HIPAP 8: HAZOP Guidelines | January 2011

Figure 3: Example P&ID (Original)

27 | Department of Planning

HIPAP 8: HAZOP Guidelines | January 2011

DOP REFINERY

HAZOP MINUTE SHEET

Project: PRODUCT DISTILLATION UNIT WASTE OIL (kerosene ex engine washing)

Node: L0

Page: 1

Node Description: Product feed line

Date:

07.09.94

Drw No DOP 001 Rev 1

GUIDEWORD
1. High Flow

CAUSE

CONSEQUENCE

Flow controller

Level in column rises and hence

fault

temperature falls. Product

reboiler will attempt to
maintain temperature in
column until reboiler capacity
is reached. After this point
liquid level will rise arid -Mood
line LS. Column stops
operating.

2. Low Flow

1. Product feed

Temperature rise in column.

pump failed.
2. Isolating

Drop in liquid level in column.

Overheating. Reboiler can

valve jammed

handle this. TIC will in

addition control gas/air feed to
furnace H1. Not a problem.

3. Zero Flow

As above

28 | Department of Planning

As above

SAFEGUARD

REC#
1

RECOMMENDATION
Independent high flow
alarm on LO.

INDIV
NJ

ACTION

HIPAP 8: HAZOP Guidelines | January 2011

DOP REFINERY

HAZOP MINUTE SHEET

Project: PRODUCT DISTILLATION UNIT WASTE OIL (kerosene ex engine washing)

Node: H3

Page: 2

Node Description: Distillation column

Date:

07.09.94

Drw No DOP 001 Rev 1

GUIDEWORD
4. High Level

CAUSE

CONSEQUENCE

Level controller

Flooding of L6 and reboiler

fault

operation stops.

SAFEGUARD

REC#
2

RECOMMENDATION
High level alarm

INDIV
NJ

independent, of level
controller LIC. Alarm
level below L6.

5. Low Level

6. High Pressure

Level controller

Not a problem (as for No

malfunction or
low flow.

Flow).

Water failure in
condenser.

Condenser vent will act as

relief device. No adverse effect.

Low level alarm.

NJ

Pressure indicator on
column. High pressure

NJ

alarm + trip on gas/air

control valve V1.

7. High

Loss of feed.

Temperature

No adverse effect.

Temperature alarm
(high & low) on TIC.
Additional high temp
alarm linked to
furnace gas inlet shut
off.

29 | Department of Planning

NJ

ACTION

HIPAP 8: HAZOP Guidelines | January 2011

DOP REFINERY

HAZOP MINUTE SHEET

Project: PRODUCT DISTILLATION UNIT WASTE OIL (kerosene ex engine washing)

Node: C1

Page: 3

Node Description: Condenser, water cooled

Date:

07.09.94

Drw No DOP 001 Rev 1

GUIDEWORD

CAUSE

CONSEQUENCE

8. Reverse Flow

Cooling of

Suck back of air into H3 on

condenser and H3

cooling.

SAFEGUARD

REC#
6

RECOMMENDATION
Consider nitrogen

INDIV
JS

purge.

after shutdown.

9. High Pressure

Water failed or
[low.

Excess pressure

1. backup cooling water

2. Thermocouple on
vent.
3. Reorient water line
for counter-current
flow.

30 | Department of Planning

JS

system.
JS
JS

ACTION

HIPAP 8: HAZOP Guidelines | January 2011

DOP REFINERY

HAZOP MINUTE SHEET

Project: PRODUCT DISTILLATION UNIT WASTE OIL (kerosene ex engine washing)

Node: T1, LS, L9

Node Description: Product receiver and associated pipework

Page: 4
Date:

07.09.94

Drw No POP 001 Rev 1

GUIDEWORD
10. High Level

11. Low Level

CAUSE

CONSEQUENCE

Pump P2 fault

T1 overfills. High pressure in C1

LIC fault
V10 fault

and H3 if CI floods.

LIC fault

Pump damage

V10 fault

31 | Department of Planning

SAFEGUARD

REC#
8

RECOMMENDATION
LAH (independent) on

INDIV
NJ

T1.

Consider LAL
(independent)

NJ/JS

ACTION

HIPAP 8: HAZOP Guidelines | January 2011

DOP REFINERY

HAZOP MINUTE SHEET

Project: PRODUCT DISTILLATION UNIT WASTE OIL (kerosene ex engine washing)

Node:

L3, P1, L4, H1, L2

Node Description: Hot oil furnace, Hot oil circulation pump and pipework

Page: 5
Date:

07.09.94

Drw No DOP 001 Rev 1

GUIDEWORD

CAUSE

CONSEQUENCE

12. Low Flow

P1 fails

Loss of heat to H2; TIC will call

for further opening of V1

SAFEGUARD

REC#
10

Heating/

INDIV

Install flow sensor/

indicator/alarm to trip

NJ

furnace via V1 or other.

resulting in temperature rise in

H1.
13. High Pressure

RECOMMENDATION

Burst pipe, etc.

11

Surge tank in oil

expansion of hot

system. Evaluate

oil

location of tank: on L3
(at pump suction) or

JS

on L2. Check: Dead leg

and condensation of
moisture in oil.
14, High

1. High product

Temperature

load on H3
causing high

High temperature in furnace.

12

JS

Pyrometer in furnace
to alarm/trip gas
supply.

flame in H1
2. TIC on H3 failed
V1 failed open
3. H2 partly
blocked or heat
transfer poor
15. Contamination

Water from

Water turns to steam and

(water in oil)

atmosphere
through vent

explodes.

13

Locate surge tank to be

in hot system. Avoid
dead legs. Steam vents
at high points in pipe
system. Nitrogen
connection on vent

32 | Department of Planning

JS

ACTION