Cdu Hazop PRL Sep 2014

HAZOP RECORD - MINUTES Revision 0 Final Issue
Template Revisions
Rev 1 Jun-05 First issue
Rev 2 Feb-06 Second issue. Added Node summary, Categorisation Count and print formatting
Rev 3 Mar-06 3rd issue. Added Guideword naming update macro to allow more flexibility
Rev 4 May-06 Added Logos for printing, data entry etc
Rev 5 Aug-06 Minor formatting changes for printing to PDF
Rev6 Feb-08 Added drawing list, rev history and rev info to reports
Rev7 Dec-08 Added extra columns to Summary (Node Description and name)
Rev 8 Feb-11 Minor updates to formatting, extra guidewords
General Notes
1. Don’t change the structure of the Node sheets as the Macros probably won’t work. A lot of it is based on the structure set up in Blank Node and this being the same for all Individual Node Sheets
BEFORE Workshop
1. Set up project info in sheet "Session Info" first
2. Ensure guidewords to be used are set up in guide word sheet. Only words listed can be used when recording minutes. You can add new columns of guidewords as needed.
3. Don’t leave blank rows in guideword set or blank columns between sets of guidewords.
4. Set up Lists sheet (if using). This has the Categories for the actions and the Action status
5. Set up blank_node sheet as you want it to appear - ie zoom %, hide columns etc. Also hide any sheets that you want to.
TO record minutes in WORKSHOP

1. All data entry is done in Node sheets
2. Go to sheet name "1". Select set of guidewords to be used for first node from drop down list, eg Continuous, Batch etc
3. If Node name / number needs changing (eg to "overview", "Project Discussion etc), change as appropriate. This will rename sheet automatically.
If node name already exists, error message will appear. Try a new (unique) name for the node.
4. Enter Node description and design information details as relevant
5. To add first record, select first guideword from drop down list , eg "General Discussion, High Flow" etc
6. Record minutes as usual
7. To add a new row, Select guideword from the drop down list in the line marked with an asterix *. A new line will appear. Do NOT leave blank rows
8. When finished node, press "Add New Node" Button. Fill in new node number and change guideword set as appropriate
9. DO NOT use Sort Ascending / Sort descending feature in NODE sheets it will mess up the numbering. You can use Filter
Column Name Contents Comments
Minute ID Numbered automatically NO DATA ENTRY

Action ID Numbered automatically (number is NO DATA ENTRY
generated based on a entry being
made in the "action By Column)
PIDs Enter PID / Rev number details. Enter manually

Each P&ID on new row. One line per PID (limit of 6 - if it becomes a problem we'll change it)
Don't insert rows in this section - it will mess up the macros which are all referenced from the same row in every sheet
Node Enter number as defined in HAZOP Repeating number can't be entered - error message will come up. Choose another number
sessions.
Guide Word Choose guideword from drop down (Note option is limited based on Category chosen in Guideword Set)
list If you need to use two sets of Guidewords start a new node sheet for each set of guidewords
Causes Enter details as required
Consequences Enter details as required
Controls / Safeguards Enter details as required
Other Comments Enter details as required
file:///conversion/tmp/scratch/405186019.xls
How_to_Use
PRINT DATE:12/21/2018
Actions Enter details as required - For each

separate action a new row should
be defined.
Category Select from drop down list as You can set up whatever categories you like in the Lists sheet, the list automatically expands so it can be as many as
required you want.
The Categorisation Count formulas will be updated when the Update Summary macro is run from the summary sheet.
By Enter details as required Note - entry in this field triggers Action Nos. If no action leave this blank
After Workshops
Two options if a project wants to use this for action tracking :
1. Use Node sheets - in which case wee need top give them the entire spreadsheet - wouldn’t recommend this - option 2 is easier
a) Use additional columns in Node sheets for adding action status and details of action taken.
Due Date Enter details as required Can be completed after meeting
Status Select from drop down list as Can be completed after meeting
required
Details of action comp Enter details as required Completed after meeting
b) Use the summary sheet to get an overall report of number of outstanding actions by person etc.
2. Generate Summary sheet and Node Summary . Save only these into a new spreadsheet and give to project. The Node sheets form part of the HAZOP report and are a record of the workshop - provided in PDF only.
3. Update revision history in Session_Info sheet. Latest reviion will appear on report header.
To generate Summary Sheet
Click Update Summary A dialog box comes up when you This OVERWRITES any existing Summary Sheet and also updates the action category count on the Lists page
Sheet button enter the page to ask if you wantto
update summary
Basically copies all action items from individual Node sheets. It is not linked - pastes values only.
To generate Node Summary
Click Update Node A dialog box comes up when you This OVERWRITES any existing Node Summary Sheet
Summary Sheet button enter the page to ask if you wantto
update summary
Basically copies all Node info from individual Node sheets. It is not linked - pastes values only.
Reporting - Generating Printouts
Hold down SHIFT and select all sheets you would like to print. Header and Footers are automatically updated
Print to PDF
How_to_Use
PROJECT PRL CDU HAZOP September 2014here

Add Project Name For report headers Revision
The last entries in the columns

Revision Date
arehere Description
used in report headers etc. Comments By Approved
Add Project Name
0 PRL CDU HAZOP September 2014
0
0
Session Dates Team Leader Scribe Main Systems / Scope Covered

1 15-Sep-14 Abdul Majid Abdul Majid Sajid Jawaid KhanPumps
2 16-Sep-14 Fawad Hussain Compressors
3 17-Sep-14 Irfan Patel Pipelines
4 18-Sep-14 Tariq Masood Vessels
5 19-Sep-14 Asim Hayat Instruments
6 22-Sep-14 Mustafa Khan Safety equipments
7 23-Sep-14 Akhtar Hussain Khatri Process pipings
Sajid Jawaid Khan Burner fuel system
Muhammad Bakhsh
405186019.xls
Session_Info
Print Date: 12/21/2018
Type Drawing / Doc No Rev Date Title Comments

PID PRL17902 6 12.12.2011 Crude Distillation Unit LPG & CTC Plant Section P&ID Rev date shows rev 6 while rev no is 5
PID PRL10036 6 08.09.2011 Crude Distillation Unit Oil Flow Diagram
Type Drawing / Doc No Rev Date Title Comments

Reference
HAZOP RECORD - NODE SUMMARY
Node System Node Description P&IDs

1 CDU Unit From crude pump suction strainer to 101 CN inlet PRL 10022
2 CDU Unit To preheat and desalt the crude feed PRL 10036
3 CDU Unit From 104 C outlet I/V till 101 E covering 101 B /103 B & 104 B PRL 10036
4 CDU Unit CDU furnaces combustion chamber fuel system PRL 10036
5 CDU Unit From 101 E inlet nozzle to bottom supply via 105 JA till run down PRL 10036
isolation valve
6 CDU Unit CDU furnaces damper operation PRL 10036
7 CDU Unit Gas oil circuit from 103 E inlet to run down PRL 10037
8 CDU Unit From 105 J inlet suction line upto 101 E inter reflux inlet line PRL 10037
9 CDU Unit From 101 E top reflux to 102 J back to 101 E PRL 10037
10 CDU Unit From 101 E OVHD to OVHD receiver vessel PRL 10037/10040
11 CDU Unit From 108 C shell side inlet till 102 E PRL 10037/10038
12 CDU Unit From 103 J suction pipe till Kero run down isolation valve including PRL
111 C reboiler circuit 10038/10036/10040
13 CDU Unit From 104 E inlet line to rundown product including 104 E Interreflux PRL 10038
14 CDU Unit From 102 E OVHD to OVHD receiver vessel and reflux line to 102 E PRL 10038
15 CDU Unit From 110 J suction line to 105 E including column PRL 10038/10039
16 CDU Unit 105 E and bottom product to rundown PRL 10039
17 CDU Unit 105 E OVHD to 103 F and reflux back to 105 E and 108 F PRL 10039
18 CDU Unit From 103 C outlet crude to Desalter and crude back 107 C inlet PRL 18653
405186019.xls
Node_Summary
Page 5 of 102
HAZOP ACTION SUMMARY
PROJECT PRL CDU HAZOP September 2014
Node System Node Description Item ID Action ID Guide Word Causes Consequences Controls / Safeguards Other Comments Actions Category By
1 #REF! #REF! 1.2 Action 1 High Flow Down stream pipeline leak Spill & Fire FR 100 available with low flow Scope of crude feed pump's Asset Sr. Engr
alarms. Crude FRC's are available discharge line inspection needs to be damage Inspection
with auto controlling and flow alarms. stretched from crude pump discharge
Inspection plans are available till WBL
1 #REF! #REF! 1.5 Action 2 Low Flow NRV partially stucking issue 1101 J/JA cavitation, furnace tubes Stand by pump available with auto Develop a procedure for the Asset Manager
may damage cut in function periodical checking of NRV (Unit damage stationary/
Feed Pumps). Ops to provide list of Manager P
critical pumps NRV's to maintenance &U
for execution
1 #REF! #REF! 1.13 Action 3 High Pressure External fire Over pressurization of lines, line may RV available at pump discharge line RV preventive maintenance plan is in Crude feed pump discharge line RV Personnel Manager
rupture, LOPC for over pressurization protection place near old crude pump office back side safety Engineerin
exhaust tail pipe needs to be g office
diverted towards safe location to
avoid human exposure incase it lifts
1 #REF! #REF! 1.14 Action 4 High Pressure 101 CN inlet valve inadvertently LOPC, line may rupture RV 's available at pump discharge Line max operating pressure is below 1101 J discharge line till 101 CN inlet Asset Engineerin
closed line till 101 CN inlet, PIT 101-5 pump 1101 J shut off pressure as per needs to be evaluated for MAWP as damage g Office
available with high alarms available data Llne max operating pressure is below
pump 1101 J shut off pressure as per
available data
1 #REF! #REF! 1.24 Action 5 Drawing correction PRL # 10022 needs to be updated Drawing Manager
for errors correction Engineerin
/ update g office
2 #REF! #REF! 2.3 Action 6 High Flow Leak in heat exchangers 101 CN 101 E top reflux will be contaminated Pressure transmitter with high alarm 101 E RV exhaust is open vent which 101 E RV exhaust is open vent which Significant Sr.
tube side resulting in column over and RV's are available at 101 E, can result in personal exposure OR can result in personal exposure OR HSE Manager
pressurization . LOPC FR100 available at 101 CN outlet. fire incase RV lifts fire incase RV lifts therefore 101 E Technical
PM plans are in place RV's exhaust is line should be routed
to closed loop
2 #REF! #REF! 2.4 Action 7 High Flow Leak in heat exchangers 102 C tube Product (Kero) off spec. Low flow Flow transmitters at crude FRC's and 102 C is not as per refinery standards 102 C design should be changed Design Sr.
side towards furnace, tubes may damage Kero production available. 04 hourly from TEMA "C" to TEMA "R" as per Manager
lab analysis are in place to reveal specification Technical
any impurity. PM plans in place
2 #REF! #REF! 2.5 Action 8 High Flow Leak in heat exchangers 103 C tube Product (diesel) off spec. Low flow Flow transmitters at crude FRC's and 103 C is not as per refinery standards 103 C design should be changed Design Sr.
2 #REF! #REF! 2.6 Action 9 High Flow Leak in heat exchangers 107 C tube Product (furnace) off spec. Low flow Flow transmitters at crude FRC's and 107 C is not as per refinery standards 107 C design should be changed Design Sr.
2 #REF! #REF! 2.7 Action 10 High Flow Leak in heat exchangers 107 CA 101 E inter-reflux will be Pressure transmitter with high alarm 107 CA is not as per refinery 107 CA design should be changed Design Sr.
tube side contaminated resulting in column and RV's are available at 101 E, standards from TEMA "C" to TEMA "R" as per Manager
over pressurization . LOPC. Low flow Flow transmitters at crude FRC's and specification Technical
towards furnace, tubes may damage Kero production available.
2 #REF! #REF! 2.8 Action 11 High Flow Leak in heat exchangers 104 C tube Product (furnace) off spec. Low flow Flow transmitters at crude FRC's and 104 C is not as per refinery standards 104 C design should be changed Design Sr.
2 #REF! #REF! 2.20 Action 12 High Pressure External fire Over pressurization of lines, line may Pressure transmitters available at LEL detectors needs to be installed Significant Manager
rupture, LOPC crude pre heat train. RV 104 CT in process area for early identification HSE HSEQ
available, RV 155 available at 151 F. of HC leak in area
PTW available for safe work practice.
Summary
Page 6 of 102
3 #REF! #REF! 3.1 Action 13 High Flow Furnace Tube leakage LOPC, Fire Plant monitoring / visual inspection. Presently there is no protection on Presently there is no protection on Asset Sr.
Scheduled replacement of tubes CDU furnaces in case of fire or other CDU furnaces in case of fire or other damage Manager
after useful life (ref Inspection consequences, no provision of ESD consequences, no provision of ESD Technology
plan).For significant leaks Skin as well as wel therefore detailed engineering
temperature hi alarm, Flue gas of CDU furnaces safeguarding/
temperature, furnace box protection needs to b e conducted for
temperature, flue gas analyzers the provision of ESD
available,
3 #REF! #REF! 3.5 Action 14 Low Flow Effect of air fail on furnaces feed LOPC , fire, asset damage Furnaces feed valves are equipped Arrangement on furnace feed valve CDU furnaces feed valves needs to Asset Manager E
valve with lock up valve, flow transmitter are done on make shift basis be replaced with standard feed damage &I
with alarms available, feed valve control valve with air fail safe open
manual I/V are available with a by action. More over current fail safe
pass valve lock up function test needs to be
assured in routine PM
3 #REF! #REF! 3.7 Action 15 Low Flow Partial closing of 101 B inlet block Furnace tubes may rupture, LOPC, Flow and pressure transmitter 101 B coil inlet & 103 B inlet main Operation Manager P
valves and 103 B inlet main block fire available on both furnaces with block valve I/V unwanted operation s &U
valve, operator error OR stem alarm, Temp transmitter available at needs to be restricted by provision of improvem
breaking furnaces outlet appropriate mechanism. ents
3 #REF! #REF! 3.8 Action 16 Low Flow Partial closing of 103 B common Furnace tubes may rupture, LOPC, Flow and pressure transmitter All valves which are business critical Operation Manager P
outlet I/V's and 104 B coil outlet fire available on both furnaces with needs to be identified (Manager P & s &U
isolation valves alarm, Temp transmitter available at U) and frequency needs to be improvem Manager
furnaces outlet developed for servicing/testing ents Inspection
(Manager Inspection & Manager Manager
Stationary) and also unwanted Stationary
operation needs to be restricted by
provision of appropriate mechanism
3 #REF! #REF! 3.11 Action 17 Reverse Flow Leakage in furnaces tubes and back Fire, LOPC 103 B and 104 B are equipped with Provision of Manual I/V at 101 B Significant Sr.
flow from 101 E and associated I/V's at furnace outlet to restrict outlet needs to be studied as similar HSE Manager
circuit towards 101 B reverse where as 101 B is not to other Cdu furnaces to avoid back Technology
equipped with this arrangement to flow
avoid back flow
3 #REF! #REF! 3.13 Action 18 High Temperature Furnaces tubes leakage Tubes exposed to high temp, HC Flow and temp transmitter available Procedure/guidelines needs to be Asset Sr. Engr
escape to environment, fire, LOPC with alarm, inspection plan in place developed for furnace tubes damage Process
for tubes integrity check preservation pre and post fabrication Safety
to avoid ingress of foreign material
3 #REF! #REF! 3.15 Action 19 High Temperature CDU furnaces coil outlet TRC's temp Tubes exposed to high temp, HC 101 B, 103 B and 104 B outlet coils All business critical thermo well Asset Manager P
sensors thermo well internal damage escape to environment, fire, LOPC have individual temp indication and needs to be identified (Manager P & damage & U and
alarms with skin temp and flow U & Manager E & I) for inspection Manager E
meters during TA's &I
3 #REF! #REF! 3.17 Action 20 High Pressure CDU furnace tubes internal choking Tubes may damage, LOPC, fire Flow transmitters with alarms Furnaces individual coil pressure Asset Manager E
available, Local PI available for indicators needs to be converted into damage &I
monitoring, area surveillance in place transmitters
e
4 #REF! #REF! 4.2 Action 21 High Flow Malfunctioning (TRC,s CV Flame-out of burners, fire and Pilot burners are available, snuffing To Install Burner Management Asset Sr.
momentarily closed) explosion on re-ignition steam available having access from System on CDU furnaces damage Manager
remote area Technical
5 #REF! #REF! 5.11 Action 22 High Flow Tube leakage at 181 CA, 181 C & HC ingress in CW, fire 02 Hours monitoring, CW sampling in Need to explore analyzer for cooling Significant Manager E
154 C place twice a day, inspection and PM water contamination with HC incase HSE &I
plan in place for equipment health trim coolers leak and contaminates
check CW
5 #REF! #REF! 5.15 Action 23 Low Flow Malfunctioning of LC103 towards Level of 101 E will increase, flooding High Level Alarm on LC103 Provision of independent high and Significant Manager E
lower side in tower, column can get hydraulic, available, Fra 102 available with flow low level alarms on 101 E needs to HSE &I
high pressure, RV pop up, LOPC, fire alarms, Pra 101 available with high be explored for high and low level
pressure alarm, LG104 available for detection
verification, operational staff are
trained
5 #REF! #REF! 5.37 Action 24 General discussion It was observed that analyzing the It was observed that analyzing the Design Manager
residue circuit that piping residue circuit that piping Engineerin
specification is not compliant to specification is not compliant to g Office
existing process variables existing process variables therefore
revalidation of piping specification for
max pressure and temp. Initially line
from 106 J to run down LC 103
needs to be conducted
7 #REF! #REF! 7.2 Action 25 High Flow Pipeline Leakage LOPC and fire Low Level Alarm on LC102 available. Study needs to be carried out for Significant Sr.
FRc 102 available with low flow provision of remote operated block HSE Manager
alarm. LG 103 available @ 103 E for valve incase of heavy leakage @ Technology
verification bottom of 103 E
Summary
Page 7 of 102
7 #REF! #REF! 7.27 Action 26 High Temperature External fire Liquid expansion, higher pressure, Temperature and pressure No on line temp transmitter at On line temp transmitter needs to be Significant Manager E
RV pop up, LOPC, fire transmitters available with high products run down lines. High run installed on all run down products to HSE &I
alarms, columns are externally down product temp can result in fire monitor run down temp
insulated
10 #REF! #REF! 10.18 Action 27 High Level LC 101 malfunctions to close position High level in 101 F, hydro feed LRCa 101 available with high level Independent high level switch needs Significant Manager E
contamination due to water carry alarm, LG 101 available, Interface to be installed at 101 F for high level HSE &I
over, no safety consequence LG 102 available detection
10 #REF! #REF! 10.19 Action 28 Low Level LC 101 malfunctions to open position HC spill in area, LOPC, fire LRCa 101 available with high level HC detector installation is being Independent low level switch needs Significant Manager E
alarm, LG 101 available, Interface planned to be installed at 101 F for low level HSE &I
LG 102 available, area monitoring in detection in case HC's spills via drain
place
10 #REF! #REF! 10.28 Action 29 Plant Items (Operable / People cross over 105 C fins Fins get damage, heat transfer area Temporary wooden planks are Permanent cross over platform Asset Manager
Maintainable) reduction, fins may damage due to placed, make shift arrangements needs to be installed for easy access damage Engineerin
load from front to back side to avoid 105 g
C fins from damaging as its used as
cross over
11 #REF! #REF! 11.10 Action 30 Low Level LC 106 output signal malfunctions 102 E level drop to minimum LC 106 available with low level No independent low level switch Independent low level switch needs Asset Manager E
and gives high OP resulting in 103 J cavitation, seal alarm, FR ?? Available on Kero run available at 102 E to be provided at 102 E for low level damage &I
damage, LOPC, fire down with low flow alarm, 102 E protection
equipped with low pressure and temp
alarms,
11 #REF! #REF! 11.11 Action 31 High Level LC 106 output signal malfunctions 102 E level will rise, column flooding, LC 106 available with high level No independent high level switch Independent high level switch needs Asset Manager E
and gives low OP over pressurization, RV pop, LOPC, alarm, 102 E equipped with high available at 102 E to be provided at 102 E for high level damage &I
fire pressure and temp alarms, LG 109 protection
available at 102 E, RV PM plan in
place
11 #REF! #REF! 11.17 Action 32 Impurities (Gas, Liquid, Scale deposition/formation on 102 E Distillation process may be disturbed, No safeguard available In TA 2014, scale formation will be Study needs to be carried out to Operation Sr.
Solid) internal trays quality issue, no safety consequence eliminated by trays replacement in install filters on 102 E feed and reflux s Manager
102 E streams to avoid scale travelling to improvem Technology
tower ents
12 #REF! #REF! 12.8 Action 33 High Flow 111 C shell side leakage Flashing in 102 E resulting in over Level Alarm on LC106 available, Fra 111 C is not as per refinery standards 111 C design should be changed Design Sr.
pressurization, LOPC, fire, product 103 available with indication, LG109 from TEMA "C" to TEMA "R" as per Manager
off spec available for verification, LC 106 specification Technical
available at 102 E with level alarm,
Pra 102 and TI 101-21 available at
102 E with alarm, Inspection and PM
plan in place for equipment health
check
12 #REF! #REF! 12.16 Action 34 Zero Flow Duty pump fails Level of 102 E will increase, flooding High Level Alarm on LC106 RV are available at 102 E but its vent Study needs to be carried out to Significant Sr.
in tower, column can get hydraulic, available, Fra 103 available with flow is open to atmosphere route 102 E RV's towards closed HSE Manager
high pressure, RV pop up, LOPC, fire alarms, Pra 102 available with high safe network Technology
pressure alarm, LG109 available for
verification, standby pump available
12 #REF! #REF! 12.33 Action 35 General discussion 183 C detail drawings are not 183 C details drawing and Design Manager
available engineering needs to be developed Engineerin
g Office
14 #REF! #REF! 14.4 Action 36 Low Flow 106 C's tube side leakage LOPC, fire LRCa 102 equipped with low level Incase of 106 C's leakage, no Isolation valve needs to be provided Significant Sr.
alarm, PRCa 102 available with isolation is available for online at 106 C's inlet and outlet for leakage HSE Manager
pressure alarm, Inspection PM plan rectification rectification Technology
in place,
14 #REF! #REF! 14.18 Action 37 Low Pressure PIC 102 malfunctions and opens Low pressure in 102 F, pump PRCA 102 available for controlling, Low pressure alarm to be provided at Operation Manager E
completely cavitate, high level in 102 F, FE 108 available, LRCA 102 PRCa 102 s &I
compressor damage due to liquid available with high level alarm, PM improvem
carry over plan in place, manual valve available ents
for isolation
14 #REF! #REF! 14.20 Action 38 High Pressure PIC 102 upstream isolation valve Incase of high pressure, PIC 102 PIC 102 and PRCa 102 equipped PIC 102 upstream isolation valve Significant Manager P
closes inadvertently function will fail, system with high pressure alarm, RV 102 needs to be chain locked to avoid HSE &U
pressurization, column E1-3 available at 102 E inadvertently closure of valve
pressurization, RV pop, LOPC, fire
14 #REF! #REF! 14.21 Action 39 High Pressure PIC 102 downstream NRV to stuck to Incase of high pressure, PIC 102 PIC 102 and PRCa 102 equipped Existing PM plan of PIC 102 and Operation Sr.
close position function will fail, system with high pressure alarm, RV 102 NRV servicing doesn't assure quality s Manager
pressurization, column E1-3 available at 102 E PM as handover of these system improvem Technology
pressurization, RV pop, LOPC, fire require by pass arrangement. Study ents
needs to be carried out for safely
handing over of PIC 102 and its
downstream NRV for PM
Summary
Page 8 of 102
15 #REF! #REF! 15.1 Action 40 High Flow Pipeline leakage at suction/discharge LOPC & fire Piping inspection plan in place. PI 151 at 110 JA needs to be Operation Manager E
of compressor Pressure controller alarm (PIC 102, replaced with online pressure s &I
PRCa 102), PTI 127 at 105 E, FE transmitter with indication on DCS improvem
104 with low flow alarm, Local PI's ents
available for monitoring
15 #REF! #REF! 15.6 Action 41 Low Flow 104 F drain valve in advertantly LOPC & fire FR 104 available with flow alarm, PI PI 152 at 110 JA needs to converted Operation Manager E
opens 152 available at suction to online pressure transmitter with s &I
indication on DCS improvem
ents
15 #REF! #REF! 15.15 Action 42 High Temperature Lube oil high temp due CW Compressor may damage Physical monitoring of lube oil Temp transmitters needs to be Asset Manager E
unavailability provided on 110 JA lube oil cooler damage &I
outlet lube side with alarms on DCS
15 #REF! #REF! 15.28 Action 43 Plant Items (Operable / Suction bottle drain (2 & 4) creates Injury No control available 110 JA suction bottle # 2 & 4 drain Significant Manager
Maintainable) ergonomics issue lines I/V needs to be rerouted for HSE Drawing
easy access and safe operation office
16 #REF! #REF! 16.1 Action 44 High Flow Malfunctioning of LC107 towards Low level of 105 E, vapor escape to LC 107 with low level alarm, Fra 105 No independent low level switch Independent low level switch needs Significant Manager E
higher side storage tank, LOPC, fire with low flow alarm, PTI 127 available to be installed at 105 E HSE &I
available, LG 112 available, PM plan
in place
16 #REF! #REF! 16.11 Action 45 Zero Flow LC107 shuts to zero OP and stucks 105 E flooding, over pressurization, LC 107 high alarm, Fra 105 with low Independent high level switch needs Operation Manager E
RV pop, LOPC, fire flow alarm, PTI 127 available, LG to be installed at 105 E s &I
112 available, PM plan in place improvem
ents
16 #REF! #REF! 16.12 Action 46 Zero Flow Manual isolation valve complete 105 E flooding, over pressurization, LC 107 with high alarm, Fra 105 with 105 E RV exhaust is open vent which Significant Sr.
closed inadvertently RV pop, LOPC, fire low flow alarm, PTI 127 available, LG can result in personal exposure OR HSE Manager
112 available, PM plan in place fire incase RV lifts therefore 105 E Technology
RV's exhaust is line should be routed
to closed loop
16 #REF! #REF! 16.26 Action 47 General discussion 105 E have single RV with no Provision of stand by RV with Operation Sr.
isolation. Incase of RV passing no isolation valve needs to be provided s Manager
standby available for on line RV maintenance improvem Technology
ents
16 #REF! #REF! 16.27 Action 48 General discussion 182 C detail drawings are not 182 C details drawing and Design Manager
available engineering needs to be developed Engineerin
g Office
17 #REF! #REF! 17.28 Action 49 High Level LC108 (transmitter) malfunctions to High level in 103 F, liquid carry over LG 101 available, High level alarm at Independent high level switch needs Operation Manager E
lower side to fuel gas circuit, liquid further carry 107 F to be provided at 103 F s &I
over to fuel gas burner improvem
ents
17 #REF! #REF! 17.30 Action 50 Low Level Manual draining of interface water HC splash in area, LOPC, fire Interface gauge LG 111 available, Automated interface level controller Operation Manager E
from 103 F operators are trained needs to be provided for the safe s &I
draining of 103 F water side improvem
ents
18 #REF! #REF! 18.24 Action 51 Low Level Pipeline leak at down stream of 152 F Level drop in 152 F, pump 153 J/JA LICA 152 available with low level Inspection plan to be developed for Asset Sr.
seal damage alarm, FRC 155/FRC 153 available desalter water injection, water damage Engineer
with low and high flow alarm, LT 154 effluent and chemical injection lines Inspection
and 155 available at 151 F with low
interface level alarms, LG 153
available
18 #REF! #REF! 18.29 Action 52 High Pressure No credible cause identified for 152 F 152 F vent to atmosphere is not safe, 152 F vent to atmosphere is not safe, Significant Manager
as its atmospheric its showering may in case of crude its showering in case of crude may HSE Engineerin
may result in human exposure and result in human exposure and g
ultimately injury ultimately injury therefore rerouting of
152 F vent line to oily water drain
network is required
18 #REF! #REF! 18.32 Action 53 High Temperature 151 F transformer low oil level Transformer may damage, Injury TSH 202 available at transformer for Desalter transformer security PM Asset Manager
high temp protection plan for TSH 202, PSH 201, TAH 202 damage Electrical
& PAH 201 needs to be developed
TOTAL Actions 53
Summary
Page 9 of 102
Continuous Batch
High Flow General discussion

Low Flow Drawing correction
Zero Flow batch 1
Reverse Flow batch 2
Misdirected Flow batch3
High Level batch4
Low Level batch5
Empty batch6
High Pressure batch7
Low Pressure batch8
High Temperature batch9
Low Temperature batch10
Impurities (Gas, Liquid, Solid) batch11
Change in Composition (eg Concentration, 2 batch12

Phase Flow, Reactions)
Testing - Equipment batch13
Testing - Product batch14
Plant Items (Operable / Maintainable) batch15
Instruments batch16
Instruments - Sufficient for Control batch17
Instruments - Correct Location batch18
Instruments - Too Many batch19
Materials of Construction batch20
General discussion
Drawing correction
Overview Mat_Handling User_Defined
General discussion General discussion General discussion

Drawing correction Drawing correction Drawing correction
Toxicity Too High etc 3
Services Required Too Low etc 4
Breakdown Too far test
Commissioning Misaligned
Startup Wrong position
Shutdown High speed
Effluent (gaseous, liquid, solid) Low speed
Noise No movement
Fire / Explosion Reverse
Safety Equipment Obstacles
Electrical Slip
Breakdown - Fuel / power Too large
Impurities (Gas, Liquid, Solid) Too small

Breakdown - Comms Too long
Breakdown Too short
Effluent (gaseous, liquid, solid) Too wide
Noise Too narrow
Commissioning High load
Startup Low load
Shutdown High flow
Quality&Consistency Low flow
Output-reliability & bottlenecks Loss of containment
Efficiency/losses Too late
Simplicity Too early
Too short
Too long
Incorrect sequence
Low energy
High energy
Energy failure
CONTAMINATION
PROCESS CONTROL
ELECTRICAL SYSTEMS
MAINTENANCE
System_Overview System_Block_By_Bloc System_Application_I Loop_by_Loop
k ssues
General discussion General discussion General discussion General discussion
Drawing correction Drawing correction Drawing correction Drawing correction
Introduction System Block Diagram Application Programs Loop by Loop
Identification Phase
Standards System Communication Special Applications Loop Input -
Failure Connection Failures
System Communication Processing Failure Shared Control Loop Inputs - Possible
Problems
Maintenance External Influences Loop Inputs - Setup
Earthing/Isolation Loss of Power Supply Loop Inputs -

Experiences
Power Distribution Re-Energisation of Power Loop Output -
Supply Connection Failures
Operability Loss of Communications Loop Outputs -
Link Possible Problems
Trending Spurious Data on Loop Outputs - Setup
Computer Link
Alarms Watchdog/Hardware Loop Outputs -
Alarms Experiences
Protective Systems Abnormal Operations Loop Control
Philosophy
Performance Loop Safety
Environment Loop Performance
Increased Temperature Loop Overview

Reduced Temperature
External Influences
Fire
Loop_Overview Sequence_Overvie Sequence_Modules/St Sequence_Final_O
w ep_Checks verview
General discussion General discussion General discussion General discussion
Drawing correction Drawing correction Drawing correction Drawing correction
Interaction Between Identification What Testing
Loops
Startup/Shutdown Operability When Simulation
Order of Execution How Commissioning

tuning/implementing
Testing Other Requirements Inputs and Outputs Training
Commissioning Sequence Control and

Management
Processor/ Memory Sequence Flow
Loading
Safety Requirements Sequence Interactions
Quality requirements Sequence Timing
Documentation Sequence
Dependencies
Maintenance Operator Interaction
Modification Control Impact on continuous

control
Common/ Past Design Issues
Problems
Training Other Issues
Manning Levels
Category Number of %
Actions
Asset damage 15 28
Commissioning 0 0
Control 0 0
Design 9 17
Design - all areas 0 0
Drawing correction / update 1 2
Operations improvements 11 21
Production shutdown 0 0
Reduced production 0 0
Personnel safety 1 2
Significant HSE 16 30
TOTAL 53 100
Lists
HAZOP RECORD - MINUTES

Session 1 Date 15/09/2014
Guideword set Continuous
Node System Node Description

1 CDU Unit From crude pump suction strainer to 101 CN inlet
PIDs PRL 10022 Temp Design: 30~ 35 C Ops: 30 ~ 35 C
Pressure Design: 425 psi Ops: 21 Kg/cm2
Flow Design: 1410 USGPM Ops: 4600 MTD
Other
Design Intent To supply crude to CDU
Item
Action ID Guide Word Causes Consequences Controls / Safeguards Other Comments Actions Category By
ID
1101 J pump racing Tank farm tank level will FR 100 available with
drop. No safety high flow alarms. Crude
1.1 - High Flow consequence FRC's are available with
auto controlling and flow
alarms
Down stream pipeline Spill & Fire FR 100 available with Scope of crude feed Asset Sr. Engr Inspection
leak low flow alarms. Crude pump's discharge line damage
FRC's are available with inspection needs to be
1.2 Action 1 High Flow auto controlling and flow stretched from crude
alarms. Inspection plans pump discharge till WBL
are available
Stand by pump Tank farm tank level will FR 100 available with
operated while main drop. No safety high flow alarms. Crude
1.3 - High Flow pump is in operation consequence FRC's are available with
alarms
Suction strainer 1101 J/JA cavitation Stand by pump available
choking with auto cut in function
(??). Strainer cleaning
frequency in place. FR
1.4 - Low Flow 100 available with low
flow alarms Pump switch
over plan is followed
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Item
ID
NRV partially stucking 1101 J/JA cavitation, Stand by pump available Develop a procedure for Asset Manager
issue furnace tubes may with auto cut in function the periodical checking of damage stationary/Manager
damage NRV (Unit Feed Pumps). P&U
1.5 Action 2 Low Flow Ops to provide list of
critical pumps NRV's to
maintenance for execution
Down stream manual Low flow in furnace FR 100 available with

valve partially closed tubes, tubes may rupture low flow alarms. Crude
by operator FRC's are available with
inadvertently auto controlling and flow
1.6 - Low Flow alarms. Operators are
trained and SOP's are
available
Suction flange leakage 1101 J/JA cavitation, low FR 100 available with
flow in furnace tubes, low flow alarms. Crude
1.7 - Low Flow tube may rupture FRC's are available with
alarms
1101 J/JA circulation Low flow in furnace FR 100 available with
valve inadvertently tubes, tube may rupture, low flow alarms. Crude
1.8 - Low Flow opening OR passing Fire FRC's are available with
issue auto controlling and flow
alarms
1101 J/JA discharge Low flow in furnace FR 100 available with
relieve valve passing tubes, tube may rupture, low flow alarms. Crude
issue Fire FRC's are available with
1.9 - Low Flow auto controlling and flow
alarms. Stand by RV
available.
1101 J/JA suction OR Low flow in furnace FR 100 available with

discharge valve tubes, tube may rupture, low flow alarms. Crude
inadvertently closed Fire FRC's are available with
1.10 - Low Flow auto controlling and flow
alarms
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Item
ID
1101 J/JA Pump No flow in furnace tubes, Stand by pump available
failure tube may rupture, Fire with auto cut in function
1.11 - Zero Flow (??), low flow alarm (FR
100) available
1101 J/JA failure Hot stream may back NRV's are available at
1.12 - Reverse Flow flow towards storage 1101 J/JA, FR 100 low
tank flow alarm is available
External fire Over pressurization of RV available at pump RV preventive Crude feed pump Personnel Manager
lines, line may rupture, discharge line for over maintenance plan is discharge line RV near old safety Engineering office
LOPC pressurization protection in place crude pump office back
side exhaust tail pipe
1.13 Action 3 High Pressure needs to be diverted
towards safe location to
avoid human exposure
incase it lifts
101 CN inlet valve LOPC, line may rupture RV 's available at pump Line max operating 1101 J discharge line till Asset Engineering Office
inadvertently closed discharge line till 101 CN pressure is below 101 CN inlet needs to be damage
inlet, PIT 101-5 available pump 1101 J shut off evaluated for MAWP as
1.14 Action 4 High Pressure with high alarms pressure as per Llne max operating
available data pressure is below pump
1101 J shut off pressure
as per available data
Covered under low

1.15 - Low Pressure
flow scenario
High Covered under high
1.16 -
Temperature pressure scenario
Low External weather No safety consequence
1.17 -
Temperature condition
N/A
Impurities (Gas,
1.18 -
Liquid, Solid)
Change in No significant cause

Composition identified
(e.g.
1.19 -
Concentration, 2
Phase Flow,
Reactions)
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Item
ID
RV # ??? failure LOPC, fire PM plans are in place
Testing -
1.20 -
Equipment
Plant Items No cause identified

1.21 - (Operable /
Maintainable)
Instruments - Controlling is sufficient
1.22 - Sufficient for
Control
Materials of No cause identified
1.23 -
Construction
PRL # 10022 needs to be Drawing Manager
Drawing
1.24 Action 5 updated for errors correction / Engineering office
correction
update
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2 CDU Unit To preheat and desalt the crude feed
PIDs PRL 10036 Temp Design: 188 C Ops: 230 C
Pressure Design: 28 kg/cm2 Ops: 12.5 Kg/cm2
Flow Design: 6400 MTD Ops: 4600 MTD
Other
Design Intent To supply crude to CDU
Item
ID
2.1 - High Flow
Down stream pipeline Spill & Fire FR 100 available for
leak leakage across 101 CN
with high flow indication,
Flow transmitter (coil
FRC's)available at
2.2 - High Flow furnace inlet along with
online pressure
transmitter @ 104 C
outlet
Leak in heat 101 E top reflux will be Pressure transmitter with 101 E RV exhaust is 101 E RV exhaust is open Significant Sr.
exchangers 101 CN contaminated resulting in high alarm and RV's are open vent which can vent which can result in HSE Manager
tube side column over available at 101 E, result in personal personal exposure OR fire Technical
pressurization . LOPC FR100 available at 101 exposure OR fire incase RV lifts therefore
2.3 Action 6 High Flow CN outlet. PM plans are incase RV lifts 101 E RV's exhaust is line
in place should be routed to closed
loop
Leak in heat Product (Kero) off spec. Flow transmitters at 102 C is not as per 102 C design should be Design Sr.
exchangers 102 C Low flow towards crude FRC's and Kero refinery standards changed from TEMA "C" Manager
tube side furnace, tubes may production available. 04 to TEMA "R" as per Technical
2.4 Action 7 High Flow damage hourly lab analysis are in specification
place to reveal any
impurity. PM plans in
place
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Item
ID
Leak in heat Product (diesel) off spec. Flow transmitters at 103 C is not as per 103 C design should be Design Sr.
exchangers 103 C Low flow towards crude FRC's and Kero refinery standards changed from TEMA "C" Manager
place to reveal any
place
Leak in heat Product (furnace) off Flow transmitters at 107 C is not as per 107 C design should be Design Sr.
exchangers 107 C spec. Low flow towards crude FRC's and Kero refinery standards changed from TEMA "C" Manager
place to reveal any
place
Leak in heat 101 E inter-reflux will be Pressure transmitter with 107 CA is not as per 107 CA design should be Design Sr.
exchangers 107 CA contaminated resulting in high alarm and RV's are refinery standards changed from TEMA "C" Manager
tube side column over available at 101 E, Flow to TEMA "R" as per Technical
2.7 Action 10 High Flow pressurization . LOPC. transmitters at crude specification
Low flow towards FRC's and Kero
furnace, tubes may production available.
damage
Leak in heat Product (furnace) off Flow transmitters at 104 C is not as per 104 C design should be Design Sr.
exchangers 104 C spec. Low flow towards crude FRC's and Kero refinery standards changed from TEMA "C" Manager
place to reveal any
place
RV 155 passes Low flow towards Flow transmitters at

towards flare furnace, tubes may crude FRC's. High level
2.9 - High Flow damage. alarm in flare flare KO
vessel.
RV 104 CT passes Low flow towards Flow transmitters at
furnace, tubes may crude FRC's. Level
2.10 - High Flow damage. transmitter available at
101 E with high alarm
LCV 155 stucks in Low flow towards LA 154 available with
2.11 - High Flow open position furnace, tubes may low level alarm
damage.
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Page 20 of 102
Item
ID
Fouling of crude pre Low flow towards FR 100 available for
heat exchangers tube furnace, tubes may leakage across 101 CN
side damage. with low flow indication,
Flow transmitter (coil
FRC's)available at
furnace inlet along with
online differential
2.12 - Low Flow pressure transmitters
across each exchanger.
02 hours operator
logging in place.
Exchanger by pass
available
Pipeline leakage Low flow towards FR 100 available for

furnace, tubes may leakage across 101 CN
damage. with low flow indication,
2.13 - Low Flow Flow transmitter (coil
FRC's)available at
furnace
Manual Isolation Low flow towards FR 100 available for

valves inadvertently furnace, tubes may leakage across 101 CN
closed/partially closed damage. with low flow indication,
2.14 - Low Flow across crude Flow transmitter (coil
preheaters FRC's)available at
furnace
Gas oil flushing and Low flow towards FR 100 available for
exchanger pump out furnace, tubes may leakage across 101 CN
isolation valve passes damage. with low flow indication,
& inadvertently opens Flow transmitter (coil
FRC's)available at
furnace. Drain lines are
2.15 - Low Flow
always spaded as per
SOP. Slope tank
equipped with level
alarms
Covered under low

2.16 - Zero Flow
flow
Covered under node
2.17 - Reverse Flow
01 reverse flow
2.18 - High Level Not applicable
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Page 21 of 102
Item
ID
2.19 - Low Level Not applicable
External fire Over pressurization of Pressure transmitters LEL detectors needs to be Significant Manager
lines, line may rupture, available at crude pre installed in process area HSE HSEQ
2.20 Action 12 High Pressure LOPC heat train. RV 104 CT for early identification of
available, RV 155 HC leak in area
available at 151 F. PTW
Crude Preheat train LOPC, furnace tubes Pressure transmitters
available for safe work
inlet OR outlet may damage due to no available at crude pre
practice.
isolation valve closes OR low flow heat train. RV's available
inadvertently at 151 F, crude pump
discharge line. Flow
2.21 - High Pressure
transmitters with low
alarms are available at
crude coils
Covered in low flow

Crude preheat train Low flow towards Thi 156-1 available at

Tube side fouling furnace, tubes may 104 C outlet & Ti 101-1
resulting in low flow damage, thermal shock available at furnace
High to exchangers tubes and inlet, pressure
2.23 - may damage gaskets, transmitters available
Temperature
across crude preheat
train, 02 hours physical
logging
Low No significant safety

2.24 -
Temperature cause identified
No significant safety
Impurities (Gas, cause identified
2.25 -
Liquid, Solid)
Water carry over from High pressure in LT 155 available at 151

Change in 151 F with crude preheaters and 101 E F, LT 154 available with
Composition (eg and furnaces high level alarm,
2.26 - Concentration, 2 pressure transmitters
Phase Flow, across pre heat train
Reactions)
Equipment didn’t Equipment may damage Routine switch over and

Testing -
2.27 - function when required PM plans are in place
Equipment
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Item
ID
Plant Items No significant safety
2.28 - (Operable / cause identified
Maintainable)
Instruments - Instruments are
2.29 - Sufficient for sufficient
Control
Materials of Discussed in high flow As per Kellogg design
2.30 -
Construction guideword specs
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3 CDU Unit From 104 C outlet I/V till 101 E covering 101 B /103 B & 104 B
Pressure Design: 28.3 kg/cm2 Ops: 13 Kg/cm2
Flow Design: 7200 MTD (03 furnaces) Ops: 4600 MTD
Other
Design Intent To heat crude before feeding to 101 E
Item
ID
High Flow Furnace Tube leakage LOPC, Fire Plant monitoring / visual Presently there is no Presently there is no Asset Sr.
inspection. Scheduled protection on CDU protection on CDU damage Manager
replacement of tubes furnaces in case of furnaces in case of fire or Technology
after useful life (ref fire or other other consequences, no
Inspection plan).For consequences, no provision of ESD as wel
significant leaks Skin provision of ESD as therefore detailed
3.1 Action 13 temperature hi alarm, well engineering of CDU
Flue gas temperature, furnaces safeguarding/
furnace box protection needs to b e
temperature, flue gas conducted for the
analyzers available, provision of ESD
High Flow Flow control valves No safety consequence Flow transmitter and
wide opens temperature transmitter
with alarm available, O2
3.2 - analyzer available with
and isolation valve
available,
High Flow CDU furnaces outlet Fire, Injury, LOPC, Asset Flow transmitter with
line towards crude damage alarms available,
tower leakage pressure transmitter with
alarm available, lines
integrity inspection plan
3.3 - in place, area
surveillance by ops in
place
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Page 24 of 102
Item
ID
Low Flow Fouling in the furnace Overheating of the tubes, Skin temperature alarms
3.4 - tubes. resulting in tube rupture (TIM 101) available
and fire
Low Flow Effect of air fail on LOPC , fire, asset Furnaces feed valves Arrangement on CDU furnaces feed valves Asset Manager E
furnaces feed valve damage are equipped with lock furnace feed valve needs to be replaced with damage &I
up valve, flow transmitter are done on make standard feed control
with alarms available, shift basis valve with air fail safe
feed valve manual I/V open action. More over
3.5 Action 14
are available with a by current fail safe lock up
pass valve function test needs to be
assured in routine PM
High Flow Passing of CDU LOPC, fire Flow transmitters with HC detection
furnaces coil outlet alarms available, mechanism covered
lines drain points Pressure transmitter with under item # 2.20
isolating valves alarms available, Drain
points are end blinded,
3.6 - SOP in place for
provision of end blinds
on all drains, area
surveillance is place by
ops
Partial closing of 101 Furnace tubes may Flow and pressure 101 B coil inlet & 103 B Operations Manager P
B inlet block valves rupture, LOPC, fire transmitter available on inlet main block valve I/V improveme & U
and 103 B inlet main both furnaces with unwanted operation nts
3.7 Action 15 Low Flow block valve, operator alarm, Temp transmitter needs to be restricted by
error OR stem available at furnaces provision of appropriate
breaking outlet mechanism.
Partial closing of 103 Furnace tubes may Flow and pressure All valves which are Operations Manager P
B common outlet I/V's rupture, LOPC, fire transmitter available on business critical needs to improveme & U
and 104 B coil outlet both furnaces with be identified (Manager P nts Manager
isolation valves alarm, Temp transmitter & U) and frequency needs Inspection
available at furnaces to be developed for Manager
outlet servicing/testing (Manager Stationary
3.8 Action 16 Low Flow Inspection & Manager
Stationary) and also
unwanted operation
needs to be restricted by
provision of appropriate
mechanism
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Page 25 of 102
Item
ID
CDU furnaces feed Furnace tubes may Flow transmitter
control valves rupture, LOPC, fire available with flow
3.9 - Low Flow malfunctions alarm, by pass of each
flow control valve is
available
CDU furnaces feed Furnace tubes may Flow and temp Action item discussed
manual I/V's @ 101 B rupture, LOPC, fire, transmitter available with in furnaces
coils and 103 B assets damage alarm protection/safeguardi
3.10 - Zero Flow common valve ng ESD
inadvertently closed
OR internal gate fails
to close position
Reverse Flow Leakage in furnaces Fire, LOPC 103 B and 104 B are Provision of Manual I/V at Significant Sr.
tubes and back flow equipped with I/V's at 101 B outlet needs to be HSE Manager
from 101 E and furnace outlet to restrict studied as similar to other Technology
associated circuit reverse where as 101 B Cdu furnaces to avoid
3.11 Action 17 towards 101 B is not equipped with this back flow
arrangement to avoid
back flow
High Overfiring of furnaces Overheating of tubes Furnace temperature is

Temperature may lead to LOPC and maintained by TRC's
3.12 - fire high temperature and
deviation alarm. Skin
temperature alarms
High Furnaces tubes Tubes exposed to high Flow and temp Procedure/guidelines Asset Sr. Engr
Temperature leakage temp, HC escape to transmitter available with needs to be developed for damage Process
environment, fire, LOPC alarm, inspection plan in furnace tubes Safety
3.13 Action 18 place for tubes integrity preservation pre and post
check fabrication to avoid
ingress of foreign material
High Furnace outlet temp Tubes exposed to high 101 B, 103 B and 104 B
Temperature sensor faulty at lower temp, HC escape to outlet coils have
side environment, fire, LOPC individual temp
3.14 - indication and alarms
with skin temp and flow
meters
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Page 26 of 102
Item
ID
High CDU furnaces coil Tubes exposed to high 101 B, 103 B and 104 B All business critical Asset Manager P
Temperature outlet TRC's temp temp, HC escape to outlet coils have thermo well needs to be damage & U and
sensors thermo well environment, fire, LOPC individual temp identified (Manager P & U Manager E
3.15 Action 19 internal damage indication and alarms & Manager E & I) for &I
with skin temp and flow inspection during TA's
meters
CDU furnaces outlet No safety consequence 101 B, 103 B and 104 B

TRC's malfunctions outlet coils have
Low individual temp
3.16 - indication and alarms
Temperature
with skin temp and flow
meters
CDU furnace tubes Tubes may damage, Flow transmitters with Furnaces individual coil Asset Manager E
internal choking LOPC, fire alarms available, Local pressure indicators needs damage &I
3.17 Action 20 High Pressure PI available for to be converted into
monitoring, area transmitters
surveillance in place e
104 B and 103 B Tubes may damage, Flow transmitters with
individual common LOPC, fire alarms available, Local
3.18 - High Pressure outlet valve PI available for
inadvertently closed monitoring, area
Overfiring of furnaces Overheating of tubes Furnace temperature is
due to TRC may lead to LOPC and maintained by TRC's
3.19 - High Pressure malfunction fire high temperature and
deviation alarm. Skin
temperature alarms
Leakage in the LOPC and fire Flow transmitters with
furnace tubes alarms available, Local
3.20 - Low Pressure PI available for
monitoring, area
No significant cause
Impurities (Gas, identified
3.21 -
Liquid, Solid)
Change in Ingression of steam in Vapor expansion, LOPC, Lines are positively

Composition (eg furnaces feed line fire isolated and spaded as
3.22 - Concentration, 2 spool via decoking well. SOP in place to
Phase Flow, lines ensure spading before
Reactions) startup
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Page 27 of 102
Item
ID
PM plans are in place
Testing - for equipment testing
3.23 - and health check
Equipment
Plant Items No significant cause

3.24 - (Operable / identified
Maintainable)
Instruments - Identified in item #
3.25 - Sufficient for 3.17
Control
Materials of As per specification
3.26 -
Construction
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Page 28 of 102


4 CDU Unit CDU furnaces combustion chamber fuel system
PIDs PRL 10036 Temp Design: Gas 65 C, FO: 95 C Ops: Gas 40~45 C, Fuel oil (FO): 90 C
Pressure Design: Gas , FO: Ops: Gas: 2.3 kg/cm2, FO: 4 kg/cm2
Flow Design: Gas/FO: 15 MTD Ops: Gas/FO: 15 MTD
Other
Design Intent To provide heat to CDU feed prior separation in 101 E
Item
ID
Malfunctioning of CDU Excessive Firing in High Temperature,
furnaces TRC's furnace resulting Deviation alarm on
4.1 - High Flow overheating and flame TRC's, Skin high
impingement leading to temperature alarm on
tube failure individual furnace coil
Malfunctioning (TRC,s Flame-out of burners, fire Pilot burners are To Install Burner Asset Sr.
CV momentarily and explosion on re- available, snuffing steam Management System on damage Manager
4.2 Action 21 High Flow closed) ignition available having access CDU furnaces Technical
from remote area
Inadvertent opening of Excessive Firing in High Temperature,

CDU furnaces TRC,s furnace resulting Deviation alarm on
By-pass valve OR overheating leading to TRC's, Skin high
adjustment of furnace tube failure as well as temperature alarm
outlet temp manually high temperature of available
4.3 - High Flow via CV outlet line
Malfunctioning of CDU Low firing lead to Low Temperature/

4.4 - Low Flow furnaces TRC,s temperature decrease Deviation alarm on
resulting quality issue. TRC's are available
Malfunctioning of CDU Flame-out of burners, fire Pilot burners are Action covered under
furnaces TRC's and explosion on re- available, snuffing steam item ID # 4.2
4.5 - Low Flow ignition available having access
from remote area
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Page 29 of 102
Item
ID
Pipeline leakage LOPC and Fire Pressure transmitters
alarms are available,
4.6 - Low Flow Inspection Plan in place,
plant monitoring
Interruption of Fuel Flame-out of burners, fire Pressure Alarm at Action covered under
Supply System due and explosion on re- external gas supply item ID # 4.2
inadvertent closure ignition system available.
Separate arrangement
for Pilot burner in place.
4.7 - Low Flow
Snuffing steam available
having access from
remote area. Plant
monitoring
Burner Tips chocked Poor heating, low outlet Plant monitoring in place
4.8 - Low Flow temperature that may to check flame size
lead to quality issue
Failure of CDU Flame-out of burners, fire Alarm on TRC's. Action covered under
furnaces TRC's in and explosion on re- Separate arrangement item ID # 4.2
4.9 - Zero Flow close position ignition for Pilot burner in place.
4.10 - Zero Flow Pipeline leakage Covered in low flow

No credible cause
4.11 - Reverse Flow
found.
4.12 - High Pressure Covered in low flow
4.13 - Low Pressure Covered in high flow
High Refer to High Flow
4.14 -
Temperature
Low Refer to Low Flow
4.15 -
Temperature
Impurities (Gas, Scale in pipeline choking of burner tips Covered in Low Flow
4.16 -
Liquid, Solid)
HC liquid ingress in Excessive Firing in High Temperature,
fuel gas pipeline furnace resulting Deviation alarm on
Change in overheating leading to TRC's, Skin high
Composition (eg tube failure as well as temperature alarm
4.17 - Concentration, 2 high temperature of available. KO vessel
Phase Flow, outlet line available at upstream
Reactions) supply with high level
liquid alarm
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Page 30 of 102
Item
ID
Online field measuring
instrument and RV
Testing - testing as per PM plan
4.18 -
Equipment done
Instruments - Sufficient
Control
Plant Items No credible cause
Maintainable)
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Page 31 of 102


5 CDU Unit From 101 E inlet nozzle to bottom supply via 105 JA till run down isolation valve
PIDs PRL 10036 Temp Design: 371 C (101 E as per FW), Ops: 360 C (101 E)
Pressure Design: 2.04 Kg/cm2 (101 E), 14.5 Kg/cm2 (106 J) Ops: 1.6 Kg/cm2 (101 E)
Flow Design: 7400 MTD (101 E) Ops: 4600 MTD (101 E)
Other
Design Intent To separate crude fractions via fractional distillation and supply residue to run down tanks
Item
ID
High Flow Malfunctioning of Level of 101 E will Low Level Alarm on LC103
LC103 towards higher decrease resulting in available, Fra 102 available with
5.1 - side cavitation of 106 J flow alarms, LG104 available for
leading to pump verification
damage, spill and fire.
High Flow LC103 By-pass Valve Level of 101 E will Low Level Alarm on LC103
remains open OR decrease resulting in available, Fra 102 available with
5.2 - inadvertently opened cavitation of 106 J flow alarms, LG104 available for
High Flow Pipeline Leakage LOPC and fire Low Level Alarm on LC103 It is planned to
available, Fra 102 available with provide remote
flow alarms, LG104 available for operated block valve
verification. 101 E bottom chain instead to current
5.3 - operated valve available chain valve scheme
to minimize human
exposure incase of
heavy leakage
High Flow RV 181C fails in open HC liquid carry over to FR 102 available with alarms,
position flare KO drum, liquid LC 103 available with level
5.4 - showering from flare alarms, level alarm & level
stack, fire independent switch available at
KO drum
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Page 32 of 102
Item
ID
RV 104 C's fails in HC liquid carry over to FR 102 available with alarms,
open position flare KO drum, liquid LC 103 available with level
5.5 - Low Flow showering from flare alarms, level alarm & level
KO drum
High Flow Pump 106 J racing Level of 101 E will Low Level Alarm on LC103
decrease resulting in available, Fra 102 available with
5.6 - cavitation of 106 J flow alarms, LG104 available for
High Flow 111 C tube side Flashing in 102 E Low Level Alarm on LC103
leakage resulting in over available, Fra 102 available with
pressurization, LOPC, flow alarms, LG104 available for
fire, product off spec verification, TRCa available with
temp alarm, LC 106 available at
102 E with level alarm, Pra 102
5.7 - and TI 101-21 available at 102
E with alarm, Inspection and
PM plan in place for equipment
health check
High Flow 104 C shell side Crude oil mixed with FR 102 available with alarms,
leakage residue resulting in flash Crude FRC's available with low
point reduction in residue flow alarms, PIT 185 available
5.8 - storage tank, fire, LOPC with low pressure alarm, ,
Inspection and PM plan in place
for equipment health check
High Flow 107 C shell side Crude oil mixed with FR 102 available with alarms,
High Flow 121 C tubes leakage LOPC, fire, FAC Low Level Alarm on LC103
available, Fra 102 available with
flow alarms, LG104 available for
5.10 - verification, Inspection and PM
plan in place for equipment
health check
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Page 33 of 102
Item
ID
High Flow Tube leakage at 181 HC ingress in CW, fire 02 Hours monitoring, CW Need to explore analyzer Significant Manager E
CA, 181 C & 154 C sampling in place twice a day, for cooling water HSE &I
5.11 Action 22 inspection and PM plan in place contamination with HC
for equipment health check incase trim coolers leak
and contaminates CW
High Flow Parallel pump Level of 101 E will Low Level Alarm on LC103
operation decrease resulting in available, Fra 102 available with
5.12 - cavitation of 106 J OR flow alarms, LG104 available for
105 JA leading to pump verification, operational staff are
damage, spill and fire trained
5.13 -
Low Flow Inadvertent Opening LOPC and fire. SOPM-01, drain lines are
5.14 -
of Drain Valve spaded
Low Flow Malfunctioning of Level of 101 E will High Level Alarm on LC103 Provision of independent Significant Manager E
LC103 towards lower increase, flooding in available, Fra 102 available with high and low level alarms HSE &I
side tower, column can get flow alarms, Pra 101 available on 101 E needs to be
5.15 Action 23 hydraulic, high pressure, with high pressure alarm, explored for high and low
RV pop up, LOPC, fire LG104 available for verification, level detection
operational staff are trained
Fouling across Level of 101 E will High Level Alarm on LC103

exchanger residue increase, flooding in available, Fra 102 available with
side tower, column can get flow alarms, Pra 101 available
5.16 - Low Flow hydraulic, high pressure, with high pressure alarm,
RV pop up, LOPC, fire LG104 available for verification,
Suction strainer Level of 101 E will High Level Alarm on LC103

chokes increase, flooding in available, Fra 102 available with
tower, column can get flow alarms, LG104 available for
5.17 - Low Flow hydraulic, high pressure, verification, Pump routine
RV pop up, LOPC, fire switch over plan in place with
strainer cleaning
Manual isolation valve Level of 101 E will High Level Alarm on LC103
partially closure increase, flooding in available, Fra 102 available with
5.18 - Low Flow inadvertently tower, column can get flow alarms, LG104 available for
hydraulic, high pressure, verification
RV pop up, LOPC, fire
405186019.xls
NODE: 5
Page 34 of 102
Item
ID
Duty pump fails Level of 101 E will High Level Alarm on LC103 RV are available at
increase, flooding in available, Fra 102 available with 101 E but its vent is
tower, column can get flow alarms, LG104 available for open to atmosphere
5.19 - Zero Flow hydraulic, high pressure, verification, standby pump
RV pop up, LOPC, fire available, routine switching in
place, scheduled maintenance
in place
Pump discharge NRV Level of 101 E will High Level Alarm on LC103 NRV PM plan will be
stucks in close increase, flooding in available, Fra 102 available with developed and
position tower, column can get flow alarms, LG104 available for implemented as
5.20 - Zero Flow hydraulic, high pressure, verification, standby pump according
RV pop up, LOPC, fire available
LC103 shuts to zero Level of 101 E will High Level Alarm on LC103
OP and stucks increase, flooding in available, Fra 102 available with
5.21 - Zero Flow tower, column can get flow alarms, LG104 available for
hydraulic, high pressure, verification, by pass of LC 103
RV pop up, LOPC, fire available
complete closed increase, flooding in available, Fra 102 available with
5.22 - Zero Flow inadvertently tower, column can get flow alarms, LG104 available for
hydraulic, high pressure, verification, operational staff
RV pop up, LOPC, fire trained, SOP's in place
No credible cause
identified
5.23 - Reverse Flow
Level controller failure Level of 101 E will High Level Alarm on LC103
LC 103, close position increase, flooding in available, Fra 102 available with
5.24 - High Level (malfunction) tower, column can get flow alarms, LG104 available for
hydraulic, high pressure, verification
Covered under low
flow guideword
5.25 - High Level
405186019.xls
NODE: 5
Page 35 of 102
Item
ID
Covered under high
flow guide word
5.26 - Low Level
Covered under high

flow guide word
Covered under low

flow guideword
5.28 - Low Pressure
External fire Liquid expansion, higher Temperature and pressure

pressure, RV pop up, transmitters available with high
High LOPC, fire alarms, columns are externally
5.29 -
Temperature insulated
identified
Low
5.30 -
Temperature
identified
Impurities (Gas,
5.31 -
Liquid, Solid)

Composition (eg identified
5.32 - Concentration, 2
Phase Flow,
Reactions)
Equipment's fails to Process out of control, Scheduled maintenance PM
work when required LOPC, Fire plans are in place
Testing -
5.33 -
Equipment
405186019.xls
NODE: 5
Page 36 of 102
Item
ID
Plant Items
identified
5.34 - (Operable /
Maintainable)
Instruments - LC 103 malfunctions Circuit will be exposed to Local PI's available with
5.35 - Sufficient for with zero OP high pressure, LOPC, fire monitoring in place
Control
As per design
Materials of
5.36 -
Construction
It was observed that It was observed that Design Manager

analyzing the residue analyzing the residue Engineerin
circuit that piping circuit that piping g Office
specification is not specification is not
compliant to existing compliant to existing
process variables process variables
General therefore revalidation of
5.37 Action 24
discussion piping specification for
max pressure and temp.
Initially line from 106 J to
run down LC 103 needs to
be conducted
405186019.xls
NODE: 5
Page 37 of 102


6 CDU Unit CDU furnaces damper operation
PIDs PRL 10036 Temp Design: 341 C (103 B), 297 C (101 B), 604 C (104 B) Ops: 310 C (101 B), 380 C (103 B), 600 C (104
Pressure Design: Draft 0.12 mbar @ Arch B)
Ops: Draft
Flow Design: 1468 MTD (101 B), 536 MTD (103 B), 600 MTD (104 B)
Other
Design Intent To maintain draft inside CDU furnaces for combustion
Item
ID
High Flow High flow due to over- High tube temperature Draft pressure transmitter available with
firing inside CDU and consequent damage alarm, Tube skin TCs, TRC's and local draft
6.1 - furnaces to tubes. Fluctuation of gauge available, O2 analyzer, flow
draft on CDU furnaces. transmitters at fuel gas and fuel oil of CDU
furnaces, local monitoring in place
Inadvertently damper Fluctuation in furnace Draft pressure transmitter available with
malfunction at high draft, loss of firing, TRC's alarm, Tube skin TCs, TRC's and local draft
OP/wide open opening, fire, tubes gauge available, O2 analyzer, flow
6.2 - High Flow damage transmitters at fuel gas and fuel oil of CDU
furnaces, local monitoring in place.
Operational staff trained, PM plan in place,
SOP being followed for damper operation
Air register high OP Fluctuation in furnace Draft pressure transmitter available with
draft, loss of firing, TRC's alarm, Tube skin TCs, TRC's and local draft
opening, fire, tubes gauge available, O2 analyzer, flow
6.3 - High Flow damage transmitters at fuel gas and fuel oil of CDU
Low Flow Low flow (flue gases) Low draft in furnaces, Draft pressure transmitter available with
due to under-firing positive pressure, alarm, Tube skin TCs, TRC's and local draft
inside CDU furnaces furnace back fire gauge available, O2 analyzer, flow
6.4 - transmitters at fuel gas and fuel oil of CDU
405186019.xls
NODE: 6
Page 38 of 102
Item
ID
Damper inadvertently Positive pressure inside Draft pressure transmitter available with
closed to minimum furnaces, flame off, back alarm, Tube skin TCs, TRC's and local draft
position fire gauge available, O2 analyzer, mechanical
stopper at damper minimum opening, flow
transmitters at fuel gas and fuel oil of CDU
6.5 - Low Flow
Low Flow Air register low OP Draft disturbance inside Draft pressure transmitter available with
furnace alarm, Tube skin TCs, TRC's and local draft
gauge available, O2 analyzer, flow
6.6 - transmitters at fuel gas and fuel oil of CDU
Mechanical stop in case

6.7 -
sling breaks
405186019.xls
NODE: 6
Page 39 of 102


7 CDU Unit Gas oil circuit from 103 E inlet to run down
PIDs PRL 10037 Temp Design: 277 C (103 E) Ops: 270 C (103 E)
Pressure Design: 2.04 Kg/cm2 (101 E) Ops: 1.6 Kg/cm2 (103 E)
Flow Design: 1691 MTD Ops: 1500 MTD HSD
Other
Design Intent To stabilize gas oil and product to run down
Item Other
Action ID Guide Word Causes Consequences Controls / Safeguards Actions Category By
ID Comments
High Flow Malfunctioning of Level of 103 E will High Level Alarm on LC102 available, 101 E
LC102 towards higher increase resulting in equipped with high level and pressure
side column flooding, loss in transmitter, RV 101 E 1-3 available, RV PM
7.1 - diesel stabilization, plan in place, LG104 available @ 101 E and
LG 103 available @ 103 E for verification
High Flow Pipeline Leakage LOPC and fire Low Level Alarm on LC102 available. FRc Study needs to be carried Significant Sr.
102 available with low flow alarm. LG 103 out for provision of remote HSE Manager
available @ 103 E for verification operated block valve Technology
7.2 Action 25 incase of heavy leakage
@ bottom of 103 E
Low Flow RV 103 C fails in open HC liquid carry over to FRCa 102 available with flow alarms, LG 103
position flare KO drum, liquid available, level alarm & level independent
7.3 - showering from flare switch available at KO drum, area
stack, fire surveillance in place
High Flow Duty pump 104 J Level of 103 E will Low Level Alarm on LC102 available, Frca
racing decrease resulting in 102 available with flow alarms, LG103
7.4 - cavitation of 104 J available for verification
leading to pump
405186019.xls
NODE: 7
Page 40 of 102
Item Other
ID Comments
High Flow 109 C tube side Flashing in 102 E High level alarm on 102 E available, Pressure
leakage resulting in over transmitter available with RV for over
pressurization, LOPC, pressurization protection, FRCa 102 available
7.5 - fire, product off spec with low/high flow alarms. Temp transmitter
with high alarm available at 102 E ,
Inspection and PM plan in place for
equipment health check
High Flow 103 C shell side Crude oil mixed with gas FRCa 102 available with alarms, Crude
leakage oil resulting in flash point FRC's available with low flow alarms, PIT 185
7.6 - reduction in residue available with low pressure alarm, ,
storage tank, fire, LOPC Inspection and PM plan in place for
High Flow 115 C tube side LOPC, fire, FAC Low Level Alarm on LC102 available, Frca
leakage 102 available with flow alarms, LG103
7.7 - available for verification, Inspection and PM
plan in place for equipment health check
High Flow Tube leakage at 184 C HC ingress in CW, fire 02 Hours monitoring, CW sampling in place Need to
twice a day, inspection and PM plan in place explore
for equipment health check analyzer for
7.8 - cooling water
contamination
with HC
High Flow Parallel pump Level of 103 E will Low Level Alarm on LC102 available, Frca
operation decrease resulting in 102 available with flow alarms, LG103
7.9 - cavitation of 104 J OR available for verification, operational staff are
104 JA leading to pump trained
damage, spill and fire
7.10 -
Low Flow Inadvertent Opening LOPC and fire. SOPM-01, drain lines are spaded
7.11 -
of Drain Valve
Low Flow Malfunctioning of Level of 103 E will Low Level Alarm on LC102 available, Frca
LC102 towards lower decrease, pump 102 available with flow alarms, LG103
7.12 - side cavitation, seal damage, available for verification, operational staff are
fire, LOPC trained
Low Flow Inadvertent closing of Level of 101 E and 103 E High Level Alarm on LC103 & LC102
Frca 102 will increase, flooding in available, Frca 102 available with flow
towers, column can get alarms, Pra 101 available with high pressure
7.13 - hydraulic, high pressure, alarm, LG104 and LG 103 available for
RV pop up, LOPC, fire verification, operational staff are trained
405186019.xls
NODE: 7
Page 41 of 102
Item Other
ID Comments
Fouling across Level of 101 E and 103 E High Level Alarm on LC103 & LC102
exchanger gasoil side will increase, flooding in available, Frca 102 available with flow
towers, column can get alarms, Pra 101 available with high pressure
7.14 - Low Flow hydraulic, high pressure, alarm, LG104 and LG 103 available for
RV pop up, LOPC, fire verification, operational staff are trained
Suction strainer Level of 101 E and 103 E High Level Alarm on LC102 available, Frca
chokes will increase, flooding in 102 available with flow alarms, LG103
towers, column can get available for verification, Pump routine switch
7.15 - Low Flow hydraulic, high pressure, over plan in place with strainer cleaning.
RV pop up, LOPC, fire Stand by pump available
Manual isolation valve Level of 103 E will High Level Alarm on LC102 available, Frca
partially closure increase, flooding in 102 available with flow alarms, LG103
inadvertently tower, column can get available for verification, local PI's are
7.16 - Low Flow hydraulic, high pressure, available for pressure monitoring, operators
RV pop up, LOPC, fire are trained, SOP's available
Duty pump fails Level of 103 E will High Level Alarm on LC102 available, Frca RV are
increase, flooding in 102 available with flow alarms, LG103 available at
tower, column can get available for verification, standby pump 101 E but its
hydraulic, high pressure, available, routine switching in place, vent is open to
7.17 - Zero Flow RV pop up, LOPC, fire scheduled maintenance in place atmosphere.
Action
discussed in
node # 5
Pump discharge NRV Level of 103 E will High Level Alarm on LC102 available, Frca NRV PM plan
stucks in close increase, flooding in 102 available with flow alarms, LG103 will be
position tower, column can get available for verification, standby pump developed and
7.18 - Zero Flow hydraulic, high pressure, available, routine switching in place, implemented
RV pop up, LOPC, fire scheduled maintenance in place as according
LC102 shuts to zero Level of 103 E will Low Level Alarm on LC102 available, Frca
OP and stucks decrease, duty pump 102 available with flow alarms, LG103
7.19 - Zero Flow cavitate, seal leak, available for verification, by pass of LC 103
LOPC, fire available
405186019.xls
NODE: 7
Page 42 of 102
Item Other
ID Comments
Manual isolation valve Level of 103 E will High Level Alarm on LC102 available, Frca
complete closed increase, flooding in 102 available with flow alarms, LG103
inadvertently tower, column can get available for verification, operational staff
7.20 - Zero Flow hydraulic, high pressure, trained, SOP's in place
101 E RV pop up, LOPC,
fire
No credible cause
7.21 - Reverse Flow
identified
Level controller failure Level of 103 E will High Level Alarm on LC102 available, LG104
LC 102, close position increase, column available for verification
7.22 - High Level (malfunction) flooding, stabilize
function disturbed, no
safety consequence
Covered under low
7.23 - High Level
flow guideword
7.24 - Low Level Covered under high
flow guide word
7.25 - High Pressure Covered under high
flow guide word
7.26 - Low Pressure Covered under low
flow guideword
External fire Liquid expansion, higher Temperature and pressure transmitters No on line On line temp transmitter Significant Manager E
pressure, RV pop up, available with high alarms, columns are temp needs to be installed on HSE &I
LOPC, fire externally insulated transmitter at all run down products to
products run monitor run down temp
High down lines.
7.27 Action 26
Temperature High run down
product temp
can result in
fire
Low No significant cause

7.28 -
Temperature identified
Impurities No significant cause
7.29 - (Gas, Liquid, identified
Solid)
405186019.xls
NODE: 7
Page 43 of 102
Item Other
ID Comments
Composition identified
(eg
7.30 - Concentration
, 2 Phase
Flow,
Reactions)
Testing - Equipment's fails to Process out of control, Scheduled maintenance PM plans are in
7.31 -
Equipment work when required LOPC, Fire place
Maintainable)
Instruments - LC 103 malfunctions Circuit will be exposed to Local PI's available with monitoring in place
7.33 - Sufficient for with zero OP high pressure, LOPC, fire
Control
Materials of As per design
7.34 -
Construction
General
7.35 -
discussion
405186019.xls
NODE: 7
Page 44 of 102


8 CDU Unit From 105 J inlet suction line upto 101 E inter reflux inlet line
Pressure Design: 13.7 kg/cm2 Ops: 2.5 kg/cm2
Other
Design Intent Cool down crude tower 101 E to get proper distillation
Item
ID
High Flow Malfunctioning of FICa Level of 101 E will FICa 101 available with high OP
101 towards higher increase resulting in alarms and deviations alarm
8.1 - side (fail safe) process disturbance. No
safety consequence
High Flow FICa 101 By-pass Level of 101 E will FICa 101 available with high OP
Valve remains open increase resulting in alarms and deviations alarm
8.2 - OR inadvertently process disturbance. No
opened safety consequence
High Flow Pipeline Leakage LOPC and fire FICa 101 available with low flow
alarm, 101 E equipped with low
8.3 - level and high temp and high
pressure alarms
High Flow RV 107 CA fails in HC liquid carry over to FICa 101 available with low flow
open position flare KO drum, liquid alarm, 101 E equipped with low
showering from flare level and high temp and high
8.4 - stack, fire pressure alarms, level alarm &
level independent switch
available at KO drum
High Flow Pump 105 J racing Temp of 101 E will FICa 101 available with high
decrease resulting in deviation alarm, temp
8.5 - process variation. No transmitter & pressure
safety consequence transmitter alarms are available
405186019.xls
NODE: 8
Page 45 of 102
Item
ID
High Flow 117 C tube side Flashing in 101 E High Level Alarm on LC103
leakage resulting in over available, FICa 101 available
pressurization, LOPC, high deviation alarm, LG104
fire, product off spec available for verification, 101 E
(gasoline will travel equipped with high pressure
8.6 -
towards 101 E) alarm and pressure transmitter.
High Flow 112 C tube side Crude oil mixed with FR 102 available with alarms,
Low Flow 110 C tube side Flashing in 102 E High level alarm on 102 E
leakage resulting in over available, Pressure transmitter
pressurization, LOPC, available with RV for over
fire, product off spec pressurization protection, FICa
101 available with low flow
8.8 - alarms. Temp transmitter with
high alarm available at 102 E ,
High Flow 107 CA shell leakage Crude oil mixed with inter FICa 101 available with high
reflux resulting in crude deviation alarm, Crude FRC's
tower pressurization, available with low flow alarms,
LOPC, fire PIT 185 available with low
pressure alarm, high pressure
8.9 -
alarm available at 101 E,
High Flow 116 C air cooler tube LOPC, fire, Injury FICa available with low flow
leakage alarm, 101 E equipped with low
8.10 - level alarm, area monitoring in
place, inspection PM plan in
place
405186019.xls
NODE: 8
Page 46 of 102
Item
ID
High Flow Parallel pump Temp of 101 E will FICa 101 available with high
operation decrease resulting in deviation alarm, temp
8.11 - process variation. No transmitter & pressure
safety consequence transmitter alarms are available
8.12 -
8.13 -
Low Flow Malfunctioning of FICa 101 E temp will increase, FICa 101 available with low flow
101 towards lower high pressure, RV pop alarm, 101 E equipped with
8.14 - side up, LOPC, fire pressure and temp transmitters,
area monitoring in place, PM
plan in place
Fouling across 101 E temp will increase, FICa 101 available with low flow
exchanger residue high pressure, RV pop alarms, exchanger PM plan
8.15 - Low Flow side up, LOPC, fire being developed and followed
Suction strainer 101 E temp will increase, FICa 101 available with flow
chokes high pressure, RV pop alarms, Pump routine switch
8.16 - Low Flow up, LOPC, fire over plan in place with strainer
cleaning
Manual isolation valve 101 E temp will increase, FICa 101 available with low flow
partially closure high pressure, RV pop alarm, operation staff being
8.17 - Low Flow inadvertently up, LOPC, fire trained
Interreflux to HSD 101 E temp will increase, FICa 101 available with low flow
jump over valves high pressure, RV pop alarm, FRC 102 equipped with
inadvertently opened up, LOPC, fire high flow alarm, 101 E
8.18 - Low Flow
at higher side equipped with high pressure
and temp alarms, operation
staff being trained
Duty pump fails 101 E temp will increase, FICa available with low flow RV are available at
high pressure, RV pop alarm, 101equipped with high 101 E but its vent is
up, LOPC, fire pressure and temp alarms, RV open to atmosphere
8.19 - Zero Flow available for over
pressurization, pump change
over plan in place
405186019.xls
NODE: 8
Page 47 of 102
Item
ID
Pump discharge NRV 101 E temp will increase, FICa available with low flow NRV PM plan will be
stucks in close high pressure, RV pop alarm, 101equipped with high developed and
position up, LOPC, fire pressure and temp alarms, RV implemented as
8.20 - Zero Flow available for over according
pressurization,
FICa 101 shuts to zero 101 E temp will increase, FICa available with low flow
OP and stucks high pressure, RV pop alarm, 101equipped with high
up, LOPC, fire pressure and temp alarms, RV
8.21 - Zero Flow available for over
pressurization, FICa 101 by
pass available, CV PM plan
being followed
Manual isolation valve 101 E temp will increase, FICa available with low flow
complete closed high pressure, RV pop alarm, 101equipped with high
inadvertently up, LOPC, fire pressure and temp alarms, RV
8.22 - Zero Flow
available for over
pressurization, FICa 101 by
pass available, operator being
No credible cause trained
identified
8.23 - Reverse Flow
identified
8.24 - High Level
identified
8.25 - Low Level
Covered under low

flow
405186019.xls
NODE: 8
Page 48 of 102
Item
ID
identified
8.27 - Low Pressure

8.28 -
Temperature insulated, PTW in place
identified
Low
8.29 -
Temperature
identified
Impurities (Gas,
8.30 -
Liquid, Solid)

Phase Flow,
Reactions)
Testing -
8.32 -
Equipment
Plant Items
identified
8.33 - (Operable /
Maintainable)
Instruments - Manual isolation valve Circuit will be exposed to Local PI's available with
8.34 - Sufficient for inadvertently closed high pressure, LOPC, fire monitoring in place
Control
405186019.xls
NODE: 8
Page 49 of 102
Item
ID
As per design
Materials of
8.35 -
Construction
General
8.36 -
discussion
405186019.xls
NODE: 8
Page 50 of 102


9 CDU Unit From 101 E top reflux to 102 J back to 101 E
Pressure Design: 10 Kg/cm2 Ops: 5 kg/cm2
Other
Design Intent Cool down crude tower 101 E to get proper distillation
Item
ID
High Flow Malfunctioning of 101 E temp will be TRCa 102 deviation alarms
TRCa 102 towards decreased, no safety available with high and low
higher side (fail safe) consequence valve OP, independent temp
9.1 - transmitter available, pressure
transmitter with low alarm
available. PM plan in place
High Flow TRCa 102 By-pass 101 E temp will be TRCa 102 deviation alarms
Valve remains open decreased, no safety available with high and low
OR inadvertently consequence valve OP, independent temp
9.2 - opened transmitter available, pressure
available
Low Flow Pipeline Leakage 101 Temp will increase, Independent temp transmitter
101 E pressurized, RV available with high alarm,
9.3 - pop up, LOPC, fire pressure transmitter with high
alarm available. Inspection plan
for pipeline in place
Low Flow RV 101 CN fails in HC liquid carry over to Deviation alarm at TRCa 102
open position flare KO drum, liquid high and low OP available, level
9.4 - showering from flare alarm & level independent
stack, fire switch available at KO drum
High Flow Pump 102 J racing Temp of 101 E will Deviation alarm at TRCa 102
decrease resulting in high and low OP available,
9.5 - process variation. No independent temp transmitter
safety consequence available with low alarm
405186019.xls
NODE: 9
Page 51 of 102
Item
ID
High Flow 101 CN shell side Flashing in 101 E High Level Alarm on LC103
side leakage resulting in over available, TRCa 102 with
pressurization, LOPC, deviation and OP alarms, Crude
fire, product off spec FRC's available with flow
(crude will travel towards alarms, LG104 available for
101 E) verification, 101 E equipped
9.6 - with high pressure alarm and
pressure transmitter. Inspection
and PM plan in place for
Low Flow 116 C air cooler tube LOPC, fire, Injury Deviation alarm at TRCa 102
leakage high and low OP available,
9.7 - independent temp transmitter
available with low alarm
High Flow Parallel pump Temp of 101 E will Deviation alarm at TRCa 102
operation decrease resulting in high and low OP available
9.8 - process variation. No
safety consequence
9.9 -
Low Flow Malfunctioning of 101 E temp will increase, TRCa 102 deviation alarms
TRCa 102 towards high pressure, RV pop available with high and low
lower side up, LOPC, fire valve OP, independent temp
9.10 - transmitter available, pressure
available. PM plan in place
Fouling across 101 E temp will increase, TRCa 102 deviation alarms
exchanger top reflux high pressure, RV pop available with high and low
side up, LOPC, fire valve OP, independent temp
9.11 - Low Flow transmitter available, pressure
available. Exchanger inspection
plan in place
405186019.xls
NODE: 9
Page 52 of 102
Item
ID
Suction strainer 101 E temp will increase, TRCa 102 deviation alarms
chokes high pressure, RV pop available with high and low
up, LOPC, fire valve OP, independent temp
transmitter available, pressure
9.12 - Low Flow transmitter with low alarm
available. Strainer cleaning with
pump change over plan in place
Manual isolation valve 101 E temp will increase, TRCa 102 deviation alarms
partially closure high pressure, RV pop available with high and low
inadvertently up, LOPC, fire valve OP, independent temp
9.13 - Low Flow transmitter available, pressure
available
Duty pump fails 101 E temp will increase, TRCa 102 deviation alarms
high pressure, RV pop available with high and low
9.14 - Zero Flow transmitter available, pressure
available. Pump change over
plan in place and standby pump
in place
Pump discharge NRV 101 E temp will increase, TRCa 102 deviation alarms NRV PM plan will be
stucks in close high pressure, RV pop available with high and low developed and
position up, LOPC, fire valve OP, independent temp implemented as
9.15 - Zero Flow transmitter available, pressure according
available
TRCa 102 shuts to 101 E temp will increase, TRCa 102 deviation alarms
zero OP and stucks high pressure, RV pop available with high and low
9.16 - Zero Flow transmitter available, pressure
available, CV PM plan in place
Manual isolation valve 101 E temp will increase, TRCa 102 deviation alarms
complete closed high pressure, RV pop available with high and low
9.17 - Zero Flow inadvertently up, LOPC, fire valve OP, independent temp
transmitter available, pressure
available
405186019.xls
NODE: 9
Page 53 of 102
Item
ID
No credible cause
identified
9.18 - Reverse Flow
identified
9.19 - High Level
identified
9.20 - Low Level
Covered under low

flow
identified
9.22 - Low Pressure

9.23 -
identified
Low
9.24 -
Temperature
identified
Impurities (Gas,
9.25 -
Liquid, Solid)
405186019.xls
NODE: 9
Page 54 of 102
Item
ID
Phase Flow,
Reactions)
Testing -
9.27 -
Equipment
Plant Items identified
9.28 - (Operable /
Maintainable)
Manual isolation valve Circuit will be exposed to Local PI's available with
Instruments -
inadvertently closed high pressure, LOPC, fire monitoring in place
Control
As per design
Materials of
9.30 -
Construction
General
9.31 -
discussion
405186019.xls
NODE: 9
Page 55 of 102


10 CDU Unit From 101 E OVHD to OVHD receiver vessel
PIDs PRL 10037/10040 Temp Design: 205 C Ops: 194 C
Pressure Design: 5.7 kg/cm2 Ops: 1.58 Kg/cm2
Other
Design Intent To cool down 101 E tower top vapors
Item
ID
Pipeline leak Spill & Fire LRCa 101 available with low
level alarm, 101 F equipped
10.1 - High Flow with independent level alarm,
PRCa available with low
pressure alarm
Operator mistakenly Spill and fire All drain lines are blinded and All drains and end
opens the drain valves vents are capped as per SOP, caps not in
10.2 - High Flow around the circuit operators are trained operational use are
end capped
108 C tube side Splitter enter OVHD LRCa 101 available with high
leakage circuit, no safety level alarm, 101 F equipped
10.3 - Low Flow consequence with independent level alarm,
PRCa available with low
pressure alarm
105 C's tube leakage LOPC, fire LRCa 101 available with high
with independent level alarm,
10.4 - Low Flow PRCa available with low
pressure alarm, inspection plan
in place
123 C shell side CW ingress in OVHD 101 F equipped with LC 101

leakage with high alarm, LG101
10.5 - Low Flow available, 101 F sampling done
twice a day
405186019.xls
NODE: 10
Page 56 of 102
Item
ID
Exchanger tubes 101 E pressurization, RV Pressure transmitter available
fouling pop up, LOPC, fire across circuit for pressure delta
calculation, LRCa 101 @ 101 F
10.6 - Low Flow with low level alarm, temp
transmitter @ 101 F with high
alarm
Manual isolation 101 E pressurization, RV Pressure transmitter available

valves partially closed pop up, LOPC, fire across circuit for pressure delta
inadvertently calculation, LRCa 101 @ 101 F
alarm
No credible cause
10.8 - Zero Flow
identified
No credible cause
10.9 - Reverse Flow
identified
PRCa 101A Lower pressure in 101 F, PRCa 101A equipped with low
malfunction to higher high level in 101 F, Flare pressure alarm, PRCa 101 B
10.1 side (fail safe) KO drum filled with HC, available to balance off 101 F
- Low Pressure LOPC, fire pressure, LRCa 101 available
0
with high level alarm, LG 101
available
PRCa 101B High pressure in 101 F, PRCa 101A to release pressure

malfunctions and LOPC, fire to flare, high pressure alarms
10.11 - High Pressure opens completely available, RV available to vent
of excessive pressure, PM plan
in place
Operator mistakenly High pressure in 101 F High pressure alarms available,
10.1 closes PRCa 101a RV available to vent of
- High Pressure manual valve excessive pressure, PM plan in
2
place
105 C's fan failure due High pressure in 101 F Back up DEG available with
to power failure auto cut in. PRCa 101A
10.1 available, RV,s available A
- High Pressure 101E. LRCa 101 available with
3
low alarm, Vessel design spec
are above operating
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Item
ID
105 C's fan High pressure in 101 F PRCa 101A to release pressure
failure/break down to flare, high pressure alarms
10.1 beyond manageable available, RV available to vent
- High Pressure
4 operating Cond of excessive pressure, PM plan
in place
PRCa 101A High pressure in 101 F High pressure alarms available,
malfunctions, fully RV available to vent of
10.1 closed/stuck excessive pressure, by pass
- High Pressure
5 valve available, PM plan in
place
PRCa 101A by pass Lower pressure in 101 F, PRCa 101A equipped with low
inadvertently opens high level in 101 F, Flare pressure alarm, PRCa 101 B
KO drum filled with HC available to balance off 101 F
10.1 pressure, LRCa 101 available
- Low Pressure with high level alarm, LG 101
6
available, High level transmitter
and pump available at flare KO
drum
LRCa 101 (transmitter) High level in 101 F, Flare LRCa 101 available with high
malfunctions to lower KO drum filled with HC level alarm, LG 101 available,
10.1 High level transmitter and pump
- High Level
7 available at flare KO drum
LC 101 malfunctions High level in 101 F, hydro LRCa 101 available with high Independent high level Significant Manager E
to close position feed contamination due level alarm, LG 101 available, switch needs to be HSE &I
10.1 to water carry over, no Interface LG 102 available installed at 101 F for high
Action 27 High Level
8 safety consequence level detection
LC 101 malfunctions HC spill in area, LOPC, LRCa 101 available with high HC detector Independent low level Significant Manager E
to open position fire level alarm, LG 101 available, installation is being switch needs to be HSE &I
10.1 Interface LG 102 available, area planned installed at 101 F for low
Action 28 Low Level
9 monitoring in place level detection in case
HC's spills via drain
Leakage in the vessel Spill and Fire LRCa 101 available with low
10.2 level alarm, LG 101 available,
- Low Level Interface LG 102 available, area
0
monitoring in place
152 J/JA parallel 101 F interface level will Interface level alarm available,
10.2
- Low Level operation decrease, no safety LG 102 available, LRCa 101
1
consequence available with low level alarm
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Item
ID
Covered under low
level guide word
10.2
- Empty
2
External pool fire BLEVE RV available at 101 E for

excessive pressure relief
10.2 High
-
3 Temperature
Covered under low

level guide word
10.2 High
-
4 Temperature
No credible cause
identified
10.2 Low
-
5 Temperature
No credible cause
identified
10.2 Impurities (Gas,
-
6 Liquid, Solid)
Equipment PM plan in
10.2 Testing - place for testing
-
7 Equipment
People cross over 105 Fins get damage, heat Temporary wooden planks are Permanent cross over Asset Manager
Plant Items C fins transfer area reduction, placed, make shift platform needs to be damage Engineerin
10.2
Action 29 (Operable / fins may damage due to arrangements installed for easy access g
8
Maintainable) load from front to back side to
avoid 105 C fins from
Discussed in 101 F damaging as its used as
Instruments - low level guide word cross over
10.2
- Sufficient for
9
Control
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Item
ID
As per design
10.3 Materials of
-
0 Construction
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11 CDU Unit From 108 C shell side inlet till 102 E
Pressure Design: 7.7 Kg/cm2 Ops: 2.5 Kg/cm2
Other
Design Intent To preheat 102 E feed to achieve proper distillation in tower
Item
ID
High Flow 108 shell side leakage High level in 101 F, no FRCa 202 available with high Exchanger inspection
safety consequence flow alarm, 101 F equipped high and PM plan in place
level alarm, LG 101 available at
11.1 - 101 F, LG 104 at 101 F, low
level alarm LC106 at 102 E, LG
109 at 102 E, low pressure
alarm at 102 E,
109 C shell side Flooding in 102 E, FRCa 202 available with high Exchanger inspection
leakage products off spec, no flow alarm, 102 E equipped and PM plan in place
safety consequence high level alarm, low flow alarm
11.2 - High Flow at diesel rundown product, LG
109 at 102 E, high pressure &
high temp alarm at 102 E
110 shell side leakage Flooding in 102 E, FRCa 202 available with high Exchanger inspection
products off spec, no flow alarm, 102 E equipped and PM plan in place
safety consequence high level alarm, low flow alarm
11.3 - High Flow at FICa 101, LG 109 at 102 E,
high pressure & high temp
alarm at 102 E
Low Flow Pipeline Leakage LOPC, fire, Injury FRCa 202 available with high Pipelines inspection
flow alarm, 102 E equipped low and PM plan in place
11.4 - level alarm, LG 109 at 102 E,
low pressure & low temp alarm
at 102 E
11.5 -
of Drain Valve spaded, operators are trained
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Item
ID
Fouling across 102 E temp will FRCa 202 available with low
exchanger top reflux decrease, no safety flow alarm, 102 E equipped low
11.6 - Low Flow side consequence level alarm, LG 109 at 102 E,
low pressure & low temp alarm
at 102 E
Inadvertent partial 102 E temp will FRCa 202 available with low
closure of manual decrease, no safety flow alarm, 102 E equipped low
isolation consequence level alarm, LG 109 at 102 E,
11.7 - Low Flow low pressure & low temp alarm
at 102 E, operators are trained
Inadvertent complete 102 E temp will FRCa 202 available with low
closure of manual decrease, no safety flow alarm, 102 E equipped low
isolation consequence level alarm, LG 109 at 102 E,
11.8 - Zero Flow low pressure & low temp alarm
at 102 E, operators are trained
No credible cause
identified
11.9 - Reverse Flow
LC 106 output signal 102 E level drop to LC 106 available with low level No independent low Independent low level Asset Manager E
malfunctions and gives minimum resulting in 103 alarm, FR ?? Available on Kero level switch available switch needs to be damage &I
11.10 Action 30 Low Level high OP J cavitation, seal run down with low flow alarm, at 102 E provided at 102 E for low
damage, LOPC, fire 102 E equipped with low level protection
pressure and temp alarms,
LC 106 output signal 102 E level will rise, LC 106 available with high level No independent high Independent high level Asset Manager E
malfunctions and gives column flooding, over alarm, 102 E equipped with level switch available switch needs to be damage &I
11.11 Action 31 High Level low OP pressurization, RV pop, high pressure and temp alarms, at 102 E provided at 102 E for high
LOPC, fire LG 109 available at 102 E, RV level protection
PM plan in place
Pra 102 malfunction Operator can be mislead PRC 102, PIC 102, DPI 102-E
11.12 - Low Pressure and gives indication to are available for verification,
higher side Operators are trained ,
Instrument PM place
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Item
ID
Pra 102 malfunction Operator can be mislead PRC 102, PIC 102, DPI 102-E
and gives indication to are available for verification,
11.13 - High Pressure lower side Operators are trained ,
Instrument PM place

11.14 -
TI 101-21 malfunction Operator can be mislead TI 101-26 with temp alarms, Thi
and gives indication to 152-4, Thi 152-5 are available
Low higher side for verification, Operators are
11.15 -
Temperature trained , Instrument PM place
TI 101-21 malfunction Operator can be mislead TI 101-26 with temp alarms, Thi
and gives indication to 152-4, Thi 152-5 are available
High lower side for verification, Operators are
11.16 -
Temperature trained , Instrument PM place
Scale Distillation process may No safeguard available In TA 2014, scale Study needs to be carried Operations Sr.
deposition/formation be disturbed, quality formation will be out to install filters on 102 improveme Manager
Impurities (Gas, on 102 E internal trays issue, no safety eliminated by trays E feed and reflux streams nts Technology
11.17 Action 32
Liquid, Solid) consequence replacement in 102 E to avoid scale travelling to
tower

Phase Flow,
Reactions)
Testing -
11.19 -
Equipment
11.20 - (Operable /
Maintainable)
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Item
ID
Instruments -
Control
As per design
Materials of
11.22 -
Construction
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12 CDU Unit From 103 J suction pipe till Kero run down isolation valve including 111 C reboiler circuit
PIDs PRL 10038/10036/10040 Temp Design: 213 C Ops: 196 C
Pressure Design: 7.8 Kg/cm2 (103 J), 9 Kg/cm2 Ops: 0.79 Kg/cm2 (102 E bottom)
Other
Design Intent To cool down Kero rundown product
Item ID Action ID Guide Word Causes Consequences Controls / Safeguards Other Comments Actions Category By
High Flow Malfunctioning of Level of 102 E will Low Level Alarm on LC106,
LC106 towards higher decrease resulting in deviation alarms and OP's
side cavitation of 103 J alarm on LC106 available, Fra
12.1 - leading to pump 103 available with high flow
damage, spill and fire. indication, LG109 available for
verification, PM plan in place
High Flow LC106 By-pass Valve Level of 102 E will Low Level Alarm on LC106,
remains open OR decrease resulting in deviation alarms and OP's
inadvertently opened cavitation of 103 J alarm on LC106 available, Fra
12.2 - leading to pump 103 available with high flow
damage, spill and fire. indication, LG109 available for
verification, Operators are
trained
High Flow Pipeline Leakage LOPC and fire Low Level Alarm on LC106 It is planned to
available, Fra 103 available with provide remote
flow indication, LG109 available operated block valve
for verification. 102 E bottom instead to current
12.3 - chain operated valve available chain valve scheme
to minimize human
exposure incase of
heavy leakage
High Flow RV 102 C fails in open HC liquid carry over to FR 103 available with flow
position flare KO drum indication, LC 106 available with
low level alarm, level alarm &
12.4 - level independent switch with
pump available at KO drum
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RV 104 C's fails in HC liquid carry over to FR 102 available with alarms,
open position flare KO drum, liquid LC 103 available with level
12.5 - Low Flow showering from flare alarms, level alarm & level
KO drum
High Flow Pump 103 J racing Level of 102 E will Low Level Alarm on LC106
decrease resulting in available, Fra 103 available with
cavitation of 103 J indication, high temp reboiler
12.6 - leading to pump transmitter available at 102 E,
damage, spill and fire. LG109 available for verification
High Flow 102 C shell side Product (Kero) off spec. Flow transmitters at crude 102 C is not as per
leakage (tube side Low flow towards FRC's and Kero production FR refinery standards
crude) furnace, tubes may 103 indication available. 04
12.7 - damage hourly lab analysis are in place
to reveal any impurity. PM plans
in place
High Flow 111 C shell side Flashing in 102 E Level Alarm on LC106 111 C is not as per 111 C design should be Design Sr.
leakage resulting in over available, Fra 103 available with refinery standards changed from TEMA "C" Manager
pressurization, LOPC, indication, LG109 available for to TEMA "R" as per Technical
fire, product off spec verification, LC 106 available at specification
12.8 Action 33 102 E with level alarm, Pra 102
and TI 101-21 available at 102
E with alarm, Inspection and
PM plan in place for equipment
health check
High Flow 183 C tube side CW mixed with kerosene FR 103 available with
leakage reducing product specs, indication, 04 hours lab
12.9 - no safety consequence sampling, Inspection and PM
plan in place for equipment
health check
High Flow Parallel pump Level of 102 E will Low Level Alarm on LC106
operation decrease resulting in available, Fra 103 available with
cavitation of 103 J indication, high temp reboiler
12.10 - leading to pump transmitter available at 102 E,
damage, spill and fire. LG109 available for verification
12.11 -
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Low Flow Malfunctioning of Level of 102 E will High Level Alarm on LC106
LC106 towards lower increase, flooding in available, Fra 103 available with
side tower, column can get flow alarms, Pra 102 available
12.12 - hydraulic, high pressure, with high pressure alarm,
operational staff are trained, PM
plans in place

exchanger Kero side increase, flooding in available, Fra 103 available with
tower, column can get flow alarms, Pra 102 available
PM plan in place
Suction strainer Level of 102 E will High Level Alarm on LC106

chokes increase, flooding in available, Fra 103 available with
tower, column can get flow alarms, Pra 102 available
hydraulic, high pressure, with high pressure alarm,
12.14 - Low Flow RV pop up, LOPC, fire LG109 available for verification,
pump switching plan in place
with strainer cleaning
partially closure increase, flooding in available, Fra 103 available with
inadvertently tower, column can get flow alarms, Pra 102 available
Duty pump fails Level of 102 E will High Level Alarm on LC106 RV are available at Study needs to be carried Significant Sr.
increase, flooding in available, Fra 103 available with 102 E but its vent is out to route 102 E RV's HSE Manager
tower, column can get flow alarms, Pra 102 available open to atmosphere towards closed safe Technology
12.16 Action 34 Zero Flow hydraulic, high pressure, with high pressure alarm, network
standby pump available
Pump discharge NRV Level of 102 E will High Level Alarm on LC106 NRV PM plan will be
stucks in close increase, flooding in available, Fra 103 available with developed and
position tower, column can get flow alarms, Pra 102 available implemented as
12.17 - Zero Flow hydraulic, high pressure, with high pressure alarm, according
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LC106 shuts to zero Level of 102 E will High Level Alarm on LC106
OP and stucks increase, flooding in available, Fra 103 available with
12.18 - Zero Flow tower, column can get flow alarms, Pra 102 available
complete closed increase, flooding in available, Fra 103 available with
12.19 - Zero Flow inadvertently tower, column can get flow alarms, Pra 102 available
No credible cause
identified
12.20 - Reverse Flow
Covered under low

flow guide word
12.21 - High Level
Covered under high

flow guide word
12.22 - Low Level
Covered under low

flow/zero guide word
identified
12.24 - Low Pressure

12.25 -
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identified
Low
12.26 -
Temperature
identified
Impurities (Gas,
12.27 -
Liquid, Solid)

Phase Flow,
Reactions)
Testing -
12.29 -
Equipment
Plant Items
identified
12.30 - (Operable /
Maintainable)
Instruments - LC 103 malfunctions Circuit will be exposed to Local PI's available with
12.31 - Sufficient for with zero OP high pressure, LOPC, fire monitoring in place
Control
As per spec
Materials of
12.32 -
Construction
183 C detail drawings 183 C details drawing and Design Manager

General
12.33 Action 35 are not available engineering needs to be Engineerin
discussion
developed g Office
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13 CDU Unit From 104 E inlet line to rundown product including 104 E Interreflux
Pressure Design: 12 kg/cm2 (108 J) Ops: 1 Kg/cm2 (104 E bottom), 8.2 kg/cm2 (108 J/JA)
Other
Design Intent To strip out lighter end from Naphtha product
High Flow Malfunctioning of LC105 Level of 104 E will increase Deviation and OP alarms on LC105
towards higher side resulting in column flooding, available, high level alarm @ 102 E, 102 E
loss in naphtha stabilization equipped with high level and pressure
transmitter, RV 102 E 1-3 available, RV PM
13.1 - plan in place, LG109 available @ 102 E and
High Flow Pipeline Leakage LOPC and fire FRCa 105 available with low flow, OP and
deviation alarm, low Deviation and low OP
alarm at LC105, LG 108 available 104 E,
13.2 - low pressure alarm at PDIC 101, high and
high high alarm at TRCa 104
Low Flow RV 112 C fails in open HC liquid carry over to FICa 102 equipped with high flow
position flare KO drum, liquid transmitter, PDIC 101 with low pressure
13.3 - showering from flare transmitter available
stack, fire
High Flow Duty pump 108 J racing Level of 104 E will decrease Deviation and OP alarms on LC105
resulting in cavitation of 108 available, FRCa with OP and deviation
13.4 - J leading to pump damage, alarms, PC103 with high pressure alarm and
spill and fire. LG 108 available @ 104 E for verification
High Flow FRCa 105 by pass valve Level of 104 E will decrease Deviation and OP alarms on LC105
inadvertently opens resulting in cavitation of 108 available, FRCa 105 with OP and deviation
J leading to pump damage, alarms, PC103 with high pressure alarm and
13.5 - spill and fire. LG 108 available @ 104 E for verification,
operators are trained
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Low Flow 112 C shell side leakage Flashing in 101 E resulting PDIC 101 available with low diff pressure
in over pressurization, alarm, TRCa 104 available with high temp
LOPC, fire alarm, Frca 105 with low flow alarm, PC 103
13.6 - equipped with low pressure alarm,
inspection plan in place
Low Flow 113 C/115 C1 tube side LOPC, fire, FAC FRCa 105 with low flow and deviation alarm
leakage available, PC103 with low pressure
transmitter, FICa 102 available with low flow
alarm, PDIC 101 equipped with low pressure
13.7 - alarm, TRCa 104 with high temp alarm,
Inspection plan in place
High Flow Parallel pump Level of 104 E will decrease Deviation and OP alarms on LC105
operation resulting in cavitation of 108 available, FRCa 105 with OP and deviation
13.8 - J leading to pump damage, alarms, PC103 with high pressure alarm and
spill and fire. LG 108 available @ 104 E for verification
Low Flow Inadvertent Opening of LOPC and fire. SOPM-01, drain lines are spaded
13.9 - Drain Valve
Low Flow Malfunctioning of LC105 Level of 104 E will Deviation and OP alarms on LC105
towards lower side decrease, pump cavitation, available, FRCa 105 available with low flow
seal damage, fire, LOPC alarm, PC 103 equipped with low pressure
alarm, high level alarm @ 102 E, 102 E
equipped with high level and pressure
13.10 - transmitter, PIC 102 available for 102 E
pressure release, LG109 available @ 102 E
and LG 108 available @ 104 E for
verification
Low Flow Inadvertent closing of Level of 102 E and 104 E Deviation and OP alarms on LC105
Frca 105 will increase, flooding in available, high level alarm @ 102 E, 102 E
towers, column can get equipped with high level and pressure
hydraulic, high pressure, RV transmitter, RV 102 E 1-3 available, RV PM
13.11 - pop up(102 E), LOPC, fire plan in place, LG109 available @ 102 E and
Low Pressure PC 103 malfunction in 305 J suction pressure PC 103 low pressure alarm, FRCa 301 with
open position low, pump may cavitate, low flow alarm, manual isolation valve
13.12 - seal damage, LOPC, fire available for controlling, PM plan in place
High Pressure PC 103 malfunction in pipeline/equipment PC 103 high pressure alarm, LC 105
close position leakage, LOPC available with high level alarm, lines are
13.13 - designed for pump shut off pressure, PC103
by pass valve available, PM plan in place
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Low Pressure PC 103 by pass valve 305 J suction pressure PC 103 low pressure alarm, FRCa 301 with
inadvertently opens low, pump may cavitate, low flow alarm, manual isolation valve
13.14 - seal damage, LOPC, fire available for controlling, PM plan in place
Fouling across System pressure increased, PDIC 101 available with low diff pressure
exchanger 112 C side LOPC alarm, TRCa 104 available with high temp
13.15 - Low Flow alarm, PC103 equipped with high pressure
alarm, inspection and PM plan in place
Low Flow Fouling across 113 305 J cavitation, seal leak. FRCa 105 with low flow and deviation alarm
C/115 C1 tube side LOPC available, PC103 with low pressure
13.16 - transmitter, , LC105 equipped with high level
alarm, Inspection and PM plan in place
Suction strainer Level of 102 E and 104 E FRCa 105 with low flow alarm, PC103 with
chokes 108 J will increase, flooding in low pressure alarm, LC105 with high level
towers, column can get alarm, PDIC 101 with low diff pressure
13.17 - Low Flow hydraulic, high pressure, RV alarm, TRCa 104 with high temp alarm,
pop up (102 E), LOPC, fire pump switch over plan in place with strainer
cleaning
Manual isolation valve 305 J cavitation, Level of FRCa 105 with low flow alarm, PC103 with
partially closure 102 E and 104 E will low pressure alarm, LC105 with high level
inadvertently increase, flooding in towers, alarm, PDIC 101 with low diff pressure
column can get hydraulic, alarm, TRCa 104 with high temp alarm,
13.18 - Low Flow high pressure, RV pop up pump switch over plan in place with strainer
(102 E), LOPC, fire cleaning
Duty pump fails 305 J cavitation, Level of FRCa 105 with low flow alarm, PC103 with RV are available at
104 E will increase, flooding low pressure alarm, LC105 with high level 102 E but its vent is
in tower, column can get alarm, PDIC 101 with low diff pressure open to atmosphere.
13.19 - Zero Flow hydraulic, high pressure, RV alarm, TRCa 104 with high temp alarm, Action discussed in
pop up (102 E), LOPC, fire pump switch over plan in place with strainer
cleaning node # 5
Pump discharge NRV 305 J cavitation, Level of FRCa 105 with low flow alarm, PC103 with NRV PM plan will be
stucks in close 104 E will increase, flooding low pressure alarm, LC105 with high level developed and
position in tower, column can get alarm, PDIC 101 with low diff pressure implemented as
13.20 - Zero Flow hydraulic, high pressure, RV alarm, TRCa 104 with high temp alarm according
pop up (102 E), LOPC, fire
FRCa 105 shuts to 305 J cavitation, seal leak. FRCa 105 with low flow alarm, PC103 with
zero OP and stucks LOPC low pressure alarm, LC105 with high level
13.21 - Zero Flow alarm, FRCa 301 with low flow alarm
No credible cause
identified
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Covered under low

13.23 - High Level
flow guideword
Covered under high
13.24 - Low Level
flow guide word
Covered under low or
13.25 - High Pressure zero flow flow guide
word
Covered under low
flow guideword
External fire Liquid expansion, higher Temperature and pressure transmitters
High pressure, RV pop up, available with high alarms, columns are
13.27 - LOPC, fire externally insulated
Temperature
113 C/115 C1 fan High pressure in at Back up DEG available with auto cut in.
failure due to power PC103, LOPC, fire PC103 high pressure available, RV,s
13.28 - High Pressure failure available at 102E. PIC 102 available at
102 E, Vessel design spec are above
operating
113C/115 C1 fan High pressure in at PC103 high pressure available, RV,s
failure/break down PC103, LOPC, fire available at 102E. PIC 102 available at
13.29 - High Pressure beyond manageable 102 E, Vessel design spec are above
operating Cond operating
Low No significant cause
13.30 -
Temperature identified
Impurities (Gas, No significant cause
13.31 -
Liquid, Solid) identified
Phase Flow,
Reactions)
Testing - Equipment's fails to Process out of control, Scheduled maintenance PM plans are
13.33 -
Equipment work when required LOPC, Fire in place
Maintainable)
Control
13.36 -
Construction
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14 CDU Unit From 102 E OVHD to OVHD receiver vessel and reflux line to 102 E
Pressure Design: 10.2 Kg/cm2 (107 J shut off) Ops: 0.7 Kg/cm2
Other
Design Intent To cool down 102 E tower top vapors
Item
ID
Pipeline leak inclusive Spill & Fire LRCa 102 available with low
102 F level alarm, 102 F equipped
14.1 - Low Flow with independent level alarm,
PRCa 102 available with low
pressure alarm
Pipeline leak after 102 Spill & Fire FRCa 103 available with low
F bottom till column deviation and high OP alarms,
14.2 - Low Flow inlet LRCa 102 available with low
with independent level alarm
Operator mistakenly Spill and fire LRCa 102 equipped with low All drains and end
opens the drain valves level alarm, PRCa 102 caps not in
around the circuit available with pressure alarm, operational use are
14.3 - Low Level All drain lines are blinded and end capped
vents are capped as per SOP,
106 C's tube side LOPC, fire LRCa 102 equipped with low Incase of 106 C's Isolation valve needs to Significant Sr.
leakage level alarm, PRCa 102 leakage, no isolation be provided at 106 C's HSE Manager
14.4 Action 36 Low Flow available with pressure alarm, is available for online inlet and outlet for leakage Technology
Inspection PM plan in place, rectification rectification
124 C shell leakage Water ingress inside 102 LRCa 102 equipped with high
F, product off spec, no level alarm, PRCa 102 available
14.5 - Low Flow safety concern with high pressure alarm,
Inspection PM plan in place,
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Item
ID
Exchanger tubes 102 E pressurization, RV Pressure transmitter available
calculation, LRCa 102 @ 102 F
14.6 - Low Flow with low level alarm, PM of air
cooler and exchanger is in
place
Manual isolation 102 E pressurization, FRCa 103 available with low

valves partially closure increase in temp RV pop deviation and OP alarm,
of 107 J outlet towards up, LOPC, fire Pressure and temp transmitter
14.7 - Low Flow 102 E reflux available at 102 E top, LRCa
inadvertently 102 @ 102 F with high level
alarm, temp tra
FRCa 103 malfunction 102 E pressurization, FRCa 103 available with low
towards closure increase in temp, RV pop deviation and OP alarm,
up, LOPC, fire Pressure and temp transmitter
14.8 - Low Flow available at 102 E top, LRCa
102 @ 102 F with high level
alarm, PM plan in place
FRCa 103 malfunction 102 E top temp FRCa 103 available with low
towards wide opening reduction, process upset, deviation and OP alarm,
no safety consequence Pressure and temp transmitter
available at 102 E top, LRCa
14.9 - High Flow 102 @ 102 F with high level
alarm, manual isolation and by
pass valve available for
controlling
FRCa 103 by pass 102 E top temp FRCa 103 available with low
valve wide opening reduction, process upset, deviation and OP alarm,
inadvertently no safety consequence Pressure and temp transmitter
14.1 available at 102 E top, LRCa
- High Flow 102 @ 102 F with high level
0
alarm, manual isolation and by
pass valve available for
controlling
Pump 107 J racing OR 102 E top temp FRCa 103 available with low
standby pump reduction, process upset, deviation and OP alarm,
operation in parallel no safety consequence Pressure and temp transmitter
14.11 - High Flow available at 102 E top, LRCa
102 @ 102 F with low level
alarm
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Page 75 of 102
Item
ID
107 J suction strainer 102 E pressurization, FRCa 103 available with low
chokes increase in temp RV pop deviation and OP alarm,
- Low Flow 102 @ 102 F with high level
2
alarm, pump changeover and
strainer cleaning plan in place
Duty pump fails 102 E pressurization, FRCa 103 available with low
increase in temp RV pop deviation and OP alarm,
- Zero Flow 102 @ 102 F with high level
3
alarm, PIC 102 available with
high pressure alarm, standby
pump available
Duty pump outlet NRV 102 E pressurization, FRCa 103 available with low Critical pumps NRV
stucks to close increase in temp RV pop deviation and OP alarm, cleaning needs to be
position up, LOPC, fire Pressure and temp transmitter developed
- Zero Flow 102 @ 102 F with high level
4
alarm, PIC 102 available with
high pressure alarm
107 J trips or stops Pumps cavitate, gas NRV available, FRC 104
travel back, 102 F/102 E available with low deviation
14.1 pressurization, RV pop alarm, PIC 102/PRCa 102
- Reverse Flow
5 up, LOPC, fire available with high pressure
alarm
14.1 No credible cause
- Reverse Flow
6 identified
PRCa 102 malfunction High pressure in 102 F PIC 102 and PRCa 102 102 E RV exhaust
to higher side and 102 E, column equipped with high pressure line is open vent,
14.1 pressurization, RV pop, alarm, RV 102 E1-3 available at study needs to be
- High Pressure
7 LOPC, fire 102 E, manual valve available conducted to reroute
for isolation to safe circuit
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Item
ID
PIC 102 malfunctions Low pressure in 102 F, PRCA 102 available for Low pressure alarm to be Operations Manager E
and opens completely pump cavitate, high level controlling, FE 108 available, provided at PRCa 102 improveme & I
14.1 in 102 F, compressor LRCA 102 available with high nts
Action 37 Low Pressure damage due to liquid level alarm, PM plan in place,
8
carry over manual valve available for
isolation
Operator inadvertently High pressure in 102 F PIC 102 and PRCa 102 102 E RV exhaust
opens PRCa 102 by and 102 E, column equipped with high pressure line is open vent,
14.1 pass valve pressurization, RV pop, alarm, RV 102 E1-3 available at study needs to be
- High Pressure
9 LOPC, fire 102 E, manual valve available conducted to reroute
for isolation to safe circuit
PIC 102 upstream Incase of high pressure, PIC 102 and PRCa 102 PIC 102 upstream Significant Manager P
isolation valve closes PIC 102 function will fail, equipped with high pressure isolation valve needs to HSE &U
14.2 inadvertently system pressurization, alarm, RV 102 E1-3 available at be chain locked to avoid
Action 38 High Pressure column pressurization, 102 E inadvertently closure of
0
RV pop, LOPC, fire valve
PIC 102 downstream Incase of high pressure, PIC 102 and PRCa 102 Existing PM plan of PIC Operations Sr.
NRV to stuck to close PIC 102 function will fail, equipped with high pressure 102 and NRV servicing improveme Manager
position system pressurization, alarm, RV 102 E1-3 available at doesn't assure quality PM nts Technology
column pressurization, 102 E as handover of these
RV pop, LOPC, fire system require by pass
14.2
Action 39 High Pressure arrangement. Study
1
needs to be carried out for
safely handing over of PIC
102 and its downstream
NRV for PM
to power failure auto cut in. PIC 102 available
with high pressure alarm, RV,s
14.2 available at 102E. LRCa 102
- High Pressure
2 available with low alarm, Vessel
design spec are above
operating
106 C's fan High pressure in 102 F PIC 102 available with high
failure/break down pressure alarm, RV,s available
14.2 beyond manageable at 102E. LRCa 102 available
- High Pressure operating Cond with low alarm, Vessel design
3
spec are above operating
405186019.xls
NODE: 14
Page 77 of 102
Item
ID
PIC 102 malfunctions, Incase of high pressure, PIC 102 and PRCa 102
fully closed/stuck PIC 102 function will fail, equipped with high pressure
14.2 system pressurization, alarm, RV 102 E1-3 available at
- High Pressure column pressurization, 102 E
4
RV pop, LOPC, fire
LRCa 102 (transmitter) High level in 102 F, liquid LRCa 102 available with high
malfunctions to lower carry over to 110 J level alarm, LG 105 available,
14.2 suction, Flare KO drum 104 F KO vessel at 110 J inlet
- High Level filled with HC with high level switch, High level
5
transmitter and pump available
at flare KO drum
FRCa 104 closes to High level in 102 F, low LRCa 102 available with high
shut position OR its level in 105 E, liquid level alarm, LG 105 available,
feed isolation valve to carry over to 110 J 104 F KO vessel at 110 J inlet
105 E closes to suction, Flare KO drum with high level switch, LC 107 at
minimum inadvertently filled with HC 102 E with low level alarm,
14.2 High level transmitter and pump
- High Level available at flare KO drum,
6
FRCa 104 equipped with low
flow deviation alarm, by pass
available, operators are trained,
PM plan in place
FRCa 104 stucks at low level in 102 F, pump LRCa 102 available with low
open position cavitate, seal damage, level alarm, LG 105 available,
14.2 LOPC, fire FRCa 104 equipped with high
- Low Level
7 flow deviation alarm, isolation
valve, PM plan in place
107 J/JA parallel 102 E top temp FRCa 103 available with low
operation reduction, process upset, deviation and OP alarm,
14.2 no safety consequence Pressure and temp transmitter
- Low Level available at 102 E top, LRCa
8
102 @ 102 F with low level
alarm
Covered under low

level guide word
14.2
- Empty
9
405186019.xls
NODE: 14
Page 78 of 102
Item
ID
14.3 High
-
0 Temperature
Covered under low

flow guide word
14.3 High
-
1 Temperature
No credible cause
identified
14.3 Low
-
2 Temperature
No credible cause
identified
14.3 Impurities (Gas,
-
3 Liquid, Solid)
No credible cause Equipment PM plan in

14.3 Testing - identified place for testing
-
4 Equipment
No credible cause
14.3
- (Operable /
5
Maintainable)
Instrument sufficient
Instruments -
14.3
- Sufficient for
6
Control
As per design
14.3 Materials of
-
7 Construction
405186019.xls
NODE: 14
Page 79 of 102


15 CDU Unit From 110 JA suction line to 105 E including column
Flow Design: Ops: 923 MTD
Other
Design Intent To compress 102 F vapors and feed to 105 E
Pipeline leakage at LOPC & fire Piping inspection plan in place. PI 151 at 110 JA needs to Operations Manager E
suction/discharge of Pressure controller alarm (PIC be replaced with online improveme & I
compressor 102, PRCa 102), PTI 127 at pressure transmitter with nts
15.1 Action 40 High Flow 105 E, FE 104 with low flow indication on DCS
alarm, Local PI's available for
monitoring
Choking of 104 F High pressure at 102 F, PIC 102 available at 102 F with
demister 102 E pressurization, RV high pressure alarm, Inspection
pop, LOPC, fire of demister pad in turnaround in
15.2 - Low Flow place. PI 150/152 available for
pressure monitoring, FR 104
available for flow
110A-1 inlet strainer High pressure at 102 F, PIC 102 available at 102 F with
choking 102 E pressurization, RV high pressure alarm, PM plan
pop, LOPC, fire for strainer cleaning in place, PI
15.3 - Low Flow 150/152 available for pressure
monitoring, FR 104 available for
flow
Partial closing of High pressure at 102 F, PIC 102 available at 102 F with
suction valves of 110 J 102 E pressurization, RV high pressure alarm, PI 150/152
15.4 - Low Flow pop, LOPC, fire available for pressure
flow
Partial closing of Compressor damage, FI 104 available with low flow PT needs to be
15.5 - Low Flow discharge valves of LOPC, fire alarm ,RV 110 JA-1 and RV 110 installed at 110 JA
110 J JA -2 available discharge
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NODE: 15
Page 80 of 102
104 F drain valve in LOPC & fire FR 104 available with flow PI 152 at 110 JA needs to Operations Manager E
advertantly opens alarm, PI 152 available at converted to online improveme & I
15.6 Action 41 Low Flow suction pressure transmitter with nts
indication on DCS
Failure of 110 J High suction pressure, PIC 102 & PRCa 102 available
operation low discharge flow, 102 E with high pressure alarms, FI
15.7 - Low Flow pressurization, RV pop, 104 available with low flow
LOPC, failure alarm
Closing discharge Compressor damage, FI 104 available with low flow PT needs to be
15.8 - Zero Flow valve of 110 LOPC, fire alarm ,RV 110 JA-1 and RV 110 installed at 110 JA
inadvertently JA -2 available discharge
Closing suction valve High pressure at 102 F, PIC 102 available at 102 F with
of 110 J inadvertently 102 E pressurization, RV high pressure alarm, PI 150/152
15.9 - Zero Flow pop, LOPC, fire available for pressure
flow
Compressor trips or Compressor damage, NRV is available, FI 104
stops liquid back flow from 107 available with flow alarm, lube
15.10 - Reverse Flow J discharge oil low pressure alarm available
NRV at 110 JA stuck at Compressor damage, fire FI 104 available with low flow
15.11 - High Pressure close position and explosion. alarm ,RV 110 JA-1 and RV 110
JA -2 available
Discharge valve of Compressor damage, fire FI 104 available with low flow
15.12 - High Pressure compressor and explosion. alarm ,RV 110 JA-1 and RV 110
inadvertently closed JA -2 available
Covered under low
flow guideword
Unavailability or High discharge temp, Compressor jacket CW high
High inadvertent of compressor may damage temp alarm available
15.14 - compressor CW in
Temperature
jacket
Lube oil high temp due Compressor may Physical monitoring of lube oil Temp transmitters needs Asset Manager E
High CW unavailability damage to be provided on 110 JA damage &I
15.15 Action 42 lube oil cooler outlet lube
Temperature
side with alarms on DCS
Lube oil pump failure Compressor may Low lube oil pressure alarm and
damage tripping available, local pressure
High gauges available, 02 hours
15.16 -
Temperature monitoring and PM plan in place
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NODE: 15
Page 81 of 102
Loss of drop feed Compressor may Low pressure alarm transmitter

High lubricator damage available, 02 hours monitoring
15.17 - is in place, operators are trained
Temperature
Low temp of jacket Compressor damage due Local temp gauges available at
Low
15.18 - cooling water to HC condensation in CW return circuit, 02 hours
Temperature
compressor cylinder monitoring in place
104 F drain line Liquid carry in gas LA 106 with high level alarm
chokes stream damaging and LA 105 with high level
15.19 - High Level compressor internals shutdown logic available, LG
107 available, 02 hours draining
in place
Liquid carry over to Liquid carry in gas LA112 available with low alarm,
110A-1 suction stream damaging LA111 with low level shutdown
dampener compressor internals logic, vapor trap available, LG
15.20 - High Level 107-1 available for local
monitoring, PM plan in place
110A-1 drain line Liquid carry in gas LA112 available with low alarm,
vapor trap chokes stream damaging LA111 with low level shutdown
15.21 - High Level compressor internals logic, vapor trap available, LG
107-1 available, drain line
bypass available
Leakage in lube oil Compressor may Lube oil low level alarm
reservoir damage available, low pressure lube oil
15.22 - Low Level alarm with tripping logic
available, gauge glass available
at reservoir
Drop feed lubricator Compressor may Low pressure alarm on pump
reservoir damage discharge, local gauge
15.23 - Low Level available, 02 hours monitoring
in place
Cylinder jacket CW Compressor may Cylinder is properly designed to
Impurities (Gas,
15.24 - gets cracked damage, process upset, withstand operating conditions
Liquid, Solid)
LOPC, fire
HC liquid in Liquid carry in gas LA 112/LA 111 high level alarm
Impurities (Gas,
15.25 - compressor stream damaging and trip logic available, LG 107-
Liquid, Solid)
compressor internals 1 available
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NODE: 15
Page 82 of 102
Change in No credible scenario

Phase Flow,
Reactions)
Equipment testing
Testing -
15.27 - and PM plan is in
Equipment
place
Suction bottle drain (2 Injury No control available 110 JA suction bottle # 2 Significant Manager
Plant Items & 4) creates & 4 drain lines I/V needs HSE Drawing
15.28 Action 43 (Operable / ergonomics issue to be rerouted for easy office
Maintainable) access and safe operation
Already covered in
Instruments - above mentioned
15.29 - Sufficient for guidewords
Control
No credible cause
identified
Materials of
15.30 -
Construction
No credible cause Equipment PM plan in

Testing - identified place for testing
15.31 -
Equipment
No credible cause
15.32 - (Operable /
Maintainable)
Instrument sufficient
Instruments -
Control
405186019.xls
NODE: 15
Page 83 of 102


16 CDU Unit 105 E and bottom product to rundown
Other
Design Intent To stabilize gasoline and cool down run down for storage
High Flow Malfunctioning of Low level of 105 E, vapor LC 107 with low level alarm, Fra No independent low Independent low level Significant Manager E
LC107 towards higher escape to storage tank, 105 with low flow alarm, PTI level switch available switch needs to be HSE &I
16.1 Action 44 side LOPC, fire 127 available, LG 112 available, installed at 105 E
PM plan in place
High Flow LC107 By-pass Valve Level of 102 E will LC 107 with low level alarm, Fra No independent low
remains open OR decrease resulting in 105 with low flow alarm, PTI level switch available
16.2 - inadvertently opened cavitation of 103 J 127 available, LG 112 available,
leading to pump PM plan in place
High Flow Pipeline Leakage LOPC and fire LC 107 with low level alarm, Fra
105 with low flow alarm, LG 112
16.3 - available, PM plan in place
Low Flow 120 C tubes leakage LOPC and fire LC 107 with low level alarm, Fra
105 with low flow alarm, LG 112
16.4 - available, PM plan in place
Low Flow 182 C shell leakage Gasoline mixed with CW, LC 107 with low level alarm, Fra Installation of HC
LOPC, fire (Cooling 105 with low flow alarm, LG 112 analyzer at CW return
16.5 - tower is non classified available, CW sampling done, already discussed
area) PM plan in place
16.6 - of Drain Valve spaded and operators are
trained
405186019.xls
NODE: 16
Page 84 of 102
Low Flow Malfunctioning of 105 E flooding, over High Level Alarm on LC107
LC107 towards lower pressurization, RV pop, available, Fra 105 available with
side LOPC, fire low flow alarms, PRCa 103 with
16.7 - high pressure alarm, LG112
available for verification,
operational staff are trained, PM
plans in place

exchanger gasoline increase, flooding in available, Fra 105 available with
side tower, column can get flow alarms, PRCa 103
16.8 - Low Flow hydraulic, high pressure, available with high pressure
RV pop up, LOPC, fire alarm, LG112 available for
Manual isolation valve Level of 102 E will LC 107 high alarm, Fra 105 with
partially closure increase, flooding in low flow alarm, PTI 127
inadvertently tower, column can get available, LG 112 available, PM
16.9 - Low Flow hydraulic, high pressure, plan in place
117 C shell side Gasoline mix with IR, LC 107 available with low level
leakage splashing in crude tower, alarm, Fra 105 with low flow
over pressurization, RV alarm, PRCa 103 with low
16.10 - Low Flow pop, LOPC, fire pressure alarm, TI 101-31 with
low temp transmitter, LG 112
available for physical
verification
LC107 shuts to zero 105 E flooding, over LC 107 high alarm, Fra 105 with Independent high level Operations Manager E
OP and stucks pressurization, RV pop, low flow alarm, PTI 127 switch needs to be improveme & I
16.11 Action 45 Zero Flow LOPC, fire available, LG 112 available, PM installed at 105 E nts
plan in place
Manual isolation valve 105 E flooding, over LC 107 with high alarm, Fra 105 105 E RV exhaust is open Significant Sr.
complete closed pressurization, RV pop, with low flow alarm, PTI 127 vent which can result in HSE Manager
16.12 Action 46 Zero Flow inadvertently LOPC, fire available, LG 112 available, PM personal exposure OR fire Technology
plan in place incase RV lifts therefore
105 E RV's exhaust is line
should be routed to closed
No credible cause loop
identified
405186019.xls
NODE: 16
Page 85 of 102
Covered under low

flow guide word
16.14 - High Level
Covered under high

flow guide word
16.15 - Low Level
Covered under low

flow/zero guide word
identified

16.18 -
identified
Low
16.19 -
Temperature
identified
Impurities (Gas,
16.20 -
Liquid, Solid)

Phase Flow,
Reactions)
405186019.xls
NODE: 16
Page 86 of 102

Testing -
16.22 -
Equipment
Plant Items
identified
16.23 - (Operable /
Maintainable)
Control
As per spec
Materials of
16.25 -
Construction
105 E have single RV Provision of stand by RV Operations Sr.

with no isolation. with isolation valve needs improveme Manager
General Incase of RV passing to be provided for on line nts Technology
16.26 Action 47
discussion no standby available RV maintenance
182 C detail drawings 182 C details drawing and Design Manager

General
16.27 Action 48 are not available engineering needs to be Engineerin
discussion
developed g Office
405186019.xls
NODE: 16
Page 87 of 102


17 CDU Unit 105 E OVHD to 103 F and reflux back to 105 E and 108 F
Flow Design: 475.2 MTD Ops: 427 MTD
Other
Design Intent To cool down 105 E OVHD product for column stabilization and product cooling
Pipeline leak Spill & Fire LC 108 available with low level
alarm, PRCa 103 available with
17.1 - High Flow low pressure alarm, LG 110 for
verification
LC 108 malfunction 103 F level increase, LC108 by pass available, FIC
towards closure pressurization of 105 E, 106 available with low flow
17.2 - Low Flow RV pop up, LOPC, fire alarm, LG 110 available for
LC108 malfunction 103 F empty out, pump LC108 available with low level
towards wide opening cavitate, sea; damage alarm, FIC 106 with high flow
17.3 - High Flow LOPC, fire alarm, LC108 isolation valve
available, LG 110 available, PM
plan in place
LC108 by pass valve 103 F empty out, pump LC108 available with low level
wide opening cavitate, sea; damage alarm, FIC 106 with high flow
inadvertently LOPC, fire alarm, LC108 isolation valve
17.4 - High Flow available, LG 110 available, PM
plan in place, operators are
trained
Pump 109 J racing OR 103 F empty out, pump LC108 available with low level
standby pump cavitate, sea; damage alarm, FIC 106 with high flow
operation in parallel LOPC, fire alarm, LC108 isolation valve
17.5 - High Flow available, LG 110 available, PM
plan in place, operators are
trained
405186019.xls
NODE: 17
Page 88 of 102
109 J suction strainer 103 F level increase, LC108 by pass available, FIC
chokes pressurization of 105 E, 106 available with low flow
RV pop up, LOPC, fire alarm, LG 110 available for
17.6 - Low Flow verification, PM plan in place,
standby pump available,
strainer cleaning plan in place
Duty pump fails 103 F level increase, LC108 by pass available, FIC
pressurization of 105 E, 106 available with low flow
RV pop up, LOPC, fire alarm, LG 110 available for
17.7 - Zero Flow verification, PM plan in place,
switching plan in place
Duty pump outlet NRV 103 F level increase, LC108 by pass available, FIC
stucks to close pressurization of 105 E, 106 available with low flow
position RV pop up, LOPC, fire alarm, LG 110 available for
17.8 - Zero Flow verification, PM plan in place,
switching plan in place
FRCa 106 malfunction 105 E pressurization, FRCa 106 available with low
towards closure increase in temp, RV pop deviation and OP alarm,
17.9 - Low Flow available at 105 E top, LC 108
@ 103 F with high level alarm,
PM plan in place
FRCa 106 malfunction 105 E top temp FRCa 106 available with low
towards wide opening reduction, process upset, deviation and OP alarm,
no safety consequence Pressure and temp transmitter
available at 105 E top, LC 108
17.10 - High Flow @ 103 F with low level alarm,
manual isolation and by pass
valve available for controlling,
PM plan in place
FRCa 106 by pass 105 E top temp FRCa 106 available with low
valve wide opening reduction, process upset, deviation and OP alarm,
inadvertently no safety consequence Pressure and temp transmitter
17.11 - High Flow available at 105 E top, LC 108
@ 103 F with low level alarm,
405186019.xls
NODE: 17
Page 89 of 102
Pump 109 J racing OR 103 F low level, pump FRCa 106 available with high
standby pump cavitate, seal damage, deviation and OP alarm,
operation in parallel LOPC, fire Pressure and temp transmitter
17.12 - High Flow available at 105 E top, LC 108
@ 103 F with low level alarm
109 J suction strainer 103 F level increase, 105 FRCa 106 available with low
chokes E pressurization, deviation and OP alarm,
increase in temp RV pop Pressure and temp transmitter
up, LOPC, fire available at 105 E top, LC 108
17.13 - Low Flow @ 103 F with high level alarm,
pump changeover and strainer
cleaning plan in place
Duty pump fails 105 E pressurization, FRCa 106 available with high
increase in temp RV pop deviation and OP alarm,
17.14 - Zero Flow available at 105 E top, LC 108
Duty pump outlet NRV 105 E pressurization, FRCa 106 available with high Critical pumps NRV
stucks to close increase in temp RV pop deviation and OP alarm, cleaning needs to be
position up, LOPC, fire Pressure and temp transmitter developed
17.15 - Zero Flow available at 105 E top, LC 108
Operator mistakenly Spill and fire LC 108 available with low level All drains and end
opens the drain valves alarm, PRCa 103 available with caps not in
17.16 - High Flow around the circuit low pressure alarm, LG 110 for operational use are
verification end capped
118 C shell side 105 E OVHD circuit LC 108 available with low level
leakage travel towards CW, alarm, PRCa 103 available with
17.17 - Low Flow LOPC, fire (non low pressure alarm, LG 110 for
classified area) verification, CW sampling in
place
405186019.xls
NODE: 17
Page 90 of 102
Exchanger shell 105 E pressurization, RV Pressure transmitter available

calculation, LC 108 @ 103 F
alarm
Manual isolation 105 E pressurization, RV Pressure transmitter PTI 127

valves partially closed pop up, LOPC, fire available for top pressure, LC
17.19 - Low Flow inadvertently 108 @ 103 F with low level
alarm
Covered under low
17.20 - Zero Flow
flow guide word
No credible cause
identified
PRCa 103 malfunction 103 F pressure decrease PRCa 103 equipped with low PRCa 103 B circuit
to higher side (fail resulting in 103 F low, deviation alarm, LC 108 is spaded and LPG
17.22 - Low Pressure safe) pump cavitate, seal available with low level alarm, unit is
damage, LOPC, fire LG 110 available decommissioned
Operator mistakenly 103 F pressure decrease PRCa 103 equipped with low
open by pass valve of resulting in 103 F low, deviation alarm, LC 108
17.23 - Low Pressure PRCa 103 pump cavitate, seal available with low level alarm,
damage, LOPC, fire LG 110 available
Vent valve inadvertent LOPC, fire SOPM available, vents are

open capped, operators are trained
PRCa 103 malfunction 103 F pressure increase, PRCa 103 equipped with high 105 E RV is open to
to close position 105 E pressure rise, RV deviation alarm, RV 105 E atmosphere, close
17.25 - High Pressure pop, LOPC, fire available, PM plan in place system rerouting
required
PRCa 103 inadvertent 103 F pressure increase, PRCa 103 equipped with high
closure 105 E pressure rise, RV deviation alarm, RV 105 E
17.26 - High Pressure pop, LOPC, fire available, operators are trained
to power failure auto cut in. PRCa 101A
available, RV,s available A
17.27 - High Pressure 101E. LRCa 101 available with
low alarm, Vessel design spec
are above operating
405186019.xls
NODE: 17
Page 91 of 102
LC108 (transmitter) High level in 103 F, liquid LG 101 available, High level Independent high level Operations Manager E
malfunctions to lower carry over to fuel gas alarm at 107 F switch needs to be improveme & I
17.28 Action 49 High Level side circuit, liquid further carry provided at 103 F nts
over to fuel gas burner
Leakage in the vessel Spill and Fire LC 108 available with low level
103 F alarm, LG 110 available,
17.29 - Low Level Interface LG 111 available, area
monitoring in place
Manual draining of HC splash in area, Interface gauge LG 111 Automated interface level Operations Manager E
interface water from LOPC, fire available, operators are trained controller needs to be improveme & I
17.30 Action 50 Low Level 103 F provided for the safe nts
draining of 103 F water
side
Covered under low
level guide word
17.31 - Empty

High
17.32 -
Temperature
Covered under low

level guide word
High
17.33 -
Temperature
No credible cause
identified
Low
17.34 -
Temperature
No credible cause
identified
Impurities (Gas,
17.35 -
Liquid, Solid)
405186019.xls
NODE: 17
Page 92 of 102
Equipment PM plan in
Testing - place for testing
17.36 -
Equipment
No credible cause
17.37 - (Operable /
Maintainable)
Sufficient
Instruments -
Control
As per design
Materials of
17.39 -
Construction
405186019.xls
NODE: 17
Page 93 of 102


18 CDU Unit From 103 C outlet crude to Desalter and crude back 107 C inlet
Pressure Design: 31.7 KG/CM2 Ops: 17.1 kg/cm2
Other
Design Intent To reduce salt contents in crude oil
Pipeline leak/vessel Spill & Fire FRa 100 available with high
leak flow alarm, PDIC 159 available
with low delta pressure alarm,
crude furnaces coil individual
low flow and low deviation
18.1 - High Flow
alarms available, PIT 185
available with low pressure
alarm, line inspection PM plan
in place
PCV 159 fails to open Inadequate water mixing, FRa 100 available with high
position salt removal function flow alarm, PDIC 159 available
reduced, 151 F internal with low delta pressure alarm,
transformer may be crude furnaces coil individual
exposed to high pressure low flow and low deviation
18.2 - High Flow alarms available, PIT 185
alarm, RV 155, isolation valve
for PCV 159 available, PM plan
in place
405186019.xls
NODE: 18
Page 94 of 102
RV 155 fails in open Crude carry over to flare FRa 100 available with high
position KO drum, LOPC, fire flow alarm, crude furnaces coil
individual low flow and low
deviation alarms available, PIT
185 available with low pressure
18.3 - High Flow alarm, PDIC 159 available with
high delta P, flare KO drum
equipped with high level switch
and pump, RV PM plan in place
151 F local drain LOPC, fire FRa 100 available with high
inadvertent opened flow alarm, crude furnaces coil
individual low flow and low
deviation alarms available, PIT
185 available with low pressure
18.4 - High Flow
alarm, PDIC 159 available with
high delta P, drain lines are end
blinded, operators are trained
PCV 159 by pass Inadequate water mixing, FRa 100 available with high
valve inadvertent salt removal function flow alarm, PDIC 159 available
opened reduced, 151 F internal with low delta pressure alarm,
transformer may be crude furnaces coil individual
exposed to high pressure low flow and low deviation
18.5 - High Flow alarms available, PIT 185
alarm, RV 155, isolation valve
for PCV 159 available, PM plan
in place
Water tie in/chemical LOPC, fire, water FRa 100 available with high
injection line to crude contamination flow alarm, PDIC 159 available
line NRV fails with low delta pressure alarm,
18.6 - High Flow low flow and low deviation
alarm, NRV's are available to
avoid back flow
405186019.xls
NODE: 18
Page 95 of 102
LCV 155 fails in open Environment excursion, Fra 100 available with high flow
position inhabitant vapor alarm, crude furnace coils
excursion individual low flow transmitters
available, PIT 185 with low
pressure alarm available, LA
154 with low interface alarm
18.7 - High Flow available, LT 155 available with
low level alarm, LSL 200
available with trip logic, by pass
and isolation valve available
plan in place
LCV 155 by pass I/V Environment excursion, Fra 100 available with high flow
opened inadvertently inhabitant vapor alarm, crude furnace coils
excursion individual low flow transmitters
18.8 - High Flow 154 with low interface alarm
available, LT 155 available with
available with trip logic,
157 C shell side CW contamination with Fra 100 available with high flow
leakage effluent water and HC, alarm, crude furnace coils
LOPC, fire individual low flow transmitters
18.9 - High Flow 154 with low interface alarm
available, LT 155 available with
available with trip logic, PM plan
in place
405186019.xls
NODE: 18
Page 96 of 102
PCV 159 fails in close Pipeline may be exposed FRa 100 available with low flow
position to high pressure, LOPC, alarm, PDIC 159 available with
fire high delta pressure alarm,
18.10 - Low Flow available with low pressure
alarm, PCV 159 by pass valve
available, PCV 159 gate is
perforated to ease minimum
flow, PM plan in place
Manual isolation valve Pipeline may be exposed FRa 100 available with low flow
partially of completely to high pressure, LOPC, alarm, PDIC 159 available with
closed inadvertently fire high delta pressure alarm,
18.11 - Low Flow available with low pressure
alarm, PCV 159 by pass valve
available, PCV 159 gate is
perforated to ease minimum
flow, Operators are trained
LCV 155 fails to close Higher interface level in LA 154 with high interface alarm
position 151 F, 101 E over available, LT 155 available with
pressurization, RV pop, high interface level alarm, LSL
LOPC, fire 200 available with trip logic, 101
18.12 - High Level E equipped with high pressure
alarm and pressure releasing
system to flare, PM plan in
place
LCV 155 isolation Higher interface level in LA 154 with high interface alarm
valve inadvertent 151 F, 101 E over available, LT 155 available with
closure pressurization, RV pop, high interface level alarm, LSL
LOPC, fire 200 available with trip logic, 101
18.13 - High Level E equipped with high pressure
alarm and pressure releasing
system to flare, operators are
trained
405186019.xls
NODE: 18
Page 97 of 102
FCV 155 fails in open Higher interface level in FRC 155 available with high
position 151 F, 101 E over flow alarm, LA 154 with high
pressurization, RV pop, interface alarm available, LT
LOPC, fire 155 available with high interface
level alarm, LSL 200 available
18.14 - High Level
with trip logic, local tricock
valves available for physical
level verification, PM plan in
place
FCV 155 by pass Higher interface level in FRC 155 available with high
valve inadvertent 151 F, 101 E over flow alarm, LA 154 with high
opens pressurization, RV pop, interface alarm available, LT
18.15 - High Level
level verification, operators are
trained
153 JA racing/parallel Higher interface level in FRC 155 available with high
pump operation 151 F, 101 E over flow alarm, LA 154 with high
18.16 - High Level
trained
FCV 153 fails in open Higher interface level in FRC 153 available with high
position 151 F, 101 E over flow alarm, LA 154 with high
level alarm, LIC 155 level
18.17 - High Level controller available, LSL 200
available with trip logic, local
tricock valves available for
physical level verification, PM
plan in place
405186019.xls
NODE: 18
Page 98 of 102
FCV 153 by pass Higher interface level in FRC 153 available with high
valve inadvertent open 151 F, 101 E over flow alarm, LA 154 with high
18.18 - High Level controller available, LSL 200
available with trip logic, local
tricock valves available for
physical level verification,
FCV155/FCV153 fails Crude can slip to API, FRC 153/FRC155 available with
to close position environment excursion, low flow alarm, LA 154 with low
vapor exposure interface alarm available, LT
155 available with low interface
18.19 - Low Level
controller available, local tricock
place
FCV155/FCV153 Crude can slip to API, FRC 153/FRC155 available with

isolation valve environment excursion, low flow alarm, LA 154 with low
inadvertent open vapor exposure interface alarm available, LT
155 available with low interface
18.20 - Low Level controller available, local tricock
trained
ZCV 159 fails to close Crude can slip to API, FRC 153/FRC155 available with
position when water environment excursion, low flow alarm, LA 154 with low
flow injection is in vapor exposure interface alarm available, LT
progress 155 available with low interface
18.21 - Low Level level alarm, LIC 155 level
controller available, local tricock
place
LC 152 @ 152 F fails Level drop in 152 F, LICA 152 available with low
18.22 - Low Level to close pump 153 J/JA seal level alarm, LG 153 available
damage
405186019.xls
NODE: 18
Page 99 of 102
Pipeline leak at water Level drop in 152 F, LICA 152 available with low
18.23 - Low Level inlet line to 152 F pump 153 J/JA seal level alarm, LG 153 available
damage
Pipeline leak at down Level drop in 152 F, LICA 152 available with low Inspection plan to be Asset Sr.
stream of 152 F pump 153 J/JA seal level alarm, FRC 155/FRC 153 developed for desalter damage Engineer
damage available with low and high flow water injection, water Inspection
18.24 Action 51 Low Level alarm, LT 154 and 155 available effluent and chemical
at 151 F with low interface level injection lines
alarms, LG 153 available
156 C shell side to Low level in 151 F, HC FRC 155/FRC 153 low flow
tube leakage drain to API, environment alarm available, ZCV 159 low
excursion, vapors flow shut off protection available
18.25 - Low Level exposure LT 155 and LT 154 low interface
alarms at 151 F available, PM
plan in place
152 F inlet manual Level drop in 152 F, LICA 152 available with low
isolation valve at water pump 153 J/JA seal level alarm, FRC 155/FRC 153
side close inadvertent damage available with low and high flow
18.26 - Low Level alarm, LT 154 and 155 available
at 151 F with low interface level
alarms, LG 153 available
Manual isolation valve High level in 152 F, low LICA 152 available with high
at 152 F d/s level in 151 F level alarm, FRC 155/FRC 153
inadvertent close available with low and high flow
alarm, LT 154 and 155 available
18.27 - High Level at 151 F with low interface level
alarms, ZCS 159 low flow shut
valve logic available, LG 153
available
High pressure causes

of 151 F covered
18.28 - High Pressure under high & low flow
guide words
405186019.xls
NODE: 18
Page 100 of 102
No credible cause 152 F vent to 152 F vent to atmosphere Significant Manager

identified for 152 F as atmosphere is not is not safe, its showering HSE Engineerin
its atmospheric safe, its showering in case of crude may g
may in case of crude result in human exposure
may result in human and ultimately injury
18.29 Action 52 High Pressure
exposure and therefore rerouting of 152
ultimately injury F vent line to oily water
drain network is required
Low pressure causes

of 151 F covered
18.30 - Low Pressure under high & low flow
guide words
No credible cause
18.31 - Low Pressure identified for 152 F as
its atmospheric
151 F transformer low Transformer may TSH 202 available at Desalter transformer Asset Manager
oil level damage, Injury transformer for high temp security PM plan for TSH damage Electrical
High protection 202, PSH 201, TAH 202 &
18.32 Action 53
Temperature PAH 201 needs to be
developed
High No credible cause for
18.33 -
Temperature crude side identified
No credible cause
High
18.34 - identified for 152 F as
Temperature
its atmospheric
LCV 155 fail, close Low temp water injection LA 154 with high interface alarm
and stuck to 151 F, low available, LT 155 available with
desalination, no safety high interface level alarm, LIC
Low consequence 155 level controller available,
18.35 - local tricock valves available for
Temperature
physical level verification, by
pass valve available
Low No credible cause

18.36 -
Temperature identified for 152 F
Impurities (Gas, No credible cause
18.37 -
Liquid, Solid) identified
405186019.xls
NODE: 18
Page 101 of 102
Change in No credible cause

Phase Flow,
Reactions)
Testing - PM plan of equipment
18.39 -
Equipment is in place
Plant Items No credible cause
Maintainable)
18.41 -
Construction
405186019.xls
NODE: 18
Page 102 of 102

Cdu Hazop PRL Sep 2014

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HAZOP RECORD - MINUTES Revision 0 Final Issue

TO record minutes in WORKSHOP

Column Name Contents Comments

Minute ID Numbered automatically NO DATA ENTRY

PIDs Enter PID / Rev number details. Enter manually

Actions Enter details as required - For each

To generate Summary Sheet

PROJECT PRL CDU HAZOP September 2014here

The last entries in the columns

Session Dates Team Leader Scribe Main Systems / Scope Covered

Type Drawing / Doc No Rev Date Title Comments

Type Drawing / Doc No Rev Date Title Comments

Node System Node Description P&IDs

PROJECT PRL CDU HAZOP September 2014

High Flow General discussion

Reverse Flow batch 2

Misdirected Flow batch3

High Level batch4

Low Level batch5

High Pressure batch7

Low Pressure batch8

High Temperature batch9

Low Temperature batch10

Impurities (Gas, Liquid, Solid) batch11

Change in Composition (eg Concentration, 2 batch12

General discussion General discussion General discussion

Services Required Too Low etc 4

Breakdown Too far test

Startup Wrong position

Shutdown High speed

Effluent (gaseous, liquid, solid) Low speed

Fire / Explosion Reverse

Safety Equipment Obstacles

Breakdown - Fuel / power Too large

Impurities (Gas, Liquid, Solid) Too small

Earthing/Isolation Loss of Power Supply Loop Inputs -

Environment Loop Performance

Increased Temperature Loop Overview

Order of Execution How Commissioning

Commissioning Sequence Control and

Quality requirements Sequence Timing

Modification Control Impact on continuous

PROJECT PRL CDU HAZOP September 2014

Node System Node Description

Down stream manual Low flow in furnace FR 100 available with

1101 J/JA suction OR Low flow in furnace FR 100 available with

Covered under low

Change in No significant cause

Plant Items No cause identified

PROJECT PRL CDU HAZOP September 2014

Node System Node Description

RV 155 passes Low flow towards Flow transmitters at

Pipeline leakage Low flow towards FR 100 available for

Manual Isolation Low flow towards FR 100 available for

Covered under low

Covered in low flow

Crude preheat train Low flow towards Thi 156-1 available at

Low No significant safety

Water carry over from High pressure in LT 155 available at 151

Equipment didn’t Equipment may damage Routine switch over and

PROJECT PRL CDU HAZOP September 2014

Node System Node Description

High Overfiring of furnaces Overheating of tubes Furnace temperature is