15-002, CS-140-PR-15-003, CS-140-PR-15-004
EQUIPMENT

Exchanger
(140-E-001A/B/C/D)
Gas Oil from
Feed Surge Drum
STREAM DETAILS
AVAILABLE CONTROL
SCHEMES
(V-001)
Inlet
SERVICE
(C)
High Pressure

Temperature

Mixing Point
6.
Exchanger Inlet
Heater Inlet
Pressure ( bar g)
Flow rate (Kg/hr)
63/120
91.3-101.0/127
120083
68.8/120
92.2-94.7/108
113540-121388
307.3-338.7/365
90.7-93.2/106.5
126850-127392
Note:
Node
Deviation
Causes
3. FC-408 malfunctions to close
FCV-408.
close
Consequences
2. Pump discharge line up to FCV408 is subjected to high pressure
Safeguards
2. Pump (P-001A/B)
discharge line is
designed for pump
shutoff pressure
1. Refer 2.1.1.1.1
7. Less/Low
Temperature
1.Potential overpressure in the H.P. section

causing likely fire and explosion.
2. FC-408 malfunctions to open 1. Low temp. at heater inlet. Upset in

FCV-408 fully.
downstream section.
8. High
Temperature
2.6.4.2
1.Depressureization
2.6.5.1.1
2.PSV-307A/B is
provided on Separator
drum.
2.6.5.1.2
1. TC-119 malfunctions to open 1. Low temp. at heater inlet may lead to

TCV-119
operational upsets
2. Reactor effluent temp., downstream of

140-EE-001 will be high and likely potential
corrosion in air cooler due to higher
concentration of ammonium bisulfide.
1. TC-119 malfunctions to close 1. No major concern w.r.t. safety.

TCV-119.
2.6.3.2.2
2.6.4.1
2. Refer 2.1.1.2.2
5. External Fire
Ref. No.
2.7.1.1
1.High temp. alarm is

provided at TI-162.
2.7.1.2.1
High flow alarm at FI448 is provided.
2.7.2.1
2.8.1.1
Page 42 of 136
Recommendations
Responsibility
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 02

Fired Heater Inlet
DESIGN INTENTION
DRAWINGS
CS-140-PR-15-002, CS-140-PR-15-003, CS-140-PR-15-004
EQUIPMENT

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

Temperature

Mixing Point
Exchanger Inlet
Heater Inlet
Pressure ( bar g)
Flow rate (Kg/hr)
63/120
91.3-101.0/127
120083
68.8/120
92.2-94.7/108
113540-121388
307.3-338.7/365
90.7-93.2/106.5
126850-127392
Note:
Node
Deviation
9.
Less/Low Level
Causes
Consequences
1. FC-408 malfunctions to open 1. Refer 2.2.1.1.1 and 2.2.2.1

FCV-408
Safeguards
Ref. No.
2.9.1.1
Recommendations
11.Provision of local temp.
gauge to be provided for
ascertaining the temperature
before taking the sample.
12.Operating procedure
should ensure temp. of
sampling fluid below 80 C.
2. LC-505 malfunctions to open 1. Refer 2.2.1.1.1 and 2.2.2.1

LCV-505
3. LC-501 malfunctions to close 1. P-001A/B may cavitate
250 LCV-011A/B/C
2.9.2.1
1. LZ-504 will activate 2.9.3.1.1

UZ701 which will trip the
pump
2.Small quantity of
2.9.3.1.2
water is not desirable
but acceptable as the
same will be vaporized
at operating conditions.
Water is not allowed at
reactor inlet.
10.
High Level
1. FC-408 malfunctions to close 1. Refer Low/No Flow of this node

FCV-408
2.10.1.1
close
2.10.2.1
1. Refer Low/No Flow of this node
Page 43 of 136
Responsibility
SEI/NOCL
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 02

Fired Heater Inlet
DESIGN INTENTION
DRAWINGS
CS-140-PR-15-002, CS-140-PR-15-003, CS-140-PR-15-004
EQUIPMENT

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

Temperature

Mixing Point
Exchanger Inlet
Heater Inlet
10.
Pressure ( bar g)
Flow rate (Kg/hr)
63/120
91.3-101.0/127
120083
68.8/120
92.2-94.7/108
113540-121388
307.3-338.7/365
90.7-93.2/106.5
126850-127392
High Level
Note:
Node
Deviation
Causes
Consequences
Safeguards
3. LC-505 malfunctions to close 1. Refer Low/No Flow of this node

LCV-505
4. LC-501 malfunctions to open 1. Overfilling of FSD (V-001)

250-LCV-011A/B/C (located at
OSBL).
2.10.3.1
1. HH Alarm LI-503
2.10.4.1.1
2. PSV-302A/B is
designed for Liquid
overfilling case
2.10.4.1.2
5.PC-343 malfunctions to open

fully
12.Composition
13. Problem/Requirements
1. Tube leakage in (EE001A/B/C/D)
Ref. No.
2.10.5
Refer 1.10.1.1.1
1. Contamination of product with feed
1. Analyzer AI-003 is
provided on product
line
2.12
2.13.1.1.1
Page 44 of 136
Recommendations
Responsibility
Remarks
HAZOP WORKSHEET
Client
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,CS-140-PR-15-0005
EQUIPMENT
STREAM DETAILS
Reactor Feed Heater (140-H001)

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)
Project :
Pressure ( bar g)
Temperature
Flow rate (Kg/hr)
(C)
SERVICE
Fired Heater Outlet to
Hydrotreater Reactor Inlet
86.4-88.9/106.5
318.3-362.5/400
126850-127392
Note:
Node
3. Reactor Feed
Heater
Deviation
1.
Low/No Flow of liquid feed.
Causes
1. U/S disturbance.
2.Low/No flow of gaseous feed.
4.b. High Flow of gaseous

stream
4.c. Reverse flow
Safeguards
1.Possible coking in heater tubes leading to

tube failure.
3. Low/No flow of off gas from

MEROX unit.
4.a. High Flow of liquid stream
Consequences
1. Loss of liquid feed causing possible
overheating of heater tubes leading to tube
failure.
1. U/S disturbances
Ref. No.
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
4. Low low flow trip is

provided at FZ-448.
3.1.1.1.4
5. Low flow alarm at

FC-408 is provided.
3.1.1.1.5
Responsibility
Remarks
3.2. .1.1
1. Low flow at FC-427
and low low trip at FZ428 is provided.
1.No significant consequences.
3.3. .1
1.No major causes identified on safety issues.
3.4a.1.1
1.No major causes identified on safety issues.
3.4b.1.1
1.Tube rupture leading to

1.Fire and explosion
reverse flow to heater tubes from
downstream system
Recommendations
1. TC-124 controls the 3.1.1.1.1

firing of heater
1.Emergency
Depressurization
system is available
Page 45 of 136
3.4c.1.1.1
In current practices of
licensor is to provide
check valve at Heater
outlet.
HAZOP WORKSHEET
Client
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,CS-140-PR-15-0005
EQUIPMENT
STREAM DETAILS
Reactor Feed Heater (140-H001)

After preheating from feed/effluent heat exchanger post heating is done in Fired Heater
PC-899(For Detail see the Heater Firing P&ID for control system)
Project :
Pressure ( bar g)
Temperature
Flow rate (Kg/hr)
(C)
SERVICE
Fired Heater Outlet to
Hydrotreater Reactor Inlet
86.4-88.9/106.5
318.3-362.5/400
126850-127392
Note:
Node
Deviation
Causes
Consequences
Safeguards
Ref. No.
5. Low Temperature from

Heater outlet
1. TC-124 malfunctions & less

firing in the heater
1. Desired reactor temp. will not be

achieved. Leads to gas oil product quality
upsets.
1.Low alarm at TI-123 2.5.1.1.1

is provided.
6. High
Temperature
1. TC-124 malfunctions and

over firing in heater
1. Possible coke formation in heater tubes
1. TI-121,TI-122,TI3.6.1.1.1
222 &TI-223 provided
with high alarm
2. TI-101 &TI-102
provided with high
alarm
Recommendations
Responsibility
3.6.1.1.2
3. TZ-123 HH will
3.6.1.1.3
activate UZ-718 to trip
the heater
7. Low pressure
1.U/S disturbances
1. Desired reactor temp./partial pressure of

hydrogen, will not be achieved. Leads to gas
oil product quality upsets.
1.Low alarm at PI-689 3.7.1.1.1

is provided at
compressor suction.
8.High pressure
1.Coking in furnace tubes.
1.Unequal flow distribution leading to high

skin temp.
1. TI-121,TI-122,TI3.8.1.1.1
222 &TI-223 provided
with high alarm
9.Composition
1.No new cause.
1. Heater tube leak
1. Fire box temp. high, possible heater

damage
1.High temp alarm at

TI-101&TI-102
3.10.1.1.1
2. Fire box pressure high.
1. PC-899 high alarm

provided.PZ-900
provided with HH
alarm and activate
UZ-718 to trip the
heater
3.10.1.2.1
13.Provide low pressure

alarm at PC-358 at 140-V006 gas outlet.
SEI
should ensure safe
shutdown of the plant
SEI/NOCL
3.9.1
Page 46 of 136
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 04
Reactor ,Effluent air cooler, Trim Cooler up to Separator inlet
DESIGN INTENTION
1.
To hydro treat Gas Oil Feed in Reactor for desulphurization, 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-15-0003,CS-140-PR-15-0005, CS-140-PR-15-0006, CS-140-PR-15-0007,CS-140-PR-15-0017
EQUIPMENT
140-R-001,140-EE-002,140-EE-001A/B/C/D,140-EA-001,140-EE-003
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)
185.5-397/430
80.2-83.4/102
45-65/130
78.8-.79.3/92
137867
144751
Note:
Node
4. Reactor inlet , Effluent Air
Cooler, Trim Cooler Up to
separator inlet
Deviation
1. Low/No Flow of liquid
stream
Causes
1. U/S disturbance
Consequences
Safeguards
Ref. No.
1. Potential channeling in rector, below

turndown
1 FC- 408 provided

with low alarm.
4.1.1.1.1.2
2. Loss of product quality
1. FZ-448 provided
with LL alarm to trip
the fired heater
4.1.1.2.1.2
1.Low hydrogen ratio leads to catalyst coking. 1. Low flow at FC427 and low low trip
at FZ-428 is
provided.
4.2.1.1.1
2. Low/No flow of gaseous

stream
1. U/S disturbance
3 Low/No flow of Quench gas
1. FC-412 /413/414/415
malfunction to close
FCV412/413/414/415 (quench
H2)
1. Temperature excursion than normal op.

1. High temp.
temp., Likely coke formation in catalyst beds. alarms are provided
for each bed.
4.3.1.1.1
4. High Flow of liquid stream
1. U/S disturbance
1. Possible incomplete reaction due to

decreased Hydrogen /HC ratio resulting in
poor product quality.
4.4.1.1.1
2. Loss of product quality.
2.Increase in Pressure drop across catalyst

beds.
4.2.1.2
1. AI-003 is
provided on product
line
4.4.1.2.1
1.PDI-349~353,are
provided with high
alarms.
5.High flow of gaseous stream
1. U/S disturbance
1. Increase in Pressure drop across catalyst

beds.
1.PDI-349~353,are
provided with high
alarms.
4.5.1.1.1
6.High flow of Quench gas
1. FC-412 /413/414/415
malfunction to fully open FCV
412/413/414/415
1. Reactor bed temp. decreases &

may lead to incomplete reaction resulting in
poor product quality.
1. AI-003 is
provided on product
line
4.6.1.1.1
Page 47 of 136
Recommendations
Responsibility
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 04
DESIGN INTENTION
1.
2.
3.

DRAWINGS
EQUIPMENT
140-R-001,140-EE-002,140-EE-001A/B/C/D,140-EA-001,140-EE-003
STREAM DETAILS
SERVICE
Temperature (C)
Flow rate (Kg/hr)

80.2-83.4/102
45-65/130
78.8-.79.3/92
137867
144751
6.High flow of Quench gas

Note:
Node
Pressure ( bar g)
185.5-397/430
Deviation
1. FC-412 /413/414/415
malfunction to fully open FCV
412/413/414/415
Causes
Consequences
2.Increase in Pressure drop across catalyst
beds.
Safeguards
Ref. No.
1.PDI-349~353,are
provided with high
alarms.
4.6.1.2.1
7.Reverse flow
1.Tube rupture leading to

1.Fire and explosion
reverse flow to heater tubes from
downstream system
1.Emergency
Depressurization
system is available
4.7.1.1.1
8. Low Pressure
1.U/S disturbances.
1.Low alarm at PI689 is provided at

compressor suction.
4.8.1.1.1
2. AI-003 is
provided on product
line
4.8.1.1.2
1. PC-358 provided
with high alarm.
4.9.1.1.1
2. PSV-307A/B
provided.
4.9.1.1.2
9.High Pressure
10. Low
Temperature
1. Disturbance in Hydrogen
recycle loop.
1. More quench Hydrogen flow

to reactor
1. Desired reactor temp./partial pressure of

hydrogen, will not be achieved. Leads to gas
oil product quality upsets.
1. Likely pressurization of the system.
4.10.1/2.1
1. Refer 4.6.1.1.1
2. U/S disturbances.
11. High
Temperature
1. Low quench gas to reactor
2. EA-001 Fan motor trips
1. Refer 4.3.1.1.1
1. Pressure buildup due to less

condensation
1. High temp.
Alarms are provided
for each bed.
4.11.1.1.1
2. Low flow alarm

at FC412/413/414/415.
4.11.1.1.2
1 High alarm at TI163
4.11.2.1.1
Page 48 of 136
Recommendations
Responsibility
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 04
DESIGN INTENTION
1.
2.
3.

DRAWINGS
EQUIPMENT
140-R-001,140-EE-002,140-EE-001A/B/C/D,140-EA-001,140-EE-003
STREAM DETAILS
11. High
Temperature
Temperature (C)
SERVICE
Flow rate (Kg/hr)

80.2-83.4/102
45-65/130
78.8-.79.3/92
137867
144751
Note:
Node
Pressure ( bar g)
185.5-397/430
Deviation
2. EA-001 Fan motor trips

Causes
Consequences
2. Higher hydrocarbons may condense in
HP Amine column (C-001) leading to foam
formation
3. Cooling water failure in EE003
Safeguards
Ref. No.
1. PC-358 is
provided with high
alarm
4.11.2.2.1
2. PSV-307A/B is
provided
4.11.2.2.2
3. TI-167 high alarm

and TI-212 high
alarm is also
provided
4.11.2.2.3
4. Hydrocarbon
skimmer for both
HP & LP amine
absorber (C-001 and
C-003) is routed to
CBD instead of
amine drain.
4.11.2.2.4
5. Trim cooler is
designed
considering air
cooler failure also
separator is
designed for air
cooler failure
considering cooling
by trim cooler.
4.11.2.2.5
3. High inlet temp. to recycle compressor.
1. Recycle
compressor trip
4.11.2.3.1
1. Refer 4.11.2.1.1 and 4.11.2.2.1~5.
1.High temp. alarm

at TI-212 is
provided.
4.11.3.1.1/2
2. High temp. alarm

at TI-167 is provided
at 140-V-006 outlet.
Page 49 of 136
Recommendations
15. All pump motor trip

alarms to be provided in
DCS.
Responsibility
SEI
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 04
DESIGN INTENTION
1.
2.
3.

DRAWINGS
EQUIPMENT
140-R-001,140-EE-002,140-EE-001A/B/C/D,140-EA-001,140-EE-003
STREAM DETAILS
SERVICE
Temperature (C)
Pressure ( bar g)
Flow rate (Kg/hr)
185.5-397/430
80.2-83.4/102
45-65/130
78.8-.79.3/92
137867
144751
Note:
Node
Deviation
13. Composition
Causes
Consequences
Safeguards
1. PDI with high
alarm provided for
each bed
Ref. No.
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.None
4.12.2.1.1
3. Tube leakage EE-003
1. Hydrocarbon may ingress in cooling

water
4.12.3.1.1
1.Hydrocarbon
detector is provided
in cooling water
tower at OSBL.
4.14
14. Others
Page 50 of 136
Responsibility
16. Maintenance schedule

for vibration checking is to
be strictly followed on
regular basis.
NOCL
4.12.1.1.1
4.13.1
1.No new cause.
Recommendations
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
NODE NO: 05
Wash Water System
DESIGN INTENTION
Sour Water/MP BFW supply to Wash Water Drum(V-004)
DRAWINGS
CS-140-PR-15-0003,CS-140-PR-15-0006,CS-140-PR-15-0008, CS-140-PR-15-0021, CS-140-PR-15-0022,CS-140-PR-15-0030,CS-140-PR-15-0037
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 and also in EE-001 A/B tube side inlet
Project :

FC-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)
65-128/150
45.0/140
Flow rate (Kg/hr)

5.0-24.0/25
5221-6212
6.4/9
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
Safeguards
Ref. No.
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.
3. Low alarm for LC- 5.1.1.1.3

516 is provided.

FCV-420
1. BFW & Recycle 5.1.2.1.1

water is available
for make up

516 is provided.

FCV-451
1. Stripped sour
water and recycle
water is available
for makeup
5.1.3.1.1

516 is provided.
4. LC-542 malfunction to close
LCV-542A
1. Stripped sour
water and BFW is
available for
makeup
5.1.4.1.1

516 is provided.
5. LC-544 malfunction to close 1. Interface level of V-009 boot will
LCV-544
be high
1. LI-560A is
provided with
HH alarm
Page 51 of 136
5.1.5.1.1
Recommendations
Responsibility
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
NODE NO: 05
Wash Water System
DESIGN INTENTION
DRAWINGS
EQUIPMENT
STREAM DETAILS
1.
2.
Project :

FC-419,PC-368,LC-516,FC-451,FC-420,LC-542& LC-544
SERVICE
Temperature(C)
water Drum
Drum
45.0/140
Note:
Node
Pressure ( bar g)
65-128/150
Deviation

LCV-544
Causes
Consequences
Safeguards
2. Stripped sour
water and BFW is
available for
makeup(*)
2. Water may carry over with diesel product. 1. SC-015 is

provided.
Ref. No.
5.1.5.1.2
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 at pump discharge,

FCV-419
1. No wash water to EA-001, will increase

salt deposition
4. NRVs are
provided at all
injection points.
5.1.7.2.4
1.FZ-450 is
provided with
LL alarm
5.1.8.1.1
Page 52 of 136
Flow rate (Kg/hr)

5.0-24.0/25
5221-6212
6.4/9
3310
Recommendations
Responsibility
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
NODE NO: 05
Wash Water System
DESIGN INTENTION
DRAWINGS
EQUIPMENT
STREAM DETAILS
1.
2.
Project :

FC-419,PC-368,LC-516,FC-451,FC-420,LC-542& LC-544
SERVICE
Temperature(C)
water Drum
Drum
Pressure ( bar g)
65-128/150
45.0/140
Note:
Node
Deviation
8. FC-419 at pump discharge,

FCV-419
Causes
Consequences
2. High level in V-004.
Safeguards
9. XZV-721 at pump discharge, 1. Refer 5.1.8.1.1~2 and 5.1.8.2.1~2

High Flow
1. FC 420 on stripped sour

water line from OSBL,
malfunctions to open FCV-420.
3310
Recommendations
Responsibility
5.1.8.1.2
5.1.8.2.2
5.1.9.1
1. Less wash water available for injection to 1 FZ-450 is

EA-001, resulting salt deposition in tubes.
provided with
LL alarm
Ref. No.
1. LI-559 is provided 5.1.8.2.1

with
HH alarm
2.LC-516 is
provided with high
alarm
2.
5221-6212
6.4/9
1. No wash water to EA-001, will increase

salt deposition
2.High tem. Alarm

TI-162 is provided
at the inlet of air
cooler.
10. FC-455A/B at pump min.

circulation line, malfunctions to
full open FCV-455A/B
Flow rate (Kg/hr)

5.0-24.0/25
5.1.10.1.1
2. FC-419
provided with low
alarm.
5.1.10.1.2
3.High tem. Alarm

TI-162 is provided
at the inlet of air
cooler.
5.1.10.1.3
1. LC-516 provided 5.2.1.1.1

with
High alarm.
2. LI-559 provided
with HH
alarm.
5.2.1.1.2
3.PSV-310A/B
designed for liquid
overfilling case
5.2.1.1.3
Page 53 of 136
17. Manual isolation

valves downstream of
FCV-455A/B,to be LO.
SEI
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
NODE NO: 05
Wash Water System
DESIGN INTENTION
DRAWINGS
EQUIPMENT
STREAM DETAILS
1.
2.
Project :

FC-419,PC-368,LC-516,FC-451,FC-420,LC-542& LC-544
2. High Flow
SERVICE
Temperature(C)
water Drum
Drum
Pressure ( bar g)
65-128/150
45.0/140
Flow rate (Kg/hr)

5.0-24.0/25
5221-6212
6.4/9
3310
Note:
Node
Deviation
Causes
Consequences
Safeguards
Ref. No.
Recommendations
Responsibility
2. FC-451 in MP BFW line

malfunctions to open
FCV-451
1. Refer 5.1.1.1.1~3.
3. LC-542 at recycle water line

from stripper reflux drum,
malfunction to open
LCV-542A
1. Refer 5.1.1.1.1
and 5.1.1.1.2
5.2.3.1.1
18. Confirm gas break

SEI
through LCV-542A case
is considered for PSV310A/B
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
19.Provide additional
control scheme on V008 boot with LT (Low
low level signal), new
shutdown valve on
recycle water line from
V-008 to avoid gas
break through.
5.2.4.1
20. Review the impact of NOCL

vapor break
through/liquid HC in unit
550.
5.2.2.1
4.LC-542 malfunctions to open 1.Boot level of V-008 may go down, HC carry

LCV-542B
over to unit 550
2.. Possible damage to P-002A/B due to

cavitation (due to presence of naphtha).
4. LC-544 at the outlet of V-009 1. Level of (V-004) may go high

boot, malfunction to open
LCV-544
Remarks
5.2.4.2
1. Refer 5.1.1.1.1
and 5.1.1.1.2
Page 54 of 136
5.2.4.1.1
SEI/PMC/NOCL Low level alarm can

/Axens
be provided on
magnetic LG-543
with switch to enable
operator action for
closing control valve
(upstream isolation
valve).
Wash water pump
operation to be
checked for HC carry
over in wash water.
NPSHr of P-002A/B
is 1.9m and vessel
elevation is 5.5m
from grade. So no
cavitation.
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
NODE NO: 05
Wash Water System
DESIGN INTENTION
DRAWINGS
EQUIPMENT
STREAM DETAILS
1.
2.
Project :

FC-419,PC-368,LC-516,FC-451,FC-420,LC-542& LC-544
SERVICE
Temperature(C)
water Drum
Drum
Pressure ( bar g)
65-128/150
45.0/140
Flow rate (Kg/hr)

5.0-24.0/25
5221-6212
6.4/9
3310
4. LC-544 at the outlet of V-009

boot, malfunction to open
LCV-544
Note:
Node
Deviation
Causes
Consequences
Safeguards
2. Boot level of V-009 may go down, HC

carry over to the reaction section. As this is
stabilized gas oil no pressure increase is
expected
5. LC-516 malfunction to open

FCV-420/451& LCV-542B
5.2.4.2
1. Refer 5.1.1.1.2
6. FC-419 at wash water pump 1. More wash water to EA-001,EEdischarge ,malfunction to open 001 (when in operation) no major concern.
FCV-419
2. Likely low level in V-004.
3.Possible water level rise in V-006.
3.Reverse Flow
1.High level In wash water drum.
Ref. No.
5.2.5.1.1
5.2.6.1
1. LZ-518 provided
with low low alarm.
5.2.6.2.1
2. LC-516 is
provided with low
alarm
5.2.6.2.2
1.High high alarm is 5.2.6.3.1

provided at LI-512.
1.Check valves are 5.3.1.1
provided on all feed
lines and also in
pump discharge.
2.Pump P-002 A/B failure.
3. XZV-721 failure.
4.FCV-419 failure.
Page 55 of 136
Recommendations
21. Provide low alarm
for LI-560A at V-009
boot
Responsibility
SEI/NOCL
Remarks
Operating procedure
should ensure
periodical checking of
LG-545.
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
NODE NO: 05
Wash Water System
DESIGN INTENTION
DRAWINGS
EQUIPMENT
STREAM DETAILS
1.
2.
Project :

FC-419,PC-368,LC-516,FC-451,FC-420,LC-542& LC-544
SERVICE
Temperature(C)
water Drum
Drum
Pressure ( bar g)
65-128/150
45.0/140
Flow rate (Kg/hr)

5.0-24.0/25
5221-6212
6.4/9
3310
Note:
Node
Deviation
Causes
Consequences
Safeguards
4.
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.
1. Water washing of EA-001 may get

affected.
Ref. No.
1.vessel operating pressure is disturbed.
1. BFW may enter into sour water line
Responsibility
5.4.1.1
1. NPSHa is
calculated
considering no
overpressure in
wash water drum.
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
3. Pump is designed 5.5.2.1.3

to work with low
NPSH (1.9m) even
in absence of
nitrogen pressure.
3. Low supply pressure of sour

water from unit 550
Recommendations
1. NRV is provided 5.5.3.1.1

downstream of FCV420.
2. Stripped sour water can not be supplied to 1. Recycle water

5.5.3.2.1
wash water drum.
from stripper reflux
drum, coalescer and
MP BFW is
available.
Page 56 of 136
Remarks
1. Ensure sampling
provision is given in
Unit
550 during detailing.
22. Operating
procedure should
ensure periodical
checking of PI369A/B at pump
suction..
SEI/NOCL
5.
Low Pressure
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
NODE NO: 05
Wash Water System
DESIGN INTENTION
DRAWINGS
EQUIPMENT
STREAM DETAILS
1.
2.
Project :

FC-419,PC-368,LC-516,FC-451,FC-420,LC-542& LC-544
3. Low supply pressure of sour

water from unit 550
SERVICE
Temperature(C)
water Drum
Drum
Pressure ( bar g)
65-128/150
2. Stripped sour water can not be supplied to
wash water drum.
45.0/140
Flow rate (Kg/hr)

5.0-24.0/25
5221-6212
6.4/9
3310
Note:
Node
Deviation
Causes
Consequences
Safeguards
Ref. No.
Recommendations
Responsibility
5.5.3.2.2
2. FC-420 is
provided with low
alarm.
6.
High Pressure
1. PC-368 malfunctions to open 1. V-004 may experience high pressure.

PCV-368A and closes PCV368B.
7.Low temperature
No significant safety issue.
8.High temperature
1. Stripped sour water is not

available from unit 550.
1. Misdistribution of wash water

in air cooler tube bundles.
10.Composition
1. No new cause
11. Part of Maintenance
1. Maintenance
1. PSV-310 A/B is
provided to take
care of this
situation.
5.6.1.1.1
5.7
1. No effective washing and this can not be

continued for a long duration due to corrosion
and pressure drop issues and cooler
efficiency.
1. Salt may deposit on air cooler tubes.
5.8
23.Provide high temp.

Alarm at TI-210.
Axens/SEI
to ensure Increase of
injection water flow rate
and/or plant capacity to
be decreased. To be
further checked for the
feasibility of this
operation.
1. Individual FI's are 5.9.1.1

available at each
injection point.
25. Operating
procedure should
ensure periodical
checking of FI458/459/460/461
SEI/NOCL
26. check working of P002A/B,when operating

only on BFW(128 C)
SEI
5.10
1. High temp.(BFW) at suction in case of only 1. Pump P-002A/B
BFW is available.
Mechanical
designed is for 150
C.
Page 57 of 136
5.11.1.1.1
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
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-15-0007
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)
LC-514.LC-556,LC542
Project :

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)
45/130
6.4-78.8/92
10085
45/120
4.0-6.4/9
10080
Note:
Node
6. Separator bottom to Sour water Flash
Drum and B/L
Deviation
1.
Low/No Flow
Causes
Consequences
Safeguards
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
leading to off-spec product.
HH alarm.
2. AI-003 is
provided at gas oil
product line.
2. Potential overpressure upstream TC191A/B due to higher vaporization,
Ref. No.
Recommendations
Responsibility
6.1.1.1.1
6.1.1.1.2
1. PI-903 is provided 6.1.1.2.1

with high pressure
alarm at stripper
overhead
3. Potential overpressure in stripper, leading

to water carryover in wild naphtha as well as
in diesel .Major system upset.
2. LC-556 malfunctions to close 1. V-017 water side level may go high

LCV-556
leading to water carry over to closed drain
system, resulting in water carryover to LP
amine absorber KO pot leading to potential
foaming in amine system and contamination
of amine.
6.1.1.3
1.Low alarm at FI417 is provided..
6.1.2.1.1
2. High alarm at LC- 6.1.2.1.2

514 is provided.
3. Automatic drain
facility to closed
drain is provided.
6.1.2.1.3
4. High alarm at LC- 6.1.2.1.4

530 is provided.
3. LC-514 malfunctions to close 1. V-017 Hydrocarbon side level may go

LCV-514
high and ultimately over the period of time
HC carryover to V-010.
1.High alarm at LC556 is provided.
6.1.3.1.1

checking of LG515
SEI/NOCL
28. Ensure LG-515 facing SEI

with LCV-514 bypass valve
Page 58 of 136
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
NODE NO: 06
DESIGN INTENTION
DRAWINGS
CS-140-PR-15-0006,CS-140-PR-15-0007
EQUIPMENT
STREAM DETAILS
LC-514.LC-556,LC542
Project :

SERVICE
Temperature(C)
3. LC-514 malfunctions to close 1. V-017 Hydrocarbon side level may go
45/130
LCV-514
high and ultimately over the period of time
HC carryover to V-010.
45/120
Sour water B/L
Pressure ( bar g)
Flow rate (Kg/hr)

6.4-78.8/92
10085
4.0-6.4/9
10080
Note:
Node
Deviation
2.
High Flow
Causes
Consequences
Safeguards
Ref. No.
2.High alarm at LC530 is provided.
6.1.3.1.2
4. Low pressure in LP amine

absorber
1.Over filling of vessel
1.Low pressure
alarm PI-999 is
provided.
6.1.4.1.1.
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 to
sour water flash drum.
1. LZ 513 is
provided with LL
alarm will activate
UZ-704 to close
XZV704.
6.2.1.1.1
2 Potential HC carryover to LP amine

absorber KOD and eventually leading to
foaming in LP amine absorber.
Recommendations
Responsibility
Remarks
2. High alarm at LC514 is provided.

3. High alarm at LC530 is provided.
2. LC-514 malfunctions to open 1.Gas break through to CBD and potential

LCV-514
reduction of pressure in amine column
1. CBD vessel is
connected to flare.
6.2.2.1.1
SEI/NOCL
Operating procedure
should ensure
periodical checking of
LG-515/LCV-514.
PMC/\NOCL
1. Provision for HC
carryover with sour
water to be considered
in unit 550.
2. PI-999 is provided 6.2.2.1.2

with low alarm at LP
amine absorber top.
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
3. Reverse flow
Refer 6.1.2.1.1 ~ 6.1.2.1.4
6.3
4. High Pressure
Refer 6.1.1.1.1, 6.1.1.1.2,

6.1.1.2.1 and 6.1.1.3
6.4
5. Low pressure
Refer 6.2.2.1.1 and 6.2.2.1.2
6.5
Page 59 of 136
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
NODE NO: 06
DESIGN INTENTION
DRAWINGS
CS-140-PR-15-0006,CS-140-PR-15-0007
EQUIPMENT
STREAM DETAILS
LC-514.LC-556,LC542
Project :

SERVICE
Temperature(C)
Sour water B/L
Pressure ( bar g)
Flow rate (Kg/hr)
45/130
6.4-78.8/92
10085
45/120
4.0-6.4/9
10080
Note:
Node
Deviation
Causes
Consequences
Safeguards
Ref. No.
6.Low temperature
NO new causes
6.6
7. High temperature
NO new causes
6.7
8. Composition
NO new causes
6.8
9. Others
NO new causes
6.9
Page 60 of 136
Recommendations
Responsibility
Remarks
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)
45-51/130
11.9-78.8/92
41810-119768
213-260/390
8.9-10.3/75
119768
Note:
Node
Deviation
7. Separator Drum to Stripper

Inlet
1.
Low/No Flow
Causes
close.
Consequences
Safeguards
1. Level of V-006 increases
1. LC 507 high
alarm is provided.
2. Liquid HC carryover in vapor line leading

to foaming in HP amine absorber C-001.
1. K.O.D V-007 is 7.1.1.2.1

provided with high
level alarm.
Ref. No.
Recommendations
Responsibility
2. Deviation alarm 7.1.1.2.2

at XZV-703 is
provided
V-006 is designed for

14min holdup time
between normal and
high levels.
29. Consider FC-416 low

alarm is set below
turndown flow.
SEI/AXENS
3. High level alarm 7.1.1.2.3

LI-509 is provided
at V-006.
3. High temp to stripper preheater EE-002,

leading to high heater temp. Making the
heater firing control difficult (firing turn down
issues), leading to high temp. to reactor
None
7.1.1.3
30. Consider installation of AXENS/SEI

limiting temp. controller
(TI-120) in heater inlet.
31. SOP to address lining SEI/NOCL

of quench gas in the
bottom bed which will help
in reducing the reactor
outlet temp. minimizing
the disturbance.
4. Higher inlet temp. across EE-001 A/B/C/D

and inlet of air cooler EA-001.
1. Air cooler is
designed for 10%
higher heat duty.
Page 61 of 136
Remarks
7.1.1.1.1
7.1.1.4.1
32. Check the impact on

the inlet piping and
equipments due to
increased inlet temp. to
EE-001A/B/C/D and
reactor effluent air cooler
EA-001
SEI
7. Separator Drum to Stripper

Inlet
1.
Low/No Flow
close.
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 07
DESIGN INTENTION
DRAWINGS
CS-140-PR-15-0007, CS-140-PR-15-0017, CS-140-PR-15-0018
EQUIPMENT

STREAM DETAILS

SERVICE
Temperature(C)
Preheater inlet
Stripper Inlet
Pressure ( bar g)
Flow rate (Kg/hr)
45-51/130
11.9-78.8/92
41810-119768
213-260/390
8.9-10.3/75
119768
Note:
Node
Deviation
Causes
2. LC-507/FC-416 malfunctions
to close FCV-416.
Consequences
Safeguards
Ref. No.
5. Higher inlet temp. across the EE006A/B/C/D and inlet of air cooler EA-003.
7.1.1.5
1. Refer 7.1.1.1.1, 7.1.1.2.1 and 7.1.1.2.3
7.1.2.1
3. TC-191 malfunctions to close 1. Pressure of system up to EE-002 may

TCV-191B
increase
2. Low stripper inlet temperature possibly

leading to product off spec.
1. PSV-930A/B is
provided at tube
side inlet line to
EE-006.
7.1.3.1.1
Recommendations
Responsibility

equipments due to
EE-006A/B/C/D and gas
oil air cooler EA-003.
SEI
34. Provide DCS PI with

high alarm upstream of
EE-006A/B/C/D.
SEI
35. Provide high alarm at

analyzer AI-003.
SEI
1. Mechanical
7.1.3.2.1
Limit stop
provided at TCV191A for minimum
flow to avoid total
blockage.
2. TI-192 at
stripper overhead
with low alarm is
provided.
7.1.3.2.2
3. Product
7.1.3.2.3
analyzer AI-003 is
provided.
1. Refer 7.1.1.4.1
7.1.3.3.1
3.Reduced duty of EE-002 leading to high

temp to EE-001 A/B/C/D
4. TC-191 malfunctions to open 1. Refer 7.1.3.1.1, 7.1.3.2.1~3 and 7.1.3.3.1.

TCV-191A
7.1.4.1
Page 62 of 136
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 07
DESIGN INTENTION
DRAWINGS
CS-140-PR-15-0007, CS-140-PR-15-0017, CS-140-PR-15-0018
EQUIPMENT

STREAM DETAILS

SERVICE
Temperature(C)
Preheater inlet
Stripper Inlet
Pressure ( bar g)
Flow rate (Kg/hr)
45-51/130
11.9-78.8/92
41810-119768
213-260/390
8.9-10.3/75
119768
Note:
Node
Deviation
4. TC-191 malfunctions to open Consequences

Causes
TCV-191A
2. Higher outlet temp. at EE-002
5 TC-191 malfunctions to close 1. Higher stripper inlet temp. leading to loss

TCV-191A
of diesel to wild naphtha.
Safeguards
Ref. No.
Recommendations
Responsibility
36. Provide high temp.

alarm TI-192.
SEI
Remarks
1. Line is designed 7.1.4.2.1

for 390 C.
None
7.1.5.1
Axens/PMC/SEI
37. Consider converting
TI-192 to TC and put
reflux on TC/FC cascade.
2.
3.
High Flow
As well as
to open FCV-416.
1. Level of V-006 decreases and down

stream system will face high pressure
due to gas break through.
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
designed for gas
blow case.
7.2.1.1.2
2. TC-191 malfunctions to open 1. Refer 7.1.1.3

TCV-191B
7.2.2.1
No new cause.
7.3
Page 63 of 136
38. Check the system

SEI
integrity upstream of TCV191A/B during gas break
through.
SEI
Min. flow stop limit

note ref. from TCV191A is to be
removed from P&ID
and Data sheet.
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 07
DESIGN INTENTION
DRAWINGS
CS-140-PR-15-0007, CS-140-PR-15-0017, CS-140-PR-15-0018
EQUIPMENT

STREAM DETAILS

SERVICE
Temperature(C)
Preheater inlet
Stripper Inlet
Pressure ( bar g)
Flow rate (Kg/hr)
45-51/130
11.9-78.8/92
41810-119768
213-260/390
8.9-10.3/75
119768
Note:
Node
Deviation
4. Low interface level Boot)
Causes
Consequences
Safeguards
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 to
sour water flash drum.
1. LZ 513 is
provided with LL
alarm will activate
UZ-704 to close
XZV704.
2 Potential HC carryover to LP amine

absorber KOD and eventually leading to
foaming in LP amine absorber.
Ref. No.
7.4.1.1.1/2/3
2. High alarm at
LC-514 is
provided.
3. High alarm at
LC-530 is
provided.
5. Low level
6. High interface level Boot)
Refer 7.1.1.1.1
7.5
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
leading to off-spec product.
HH alarm.
7.6.1.1.1
2. AI-003 is
7.6.1.1.2
provided at gas oil
product line.
close.
1. PI-903 is
7.6.1.2.1
provided with high
pressure alarm at
stripper overhead
3 Potential overpressure in stripper, leading

7.6.1.3
1. Boot level of V-006 may go high resulting 1. LI 512 is

in water carry over with gas oil product.
provided with
HH alarm.
7.6.2.1.1
Page 64 of 136
Recommendations
Responsibility
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 07
DESIGN INTENTION
6. High interface level Boot)

DRAWINGS
CS-140-PR-15-0007, CS-140-PR-15-0017, CS-140-PR-15-0018
EQUIPMENT

STREAM DETAILS

SERVICE
Temperature(C)
Preheater inlet
Stripper Inlet
Pressure ( bar g)
Flow rate (Kg/hr)
45-51/130
11.9-78.8/92
41810-119768
213-260/390
8.9-10.3/75
119768
Note:
Node
Deviation
Causes
Consequences
Safeguards
1. Deviation alarm 7.6.2.2.1

at XZV-704 is
provided
Recommendations
Responsibility
3 Potential overpressure in stripper, leading

1.Low alarm at
LC-510 is
provided.
7.9.1.2.1

equipments due to
EE-001A/B/C/D and
reactor effluent air cooler
EA-001
SEI
7.9.1.3

equipments due to
EE-006A/B/C/D and gas
oil air cooler EA-003.
SEI
Ref. No.
7.6.2.3.1
2. PI-903 is
7.6.2.3.2
provided with high
pressure alarm at
stripper overhead
7. High level
8. Low
Temperature
Refer 7.2.1.1.1 and 7.2.1.1.2
7.7
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.
1. Refer 7.1.3.2.1
9. High
Temperature
1. Malfunction of TCV-191 A
7.8.1.1.1
7.8.1
1. Refer 7.1.5.1
2. Higher inlet temp. across EE-001 A/B/C/D

and inlet of air cooler EA-001.
7.9.1.1
1. Air cooler is
designed for 10%
higher heat duty.
3. Higher inlet temp. across the EE006A/B/C/D and inlet of air cooler EA-003.
Page 65 of 136
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 07
DESIGN INTENTION
DRAWINGS
CS-140-PR-15-0007, CS-140-PR-15-0017, CS-140-PR-15-0018
EQUIPMENT

STREAM DETAILS

SERVICE
Temperature(C)
Preheater inlet
Stripper Inlet
Pressure ( bar g)
Flow rate (Kg/hr)
45-51/130
11.9-78.8/92
41810-119768
213-260/390
8.9-10.3/75
119768
Note:
Node
Deviation
Causes
Consequences
1. Tube leak in EE-006
1. Stripper bottom will ingress in unstable

gas oil. Product contamination and potential
overpressure in product tank.
1. Reactor effluent may ingress in

Unstable gas oil leading to off-spec product
Safeguards
1. PSV-319A/B is
provided for tube
rupture case.
Recommendations
Responsibility
7.10.1.1
41. Check if downstream

product tank can be
pressurized due to tube
rupture.
SEI
7.10.1.2
42. Consider increase in

operating pressure of
product.
SEI
43. Check the

overpressurization of
system and confirm that
PSVs are sized for this
case.
SEI
Ref. No.
7.10.2.1.1
2. AI-003 is
7.10.2.1.2
provided at gas oil
product line.
2. Potential overpressurization of stripper
11. Operation/Maintenance
1. PI-903 With
high alarm is
provided.
No new cause.
7.10.2.2.1
7.11
Page 66 of 136
Remarks
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
CS-140-PR-15-0007, CS-140-PR-15-0009, CS-140-PR-15-0010, CS-140-PR-15-0012
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
Pressure ( bar g)
Flow rate (Kg/hr)
Temperature (C)
SERVICE
Separator overhead to
HP amine absorber
HP Amine absorber to
Recycle gas compressor
45 /130
78.8/92
15891-18053
54/130
78.4/92
13337-15497
Note:
Node
8. Separator Overhead to
Recycle gas compressor Inlet
Deviation
1.
Causes
Low/No Flow to compressor 1. HCV-826 malfunction to full

suction
open (No flow through to
column)
Consequences
Safeguards
Ref. No.
1. High H2S concentration in recycle gas

lead to off spec product(*)
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(at separator)/FC1. Suction pressure comes down and

423(at recycle gas KOD
potentially leads to surge.
downstream) malfunction to
open FCV-423(Less flow in
Recycle gas compressor Suction
line)
8.1.2.1
1. PI-689/377 is
provided with low alarm
8.1.2.1.1
2. FI-429 is provided
with low alarm
8.1.2.1.2
2. Low pressure in reaction section leading to 1.Low low suction

off spec. product.
pressure trip PZ690A/B/C (2oo3) is
provided.
8.1.2.2.1
Recommendations
Responsibility
44.Operating procedure to
include operation of HS-822 to
select FCV-423 to purge H2S to
flare header
SEI/NOCL
45.low low suction pressure

compressor trip PZ-378 is not
required as per process reason
and to be deleted.
SEI
46.Operating instruction to
include feed cut-off if system
pressure is below 80% of the
normal pressure.
47.BHEL to confirm if low low
suction pressure trip is required
for machine protection.
3. Fuel gas line may subjected to high

pressure.
1. PSV-941A/B is
designed for this case.
8.1.2.3.1
48. Ensure refinery fuel gas

composition has considered
addition of hydrogen from this
unit.
Axens
BHEL
NOCL
49. Flow indication is to be

repeated in fuel gas unit.

LCV-519

LCV-524
1. Low level in V-007,stripper (C002)/(EE-006A/B/C/D) / (EE002)may subject to high pressure due to gas
blow by, possible damage to column
internals.
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
1. Level loses in V-005, Gas blow by may 1. PC-394 is provided

happen to C-003, damage to C-003 internals with high alarm.
8.1.4.1.1
Page 67 of 136
50. Move high alarm from PC394 to PI-999.
SEI
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 08
DESIGN INTENTION
1.
2.
DRAWINGS
EQUIPMENT
STREAM DETAILS

Pressure ( bar g)
Flow rate (Kg/hr)
Temperature (C)
SERVICE
HP amine absorber
Note:
Node
Deviation
45 /130
78.8/92
15891-18053
54/130
78.4/92
13337-15497

LCV-524
1. Level loses in V-005, Gas blow by may

happen to C-003, damage to C-003 internals
Causes
Consequences
50. Move high alarm from PC394 to PI-999.

Safeguards
2. PSV-318A/B is
designed for this gas
blowby case.
Ref. No.
1.Compressor is likely to go on surge, in case 1. Anti-surge system is

of sudden pressure drop.
provided.
6. Compressor suction strainer

choked
1. Suction pressure comes down and

1.PDI-688 is provided
8.1.6.1.1
7. Compressor trip.
1. Potential hot spots in the reactor.
1. Bed temp. alarms are

provided on reactor.
8.1.7.1.1
2. Activation of UZ-705
leading to trip of heater
and liquid feed pumps.
8.1.7.1.2
1.None as anti-surge
valve (XCV-715)
discharge is not coming
back to suction of
compressor as suction
MOV is closed.
8.1.7.2.1
8.Compressor trip is initiated due 1.Potential liquid carryover to compressor as

to high level in the suction
there is a time delay in closure of suction
KOD(LZ-526).
MOV.
None
8.1.8.1
9. MOV-002 misoperate to close.
1. PI-689/377 is
8.1.9.1.1
2. Low low suction

pressure trip PZ690A/B/C (2oo3) is
provided.
8.1.9.1.2
1. Suction pressure comes down and

SEI
Responsibility
8.1.4.1.2
5. XZV-702A malfunctions to
open.
2. Suction and discharge MOVs-002/003

respectively will close automatically leading
to compressor in surge
Recommendations
8.1.5.1.1
51. Provide high alarm on PDI688.
SEI
BHEL/PMC/SEI/NOCL/A
xens
52. BHEL recommends the

closing of MOVs with a time
delay while rpm is reduced to
500.
BHEL/PMC/SEI/NOCL/A
xens
53. System to be reviewed for
required protection.
3.If full open signal is lost 8.1.9.1.3

interlock system will trip
the compressor.
Page 68 of 136
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 08
DESIGN INTENTION
1.
2.
DRAWINGS
EQUIPMENT
STREAM DETAILS

Pressure ( bar g)
Flow rate (Kg/hr)
Temperature (C)
SERVICE
HP amine absorber
45 /130
78.8/92
15891-18053
54/130
78.4/92
13337-15497
Note:
Node
Deviation
2.
High Flow
Causes
Consequences
1. Compressor speed controller 1 Possibility of machine surge as anti-surge

malfunctions to high speed.
valve XCV-715 opens in case of system
could not consume the higher flow.
Safeguards
8.2.1.1.1
2. Possible compressor damage due to max. 1.High high speed trip

speed.
SZ-002 is available.
8.2.1.2.1
3.
Low Pressure
1. XZV-702A malfunctions to
open.
1. Refer 8.1.5.1.1
4.
High Pressure
1. Higher than required flow

from MUG compressor/
Reduction in feed.
1. Over pressurizing the system.
6.
High Level
Recommendations
1. P&ID is to be updated to
show details of anti-surge
valve as per vendor P&ID.
1. PC-358 provided with 8.4.1.1.1

high alarm.
8.4.1.1.2
1. Refer Node-4, high temp.
8.5.1.1
2. Nitrogen startup operation for

refractory dryout feed heater.
1. Possible high suction temp. leading to high Not known

discharge temp. (higher than current design).
8.5.2.1
54. Check the feasibility of this

operation

LCV-519
1. HC Liquid carry over to C-001
8.6.1.1.1
55. 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.
1. LC-521 is provided
with
High alarm.
Remarks
SEI
1. U/S disturbance
2. LC-524 malfunctions to close 1. Liquid carry over with recycle gas to KLCV-524
002
1. LZ-526 provided with 8.6.2.1.1

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

system due to some
emergencies
1. Emergency
8.7.1.1.1
depressurization
safeguarding system UZ702 is provided.
1. Possible loss of life and property.
Responsibility
8.3.1.1
2. PSV-307 A/B is
provided.
5. High
Temperature
Ref. No.
1.Anti-surge system is
available.
Page 69 of 136
SEI
SEI/NOCL
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 08
DESIGN INTENTION
1.
2.
DRAWINGS
EQUIPMENT
STREAM DETAILS

Pressure ( bar g)
Flow rate (Kg/hr)
Temperature (C)
SERVICE
HP amine absorber
45 /130
78.8/92
15891-18053
54/130
78.4/92
13337-15497
Note:
Node
Deviation
Causes
Consequences
Safeguards
Ref. No.
8.8
Recommendations
Responsibility
56. Confirm that the max.

allowable trip temp. (while
running in nitrogen service) & all
trip set points for machine
safeguards for startup nitrogen
case are not different from the
normal operating case.
BHEL
Remarks
57. If set points are different

separate modes of operation to
be programmed in DCS and in
safeguarding system.
9.Composition
1. HCV-826 malfunction to full

open (No flow through to
column)
1. High H2S concentration in recycle gas

lead to off spec product
2. System pressure may increase due to

non removal of H2S
1. AI-001 is provided on
K-002 suction line
8.9.1.1.1
2. AI-003 is provided in
final gas oil product line.
8.9.1.1.2
with high alarm
8.9.1.2.1
Page 70 of 136
58. Operating procedure to

include operation of HS-822 to
select FCV-423 to purge H2S to
flare header.
SEI/NOCL
1.Purity of recycle gas is to

maintained as per
limitation on primary seal
is to be confirmed by seal
vendor.
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-15-0003,CS-140-PR-15-0005,CS-140-PR-15-0006,CS-140-PR-15-0011
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
Pressure ( bar g)
Flow rate (Kg/hr)
Temperature (C)
SERVICE
Recycle gas compressor to
Mixing point
75.7-79/150
92.5-95.2/108.5
4310-5022
Note:
Node
9. Recycle Gas compressor to
Mixing Point
Deviation
1.
Low/No Flow
Causes
1. K-002 trip Refer node 8
,compressor trip)
Consequences
1. No hydrogen supply to reactor.
Safeguards
1. UZ-705 will
activate
UZ-706
2. Reduction in makeup hydrogen flow and

ultimately make hydrogen flow is likely to
stop.
Ref. No.
9.1.1.1.1
9.1.1.2
3. Gas oil may enter Compressor discharge 1. NRV is provided.

line
9.1.1.3.1
2. UZ-706 will activate 9.1.1.3.2

UZ719(back flow
protection system) to
close XZV-719
4.Liquid backup in recycle and makeup gas

line from mixing point.
2. FC-427 malfunction to close

FCV-427(Antisurge line)
3. Malfunctioning of XCV715(Antisurge valve) to open
1.NRV is provided
near to tie in point.
1. Possibly more hydrogen to Reactor

section. NO major concern.)
9.1.1.4.1
9.1.2.1
1.Low hydrogen-HC ratio leading to catalyst 1.FC-427 low alarm is 9.1.3.1.1

coking and potential damage to heater tubes. provided.FZ-428 will
initiate UZ-706.
2.FC-412-415
9.1.3.1.2
provided with low flow
alarms.
3. TZ-123 is provided
with HH temp. trip.
4. FC-427 malfunction to open 1. Same as low flow in anti-surge line with

FCV-427(Recycle gas and
less severity
quench gas line)
9.1.3.1.3
9.1.4.1
Page 71 of 136
Recommendations
Responsibility
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 09
DESIGN INTENTION
DRAWINGS
EQUIPMENT
STREAM DETAILS

Pressure ( bar g)
Flow rate (Kg/hr)
Temperature (C)
SERVICE
Mixing point
75.7-79/150
92.5-95.2/108.5
4310-5022
Note:
Node
Deviation
Causes
Consequences
5. High pressure drop in the

downstream system.
1. Less recycle gas flow will lead to possible

surging of compressor.
6. SC-002A malfunctions and

lower the speed of turbine.
1.Less recycle gas flow (Refer low flow case

of recycle gas)(*)
7. MOV-003 malfunctions to
close.
1.Compressor likely to see surge.
Safeguards
1. Anti surge valve
XCV715 provided.
High Flow
9.1.7.1.2
9.2.1.1.1
2. FZ-428 is provided 9.2.1.1.2

with
LL alarm
1. Refer 8.2.1.1.1 and 8.2.1.2.1
Flow
2. K-002 trips
1. Make up hydrogen may back up in

recycle compressor discharge
4.
1.Compressor K-002 high speed. 1. Potential surging of compressor.
High Pressure
Responsibility
1.Anti-surge system is 9.1.7.1.1

provided
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.
2. SC-002A malfunctions and

increases the speed of turbine.
Recommendations
9.1.6.1
2.If full open signal is

lost interlock system
will trip the
compressor.
2.
Ref. No.
9.1.5.1.1
9.2.2.1
1. NRV is provided.
9.3.2.1.1
1.Anti-surge system is 9.4.1.1.1

provided
Page 72 of 136
59. Considering full flow

SEI
through FCV-427, verify lowlow flow alarm on FZ-428.
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 09
DESIGN INTENTION
DRAWINGS
EQUIPMENT
STREAM DETAILS

Pressure ( bar g)
Flow rate (Kg/hr)
Temperature (C)
SERVICE
4.
High Pressure

Mixing point
75.7-79/150
92.5-95.2/108.5
4310-5022
Note:
Node
Deviation
Causes
2.More flow of hydrogen from
MUG compressor.
5. High
Temperature
1. U/S disturbances.
Consequences
1.Potential overpressure of system
1. High discharge temperature may lead to

compressor damage
2.Low quench efficiency leading to potential

reactor damage.
2. High speed of compressor
Safeguards
Ref. No.
1.PSV-307A/B is
provided at V-006
9.4.2.1.1
1. TI-643 is provided
with high alarm.
9.5.1.1.1
2. TZ-644A/B/C will
activate UZ-731.
9.5.1.1.2
1.HH alarm TIs are

available on the
reactor.
9.5.1.2.1
1. Refer 9.4.1.1.1
9.5.2.1
6.High level
NA
9.6
7.Low level
NA
9.7
8.composition
NA
9.8
9.others
NA
9.9
Page 73 of 136
Recommendations
Responsibility
Remarks
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 :

Pressure ( bar g)
Flow rate (Kg/hr)
Temperature (C)
SERVICE
Lean Amine from B/L to LP Amine
absorber column
Lean Amine from B/L to HP Amine
absorber column
50 /85
9.5 /14
17649-18370
50 /130
9.5-86.5/92
57857
Note:
Node
10.
Lean Amine from B/L to LP and HP 1.

Amine Absorber column
Deviation
Low/No Flow
Causes
1. U/S disturbance
Consequences
1. P-003A/B may starve and get damaged
Safeguards
1. PI-373 is provided with
low alarm
Ref. No.
10.1.1.1.1
2. No flow will be available to L.P./H.P. Amine 1. FZ-443 provided with

Absorbers.
LL alarm to activate UZ720(Lean amine to C001)
10.1.1.2.1
3. Less/No removal of H2S from recycle gas 1. FC-434/424 are

leading to off spec product hue to high partial provided with low flow
pressure of H2S in recycle gas.
alarm.
10.1.1.3.1
4. Less/No removal of H2S from off gas

leading to high H2S in unit 350.
3. AI-002 provided on off

gas drum outlet
10.1.1.4.3
1. Refer 10.1.1.4.3
1. Refer 10.1.1.3.2
10.1.2.1.1
2. back flow from HP Amine absorber to

lean amine pump(P003A/B)
1. Refer 10.1.1.1.1
10.1.2.2.1
Page 74 of 136
Responsibility
60. For low flow alarm FC-424

SEI
and low low trip FZ-443,trip
values are presently given as
per process point of view, which
needs to be verified based on
pump vendor min flow
requirement. So UZ-720 should
also activate UZ-710 to trip
pump (P-003A/B)-logic to be
implemented Consider clubbing
of UZ-710 & UZ-720).
SEI/NOCL
61. Operating procedure should
ensure routing of off gas to flare
header when there is
disturbance in lean amine
supply to C-003
2. AI-001 provided on
10.1.1.3.2
recycle gas line overhead
of V-005 for monitoring.
2. P-003A/B trips Lean Amine

to
C-001)
Recommendations
62. Provide high alarm at AI002.
63. Check unit 350 design for

possible increase of H2S in feed
gas from DHU.
SEI
NOCL/PMC
Remarks
10.
Lean Amine from B/L to LP and HP 1.

Amine Absorber column
Low/No Flow
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
NODE NO: 10
DESIGN INTENTION
DRAWINGS
CS-140-PR-15-0009, CS-140-PR-15-0010, CS-140-PR-15-0016
EQUIPMENT
STREAM DETAILS
FC-434,FC-424
Project :

Pressure ( bar g)
Flow rate (Kg/hr)
Temperature (C)
SERVICE
absorber column
absorber column
Note:
Node
Deviation
50 /85
9.5 /14
17649-18370
50 /130
9.5-86.5/92
57857
2. P-003A/B trips Lean Amine

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

FCV-434(Lean Amine to C003)
Consequences
2. back flow from HP Amine absorber to
lean amine pump(P003A/B)
1. Refer 10.1.2.1.1
4. FC-424 malfunctions to close 1. Refer 10.1.2.1.1

close Lean Amine to C-001)
High Flow
1. FC-434 malfunction to open

2. NRVs at the pump

discharge and inlet of C003 are provided.
1. C-003 level increases, possible column

flooding
Ref. No.
1. AI-001 provide on
recycle gas line for
monitoring
Responsibility
10.1.2.2.2
10.2.4.1.1
10.2.5.1
1. AI-001 provide on
recycle gas line for
monitoring
10.2.6.1.1
2. FC-424 provided with

Low alarm
10.2.6.1.2
1. LC-532 is provided with 10.2.1.1.1

high alarm
2. LI-560 is provided with
HH alarm
10.2.1.1.2
2. FC-424 malfunctions to open 1. C-001 level increases, possible column

FCV-424(Lean Amine to Cflooding
001)

high alarm
Flow
1. U/S disturbance
1. NRVs are provided in

both the lines.
4. Low pressure
No new cause
1. Off/Fuel gas may come from OSBL (unit

350/fuel gas return header)
Recommendations
1. AI-002 provided on off 10.2.3.1.1

gas drum outlet
1. Refer 10.1.2.1.1
6. FC-456A/B malfunction to full 1. Refer 10.1.2.1.1

open FCV-456A/B(Low flow of
Lean amine to C-001)
2.
Safeguards
10.3.1.1.1
10.4
Page 75 of 136
64. UZ-720 should activate UZ710 to trip pump (P-003A/B)
SEI
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
NODE NO: 10
DESIGN INTENTION
DRAWINGS
CS-140-PR-15-0009, CS-140-PR-15-0010, CS-140-PR-15-0016
EQUIPMENT
STREAM DETAILS
FC-434,FC-424
Project :

Pressure ( bar g)
Flow rate (Kg/hr)
Temperature (C)
SERVICE
absorber column
absorber column
50 /85
9.5 /14
17649-18370
50 /130
9.5-86.5/92
57857
Note:
Node
Deviation
5.
High Pressure
6. Low
Temperature
Causes
Consequences
Safeguards
Ref. No.
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 10.5.1.1.1

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 10.5.2.1.1

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 10.6.1.1.1

low alarm (for C-001), TI186 is provided with low
alarm (for C-003)
Recommendations
Responsibility
2. TDI-213 is provided
10.6.1.1.2
with low alarm (for C001),TDI-214 is provided
with low alarm (for C-003)
3. Antifoaming agent
dosing is provided
10.6.1.1.3
4. PDI-372/392 are
provided with high alarms
at C-001 & C-003
respectively.
10.6.1.1.4
2. Temp. drop due to low ambient temp.

leading to low amine temp. at B/L.
7. High
Temperature
1. U/S disturbance- Refer

10.1.1.4.3
1. Poor removal of H2S from

Recycle gas/Off gas
1. AI-001/AI-002 is
provided for monitoring
Page 76 of 136
10.6.1.2
65. Provide low alarm at TI170.
SEI
10.6.1.2
66. Ensure the provision of Hot PMC/NOCL

insulation on the lean amine line
coming from ARU (Outside DHU
B/L).
10.7.1.1.1
67. Provide High alarm on TI170 at lean amine B.L
SEI
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
NODE NO: 10
DESIGN INTENTION
DRAWINGS
CS-140-PR-15-0009, CS-140-PR-15-0010, CS-140-PR-15-0016
EQUIPMENT
STREAM DETAILS
FC-434,FC-424
Project :

Pressure ( bar g)
Flow rate (Kg/hr)
Temperature (C)
SERVICE
absorber column
absorber column
50 /85
9.5 /14
17649-18370
50 /130
9.5-86.5/92
57857
Note:
Node
Deviation
Causes
8. High level
1. Refer 10.2.1.1.1~2, 10.2.2.1.1
9. Low level
1. Refer 10.1.1.1.1
10. Composition
1.Contamination of CO/CO2 in
lean amine supply
11. Others
No new cause
Consequences
Safeguards
Ref. No.
Recommendations
Responsibility
10.8.1
10.9.1
1.Accumulation of CO/CO2 in the system
leading to reduction in catalyst activity.
10.1.1.1.
10.11
Page 77 of 136
68. SOP to address regular

sampling of recycle gas for
CO/CO2.
SEI/NOCL
Remarks
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-15-0010, 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

Pressure ( bar g)
Flow rate (Kg/hr)
Temperature (C)
SERVICE
Rich amine from HP
amine absorber column to LP
Amine absorber column
56-57/130
6.2-78.6/92
60413
Note:
Node
Deviation
11. Rich Amine from HP Amine 1.

Absorber ,LP Amine Absorber
bottom to B/L.
2.
Less/No flow
High Flow
Causes
Consequences
Safeguards
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. LZ-523 LL alarm
will activate UZ-709.
11.2.1.1.1
1. PSV-318 A/B sized

for gas break through
case.
11.2.1.2.1
1. LC-521 Malfunctions to open 1. Level of C-001 may go down.

LCV-521
2. Possible gas breakthrough leading to

overpressurization of C-003.
2. LC-532 Malfunctions to open 1. Level of C-003 may go down.
LCV-532
11.1.1.1
4. Low pressure
1. Reverse flow of Rich amine

from B.L to C-003 bottom.
1. Level in C-003 may go high
Recommendations
Responsibility
69. LG-522A/B (Magnetic

type) are to be provided
with high high alarm with
switch.
SEI
70. Ensure this gas

breakthrough case has
been considered in design
of safety valve in ARU
(Receiving flash drum
vessel).
PMC/NOCL
1. Low low alarm at LA- 11.2.2.1.1

560 is provided.
2. Possible gas breakthrough to ARU .
Flow
Ref. No.
11.2.2.2
1. NRV is provided at
B.L
11.3.1.1.1
with high alarm.
11.3.1.1.2
3. LI-560 is provided
with high high alarm.
11.3.1.1.3
1.Refer 8.3.1.1
11.4.1
Page 78 of 136
Remarks
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-15-0010, 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

Pressure ( bar g)
Flow rate (Kg/hr)
Temperature (C)
SERVICE
Rich amine from HP
amine absorber column to LP
Amine absorber column
56-57/130
6.2-78.6/92
60413
Note:
Node
Deviation
5. High pressure
Causes
Consequences
Safeguards
1. Refer 8.4.1.1.1 and 8.4.1.1.2
2.External fire
Ref. No.
11.5.1
1.Overpressurization of Column C-001
1.PSV-312 designed for 11.5.2.1.1

external fire case
2.Overpressurization of Column C-003.
1.PSV-318A/B design
covers external fire
case
11.5.2.2.1
6. Low
Temperature
1. Refer 10.6.1.1.1~4 and

10.6.1.2
11.6.1
7.
1. Refer 10.7.1.1.1
11.7.1
1. Refer 11.1.1.1, 11.1.2.1.1 and

11.1.3.1.1
11.8.1
High Temperature
8. High level
1. Low pressure in C-003
9. Low level
1. Refer 11.2.1.1.1 and 11.2.2.1.1
10. Composition
No new cause.
1.No sufficient pressure in C-003 to push rich 1.Low alarm at PI-999

amine to ARU leading to increase in level in is provided on C-003.
column.
11.8.1.1.1
2.LC-532 is provided
with high alarm
11.8.1.1.2
3.LI-560 is provided
with high high alarm.
11.8.1.1.3
11.9.1
11.1
11. Others
11.11
Page 79 of 136
Recommendations
Responsibility
Remarks
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 sour water flash drum and stripper reflux drum to B/L Unit-350.
DRAWINGS
CS-140-PR-15-0021, CS-140-PR-15-0016,CS-140-PR-15-0006
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
Pressure ( bar g)
Flow rate (Kg/hr)
Temperature (C)
SERVICE
Off gases from reflux drum to
KOD of LP Amine absorber
Off gases/Fuel gases LP
amine KOD to B/L
45.0 /65
6.4 /8
1172-1371
45.0 / 65
2.6 - 6.3 /8
512-741
Note:
Node
Deviation
12. LP Amine Absorber system 1.

(LP Amine column KOD, Off Gas
KOD) to B/L
Less/No flow
Causes
Consequences
1. PC-394 malfunctions to close 1 Increase in pressure in sour water flash

PCV-394A/B.
drum and stripper resulting in improper
flashing of HC leading to HC carryover with
Sour water and off spec product due to poor
stripping in stripper.
Safeguards
Ref. No.
Recommendations
Responsibility
1. PSV-318A/B is provided 12.1.1.1.1

high alarm at C-002
overhead
3. AI-003 is provided
2.
High Flow
2. LC-551 malfunctions to close 1. V-018 level will increase & Liquid may
LCV-551 located at Off gas
carryover with off gas/fuel gas
KOD(V-018).
12.1.2.1
71. LG-552 to be converted

to Mag. Type with provision
of high level alarm with
switch.
SEI
3. LC-530 malfunctions to close 1. V-010 level will increase & Liquid may
LCV-530 when required.
carryover with off gas to C- 003 leads to
foaming in C-003.
12.1.3.1
72. Periodical checking of

interface in LG-533A/B/C/D.
SEI/NOCL
1. PC-394 malfunctions to open 1. Column level in C-003 will increase due

PCV-394A/B.
to fall in system pressure

high alarm.
2. AI-002 is provided for
monitoring.
3. Pressure transmitter
PT-999 is provided with
low alarm at top of C003.
2. Less removal of H2S from off gas

(Also Refer 10.1.1.4.3)

HH alarm.
12.2.1.2.1
2. H2S analyzer (AI-002)

in the product line
indicates off-spec off gas
12.2.1.2.2
2. LC-551 malfunctions to open

LCV-551.
1. Gas break through
12.2.2.1
Page 80 of 136
Remarks
12. LP Amine Absorber system

(LP Amine column KOD, Off Gas
KOD) to B/L
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 sour water flash drum and stripper reflux drum to B/L Unit-350.
DRAWINGS
CS-140-PR-15-0021, CS-140-PR-15-0016,CS-140-PR-15-0006
EQUIPMENT
Stripper
2.
HighReflux
Flow 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
Pressure ( bar g)
Flow rate (Kg/hr)
Temperature (C)
SERVICE
Off gases from reflux drum to
KOD of LP Amine absorber
Off gases/Fuel gases LP
amine KOD to B/L
45.0 /65
6.4 /8
1172-1371
45.0 / 65
2.6 - 6.3 /8
512-741
Note:
Node
Deviation
Causes
Consequences
3. LC-530 malfunctions to open 1. Gas break through to CBD leading to low

LCV-530.
pressure in LP amine absorber.
3. Reverse/Misdirected flow
4.
High Pressure
1. Choking of Packed Beds in

C-003
2. External fire
Safeguards
Ref. No.
1. Pressure transmitter PI- 12.2.3.1.1

999 is provided with low
alarm at top of C003.
1.Reverse flow from ARU,unit-350,fuel gas

return header
1. NRVs are provided on

respective lines
1. High Pressure drop in Column leading to

Improper H2S removal.
1. PDI-392 provided with 12.4.1.1.1

high alarm.
1. Overpressurization of C-003,V-018,V-017
5. Low temp.
No new cause
6. High
Temperature
1. U/S disturbance (from V-008) 1. Possible condensation of Heavier HC in

C-003 resulting in foaming in C-003.
12.3.1.1
2. PSV-318A/B is
provided.
12.4.1.1.2
1.PSVs are provided

covering fire case.
12.4.2.1.1
12.5
1. TI-208 at V-008 top is

provided with high alarm.
12.6.1.1.1
2. TI-184 on inlet of C003 is provided with high

alarm.
12.6.1.1.2
3. TDI-214 is provided.
12.6.1.1.3
12.7
7. Low level
Same as high flow
8. high level
Same as low flow
12.8
9. composition
No new cause
12.9
10. others
No new cause
12.1
Page 81 of 136
Recommendations
Responsibility
Remarks
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)
65-252.1/300
40.0/ 140
7.3-11.8/15
115553
5.0-7.3 /9
115214
Note:
Node
13. Stripper bottom to Gas oil Air 1.
cooler, Coalescer and Salt Dryer
to B/L
Deviation
Less/No flow
Causes
1. P-005A/B trips.
Consequences
1. C-002 level will increase, ultimately
leading to filling of column.
Safeguards
1. LC-535 on stripper
provided with high alarm
Ref. No.
Recommendations
Responsibility
13.1.1.1.1
2. Continued steam supply to the stripper will 1. LZ-537 is provided n

13.1.1.2.1
damage the trays.
stripper C-002 with HH
alarm & activates UZ-717
to isolate MP Steam to C002
3. System pressure at pump P-005 D/S will

come down, will lead to non-availability of
backwash fluid for feed filter
2. LC-535/FC-442 malfunctions 1. System will face P-005 shut off pressure

to close FCV-442(downstream of
salt dryer).
1.Pressure transmitter PT- 13.1.1.3.1

444 is provided with low
alarm downstream of V019, before FCV-442 on
line P-103.
1. System is designed for

pump shut off pressure.
13.1.2.1.1
2. High pressure alarm PI444 is provided.
2. C-002 level will increase, ultimately

leading to filling of column.
3. LC-535(maintaing stripper
bottom level)/FC-454
malfunctions to close FCV454(Start-up recirculation line).
1. Same as safeguards 1, 13.1.2.2.1

2 for cause 1 in this
node.
1. Refer 13.1.2.1.1 and 13.1.2.2.1
13.1.3.1
Page 82 of 136
73. .Keep the spectacle

blind located in startup
recirculation line in open
position to maintain unit
under circulation during
upset without loosing much
time.
SEI
Remarks
13. Stripper bottom to Gas oil Air 1.

cooler, Coalescer and Salt Dryer
to B/L
Less/No flow
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 13
DESIGN INTENTION
DRAWINGS
EQUIPMENT
STREAM DETAILS
SERVICE
Temperature(C)
Trim cooler
Pressure ( bar g)
Flow rate (Kg/hr)
65-252.1/300
40.0/ 140
7.3-11.8/15
115553
5.0-7.3 /9
115214
Note:
Node
Deviation
Causes
Consequences
4. MOV -004 in closed condition 1. Pump will run dry.

Refer -13.1.1.1.1, 13.1.1.2.1 and 13.1.1.3.1
for remaining consequences
Safeguards
Ref. No.
Recommendations
Responsibility
1.If MOV-004 full open

13.1.4.1.1
signal is lost, interlock will
stop the pump.
2.Start permissive is
included as a part of safe
guarding system for Pump
P-005A/B.
5. Choking of coalescer in V009
Refer 13.1.2.2.1
1.PDI-914 provided with

High alarm.
6. Choking of salt dryer in V019
Refer 13.1.2.2.1
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 1. SC-011(type B) is
FCV-436
content of Gas oil)
provided at downstream
of salt dryer.
2.
High Flow
Flow
13.1.7.1.1
2. AI-003 is provided for

monitoring
13.1.7.1.2
13.1.8.1.1
close
1. Refer 13.1.7.1.1 and 13.1.7.1.2
1. FC-436 provided with

low alarm.
to open FCV-442.
1. Level of C-002 may go down.

2. Product quality may get affected due to
less residence time in V009/V-019 respectively.
13.1.5.1.1
74. FC-436 should be force

closed when UZ-717 is
activated.
SEI
1. LZ-538 is provided with 13.2.1.1.1

LL alarm to activate UZ712.
13.2.1.2.1
75. Provide high alarm for

FC-442.
SEI
76. Provide independent

SEI
DCS low low alarm from LZ537
to open FCV-454(Start-up
recirculation line).
1. Level of C-002 may go down and

ultimately pump may run dry damaging the
accessories.
1. LZ-538 is provided
with LL alarm to activate
UZ-712.
13.2.2.1.1
1. P-005 A/B trips
1. Gas oil may backup from storage
1. NRV provided in
Rundown line at B.L.
13.3.1.1.1
Page 83 of 136
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 13
DESIGN INTENTION
DRAWINGS
EQUIPMENT
STREAM DETAILS
SERVICE
Temperature(C)
Trim cooler
Pressure ( bar g)
Flow rate (Kg/hr)
65-252.1/300
40.0/ 140
7.3-11.8/15
115553
5.0-7.3 /9
115214
Note:
Node
Deviation
4.
Low Pressure
Causes
1. U/S disturbance
Consequences
1. P-005 capacity reduces and level in
column will rise.
Safeguards
1. LZ-537 HH will
activate
UZ-717 to close XZV717 on M.P steam line.
2. Refer low no flow P-005A/B

trips conseq. 3.(*)
5. High
Temperature
1. EA-003 trips
Ref. No.
Recommendations
Responsibility
13.4.1.1.1
13.4.2
1. Likely Poor performance of V009/V-019. If temp. raises above 60 C

melting/caking of salt in salt dryer may take
place.
1. High alarm provided

at TI-203/204.
13.5.1.1.1
77. Possibility of dissolution Vendor/SEI

of salt in gas oil product is to
be confirmed.
2. Separate electric
13.5.1.1.2
supply line is provided for
the fans in EA-003.
1. Refer 13.5.1.1.1 ~2
3. Cooling medium failure in

EE-006
1. Refer 7.8.1.1.1
13.5.2.1

at TI-203.
13.5.3.1.1

at TI-204.
13.5.3.1.2
1. Not Draining of salt dryer
1. Water may carry over with diesel product 1.AI-003 is provided

leading to off spec product quality
2. Loss of salt in salt dryer
1. Water may carry over with diesel product. 1. SC-011 is provided for 13.6.2.1.1
sampling
2. PDI-923 is provided
with high alarm.
Page 84 of 136
13.6.1.1.1
13.6.2.1.2

SEC/NOCL
should ensure draining of
salt dryer at regular intervals
by checking LG554.
79. Regular top up

SEI/NOCL
procedures/schedules to be
mentioned in SOP.
80. P&ID is to be updated
for maintenance /Top up
discharge/bypassing salt
dryer procedure.
SEI/VENDOR
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 13
DESIGN INTENTION
DRAWINGS
EQUIPMENT
STREAM DETAILS

SERVICE
Temperature(C)
Trim cooler
Pressure ( bar g)
Flow rate (Kg/hr)
65-252.1/300
40.0/ 140
7.3-11.8/15
115553
5.0-7.3 /9
115214
Note:
Node
Deviation
Causes
3. Leakage through Seal in P005A/B
Consequences
1. Possible fire
Safeguards
2. HZ-850 is provided at
safe distance to activate
UZ-712.
Ref. No.
Recommendations
Responsibility
1. Pump is provided with 13.6.3.1.1

double mechanical seal
1. Stripper bottom will ingress in cooling

water line
13.6.3.1.2
13.6.4.1
13.7
Page 85 of 136
81. Confirm that

hydrocarbon detectors are
provided in cooling tower
area.
NOCL
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 14
Stripped overhead system, including corrosion inhibitor injection
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,CS-140-PR-15-0023
EQUIPMENT
Stripper Air Condenser(140-EA-002), Stripper Trim Condenser(140-EE-005),Stripper

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

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)
45/140
45/140
9.5-11.5/15
6.0-11/15
9105
2956
Note:
Node
14. Stripper Overhead system
Deviation
1. Low/No Flow of overhead
vapors
Causes
Consequences
1. U/S disturbance (stripping

steam failure/Low feed inlet
temperature to C-002)
1. Product quality may get affected

(Gas oil) due to poor stripping.
Safeguards
2. Low/no flow of reflux
1. P-004A/B trips (reflux)
Respons
ibility
14.1.2.1
2 Pump running in zero forward flow leading

to potential damage.
14.1.2.2
1. V-008 level may go high
with high alarm.
14.2.1.1.1
2. C-002 overhead pressure &

temp. may increase.
1. FC-439/441 is
14.2.1.2.1
2. PI-903 is provided with 14.2.1.2.2

high alarm.
3. PSV-319A/B is
14.2.1.2.3
designed for reflux failure
case
2. FC 439 malfunctions to close 1. Refer 14.1.2.1 and 14.1.2.2
FCV-439
14.2.1
with high alarm.
Page 86 of 136
14.2.3.1.1
Remarks
In case TC/FC cascaded
rearrangement is accepted
then FC-439 low alarm is
there.
14.1.1.1.2
1. No hazardous consequences.
3. FC 441 malfunctions to close 1. V-008 level may go high

FCV-441.
Recommendations
1. AI-003 is provided on 14.1.1.1.1

gas oil product line.
2. TI-192 with low alarm

is provided.
2. Feed failure
Ref. No.
82. TBC from vendor

regarding the requirement
of min. flow to avoid
churning.
SEI
14. Stripper Overhead system
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 14
DESIGN INTENTION
DRAWINGS
CS-140-PR-15-0017,
2. Low/no flow of refluxCS-140-PR-15-0020, CS-140-PR-15-0021,CS-140-PR-15-0023
EQUIPMENT

STREAM DETAILS

SERVICE
Temperature(C)
Stripper Reflux
.
Pressure ( bar g)
Flow rate (Kg/hr)
45/140
45/140
9.5-11.5/15
6.0-11/15
9105
2956
Note:
Node
Deviation
Causes
LCV-540B/FCV-441
Consequences
Safeguards
1. V-008 level may go high causing

1. FI-438 with high alarm
overpressurization of stripper, liquid carryover is provided .
to V-010 and potential foaming in LP amine
absorber.
with low level alarm.
Ref. No.
14.2.4.1.1
Recommendations
Respons
ibility
Remarks
83.Consider providing
SEI
independent level
transmitters with high alarm
and delete the high alarm
from LC-540
1. Provide flow totalizer

(FI-446 & 441) with low
alarm
84.Consider Providing
independent level
transmitters with high
alarm and delete the high
alarm from LC-540
High level alarm to be

provided on magnetic LG541 with switch
2. High level alarm to be

14.2.4.1.2

high alarm.
3.
High Flow
1. FC 439 malfunctions to open 1. Column overhead temperature comes

FCV-439
down which lead to gas oil product off spec
(Flash point)
1.Low alarm at TI-192 is

provided.
14.3.1.1.1
with low alarm.
14.3.1.2.1
2. FC 441 malfunctions to open 1. V-008 level may go down

FCV-441
with low alarm.
14.3.2.1.1

LCV-540B/FCV-441
1. FC-441/FC-439 is
provided with Low alarm
14.3.3.1.1
2. V-008 level may come down and leading

to loss of reflux.
1. V-008 level may go down leading to loss

of reflux.
Page 87 of 136
SEI
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 14
DESIGN INTENTION
3. High Flow
DRAWINGS
EQUIPMENT

STREAM DETAILS


LCV-540B/FCV-441
SERVICE
Temperature(C)
Stripper Reflux
.
Pressure ( bar g)
Flow rate (Kg/hr)
45/140
45/140
9.5-11.5/15
6.0-11/15
9105
2956
Note:
Node
Deviation
Causes
Consequences
2. Pump will loose suction.
Safeguards
1. Sufficient time is
available for V-008 to
loose liq. Level.
Ref. No.
NA
14.4
5.
1. D/S disturbance(PCV-394A/B 1. Carry over of diesel in stripper overhead. 1. LC-540 is provided

full open)
heavies in wild naphtha to unit -160/200.No
with high alarm
hazardous consequences.
14.5.1.1.1
6. High
Temperature
1. EA-002 partial failure
2. P-004 discharge pressure will come down 1. Low pressure alarm

leading to increase of level in V-008.
PI-999 is provided at LP
amine absorber outlet.
14.5.1.2.1
1. Heavier hydrocarbon carryover with Off

gas leading to foaming in C-003.
1.FI-438 is provide with

high alarm
14.6.1.1.1
2.TI-208 is provided with

high alarm.
14.6.1.1.2
2. Level of V-008 may come down which

leads to reflux failure,
Respons
ibility
Remarks
14.3.3.1.1
Flow
Low Pressure
Recommendations
14.6.1.2
85.Consider Providing
independent level
transmitters with high
alarm and delete the high
alarm from LC-540
SEI
High level alarm to be

1. PSV-319A/B is
14.6.1.2.1
designed for reflux failure
case
high alarm
Page 88 of 136
86.Provide high temp alarm

on TI-192
SEI
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 14
DESIGN INTENTION
DRAWINGS
EQUIPMENT

6. High
Temperature
STREAM DETAILS

SERVICE
Temperature(C)
Stripper Reflux
.
Pressure ( bar g)
Flow rate (Kg/hr)
45/140
45/140
9.5-11.5/15
6.0-11/15
9105
2956
Note:
Node
Deviation
7. Low temp.
Causes
Consequences
Ref. No.
2.Reflux failure
1. Refer 14.6.1.2, 14.6.1.2.1 and 14.6.1.2.2
14.6.2.1
1. Refer 14.6.1.2, 14.6.1.2.1 and 14.6.1.2.2
14.6.3.1
1.U/S disturbances.
1. Lower temp at the top of stripper overhead 1.Corrosion inhibitor

line leading to Corrosion in stripper top trays. injection is provided.
14.7.1.1.1
2.Low alarm TI-192 is

provided.
2.Low temp. of feed

Safeguards
Recommendations
Respons
ibility
14.7.2.1.2
1. Stripper over head will ingress in cooling

water line
14.8.1.1
87.Confirm that
hydrocarbon detectors are
provided in cooling tower
area.
NOCL
1 Less corrosion inhibitor

injection
1. Corrosion of overhead line and

downstream air cooler
14.9.1.1
88.SOP to ensure that the

proper dosing rate is
maintained and confirmed
with proper lineup.
SEI/NOC
L
2. overdosing of corrosion
inhibitor
1. No major safety concerns.
14.9.2.1
Page 89 of 136
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 15
Makeup H2 Compressor System
DESIGN INTENTION
To supply Hydrogen to make-up Compressor supply from B/L.
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)
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 /120
20 /26
2457
Note:
Node
15. Makeup H2
Compressor system
Deviation
1.
Low/No Flow
Causes
1. U/S disturbance
Consequences
Safeguards
Ref. No.
1. Less/No hydrogen make up to reaction

section because compressor is in recycle
mode leading to low pressure in reaction
section.
1. FI-432 at hydrogen
makeup line from B/L, is
provided with low alarm.
15.1.1.1.1
2. Suction pressure of compressor may go

down
with low alarm
15.1.1.2.1
2. PZ-385/PZ-956 LL
alarm will activate UZ707 to trip K-001A/B
15.1.1.2.2
Recommendations
89. Provide low alarm at PI358A on separator drum.
Responsibility
SEI
Remarks
P&ID is to be updated for
HydroCOM signals.
3.Note-13 is provided in 15.1.1.2.3

P&ID stating that signals
from non running
compressor instruments
shall not be used for
control and trip of the
running compressor.
2. Running compressor K-001A/B trips
1. No hydrogen make up to reaction

section.
1.No safeguard till start

up of spare compressor
(spare compressor will
take time for startup).
15.1.2.1.1
90.Check the time required to SEI/NOCL

startup spare compressor .
1.DHU feed can be

maintained till hydrogen
pressure is available upto 63
bar. Meanwhile standby
compressor has to be started.
The start-up philosophy of
keeping the compressor in
standby condition accordingly.
2 Vendor P&ID is to be
updated for all operator
controls, DCS interfaces of
HydroCOM.
3. XZV-707 at compressor discharge line to
reaction section, malfunction to close
1. No hydrogen make up to reaction section 1. PC-974 is provided

with high alarm
15.1.3.1.1
2. Compressor discharge may experience

high pressure.
15.1.3.2.1
1. Spill back line is

provided.
2. FI-432 is provided with 15.1.3.2.2

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

section
1. FI-432 is provided
with low alarm
15.1.4.1.1
5. FC-431/ malfunctions to close FCV431(Spill back line)
1. System pressure may go high
with high alarm
15.1.5.1.1
Page 90 of 136
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 15
DESIGN INTENTION
DRAWINGS
CS-140-PR-15-0013, CS-140-PR-15-0014, CS-140-PR-15-0015
EQUIPMENT
STREAM DETAILS

SERVICE
Temperature(C)
Hydrogen from B.L.
.
Pressure ( bar g)
20 /26
5. FC-431/ malfunctions to close FCV431(Spill back line)
Note:
Node
Flow rate (Kg/hr)
45 /120
Deviation
Causes
1. System pressure may go high

Consequences
Safeguards
2. PSV-316/317 is
provided.
6.PC-383 /PC-974 malfunctions to close FCV431(Spill back line)
1. Low pressure in suction
7. PC-922 malfunction to close,

PCV-922,at the inlet line to hydrogen cooler
(hydrogen to Unit2500)
1. No major concern as this line is

NNF.
8. PC-922 malfunction to open

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

high pressure.
9. Demister choke-up
2. Low/no flow(V),P&ID-0014
1. Pressure buildup in KO drum.
Ref. No.
15.1.5.1.2
Recommendations
Responsibility
VENDOR
1. Low low alarm at PZ- 15.1.6.1.1

901 is provided to trip the
compressor.
15.1.7.1
1. PSV-952A/B is
provided.
15.1.8.1.1
with low alarm.
15.1.9.1.1
2. PSV-315 is provided.
15.1.9.1.2
3. PZ-901 is provided to
trip the compressor.
15.1.9.1.3
10. HydroCOM malfunctions to unload
1.Less flow to reaction section
1.U/S disturbances
1.Low suction pressure.
15.2.1.1
2.Compressor trip.
15.2.1.2
2.Suction strainer choking
2457
1.HydroCOM system can 15.1.10.1.1

be bypassed/spill back
system can operate with
100%
1.Low suction pressure.
1. PDI-901 is provided.
15.2.1.1
2. compressor trip., High rod load.
1. Low suction pressure

trip PZ-901 is provided.
15.2.2.2.1
3. High discharge temp.
1.High discharge temp.

alarm TIH-902 is
provided.
15.2.2.3.1

trip TIHH-903 is
provided.
15.2.2.3.2
Page 91 of 136
91.PT with high alarm is to be SEI

provided instead of PI-953.
92.Low pressure alarm at PC- SEI

358 is to be provided on V006.
Remarks
Vendor P&IDs are to be
updated for consistency in tag
no.
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 15
DESIGN INTENTION
DRAWINGS
CS-140-PR-15-0013,
CS-140-PR-15-0014, CS-140-PR-15-0015
2. Low/no flow(V),P&ID-0014
EQUIPMENT
STREAM DETAILS

2.Suction strainer choking
SERVICE
Temperature(C)
Hydrogen from B.L.
.
Pressure ( bar g)
Flow rate (Kg/hr)
45 /120
20 /26
2457
Note:
Node
Deviation
Causes
Consequences
4. High motor current
Safeguards
1.Motor overload trip is
provided (from MCC).
5. High rod load.

3.
High Flow
1. FC-431/PC-383/PC-974 malfunctions to
close FCV431(Makeup line)
1. Refer 15.1.5.1.1 and 15.1.5.1.2
4. High flow(V),P&ID-0014
15.2.2.4.1
1.High alarm on PI-904 is 15.3.1.1.1

provided.
15.3.1.1.2
15.3.2.1
1. Refer 15.1.4.1.1
2. High suction pressure
1.Interstage PSVs are

provided for each stage.
15.3.2.2.1
3. PC-922 malfunction to open

PCV-922(hydrogen to Unit2500)
1. Refer 15.1.7.1
15.3.3.1
4. PC-922 malfunction to close

PCV-922(Make up line)
1. Refer 15.1.6.1.1
15.3.4.1
1. Loss of loop pressure
2. High upstream pressure.
1.Spillback valve FCV431 is provided.
15.4.1.1
1. High interstage discharge pressure leading 1.PC-974 is provided

to high rod load.
15.4.2.1.1
2.PSV-901 A/B/C are

provided.
15.4.2.1.2
3.PI-902 high alarm is

provided.
15.4.2.1.3
1.High discharge temp.

alarm TIH-902 is
provided.
trip TIHH-903 is
provided.
15.4.2.2.1
2. Increase in interstage discharge temp.
Recommendations
15.2.2.5
2.High alarm on PC358(at separator outlet)

is provided.
2. FC-431/PC-383 /PC-974 malfunctions to
open FCV-431(Spill back line)
Ref. No.
Page 92 of 136
15.4.2.2.2
SEI
93.Confirm that the suction
system can either withstand
with the high suction pressure
and PSV is designed for the
same.
Responsibility
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 15
DESIGN INTENTION
DRAWINGS
CS-140-PR-15-0013, CS-140-PR-15-0014, CS-140-PR-15-0015
EQUIPMENT
4. High flow(V),P&ID-0014
STREAM DETAILS

SERVICE
Temperature(C)
Hydrogen from B.L.
.
Pressure ( bar g)
Flow rate (Kg/hr)
45 /120
20 /26
2457
Note:
Node
Deviation
Flow
Causes
7.
Low Pressure
Safeguards
Ref. No.
3. HydroCOM failure to load the machine fully.
1.Low suction pressure, High flow due to

sudden loading of machine it is possible that
machine may trip due to low suction
pressure.
1.Spillback valve FCV431 is provided. PC974 ,PC-383 are

provided.
1. K-001A/B trips.
1. Recycle gas containing H2S as well as

HCs may backflow in the system and
eventually may flow to hydrogen bullet.
1. NRV is provided in
15.5.1.1.1
make up hydrogen line to
Recycle gas.
2. U/S disturbance at Unit

1500(start up line to V-008)
Flow(V),P&ID-0014
Consequences
1. Off gas may back up in the system
2. UZ-707 will close

XZV- 707 when
compressor trips.
15.5.1.1.2
1.NRV is provided at the

junction of H-162 and P079 on line H-162.
15.5.2.1.1
Not applicable.
1. Compressor malfunctioning
15.4.3.1.1
16
1. Less makeup hydrogen flow to

Reaction section
1. PI-036/037 is
15.7.1.1.1
2. PZ-385A/956A is
15.7.1.1.2
provided with LL alarm to
activate UZ-707.
3. Note-13 is provided in 15.7.1.1.3

P&ID stating that signals
from non running
compressor instruments
shall not be used for
control and trip of the
running compressor.
8. Low pressure (V),P&ID-0014 Same as low flow.
9.
High Pressure
15.8
same as high flow
15.9
Page 93 of 136
Recommendations
Responsibility
94. HydroCOM vendor to

SEI/NEA
clarify for the consequences
of sudden loading and how tp
prevent tripping of
compressor and implement
solution to provide the same.
95. Consider forced PCV-922 SEI

close when compressor trips.
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 15
DESIGN INTENTION
DRAWINGS
CS-140-PR-15-0013, CS-140-PR-15-0014, CS-140-PR-15-0015
EQUIPMENT
STREAM DETAILS

SERVICE
Temperature(C)
Hydrogen from B.L.
.
Pressure ( bar g)
Flow rate (Kg/hr)
45 /120
20 /26
2457
Note:
Node
Deviation
Causes
Consequences
Safeguards
10.High pressure(V),P&ID-0014 same as high flow

11. High
Temperature
1. Cooling water failure in EE008A/B
Ref. No.
Recommendations
Responsibility
15.1
1. Compressor may get damaged
1. TI-904/954 provided
with high alarm.
15.11.1.1.1
2. TZ-903/953 HH alarm 15.11.1.1.2

will activate UZ-707/708.
2. Compressor valve (K-001A/B)

malfunctions
1. Compressor may get damage
1. TI-904/954 is
15.11.2.1.1
provided with High alarm
2. TZ-903/953 HH alarm 15.11.2.1.2

3. Cooling water failure in EE-004
with
HH alarm
15.11.3.1.1
2. TI-901/951 is
15.11.3.1.2
3. TZ-903/953 HH alarm 15.11.3.1.3

4. Cooling water failure in EE-009
1. Hydrogen to B.L will go at High

temperature, possible damage in d/s
with high alarm
15.11.4.1.1
5. U/S disturbance
1. TI-231/233 is
15.11.5.1.1
2. TI-180/182 is
15.11.5.1.2
provided with High alarm.
3. TZ-181/183 HH alarm 15.11.5.1.3

4. TZ-232/234 HH alarm 15.11.5.1.4

Will activate UZ-707.
12. High temp. (V),P&ID-0014
1.U/S disturbance.
1.Interstage discharge temp. high.
1. TZ-181/183 HH alarm 15.12.1.1

Page 94 of 136
96. Confirm that hydrocarbon NOCL

detectors are provided in
cooling tower area.
97.Provide High alarm at TI176.
SEI
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 15
DESIGN INTENTION
DRAWINGS
CS-140-PR-15-0013, CS-140-PR-15-0014, CS-140-PR-15-0015
EQUIPMENT
STREAM DETAILS

SERVICE
Temperature(C)
Hydrogen from B.L.
.
Note:
Node
Pressure ( bar g)
Flow rate (Kg/hr)
45 /120
12. High temp. (V),P&ID-0014

Deviation
20 /26
Causes
1.Interstage discharge temp. high.

Consequences
2.Suction valve leakage.
13.
High Level
1. Tube leak in EE-004 when machine is

down and water collection in KOD.
Safeguards
Ref. No.
2457
Recommendations
Responsibility
2. TI-904 is provided with 15.12.2.2

high alarm.
1. Compressor may get damage due to
carryover of liquid.
1. LI-527 is
15.13.1.1.1
provided with High alarm.
2. LZ-529 HH
alarm will activate UZ707 to trip compressor.
15.13.1.1.2
15.14.1.1.1
14. High Level(V),P&ID-0014
1.High level in 2nd stage suction KO pot( Tube 1. Compressor may get damage due to
leak in interstage cooler EE-008A/B when
carryover of liquid.
machine is down and water collection in KOD).
1.LAH-901 is provided.
1. Tube leak in EE- 004/008A/B/009 when unit 1. Hydrogen may ingress in cooling water.
is in running condition.
No major concern for
small leak. For major leak system will loose
hydrogen and compressor suction pressure
may go down.
with low alarm
15.15.1.1.1
98.Provide High high level

NEA
compressor trip for 2nd stage
suction vessel
99.Confirm that hydrocarbon

detectors are provided in
cooling tower area.
NOCL
100. provide low point drain

SEI
valve at the shell side outlet
of EE-009 and SOP to
ensure checking of leakage of
cooling water after any
maintenance.
1.Tube leak in interstage cooler EE-008A/008B

16.
Problem/Requirements(V),P&ID0014
1.No purging facility
15.16.1
1.Contamination
1. No safeguard
Page 95 of 136
15.17.1.1.1
101. Inspection opening of

VENDOR/SEI
2nd stage suction vessel shall
be located closer to the
vanepack for inspection
purpose.
102. Venting/purge facility to
flare at EE-009 outlet is to be
provided near B/L.
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 16
Chemical Injection package (Only DMDS package is covered in HAZOP. All the applicable recommendations in this node are applicable to other injection packages.
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
System

AVAILABLE CONTROL
SCHEME
Temperature(C)
Pressure ( bar g)
Flow rate (Kg/hr)
SERVICE
Sulfiding Agent
Antifoulant
Corrosion Inhibitor Antifoaming
Anti Oxidant
Ambient/65
Ambient /65
Ambient /65
Ambient/65
Ambient/65
1.5-7.5/13
0.0-4.0/6
0-10.8/13
0-11/12
0-7.5/10
1600
14.0
1.6
0.34/0.11
6.0
Note:
Node
Deviation
16. Chemical Injection System
1.
Low/No Flow
Causes
1. P-007A trips( during
sulfidation)
Consequences
1. Discharge pressure will go down.
Delaying in sulfiding process.
Safeguards
1. Sulfiding process is
attended activity, LG549 is provided for
monitoring.
Ref. No.
Recommendations
16.1.1.1.1
Responsibility
Remarks
1. Licensor recommends to
have flow meter in DMDS
supply line from pump
discharge.
2. It is suggested to have
installed spare for DMDS pump
as to ensure continuous
operation of pump during
startup period of 26 hrs.
Reliability is to be ensured if
ware
2. Stop alarm in DCS is

provided for DMDS injection
pumps.
2.
High Flow
Flow
4. Low pressure
5.
High Pressure
16.1.1.1.2
1. High stroke in P-007A
1. No significant consequences
1. Reverse flow from unit 400
1. possible contamination
1.NRV is provided on line

CC020 near B.L.
16.2.1.1
16.3.1.1.1
2. Reverse flow from P-001

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

line
16.3.2.1.1
2. Delay in sulfiding process (during

sulfiding operation)
1. NRV is provided on the

line
16.3.2.2.1
1.Same as no/low flow(*)
16.4.1
2. PCV-332 B failure to close
1. No nitrogen supply to tank leading to low

pressure.
1. PCV-332 A failure to close in

flare line.
1. Overpressurization of DMDS tank.
16.4.2.1
1. PI-304 with high alarm is

provided overhead of tank.
16.5.1.1.1/2
2. PSV-303 A/B are

provided.
2. External fire
1. Draining of the OSBL line to

be reviewed during detail
engineering of Unit 400.
16.5.2
Page 96 of 136
103. PI-304 to be provided SEI

with low pressure alarm.
16. Chemical Injection System
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 16
Chemical Injection package (Only DMDS package is covered in HAZOP. All the applicable recommendations in this node are applicable to other injection packages.
DESIGN INTENTION
Chemical injection to prevent Corrosion/undesirable upsets in process.
DRAWINGS
CS-140-PR-15-0023, CS-140-PR-15-0025
EQUIPMENT
System
STREAM DETAILS
System

AVAILABLE CONTROL
SCHEME
Temperature(C)
Pressure ( bar g)
Flow rate (Kg/hr)
SERVICE
Sulfiding Agent
Antifoulant
Corrosion Inhibitor Antifoaming
Anti Oxidant
Ambient/65
Ambient /65
Ambient /65
Ambient/65
Ambient/65
1.5-7.5/13
0.0-4.0/6
0-10.8/13
0-11/12
0-7.5/10
1600
14.0
1.6
0.34/0.11
6.0
Note:
Node
Deviation
6.
Low Level
7.High level
Causes
Consequences
Safeguards
1. No significant cause as the

operation is required during
startup only
Ref. No.
Recommendations
Responsibility
16.6.1
1. Continuous filling from tanker 1.Over filling of drum leading to

overpressurization of DMDS tank.

high alarm.
16.7.1.1.1/2
2. PSV-303A/B design covers

overfill case.
8. Low temperature
No major issues.
16.8
9. High temperature
No major issues.
16.9
10. Composition
No major issues.
16.1
11. Others
1.Blockage of carbon canister in

the vent line.
1.Over pressurization of chemical injection

drums.
16.11.1.1
Page 97 of 136
104. Ensure that blockage NOCL

of carbon canister is not
possible.
Remarks
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 (during startup only) 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-820,PC-823,UC-001

SERVICE
Temperature(C)
Fuel Gas
Fuel Oil
Pressure ( bar g)
Flow rate (Kg/hr)
25/70
180/210
3.5/5
11/18
416
615
Note:
Node
17. Fuel oil, Fuel gas and
Heater Firing System
Deviation
1.
Low/No Flow (Fuel Gas)
Causes
1. PC -820 malfunctions to
close
PCV-820(fuel gas line)
Consequences
Safeguards
Ref. No.
1. Loss of firing of fuel gas leading to

process upset/Heater shut down.
1. PZ-821 (2oo3) is provided

with low low alarm to activate
UZ-718.
17.1.1.1.1
2. Fuel gas pressure will come down.
1. PZ-821 is low low alarm to

activate UZ-718.
17.1.1.2.1
2. XZV-718A/C malfunctions to
close (fuel gas line)
1. Refer 17.1.1.1.1 and 17.1.1.2.1
3.PCV-830 in pilot line

malfunctions to close
1.Loss of pilot gas to all the burners.

with low low alarm to activate
UZ-718.
17.1.3.1.1
4. XZV-718E/F malfunctions to
close (pilot gas line)
1. Pilot flame loss, leading to heater trip.
1. Pilot flame scanner (BZS001/002/003) is provided with

scanner alarm. Also if all the
pilots are off, heater trip is
provided through UZ-718.
17.1.4.1.1
Recommendations
Responsibilit
y
Remarks
17.1.2.1
2. PZ-823 is provided with low 17.1.4.1.2

low alarm to
activate UZ-718.
3. Deviation alarm is provided
for XZV-718 E/F.
5. PC-823 malfunctions to close 1. Loss of firing of fuel oil may lead to
PCV-823A(Fuel oil line) ,during
startup operation upset
startup case .
17.1.4.1.3
1. Low-oil pressure alarm at PI- 17.1.5.1.1

869 is provided.
Page 98 of 136
Fuel gas is provided as

alternate fuel to provide
adequate firing from
UC-001.
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 17
DESIGN INTENTION
DRAWINGS
CS-140-PR-15-0024, CS-140-PR-15-0026
EQUIPMENT
STREAM DETAILS


SERVICE
Temperature(C)
Fuel Gas
Fuel Oil
Pressure ( bar g)
Flow rate (Kg/hr)
25/70
180/210
3.5/5
11/18
416
615
5. PC-823 malfunctions to close

startup case .
Note:
Node
Deviation
Causes
Consequences
2. Fuel oil pressure may come down.
6. XZV-718N malfunctions to
close (Fuel oil line)
Safeguards
Ref. No.
17.1.6.1
7. PDC-826(on fuel oil and

1. Loss of fuel oil flame due to failure of
atomizing steam) malfunctions to atomizing steam.
close
PCV-826
2. Fuel oil spillage in heater leading to
burner tip choking.
1. PDZ-860 is provided with

low low alarm to activate UZ718.
8. Strainer choking.
1. PDI -827 is provided with

high alarm (Fuel gas line)
17.1.8.1.1
2. PDI-857 is provided with

high alarm (Fuel oil line)
17.1.8.1.2
3. All strainers are provided

with spare for change over.
17.1.8.1.3
9. PC-899/HCV-830
malfunctions to close.
1. Box pressure will increase.
Responsibilit
y
1. PZ-858 is provided with low 17.1.5.2.1

low alarm to
activate UZ-718.
1. Refer 17.1.4.1.1 ~ 3
1. Possible loss of fuel gas/oil leading to

flame failure.
Recommendations
17.1.7.1.1
17.1.7.2.1

17.1.9.1.1
with HH alarm to activate to trip
UZ-718.
105.Provide additional
flushing oil return taping
upstream of XZV-718 M
for flushing.
SEI
106. Damper open/close

indications are provided
(P&ID is to be updated
accordingly).
SEI
107. Startup and shut

down overrides for
damper control will be
included in P&ID note.
Page 99 of 136
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 17
DESIGN INTENTION
DRAWINGS
CS-140-PR-15-0024, CS-140-PR-15-0026
EQUIPMENT
STREAM DETAILS


9. PC-899/HCV-830
malfunctions to close.
Temperature(C)
SERVICE
Fuel Gas
Fuel Oil
Pressure ( bar g)
Flow rate (Kg/hr)
25/70
180/210
3.5/5
11/18
416
615
Note:
Node
Deviation
Causes
10. 180-FA-001C/D Choking
2.
High Flow
Consequences
3. PDC-826 malfunctions to
open
PCV-826
Ref. No.
2. Less air flow may lead to incomplete

combustion.
1. AI-004 provided for

monitoring.
17.1.9.2.1
3. Box temperature likely to increase
1. TI-102 is provided with high

alarm.
17.1.9.3.1
1. Unit 1800 may get disturbed (No

consequence related to DHU).
1. PDI-010 is provided with

high alarm
17.1.10.1.1
2. Spare Flame arrestor is

provided.
17.1.10.1.2
1. PDZ-860 with LL alarm will

activate UZ-718.
17.2.1.1.1
2. HH oil pressure trip is

provided(UZ-718.)
17.2.1.1.2
1. Hard firing may occur, leading to higher

Tube metal temperature.
1. Skin temp. indications are

provided with high alarm.
17.2.2.1.1
2. Fuel gas line operating pressure will

increase
2. PZ-821 HH alarm will

activate UZ-718 to trip heater.
17.2.2.2.2
1. Flame lifting/improper atomization may

occur, leading to higher Tube metal
temperature.
1. Skin temp. indications are

provided.
17.2.3.1.1
1. PC-823 malfunctions to open 1. Possible Improper atomization may lead

PCV-823A(Fuel oil line), during
to flame loss.
start up operation only.
open PCV-820(fuel gas line)
Safeguards
Page 100 of 136
Recommendations
108. Low oxygen alarm at
AI-004 is to be provided
Responsibilit
y
SEI
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 17
DESIGN INTENTION
DRAWINGS
CS-140-PR-15-0024, CS-140-PR-15-0026
EQUIPMENT
STREAM DETAILS


SERVICE
Temperature(C)
Fuel Gas
Fuel Oil
Pressure ( bar g)
Flow rate (Kg/hr)
25/70
180/210
3.5/5
11/18
416
615
Note:
Node
Deviation
Causes
4. PC-899/HCV-830
malfunctions to open.
3. Reverse/Misdirected flow
4.
Low Pressure
5. High pressure
1.High fuel oil pressure.
Consequences
Safeguards
Ref. No.
2. Steam line operating pressure will

increase
2. High alarm at PI-863 is

provided.
17.2.3.2.2
1. Fuel efficiency may decrease.
1. Oxygen analyzer AI-004 is

provided for monitoring
17.2.4.1.1
2. Draft will be increased, no major safety

concern.
1. Damper open/close
indications are provided.
17.2.4.2.1
1.Fuel oil back flow in steam line as the

steam pressure is constant.
1. PZ-858 with HH alarm will

activate UZ-718.
17.3.1.1.1
2.Check valve in steam line is

provided for individual burner.
17.3.1.1.2
1. Flame Arrester 180-FA001 is provided.
17.4.1.1.1
1. U/S disturbance (off gas

from
LPG Merox)
1. Flame may propagate back to line
close
PCV-820(fuel gas line)
1. Refer 17.1.1.1.1 and 17.1.1.2.1
17.4.2.1
3. PC-823 malfunctions to close

startup case .
1. Refer 17.1.1.1.1 and 17.1.1.2.1
17.4.3.1
1. Refer 17.2.1.1.1 and

17.2.1.1.2
17.5.1
2. Refer 17.2.2.1.1 and

17.2.2.2.2
17.5.2
3. Refer 17.2.3.1.1 and

17.2.3.2.2
17.5.3
Page 101 of 136
Recommendations
Responsibilit
y
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 17
DESIGN INTENTION
DRAWINGS
CS-140-PR-15-0024, CS-140-PR-15-0026
EQUIPMENT
STREAM DETAILS


SERVICE
Temperature(C)
Fuel Gas
Fuel Oil
Pressure ( bar g)
Flow rate (Kg/hr)
25/70
180/210
3.5/5
11/18
416
615
Note:
Node
Deviation
6. Low
Temperature
Causes
1. U/S disturbance (fuel gas
line)
2. U/S disturbance (fuel oil line)
Consequences
1. Carryover of condensate with
fuel gas line leading to backfiring in the
furnace.
1. Increase in fuel oil viscosity leading to
improper atomization and sooty flame.
Safeguards
1. Fuel gas KOD is provided
and Steam tracing is also
provided d/s V-025.
17.6.1.1.1
1.Low alarm at TI-832 is

provided.
17.6.2.1.1
3. Steam tracing failure in fuel

oil line.
7. High
Temperature
1. U/S disturbance (Fuel oil

supply)
8. Low level
No new cause.
9.
1. High level in V-025
High Level
Ref. No.
Recommendations
Responsibilit
y
17.6.3
1. Fuel oil temp increases leading to

vaporization of low boiling point components
may result in vapor lock in the burner.
17.7.1.1
109.Ensure that upstream

system is properly
monitored to avoid any
vaporization.
NOCL
17.8
1. Liquid may carry over with fuel gas
10. Problem/Requirements (Soot 1. Low/No flow of M.P steam to 1. Soot blowing will not be possible leading
blower)
soot blower(Fuel oil operation
to lower heat transfer.
only).

High alarm
17.9.1.1.1
2. LZ-810 HH alarm will

activate UZ-718.
17.9.1.1.2
1. PI-730 is provided with low

low alarm.
17.10.1.1.1
2. Low low temp. alarm at TI725 is provided.
17.10.1.1.2
Page 102 of 136
110.MP steam for soot

blower tapping to be
downstream of FI-409.
(P&ID to be updated).
SEI
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 17
DESIGN INTENTION
DRAWINGS
CS-140-PR-15-0024, CS-140-PR-15-0026
EQUIPMENT
STREAM DETAILS


SERVICE
Temperature(C)
Fuel Gas
Fuel Oil
Pressure ( bar g)
Flow rate (Kg/hr)
25/70
180/210
3.5/5
11/18
416
615
Note:
Node
Deviation
Causes
Consequences
Safeguards
(Decoking system is not
HAZOPed as it is manual &
attended operation)
(heater maintenance)
Ref. No.
17.11
1.Provide spectacle blind at the

inlet of Fuel gas KOD to ensure
positive isolation.
Page 103 of 136
17.12.1
Recommendations
Responsibilit
y
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
NODE NO: 18
DESIGN INTENTION
To supply HP steam ,MP steam and MP BFW
DRAWINGS
CS-140-PR-15-0030
EQUIPMENT
Distribution system, 140-DS-001
STREAM DETAILS
HP steam, MP Steam and MP BFW will be supplied from B/L to Unit.
TCV-239
Project :

SERVICE
Temperature(C)
HP STEAM
MP STEAM
MP BFW
Pressure ( bar g)
388/405
184/252
128/150
Flow rate (Kg/hr)

53.5/58
10/12
24/35
27437
1500
7687
Note:
Node
18.
HP/MP Steam
& MP BFW
Deviation
1.
Low/No Flow
Causes
1. U/S disturbance (HP Steam supply
failure)
2. U/S disturbance (MP Steam supply

from OSBL fails)
Consequences
Safeguards
Ref. No.
1. KT-002 trips
with low alarm.
2. MP steam not available to stripper

leading to poor stripping and off spec
product.
1. Low flow alarm at FI- 18.1.1.2.1

804A/B is provided.
3 No MP steam available to DS-001.
1. XZV-835 in MP
boiler feed water line
closes if RGC turbine
trips(UZ-705)
1. No supply of atomization steam to fuel oil

in Fired heater
18.1.1.1.1
18.1.1.3.1
18.1.2.1.1
1. FI-804A is provided
with low alarm
with low alarm.
2. No supply of MP steam to soot-blower
when required.
18.1.2.2.2
Page 104 of 136
Recommendations
Responsibility
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
NODE NO: 18
18. HP/MP Steam

DESIGN INTENTION
& MP BFW
1.
Low/No
To supply
HPFlow
steam ,MP steam and MP BFW
DRAWINGS
CS-140-PR-15-0030
EQUIPMENT
STREAM DETAILS
TCV-239
Project :

2. U/S disturbance (MP Steam supply
from OSBL fails)
Temperature(C)
SERVICE
HP STEAM
MP STEAM
MP BFW
Pressure ( bar g)
388/405
184/252
128/150
Flow rate (Kg/hr)

53.5/58
10/12
24/35
27437
1500
7687
Note:
Node
Deviation
Causes
Consequences
Safeguards
Ref. No.
3. No MP steam supply leading to lube oil

pump turbine (of RGC) trip.
1.It will automatically

changeover to motor
operated lube oil
pump.
4. RGC turbine back pressure reduces ,

leading to turbine failure.
1. HH turbine speed
18.1.2.4.1
trip SZ-002 is provided.
Page 105 of 136
Responsibility
111.HH pressure trip PZ678A/B/C requirement is to

be reviewed from vendor
in view of turbine back
pressure.
BHEL/SEI
18.1.2.3.1
18.1.2.4.2
2. Low low back
pressure trip PZ678A/B/C is provided.
Recommendations
Remarks
18.
HP/MP Steam
& MP BFW
1.
Low/No Flow
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
NODE NO: 18
DESIGN INTENTION
DRAWINGS
CS-140-PR-15-0030
EQUIPMENT
STREAM DETAILS
TCV-239
Project :

SERVICE
Temperature(C)
HP STEAM
MP STEAM
MP BFW
Pressure ( bar g)
388/405
184/252
128/150
Flow rate (Kg/hr)

53.5/58
10/12
24/35
27437
1500
7687
Note:
Node
Deviation
Causes
Consequences
Safeguards
Ref. No.
3. U/S disturbance (MP BFW supply

from OSBL fails)
1. MP steam temp. will be high. No major

consequence as the design temp. takes care
of turbine exhaust.
18.1.3.1
4. TC-239 malfunctions to close

TCV-239
1. Refer 18.1.3.1
18.1.4.1
1. TC-239 malfunctions to open

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

leading to hammering.
1. Steam trap is
provided.
18.2.1.1.1
3. Reverse/Misdirected flow.
1.Turbine trip.
1.Header steam will come back to turbine

and stripper.
1.Check valves are

provided.
18.3.1.1.1
4.
Low Pressure
1. Same as low/no flow
18.4.1
5.
High Pressure
1. Refer 18.2.1.1.1
18.5.1
2.
High Flow
Page 106 of 136
Recommendations
112.Line from
Desuperheater
downstream upto steam
trap is to be designed for
two phase flow.
Responsibility
SEI
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
NODE NO: 18
DESIGN INTENTION
DRAWINGS
CS-140-PR-15-0030
EQUIPMENT
STREAM DETAILS
TCV-239
Project :

SERVICE
Temperature(C)
HP STEAM
MP STEAM
MP BFW
Pressure ( bar g)
Flow rate (Kg/hr)
388/405
184/252
128/150
53.5/58
10/12
24/35
27437
1500
7687
Note:
Node
Deviation
6. Low temp.
Causes
1.Upset in U/S desuperheater
Consequences
Safeguards
Ref. No.
Recommendations
Responsibility
BHEL
1.Steam turbine efficiency reduces.
18.6.1.1
113. Vendor to provide

min. temp. of steam
acceptable at turbine inlet,
irrespective of min.
operating temp. specified
in B/L condition.
2.Low temp may lead to less superheat

steam to turbine likely to condense within the
turbine and damage the blades
18.6.1.2
114. TI-627 is to be
provided with low temp.
alarm in DCS.
7. High temp.
No significant cause.
18.7
8. Composition
NA
18.8
9. Others
NA
18.9
Page 107 of 136
SEI
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
NODE NO: 19
Cooling Water System
DESIGN INTENTION
Cooling water supply to exchangers
DRAWINGS
CS-140-PR-15-0032
EQUIPMENT
Cooling water distribution
STREAM DETAILS
Cooling water is supplied to all cooling water exchangers from B/L and similarly cooling water return from all exchangers to header
Project :

SERVICE
Temperature(C)
Cooling water supply
Cooling water return
Pressure ( bar g)
Flow rate (Kg/hr)
33/70
44/70
4/7
3/7
688411
688411
Note:
Node
19. Cooling water system
Deviation
1.
Low/No Flow
Causes
Consequences
Safeguards
Ref. No.
1. U/S disturbance
1. Cooling water exchangers will be starved 1. PI-816 is provided

leading to high run down/downstream temp. with low alarm
2.High flow
1. U/S disturbance
1. No major safety consequences.
3.Reverse/Misdirected flow
1. No significant causes
identified.
19.3.1
4.Low pressure
1. Refer 19.1.1.1.1
19.4.1
5.High pressure
1. Refer 19.2.1.1
19.5.1
2. Blockage in return line of

individual heat exchangers.
1.Return line may see high pressure due to

thermal expansion.
6.Low temp.
1. No significant causes
identified.
7. High
Temperature
1. High inlet temp.
1. Desired cooling of process stream is not

achieved in water cooled exchangers
2. High return temp.
1. Expected high return temperature of

cooling water
19.1.1.1.1
19.2.1.1
1. TSVs are provided on

return line of individual
exchangers.
19.5.2.1.1
19.6.1
1. High temp. alarm on

process outlet side is
provided on all critical
cooling water
exchangers
19.7.1.1.1
2. TI-816 is provided for

monitoring.
19.7.1.1.2

high alarm
Page 108 of 136
Recommendations
Responsibility
Remarks
7. High
Temperature
Node
Deviation
2. High return temp.

Causes
Consequences
Safeguards
2. Individual cooler outlet temp. can be high 1. High temp. alarm on

because of the fouling of cooler.
process outlet side is
provided on all critical
cooling water
exchangers
Ref. No.
Recommendations
Responsibility
19.7.2.2.1
8.Low level
NA
19.8
9. High level
NA
19.9
1. Possibilities of cooling water

misdistribution
1. Insufficient cooling in some exchangers
11.Composition
1. Water going to process side.
1. Possible process feed contamination
19.11.1.1
115. SOP to ensure checking of

leakage of cooling water after any
maintenance.
SEI/NOCL
2. process feed going to water

side
1. Process fluid may ingress in cooling

water. No major concern for
small leak. For major leak system will loose
process fluid/HC will go to cooling tower area
leading to fire and explosion.
19.11.2.1
116.Confirm that hydrocarbon

detectors are provided in cooling
tower area.
NOCL
1.Hydraulic Check is
carried out based on
actual plant layout.
12.Others
19.10.1.1.1
19.12
1. Unit shut down, cooling water
header maintenance.
1. Loss of circulation may lead to loss of

protective coating in cooling water line.
19.13.1.1
Page 109 of 136
117. Provide 3" jumpover

connection line (with valve and
spec. blind) between cooling water
supply and return headers near
dead end. Jumpover will be used
for initial passivation during
commissioning.
SEI
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 20
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)
152/200
Amb. /65
Amb./65
Amb./66
Amb./66
Amb/65
Flow rate (Kg/hr)

4/6
3/8
3/8
4.9/9
6.1/10
8/10
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
Safeguards
Ref. No.
1. U/S disturbance (Potable

water)
20.1.1.1
2. U/S disturbance (Service

water)
20.1.2.1
3. U/S disturbance (Plant Air)
4. U/S disturbance (Instrument 1. Instrument air pressure will come down

Air)
leading to unit shut down
20.1.3.1
1. PI-802 is provided 20.1.4.1.1
with low alarm.
2. Instrument air
backup for 20 min. is 20.1.4.1.2
provided from OSBL.
3. All instruments will
go to fail safe mode.
20.1.4.1.3
5. U/S disturbance (Nitrogen)
1. No/low pressure of nitrogen for blanketing 1. PI-806 is provided 20.1.5.1.1

and purging (refer individual nodes for
with low alarm.
possible consequences).
Page 110 of 136
Recommendations
Responsibility
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 20
DESIGN INTENTION
DRAWINGS
20.
Portable/Service Water, LP
Steam,
Plant/Instrument
Air
EQUIPMENT
and Nitrogen
CS-140-PR-15-0031,
CS-140-PR-15-0033, CS-140-PR-15-0034
1.
Low/No Flow
STREAM DETAILS


SERVICE
Temperature(C)
LP steam
Service water
Potable water
Plant air
Instrument air
Nitrogen
Pressure ( bar g)
152/200
Amb. /65
Amb./65
Amb./66
Amb./66
Amb/65
Flow rate (Kg/hr)

4/6
3/8
3/8
4.9/9
6.1/10
8/10
2818
1000(1)
1000(1)
518
215
430(2)

Node
Deviation
Causes
6.
Consequences
U/S disturbance (LP Steam) 1. No/Low flow in header will result in low
pressure of snuffing/purging steam available
when required
Safeguards
Ref. No.
1. PI-846 is provided 20.1.6.1.1

with low alarm.
2. High flow
1. No significant cause
20.2.1
3. Reverse/misdirected flow
20.3.1
4. Low pressure
1. Same as low/no flow
20.4.1
5. High Pressure
20.5.1
6. Low level
1. NA
7. High level
1. NA
8. Composition
1. NA
Page 111 of 136
Recommendations
Responsibility
Remarks
20. Portable/Service Water, LP

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

EQUIPMENT
STREAM DETAILS

SERVICE
Temperature(C)
LP steam
Service water
Potable water
Plant air
Instrument air
Nitrogen
Pressure ( bar g)
152/200
Amb. /65
Amb./65
Amb./66
Amb./66
Amb/65
Flow rate (Kg/hr)

4/6
3/8
3/8
4.9/9
6.1/10
8/10
2818
1000(1)
1000(1)
518
215
430(2)

Node
Deviation
9. Others
Causes
1. wrong connection for hoses
Consequences
1. Hazardous consequence if nitrogen is
connected when air is required.
Safeguards
Ref. No.
20.9.1.1
Page 112 of 136
Recommendations
118. Ensure different
connections are available
for air and nitrogen hose
stations to avoid wrong
connections.
Responsibility
SEI
Remarks
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.
Low/No Flow
2. High flow
45
57/250
5.5/14.5
57
Causes
Consequences
Safeguards
Ref. No.
1. U/S disturbance(No flow of

fuel gas to flare header)
1. No purge available to dead end of flare

header leading to possible air ingress into
flare header.
2. LS-806 malfunctions and P015A/B is not started when

required.
1. V-023 level may increase leading to liquid 1. LI-805 provided with

overloading in flare header and downstream high high alarm.
system.
21.1.2.1.1
1. PSV pop up,depressurization
1. More flaring,condensation in flare KOD

leading to high level.
1. Pump to autostart on
high level.
21.2.1.1.1
2. LI-805 provided with

high high alarm.
21.2.1.1.2
3. Low pressure
1. No significant causes identified
4. High pressure
1. Refer 21.2.1.1.1 and

21.2.1.1.2
1. LS-806 malfunctions ,not
stopping the pump-015A/B.
5. Low Level
Flow rate (Kg/hr)

0.25/3.5

Node
Deviation
21.
Pressure ( bar g)
45/250
1.Low alarm at PI-854

(located at Fuel gas B.L.)
is provided.
21.1.1.1.1
2. Nitrogen backup is
available.
21.1.1.1.2
Recommendations
Responsibility
21.3.1
21.4.1
1. Pump will run dry.
1. LI-805 is provided with 21.5.1.1.1

LL alarm.
6. High level
1. Refer 21.1.2.1.1, 21.2.1.1.1

and 21.2.1.1.2
21.6.1
7. Low temp.
21.7.1
8. High temp.
21.8.1
119. SOP to ensure Manual

intervention of HS-908
SEI/NOCL
Remarks
21.
Flare system
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
Pressure ( bar g)
Flow rate (Kg/hr)
45/250
0.25/3.5
45
57/250
5.5/14.5
57

Node
Deviation
9. Composition
1. NA
10.Others
1. NA
Causes
Consequences
Safeguards
Ref. No.
Recommendations
Responsibility
Remarks
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)
57/120
Amine
Flow rate (Kg/hr)
0.25/3.5
27634
Note:
Node
22. Amine drain system
Deviation
Causes
Consequences
Safeguards
Ref. No.
1. Low/No Flow of drained amine 1. LS-801 malfunctions, not

starting P-014A
1. Level of V-022 will increase
22.1.1.1
2. Low/No flow of nitrogen
1. U/S disturbance
1. Loss of nitrogen blanketing leading to likely 1. Low pressure alam 22.2.1.1.1

degradation of amine.
at PI-806 is provided.
3. High flow of nitrogen
1. U/S disturbance
1. Pressure is likely to increase.
1. RO-801 is
provided.
22.3.1.1.1
2. Vessel is floating
with flare header.
22.3.1.1.2
Flow
1. No new cause
5. Low Level

stopping the pump-014A
6. High level
1. Refer 22.1.1.1
7. Low temp.
1.No significant cause
8 .High temp.
1. U/S disturbance
9.Low pressure
22.9.1
10.High pressure
1. Refer 22.3.1.1.1 and

22.3.1.1.2
22.10.1
11.Composition
Recommendations
Responsibility
120. Provide high high alarm at

LI-800
SEI
121. Provide low low alarm at

LI-801
SEI
22.4.1
1. Pump may run dry
22.5.1.1
22.6.1
22.7.1
1. Likely to degrade amine.
1. TI-813A is provided 22.8.1.1.1

with high alarm.
Remarks
22. Amine drain system
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)
57/120
Amine
Flow rate (Kg/hr)
0.25/3.5
27634
Note:
Node
Deviation
Causes
12. Others
Consequences
Safeguards
Ref. No.
Recommendations
Responsibility
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 23
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)
40/150
Flow rate (Kg/hr)

0.25/3.5
7500
Note:
Node
23. Hydrocarbon drain system
Deviation
Causes
Consequences
Safeguards
1. Low/No Flow of HC from

pump discharge
1. LS-802 malfunctions, not

starting P-013A
1. Level of V-021 will increase
2. Low/No flow of nitrogen
1. U/S disturbance
1. Loss of nitrogen blanketing leading to likely 1. Low pressure alam 23.2.1.1.1

ingress of air.
at PI-806 is provided.
3. High flow of nitrogen
1. U/S disturbance
1. Pressure is likely to increase.
Flow
1. Possible backup of CBD pump

discharge to flare KOD via
pump(P-015) min. flow line
23.4.1
5. Low temp.
23.5.1
6. High
Temperature
1. Draining hot HC material
1. System may experience higher than the

design temperature
2. Steam coil operation
1. LI on V-021 is
provided.
Ref. No.
1. RO-802 is
provided.
Responsibility
122. Provide high high alarm at

LI-902
SEI
123. Provide NRV in the flare

KOD pump discharge line no.
P803 near to tie in point to slop
header.
SEI

should prevent draining of hot
hydrocarbon in Hydrocarbon
drain drum.
SEI/NOCL
Remarks
23.3.1.1.1
1. TI-820 is provided 23.6.1.1.1

with high alarm
1. Cooling water
provision is there.
1. Pump may run dry
23.1.1.1.1
Recommendations
23.6.2.1.1
7. Low Level

stopping the pump-013A
23.7.1.1
8. High level
1. Refer 23.1.1.1.1
23.8.1
9. Low pressure
23.9.1
Flushing oil return

connection is to be relocated
on line P-803.
Cooling water permanent

piping is to be removes as
per project philosophy
125. Provide low low alarm at
LI-902
SEI
23. Hydrocarbon drain system
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 23
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)
40/150
Flow rate (Kg/hr)

0.25/3.5
7500
Note:
Node
Deviation
Causes
10. High pressure
1. Refer 23.3.1.1.1
11. Composition
12. Others
13 . Problem/Requirements
Consequences
Safeguards
Ref. No.
23.10.1
Recommendations
Responsibility
Remarks
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)
Pressure ( bar g)
Flow rate (Kg/hr)

1030
Condensate (Water) in LP/MP

condensate header
Condensate (Water) in HP
condensate header
102/252
0.1/3.5
102/405
0.1/3.5
350
Note:
Node
24. Condensate Collection
system
Deviation
Causes
1. Low/No Flow
1. No new cause
2. High flow
1. No new cause
3. Low pressure
1. No new cause
4. High pressure
1. No new cause
5. Low Level
1. No new cause
6. High level
1. No new cause
7. Low temp.
1. No new cause
8. High temp.
1. Coolling water failure
9. Composition
1. No new cause
10.Others
1. No new cause
Consequences
1. High temp condensate routed to storm

sewer.Possible damage to coating inside the
headers.
Safeguards
Ref. No.
1. Low pressure alarm

24.8.1.1.1
at PI-816 is provided
Recommendations
Responsibility
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
NODE NO: 25
DESIGN INTENTION
To supply lube oil to cylinders and packings
DRAWINGS
CS-140-PR-D-06600002
EQUIPMENT
140-K-001A/B
Project :

STREAM DETAILS
Operating Parameters
SERVICE
Temperature(C)
Pressure ( bar g)
50
Lube oil
.
Note:
Node
25. Makeup H2
Compressor -Lube oil system
Flow rate (Kg/hr)
a} 3 barg for bearings and cross head.
Deviation
Causes
Consequences
1. Low/No Flow
1. Crank case main lube oil

pump failure.
1. Less lube oil flow and pressure.
Safeguards
Ref. No.
1. Aux. pump with auto

start is provided.
25.1.1.1.1

low alarm.
25.1.1.1.2
3. Low low pressure (PT905A/B/C, 2 out of 3) trip

the compressor.
25.1.1.1.3
2. Suction strainer upstream of

aux. pump choking.
1. Less lube oil flow and pressure leading to

compressor damage.
25.1.2.1
3. Cooler leak

compressor damage.
1. Cooler is designed
following API 10/13 rule.
25.1.3.1.1
4. TCV-901 failure close

compressor damage.
1. Thermostatic self
actuating type of
valve,During any type of
failure two ports are
available.
25.1.4.1.1
5. PCV-901 failure close

compressor damage.

low alarm.
Recommendations
126. Provide differential

pressure gauge across the
suction strainer.
Responsibility
NEA
Remarks
25. Makeup H2
Compressor -Lube oil system
1. Low/No Flow
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
NODE NO: 25
DESIGN INTENTION
DRAWINGS
CS-140-PR-D-06600002
EQUIPMENT
140-K-001A/B
Project :

STREAM DETAILS
SERVICE
Temperature(C)
Pressure ( bar g)
50
Lube oil
.
Note:
Node
Deviation
Causes
Flow rate (Kg/hr)
Consequences
Safeguards
Ref. No.
Recommendations
Responsibility
2. Low low pressure (PT- 25.1.5.1.2

905A/B/C, 2 out of 3) trip
the compressor.
6. Lube oil filter choked

compressor damage.
1.PDI 903 is provided

with high alarm.
25.1.6.1.1
2. Spare filter is provided 25.1.6.1.2

low alarm.
the compressor.
2.
High Flow
7. Lubricator failure
1. No supply of lube oil to cylinders.
1. PCV-901 failure to open
1. No significant consequances.
1.FAL-901 is provided.
25.1.7.1.1
25.2.1.1
Flow
1. No significant causes.
25.3.1
4.
Low Pressure
1. Same as No/low flow
25.4.1
5.
High Pressure
1. Any blockage in the system
6. High
Temperature
1. Cooling water to lube oil

cooler failure.
1. PSV-907/908 is
provided
1. Reduced lubrication effect leading to
damage to compressor parts at high temp.
(beyond 60 C).
25.5.1.1
1. TI-935 with high alarm 25.6.1.1.1

is provided.
127. Consider set point

change to 8.7 barg as per
project philosophy.
NEA
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
NODE NO: 25
DESIGN INTENTION
DRAWINGS
CS-140-PR-D-06600002
EQUIPMENT
140-K-001A/B
Project :

STREAM DETAILS
SERVICE
Temperature(C)
Pressure ( bar g)
50
Lube oil
.
Note:
Node
6. High
Temperature
Deviation
Causes
Consequences
Safeguards
2. Malfunction of TCV-901
7.
High Level
8. Low level
Ref. No.
Recommendations
Responsibility
128. Trip of aux. pump with

time delay is to be ensured
when compressor is
tripped(refer vendor cause
and effect diagram).
NEA
NEA
25.6.2
1. Low level in oil reservoir
due to leakage in lube oil
system.
Flow rate (Kg/hr)
25.7.1
compressor damage.
1.Low level alarm LAL902 is provided.
25.8.1.1.1

the compressor.
2. Low level in cylinder

lubricator
1. Reduced supply of lube oil to cylinders.
10. Composition
1. Lube oil cooler tube leak.
1. Lube oil leak to cooling water
25.10.1.1
129. Manual sampling

arrangement is to be
provided.
1. Improper Oil specification

(Compatibility with Process)
1. Poor Lubrication.
Leakage of Oil to Process may contaminate
the process fluid leading to off spec. product.
25.11.1.1
130. Provide prossible

leackage quantity of oil to
process gas and oil
specification, including all
impurities in the oil used for
cylinder lubrication.Axens
will confirm the acceptence.
25.8.2.1.1
25.9
NEA/Axens
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
NODE NO: 26
DESIGN INTENTION
To supply cooling water to compressor cylinders jackets and packings.
DRAWINGS
CS-140-PR-D-06600006
EQUIPMENT
140-K-001A/B
Project :
STREAM DETAILS
SERVICE
Temperature(C)
Pressure ( bar g)
cooling water
Flow rate (Kg/hr)
50
Note:
Node
26. Makeup H2
Compressor -Closed cooling water system
Deviation
1.
Low/No Flow
Causes
1. main cooling water pump
failure.
Consequences
1.Less cooling water flow and pressure
leading to higher process gas temp.
Safeguards
1. Cooling water pump
with auto start though
PT-912 is provided.
26.1.1.1.1
2. High high discharge

temp trip TIHH-903 &
906 is available.
26.1.1.1.2
2. Piston rod packing temp. likely to go high. 1. Rod packing high

temp. alarm TI-917 &
924 available.
2. cooling water pump suction

strainer choking.
1. Less cooling water flow and pressure

leading to compressor damage.
3. Cooler leak
1. No significant consequences.
4. Discharge filter blockage

leading to high process gas temp.
Ref. No.
Recommendations
Responsibility
26.1.1.2.1
2. High temp. alarm TI933 & 934 is available.
26.1.1.2.2
1. Spare pump with

strainer is available.
26.1.2.1.1
26.1.3.1
1.Bypass will be used
26.1.4.1.1
during filter maintinance.
131. Vendor operation

manual should mention
bypass operation.
NEA
2.Low pressure alarm PI- 26.1.4.1.2

913 is provided.
132. Vendor operating

manual should mention
closing of manual isolation
valve located in pump
minimum circulation line in
case both compressors are
in operation during
changeover.
NEA
Remarks
26. Makeup H2
Compressor -Closed cooling water system
1.
Low/No Flow
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
NODE NO: 26
DESIGN INTENTION
DRAWINGS
CS-140-PR-D-06600006
EQUIPMENT
140-K-001A/B
Project :
STREAM DETAILS

leading to high process gas temp.

SERVICE
Temperature(C)
cooling water
2.Low pressure alarm PI913 is provided.

Pressure ( bar g)
Flow rate (Kg/hr)
50
Note:
Node
Deviation
Causes
5. Less cooling water flow to

cooling water cooler.
2.
High Flow
Consequences
1. Cooling water temp will increase leading

high process gas temp.
Safeguards
1.High temp. alarm TI932 ia provided.
Ref. No.
Recommendations
Responsibility
133. Gate valve in min

circulation line to be
changed to globe valve.
NEA
134. Vendor to recheck

requirement of low temp
alarmTI-932 and
compressor start
permissive(refer vendor
cause & effect page 4).
NEA
26.1.5.1.1
1. No significant cause.
26.2.1
Flow
26.3.1
4.
Low Pressure
1. Same as No/low flow
26.4.1
5.
High Pressure
1. Any blockage in the system
1. System is designed for 26.5.1.1

pump max. pressure.
6. High
Temperature
1.Cooling water to CW cooler

cooler failure.
1. Closed cooling water temp. will increase

leading high process gas temp.
7. Low temp.
1. Winter season
1. Likely condensation of process gas in

cylinder.
1. TI-932 with high alarm 26.6.1.1.1

is provided.
26.7.1.1
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
NODE NO: 26
DESIGN INTENTION
DRAWINGS
CS-140-PR-D-06600006
EQUIPMENT
140-K-001A/B
Project :
STREAM DETAILS
SERVICE
7. Low temp.
cooling water
Temperature(C)
1. Winter season
Pressure ( bar g)
50
Flow rate (Kg/hr)
1. Likely condensation of process gas in

cylinder.
Note:
Node
Deviation
8.
High Level
Causes
Consequences
Safeguards
Ref. No.
Recommendations
Responsibility
135. Gas dew point to be

confirmed.
SEI
26.9.1.1.1
136. Suitable makeup water

connection to cooling water
tank is to be provided.
NEA
26.10.1.1
137. Cooling water tank

vent should be provided at
safe location.
NEA
26.8.1
9. Low level
1. Low level in closed cooling

water tank due to leakage in CW leading to compressor damage.
system.
1. Packing leakage/failure.
11. Composition
1. Not applicable
1. Process gas will leak to closed cooling

water circuit.
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
NODE NO: 27
DESIGN INTENTION
To supply Nitrogen purge to distance piece and packing
DRAWINGS
CS-140-PR-D-06600003
EQUIPMENT
140-K-001A/B
Project :
STREAM DETAILS
SERVICE
Temperature(C)
Pressure ( bar g)
Nitrogen
Flow rate (Kg/hr)
Amb.
1.5(packing)
1(distance piece)
Note:
Node
27. Makeup H2
Compressor -Distance piece/packing purge
Deviation
1. Low/No Flow
Causes
1. External nitrogen supply
failure
Consequences
1. Hydrogen accumulation.
Safeguards
1. Vent is connected to
flare.Not affecting the
environment.
Ref. No.
27.1.1.1.1
2. High alarm TI-907/908 27.1.1.1.2

is available.
2.
High Flow
1.PCV-902/903 fail to open
1. Loss of nitrogen to flare.
Flow
1.Compressor packing leaks
1. Loss of nitrogen to flare.
4.
Low Pressure
1. Refer 27.1.1.1.1 and

27.1.1.1.2
5.
High Pressure
1. Refer 27.2.1.1
Recommendations
Responsibility
138. PCV-902/903 set

points to be reviewed in
view of max. flare back
pressure of 2 barg(during
general power failure).
NEA/SEI
139. Isolation valve in vent

line to flare is to be LO.
NEA
27.2.1.1
1.NRVs are provided in
upstream and
downstream of distance
piece.
27.3.1.1.1
27.4.1
1. Rod packing damage.
1. PSV-909/910 are
provided.
27.5.1.1.1
6. High
Temperature
27.6.1
7. Low temp.
27.7.1
140. PSV discharge and

NEA
Goose neck provided on
distance piece,to be routed
to safe location.
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
NODE NO: 27
DESIGN INTENTION
DRAWINGS
CS-140-PR-D-06600003
EQUIPMENT
140-K-001A/B
Project :
STREAM DETAILS
SERVICE
Temperature(C)
Pressure ( bar g)
Nitrogen
Flow rate (Kg/hr)
Amb.
1.5(packing)
1(distance piece)
Note:
Node
Deviation
8.
High Level
Causes
Consequences
1. High level in packing drain pot.
1. High level leading to liquid carryover to

flare.
9. Low level
1. Not applicable
11. Composition
1. Not applicable
Safeguards
Ref. No.
1. Very unlikely as dew

point of gas is low.
27.8.1.1.1
2. LG-904 is provided
for monitoring.
27.8.1.1.2
Recommendations
141. Drain line from
packing drain pot to be
routed to CBD
Responsibility
NEA/SEI
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
NODE NO: 27
DESIGN INTENTION
DRAWINGS
CS-140-PR-D-06600003
EQUIPMENT
140-K-001A/B
Project :
STREAM DETAILS
SERVICE
Temperature(C)
Pressure ( bar g)
Nitrogen
Flow rate (Kg/hr)
Amb.
1.5(packing)
1(distance piece)
Note:
Node
Deviation
13. Others
Causes
1. Nitrogen Mode
Consequences
Safeguards
Ref. No.
27.13.1
Recommendations
Responsibility
NEA
Remarks
1. Machine needs separate
control and trip set points for
nitropgen case
2.Separate modes of
operation to be pragrammed
in DCS and in safeguarding
system.
3. Pressure can be developed
up to 24 barg with suction
pressure of 7 barg.
4. Flow rate of nitrogen
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
NODE NO: 27
Recycle Compressor- Lube oil (No HAZOP was done except for deviation 1 & 2. The same need to be carried out later with the vendor).
DESIGN INTENTION
To supply lube oil to turbine and compressor bearings
DRAWINGS
0-336-00-32088
EQUIPMENT
140-K-002A/B
Project :
STREAM DETAILS
SERVICE
Temperature(C)
Lube Oil
Pressure ( bar g)
Flow rate (Kg/hr)
Amb.
1.5(packing)
1(distance piece)
Note:
Node
28. Recycle
Compressor -Lube Oil
Deviation
Causes
Consequences
Safeguards
Ref. No.
1.
Low/No Flow
1. Main Lube Oil Pump failure

2. Suction strainers blockage.
3. Lube oil filter blockage.
4. Lube oil cooler leak.
5. PCV 602 malfunction to
close.
1&2. Turbine trips

3, 4 & 5. Lube oil pressure falls to turbine &
compressor bearings & turbine trips.
1&2. Auxilliary pump is

available.
3,4 & 5. Lube oil
pressure low alarm is
available & lube oil
overhead tank will take
care of the oil
requirement to bearings.
2.
High Flow
1. PCV 602 malfunction.

2. PCV 601 malfunction.
3. Turbine high speed.
1. More flow through the bearings.
1. PSV is available in
28.2.1.1.1
pump discharge.
2. PCV 602 will maintain
the bearing header
pressure.
3. PCV 601 will maintain
the pump discharge
pressure.
1. N/A
1. N/A
1. N/A
3. Reverse/Misdirected Flow
4.
Low Pressure
5.
High Pressure
6.
High Temperature
7. Low temp.
28.1.1.1.1
28.3.1.1.1
Recommendations
Responsibility
Remarks
28. Recycle
Compressor -Lube Oil
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
NODE NO: 27
Recycle Compressor- Lube oil (No HAZOP was done except for deviation 1 & 2. The same need to be carried out later with the vendor).
DESIGN INTENTION
To supply lube oil to turbine and compressor bearings
DRAWINGS
0-336-00-32088
EQUIPMENT
140-K-002A/B
Project :
STREAM DETAILS
SERVICE
Temperature(C)
Lube Oil
Pressure ( bar g)
Flow rate (Kg/hr)
Amb.
1.5(packing)
1(distance piece)
Note:
Node
Deviation
8.
High Level
9. Low level
11. Composition
13. Others
Causes
Consequences
Safeguards
Ref. No.
Recommendations
Responsibility
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
NODE NO: 29
Recycle Compressor- Seal Gas ( Vendor is expected to revise the seal gas system P&ID,Accordingly no HAZOP was done. The same need
to be carried out later once the design is firmed up by the vendor).
DESIGN INTENTION
To supply Seal gas to primary and secondary seals
DRAWINGS
1-336-00-31116
EQUIPMENT
140-K-002A/B
Project :
STREAM DETAILS
SERVICE
Temperature(C)
Nitrogen
Pressure ( bar g)
Flow rate (Kg/hr)
Amb.
1.5(packing)
1(distance piece)
Note:
Node
29. Recycle
Compressor -Seal Gas
Deviation
1.
Low/No Flow
2.
High Flow
Flow
4.
Low Pressure
5.
High Pressure
6. High
Temperature
7. Low temp.
8.
High Level
9. Low level
11. Composition
13. Others
Causes
Consequences
Safeguards
Ref. No.
Recommendations
Responsibility
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 32
Recycle Compressor- Steam &

drain
DESIGN INTENTION
To supply HP steam ,MP steam
DRAWINGS
CS-140-PR-15-0011,CS-140-PR-15-0030,1-336-00-33049(BHEL)
EQUIPMENT
Recycle Compressor Steam Turbine (140-KT-002)
STREAM DETAILS
HP Steam will be supplied from B/L 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. MP steam is
supplied to main lube oil pump from where it converts to LP steam
SCV-002A
SERVICE
Temperature(C)
HP STEAM
MP STEAM
Pressure ( bar g)
388
184
Flow rate (Kg/hr)

53.5
10
33000
1500
Note:
Node
30.
Recycle Compressor- Steam & drain 1.
Deviation
Low/No Flow
Causes
1. U/S disturbance (HP Steam
Failure)
2. PIC-691 malfunctions to close PCV691.
Consequences
1. KT-002 trips
Safeguards
Ref. No.
with low alarm.
30.1.1.1.1
2. FI-805 is provided.
30.1.1.1.2
Recommendations
1. HP steam supply to gland steam

condensor ejector failure.
30.1.2.1
142. All drains to be

properly routed.
2.Steam leaks from gland causing unsafe

work environment.
30.1.2.2
143. All condensate

collections having
temp<70 C will be routed
to ND syatem and others
having temp.> 70 C will be
routed to condensate
collection system.
3. Potential contamination of lube oil by

steam condensate.
1.Oil clarifier is
available.
30.1.2.3.1
144. BHEL confirmed that

PCV-691 is fail to close.
145. Standby PSV
requirement for PSV-691 is
to be checked as per
project standards
(considering PSV-691
failure).
3. 1. U/S disturbance (MP Steam

Failure)
1. Main Lube Oil Pump turbine Failure
1.Aux. pump is
available.
30.1.3.1.1
Responsibility
BHEL/SEI
Remarks
30.
Recycle Compressor- Steam & drain 1.
Low/No Flow
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 32

drain
DESIGN INTENTION
DRAWINGS
CS-140-PR-15-0011,CS-140-PR-15-0030,1-336-00-33049(BHEL)
EQUIPMENT
STREAM DETAILS
SCV-002A
SERVICE
Temperature(C)
HP STEAM
MP STEAM
Pressure ( bar g)
388
184
Flow rate (Kg/hr)

53.5
10
33000
1500
Note:
Node
Deviation
Causes
4. No flow of cooling water to gland
steam condensor
Consequences
1. Steam does not condense as in normal
operation.Steam leaks from gland causing
unsafe work environment.
Safeguards
Ref. No.
1. BHEL confirmed that 30.1.4.1.1

steam going out of
glands
Recommendations
Responsibility
146. All condensate

collections having
temp<70 C will be routed
to ND syatem and others
having temp.> 70 C will be
routed to condensate
collection system.
BHEL/SEI/NOCL
147. SOP to ensure

mentioning of gland steam
condensor isolation and
steam is to be vented out
through local vent.
2.
High Flow of HP steam
1. No New Cause
30.2.1
Flow
1. No New Cause
30.3.1
4.
1. U/S disturbance (HP Steam

Failure)
Low Pressure
1. KT-002 may get tripped
with low alarm.
30.4.1.1.1
2. Shutdown of DS-001 30.4.1.1.2

is considered when
KT-002 trips
5.
High Pressure
1. U/S disturbance (HP Steam high

header pressure)
6. High
Temperature
1. No New Cause
7. Low temp.
1. No New Cause
1. KT-002 may get tripped
with high alarm.
30.5.1.1.1
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
Project :
NODE NO: 32

drain
DESIGN INTENTION
DRAWINGS
CS-140-PR-15-0011,CS-140-PR-15-0030,1-336-00-33049(BHEL)
EQUIPMENT
STREAM DETAILS
SCV-002A
SERVICE
Temperature(C)
HP STEAM
MP STEAM
Pressure ( bar g)
388
184
Flow rate (Kg/hr)

53.5
10
33000
1500
Note:
Node
Deviation
8.
High Level
Causes
1. NA
9. Low level
1. NA
1. NA
11. Composition
1. NA
1. NA
13. Others
1. NA
Consequences
Safeguards
Ref. No.
Recommendations
Responsibility
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
NODE NO: 26
Recycle Compressor- cooling water System (No HAZOP was done. The same need to be carried out later with the vendor).
DESIGN INTENTION
To supply cooling water to gland steam condensor, lube oil coolers and lube oil pump turbine bearings
DRAWINGS
3-336-00-34042
EQUIPMENT
140-K-002A/B
Project :

STREAM DETAILS
SERVICE
Temperature(C)
Pressure ( bar g)
Flow rate (Kg/hr)
cooling water
Note:
Node
31. Recycle compressor-cooling water
system
Deviation
1.
2.
Low/No Flow
High Flow
Flow
4.
Low Pressure
5.
High Pressure
6. High
Temperature
7. Low temp.
8.
High Level
9. Low level
Causes
Consequences
Safeguards
Ref. No.

Gland Steam Condenser.
31.1.1

Lube Oil Cooler.
31.1.2
3. Less cooling water flow to lube

oil pump turbine bearings
31.1.3
Recommendations
Responsibility
Remarks
HAZOP WORKSHEET
Client
PROJECT NO
: SO 2331
NODE NO: 26
Recycle Compressor- cooling water System (No HAZOP was done. The same need to be carried out later with the vendor).
DESIGN INTENTION
To supply cooling water to gland steam condensor, lube oil coolers and lube oil pump turbine bearings
DRAWINGS
3-336-00-34042
EQUIPMENT
140-K-002A/B
Project :

STREAM DETAILS
SERVICE
Temperature(C)
Pressure ( bar g)
Flow rate (Kg/hr)
cooling water
Note:
Node
Deviation
11. Composition
Causes
Consequences
Safeguards
Ref. No.
Recommendations
Responsibility
Remarks

Hazop

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HAZOP STUDY REPORT

Nagarjuna Oil Corporation Ltd.

DHU Unit (Unit -1400)

NAGARJUNA OIL CORPORATION LTD.

HAZOP Study Report

Diesel Hydrodesulphurization Unit

Issued for Design

HAZOP STUDY REPORT

Nagarjuna Oil Corporation Ltd.

DHU Unit (Unit -1400)

Annexure I: Node details & HAZOP P&IDs( 60 sheets )

HAZOP STUDY REPORT

Nagarjuna Oil Corporation Ltd.

DHU Unit (Unit -1400)

HAZOP STUDY REPORT

Nagarjuna Oil Corporation Ltd.

DHU Unit (Unit -1400)

HAZOP STUDY REPORT

DHU Unit (Unit -1400)

supply to the reactor circuit or/and the HP purge gas.

HAZOP STUDY REPORT

DHU Unit (Unit -1400)

HAZOP STUDY REPORT

Nagarjuna Oil Corporation Ltd.

DHU Unit (Unit -1400)

HAZOP STUDY REPORT

Nagarjuna Oil Corporation Ltd.

DHU Unit (Unit -1400)

5. HAZOP Methodology & Technique

HAZOP STUDY REPORT

HAZOP STUDY REPORT

Nagarjuna Oil Corporation Ltd.

DHU Unit (Unit -1400)

HAZOP STUDY REPORT

Nagarjuna Oil Corporation Ltd.

DHU Unit (Unit -1400)

MORE LESS AS WELL AS

HAZOP STUDY REPORT

Nagarjuna Oil Corporation Ltd.

DHU Unit (Unit -1400)

HAZOP STUDY REPORT

Nagarjuna Oil Corporation Ltd.

DHU Unit (Unit -1400)

HAZOP STUDY REPORT

TECHNIP KT INDIA LTD.

Nagarjuna Oil Corporation Ltd.

DHU Unit (Unit -1400)

7. BASIS OF HAZOP STUDY

HAZOP STUDY REPORT

Nagarjuna Oil Corporation Ltd.

DHU Unit (Unit -1400)

8 Documents referred for HAZOP study

Process Data Book

Process flow diagram

Material Selection Diagram

Piping & instrumentation diagram

Piping & instrumentation diagram

Flare load summary

Area Classification layout

Process data sheet of equipments

Cause and effect Diagram

HAZOP STUDY REPORT

Nagarjuna Oil Corporation Ltd.

DHU Unit (Unit -1400)