HAZOP

HAZOP RECORD FORM Facility/Project MEG Reclamation Pilot Plant

Date 10/12/2014 Team Members Ana Carmem G. B.; Ana Maria G. L.; Bernardo de Sa R.; Gabriel V. S.; Gabriela F. F.; Maximiano K. F.; Raphael de Souza R.

Drawing No./Procedure 26164_P&ID_001 Subject From Chemical Dosing Tank (F100) to the Flash Separator (K200), passing through Pump J100

DEVIATION

CAUSE

High Mixing

Agitator failure (1)

Low Mixing

As for (1); paddle stirrers corrosion and/or erosion High feed rate to dosing tank (F100)

High Level

Low Level

High Flow

EFFECT

SAFEGUARDS

Temperature rise; salt’s properties alteration; vortex formation; paddle stirrers corrosion and/or erosion Desired homogeneity not achieved; pump’s erosion

Speed indicator (SIC100); mixing motor (M100); hand switch (HS100) (2)

Flooding; pressure surges (4)

Level transmitter (L100); manual drain connected to a valve (V100) (5)

Pump (J100) or valve (V101) failure

As for (4)

As for (5); Flow controller (FC102); hand switch (HS102) (6)

Low feed rate to dosing tank (F100) Pump (J100) racing

Paddle stirrers corrosion; sludge formation (8) As for (8)

Level transmitter (L100)

Pump (J100) racing

Dosing tank (F100) pressure lost; flash separator (K200) pressure gain; low level on dosing tank; high level on flash separator (K200); pump (J100) cavitation

As for (6); valve (V103) and manual drain point – valve (V100)

As for (2)

As for (6)

ACTION Send a specialist to fix the motor in order to control the agitator’s velocity (3) As for (3) Install a high level alarm; automatic switch of valve (V100) connected to level transmitter (L100) Pump and valve regular maintenance; install a speed frequency controller (7) Install a low level alarm As for (7) Install a flow transmitter (9); pump regular maintenance (10)

DEVIATION

CAUSE

EFFECT

Low Flow

Pump (J100) racing; pump (J100) cavitation;

High level on dosing tank(F100); low level on flash separator (K200); dosing tank pressure gain; flash separator pressure lost (11) As for (11)

As for (6)

As for (9); as for (10)

As for (6)

As for (9); valve regular maintenance (12)

As for (11)

As for (6)


As for (11);

As for (6); manual drain point from valve (V100) (13) Chemical dosing tank mixing motor controller (SIC100)

As for (9);

No Flow

Manual drain point failure (valve V100 failure : opened all time); Valve (V101,V102,NRV201) failure: obstructed route Pump (J100) failure

Commissioning

Wrong installation of an equipment or instrument such as a mixing motor, a pump or a valve

Dosing tank (F100) mixing motor failure; Pump (J100) failure; valve (V100, V101, V102, NRV201) failure

Contaminants

Paddle stirrers corrosion; pump (J100) corrosion; pump (J100) erosion;

Contaminate the solution; change solution’s properties;

SAFEGUARDS

No safeguards

ACTION

Install a motor controller on pump J100; pump and valve regular maintenance (14) As for (14)


Date 10/12/2014

Drawing No./Procedure 26164_P&ID_001

Team Members Ana Carmem G. B.; Ana Maria G. L.; Bernardo de Sa R.; Gabriel V. S.; Gabriela F. F.; Maximiano K. F.; Raphael de Souza R.

Subject From Pump J100 to the Pump J101 passing through the Feed Tank (F101)

DEVIATION

CAUSE

High Level

Increase in the input flow on the feed tank (F101) due to the higher pump (J100) race

Low Level

EFFECT

SAFEGUARDS

ACTION

Flooding; pressure surges

Hand switch on pump J100 (HS102); flow controller on pump J100 (FC102) (1); manual drain connected to a valve (V107); manual drain connected to a valve (V109) (2)

Pump (J101) or valve (V108) failure

Flooding; pressure surges

As for (2); feed pump (J101) over temperature; feed pump (J101) motor controller

Low feed rate on the feed tank (F101) due to a failure on pump J100

Process inefficiency since the feed tank F101 is the mainly tank in the system (6)

Pump J101 failure

As for (6)

As for (1); level switch indicating the feed tank F101 low level (LSL101) (7) As for (7); feed pump (J101) over temperature; feed pump (J101) motor controller

Install a level transmitter; install a high level alarm on the feed tank F101 (3); pump regular maintenance (4) As for (3); install an automatic switch of valve (V107,V109) connected to level transmitter; as for (4); valve regular maintenance (5) Increase the inlet flow of reagents (8) As for (8)

DEVIATION

CAUSE

High Flow

Pump (J100) racing

Low Flow

Pump (J100) racing; valve V103 failure; pump (J100) cavitation

No Flow

Pump (J100) failure; closed valve

High Concentration

Low Concentration

EFFECT Feed tank (F101) pressure gain; high level on feed tank (F101); pump (J101) cavitation Feed tank (F101) pressure lost; low level on feed tank (F101) (9)

SAFEGUARDS

ACTION Install a flow transmitter

As for (9)

As for (1); manual drain connected to a valve (V107); manual drain connected to a valve (V109); As for (1); Level switch indicating the feed tank F101 low level (LSL101) (10) As for (10)

Pump J100 racing (12)

Flash separator inefficiency (13)

Valve V103 and flow controller FC102 (14)

As for (12)

As for (13)

As for (14)

Install a flow transmitter before entering the feed tank (15) As for (15)

Commissioning

Wrong installation of an equipment such as a pump or a valve

Pump (J100,J101) failure; valve failure (V103,V107,V108,V109)

Feed pump (J101) over temperature alarm (TSH101)

As for (11)

Contaminants

Pump (J100) corrosion; pump (J100) erosion; valve (V103,V108) corrosion due mechanical friction

Contaminate the solution; change solution’s properties

No safeguards

As for (11)

Pump and valve regular maintenance (11) As for (11)


Date 10/12/2014



Subject Feed recycle loop from the Pump J101 back to the Feed Tank (F101)

DEVIATION High Flow

Low Flow

No Flow

CAUSE

EFFECT

SAFEGUARDS

ACTION

Pump (J101) racing

Increase in the recycle flow (1) Feed pump (J101) over temperature sensor (TE101), feed pump (J101) motor controller (SIC101) and feed pump (J101) over temperature alarm (TSH101) (2)

Install a flow transmitter (3); pump regular maintenance (4)

Valve (V111,V112) failure: opened route

As for (1)

As for (3); valve regular maintenance (6)

Pump (J101) racing; pump (J101) cavitation

Decrease in the recycle flow (6)

The valve type can be considered a safeguard since a globe valve uses a plug closing against the flow being good for regulating flow while the ball valve has a gate that closes across the flow that is better for on/off control without pressure drop (5) As for (2)

Valve (V111, V112) failure: obstructed route

As for (6)

As for (5)

As for (4)


Pump and valve maintenance (7)

Pump (J101) or valve No recycle loop back to the (V111,V112) failure feed tank (F101)

As for (3)

DEVIATION

CAUSE

Commissioning

Wrong installation of an equipment such as a pump or a valve Pump (J101) corrosion; pump (J101) erosion; valve (V111,V112) corrosion due mechanical friction

Contaminants

EFFECT Pump (J101) failure; valve failure (V111,V112)

SAFEGUARDS As for (2)

Contaminate the solution; No safeguards change in solution’s properties

ACTION As for (7) As for (7)


Date 10/12/2014



Subject Feed line from the Pump (J101) up to the Flash Separator (K200)

DEVIATION High Flow

CAUSE Pump (J101) racing

No Flow

SAFEGUARDS

ACTION

Feed tank (F101) pressure lost, flash separator (K200) pressure gain, low level on feed tank, high level on flash separator (K200) and pump (J101) cavitation (1) As for (1)

Feed pump (J101) over temperature sensor (TE101), feed pump (J101) motor controller (SIC101) and feed pump (J101) over temperature alarm (TSH101) (2) No safeguards

Pump (J101) racing; pump (J101) cavitation

Feed tank (F101) pressure gain, flash separator (K200) pressure lost, high level on feed tank and low level on flash separator (K200) (7)

As for (2)

Install a flow controller; install a flow transmitter; valve regular maintenance (4) As for (3)

Valve (V113, NRV200) failure: obstructed route

As for (7)

No safeguards

As for (4)

Pump (J101) failure

As for (7)

As for (2)

As for (3)

Valve (V113,NRV200) failure

As for (7)

No safeguards

As for (4)

Valve (V113, NRV200) failure: opened route

Low Flow

EFFECT

Install a flow controller, install a flow transmitter and pump regular maintenance (3)



Drawing No./Procedure 26164_P&ID_001 Subject From Storage Tank (R500) to the Feed Tank (F101)

DEVIATION

CAUSE

EFFECT Flooding; high pressure on storage tank (R500)

SAFEGUARDS

High Level (R500)

Failure of pump J400

Valve leaving the storage tank

Low Level (F101)

Failure of pump J500 (1) Inefficiency of the process since feed tank (F101) must always have a minimum level

Level control with pump J101

High Flow

As for (1)

Level rise on feed tank (F101) and level drop on storage tank (R500)

Valves installed before and after pump J500 allow regular maintenance of the pump; flow transmitter (FT101) (2)

Low Flow

As for (1)

Failure to increase the level on feed tank (F101) and/or failure to decrease the level on storage tank (R500)

As for (2)

ACTION Install a level transmitter and controller on storage tank (R500), connected to pump J500 Install a level transmitter and controller on feed tank (F101), connected to pump J500 as a second alternative Regular maintenance of the pump (3) As for (3)

DEVIATION

CAUSE

EFFECT

Contaminants

Corrosion/erosion of pump J500 and/or corrosion/erosion of valve leaving the storage tank (R500) and valve V106

Inefficiency of the process since it won’t have pure MEG

SAFEGUARDS Valves installed before and after pump J500 allow regular maintenance of the pump

ACTION Regular maintenance of the valves and the pump



Drawing No./Procedure 26164_P&ID_001 Subject From the Flash Separator (K200) to Valves V200, V201 and V203

DEVIATION

CAUSE

High Temperature

Failure in communication between controllers of the flash separator with controllers of the heat exchanger (H300) (1); overheat in the flash separator due to: heat exchanger (H300) and/or HS204, TE211, TT211, TIR211, TE212, TSH212, TZAH212 malfunction As for (1); heat exchanger (H300) and/or HS204, TE211, TT211, TIR211, TE212, TSH212, TZAH212 malfunction; malfunction of valves V309 and/or V310, PCV300

Low Temperature

EFFECT Change in solution and salt crystals properties; MEG degradation

SAFEGUARDS

Valve V204; instruments HS204, TT211, TIR211, TSH212, temperature sensors (TE211,TE212), high temperature alarm (TZAH212) and communication between controllers of the flash separator with controllers of the heat exchanger (H300); temperature sensor TE202 and transmitter TT202 could predict this outcome Inefficient MEG separation; Instruments HS204, TT211, lower salt concentration due TIR211, TSH212; to the higher presence of temperature sensors MEG, leading to a salt (TE211,TE212) and solution provided by the pipe communication between containing the valve V203 with controllers of the flash less salt than expected for the separator with controllers of heating recycle flow, and the heat exchanger (H300) probably more water and MEG

ACTION Decrease the temperature by less steam input into the heat exchanger (H300); maintenance and, if that is the case, fixing of the pipelines

Increase the temperature by more steam input on heat exchanger H300; maintenance and, if that is the case, fixing of the pipelines

DEVIATION High Pressure

High Level

Low Level

CAUSE Failure of the vacuum system; high flow into the flash separator (K200) from heat exchanger (H300) and from the feed and dosing tank (F101 and F100 respectively) combined or not with failure (not opening) of the valves V200, V201, V202, V203 (2); malfunction of the safeguards related to pressure, temperature and level (3) As for (2); as for (3)

As for (3); pump racing (J300); low flow into the flash separator (K200) from heat exchanger (H300) and from the feed and dosing tank (F101 and F100 respectively) combined or not with failure (not closing) of the valves V200, V201, V202, V203, V302, V303, V305; failure (closure) of valve NRV200

EFFECT

SAFEGUARDS

A flammable atmosphere at a temperature above the flash point may be created in the gas space within the Flash Separator, which can result in explosions

Valve V222; pressure instruments PI202, PT203, PIR203 and PIC203 connected to the pressure control valve PCV203; level instruments LT200, LTC200, LR200 and level controller LTC200 connected with heat exchanger (H300) controllers (4)

Can lead to a high pressure problem, as stated above; flooding

As for (4); valve V200 leading to a manual bleed point; flow transmitter FT200 and controller FCT200 Vortex breaker connected with As for (4); valve V202 may not deliver flow transmitter FT200 and the correct amount and controller FCT200 concentration of solution for the heating recycle flow; corrosion of equipment

ACTION Use the valve V222 and the vacuum system, always avoiding sources of ignition anywhere within the flash separator (K200)

Maintenance of the valves of the MEG Rig plant Maintenance of the valves of the MEG Rig plant; fix the pump J300

DEVIATION

CAUSE

Static Build-up

Presence of salts and variations in pressure, temperature and composition of liquid/gas Vortex formation due to vortex breaker malfunction

High Mixing

EFFECT

SAFEGUARDS

ACTION

Source of ignition

Instruments CT200, TI200, TIR200, CI200, CIR200

Correct concentration of salts into the solution

Vapour may go into the liquid, which make the separation process not as efficient as it would and should be

Vortex breaker located inside Maintenance and fixing the Flash Separator (K200) of the vortex breaker



Drawing No./Procedure 26164_P&ID_001 Subject From the Valve V202 to the Heat Exchanger (H300)

DEVIATION

CAUSE

High Temperature

Overheat in the flash separator due to: heat exchanger (H300) and/or HS204, TE211, TT211, TIR211, TE212, TSH212, TZAH212 malfunction; failure in communication between Controllers of the flash separator with controllers of the heat exchanger (H300) (1) The overheat in flash separator (K200) leads to a high temperature liquid arriving into the recycle pump Recycle pump (J300) racing (4)

EFFECT

SAFEGUARDS

ACTION

Change in solution and salt crystals properties; MEG degradation (2)

Valve V204; hand switch HS204; temperature instruments TT211, TIR211, TSH212; temperature sensors (TE211,TE212); communication between controllers of the flash separator with controllers of the heat exchanger (H300); high temperature alarm (TZAH212)

Decrease the temperature by less steam input into the heat exchanger (H300); maintenance and, if that is the case, fixing of the pipelines (3)

As for (2)

Temperature Instruments TE315, TSH315 and high temperature alarm (TZAH315)

As for (3)

High flow of a liquid with higher temperature

Temperature instruments TW322, TE322, TIR320, TDIR321, TIR322 and temperature controller TDCR321 (5)

Fix the recycle pump

DEVIATION

CAUSE

EFFECT

SAFEGUARDS

Low Temperature

As for (1); heat exchanger (H300) and/or HS204, TE211, TT211, TIR211, TE212, TSH212 malfunction; malfunction of valves V309 and/or V310, PCV300

Inefficient MEG separation; lower salt concentration due to the higher presence of MEG, leading to a salt solution provided by the pipe containing the valve V203 with less salt than expected for the heating recycle flow, and probably more water and MEG High flow into the heat exchanger (H300) may lead to an insufficient heating of the solution

As for (4); As for (5); temperature sensor (TE315)


Flow control instruments SIC300, SIR300, HS304, FT302, DIR302, FIR302, TIR323 (6); valves V303, V305 (leading to a manual drain point) As for (6); level controllers connected to the flash separator vessel (K200) As for (6)

Maintenance and fixing of the pump, the last one only if it’s necessary

As for (6)

Maintenance of the pipeline, paying special attention to the valves V303 and V305, that shouldn’t be always opened, and the valve V302 that mustn’t be always jammed or closed

High Flow

As for (4)

Low Flow

Low Level in Flash Separator (K200)

Pump failure

Recycle pump (J300) failure related to poor suction conditions

Cavitation; low flow into the heat exchanger (H300) may lead to a solution overheated; cavitation inside the recycle pump (J300) Low flow into the heat exchanger (H300) may lead to a solution overheated; cavitation inside the recycle pump (J300)

Drain leaking; valve jammed

ACTION

Look for problems related to the level of solution inside the flash Maintenance and fixing of the pump, the last one only if it’s necessary

DEVIATION

CAUSE

EFFECT

Low Flow

High concentration of salt due to low level inside the flash or errors related to the concentration of salt given by the dosing tank Recycle pump (J300) failure Valve V302 jammed and not opening at all

Blockage of pump and/or valves; low flow into the heat exchanger (H300) may lead to a solution overheated; cavitation inside the recycle pump (J300) Failure of all the heating system of the flash Failure of all the heating system of the flash

As for (6)

Gas locking due to presence of gas if the vortex breaker doesn’t work properly Recycle pump (J300) failure (pump reversed)

Heating system inefficient

As for (6)

Failure of all the heating system of the flash

As for (6)

No Flow

Reverse Flow

SAFEGUARDS

As for (6) As for (6)

ACTION Maintenance of the system and attention to the concentration of salt measured in the bottom part of the flash separator Fix the pump Change or maintenance of the valve V302 Maintenance of the vortex breaker Fix the recycle pump (J300)



Drawing No./Procedure 26164_P&ID_001 Subject From the Heat Exchanger (H300) to the Flash Separator (K200)

DEVIATION

CAUSE

EFFECT

SAFEGUARDS

ACTION

High Temperature

Overheat in the flash separator due to: heat exchanger (H300) and/or HS204, TE211, TT211, TIR211, TE212, TSH212, TZAH212 malfunction

Change in solution and salt crystals properties; MEG degradation; If the fluid is overheated, the flash separator (K200) may have its temperature risen, which can cause high pressure problems into the vessel

Valve V204; hand switch HS204; temperature instruments TT211, TIR211, TSH212; temperature sensors (TE211,TE212) (1); high temperature alarm (TZAH212); communication between controllers of the flash separator with controllers of the heat exchanger (H300) (2) temperature instruments TE315, TSH315, TW322, TE322, TIR320, TDIR321, TIR322, TW320, TE320, TW319, TE319, TSH319 and temperature controller TDCR321 (3); high temperature alarm TZAH315; high temperature alarm TZAH319; valve V205

Decrease the temperature by less steam input into the heat exchanger (H300); maintenance and, if that is the case, fixing of the pipelines

DEVIATION

CAUSE

EFFECT

High Temperature

Failure of communication among the following controllers: TDCR321, LTC200 and PCV300 (4)

If the fluid is overheated, the flash separator (K200) may have its temperature risen, which can degrade MEG and cause high pressure problems into the flash vessel as well (5)

Failure (not opening) of valves V311, V312 and V313 As for (4)

As for (5)

Failure (not closing) of valves V311, V312 and V313 Not enough steam from building supply into the heat exchanger (H300) due to: pressure indicator PI204 malfunction; valves V309 and/or V310 jammed or fail to open

As for (9)

Low Temperature

If the fluid is not hot enough, the flash separator (K200) may not be efficient to vaporize the MEG/water mixture (9)

As for (9)

SAFEGUARDS Temperature controller TDCR321, temperature instruments TIR320, TDIR321, TIR322, TW320, TE320, TW319, TE319, TSH319 (6); high temperature alarm TZAH319 (7); valve V205 (8) As for (6); as for (8) Temperature instruments TW322, TE322, TIR320, TDIR321, TIR322, TW320, TE320, TW319, TE319, temperature controllers TDCR321 (10) As for (10) As for (10); pressure indicator PI204

ACTION Maintenance and if it is necessary, change or fix the controllers

Maintenance and if it is necessary, change of fix the valves Maintenance and if it is necessary, change or fix the controllers

Maintenance and if it is necessary, change of fix the valves Maintenance and if it is necessary, change or fix the controllers and valves

DEVIATION

CAUSE

EFFECT

Low Temperature

Heat exchanger (H300) and/or HS204, TE211, TT211, TIR211, TE212, TSH212, TZAH212 malfunction

As for (1); as for (2); as for (3)


High Flow

Leak in heat exchanger (H300), promoting steam and solution mixture

Inefficient MEG separation; lower salt concentration due to the higher presence of MEG, leading to a salt solution provided by the pipe containing the valve V203 with less salt than expected for the heating recycle flow, and probably more water and MEG Solution overheated, composition changed, ingress of steam can lead to presence of contaminants that can react with the solution or equipment, damaging the operation As for (9); high flow into the heat exchanger (H300) may lead to an insufficient heating of the solution

Pressure indicator PI204; speed viewing device SG301; temperature instruments TE320, TW320, TW319, TE319, TSH319; high temperature alarm TZAH319; valve V205 As for (10); speed/frequency instruments SIC300, SIR300, hand switch HS304 and flow control instruments FT302, DIR302, FIR302, TIR323 (11); valves V303, V305 (leading to a manual drain point)

Fix the heat exchanger

Pump failure

As for (11); level controllers connected to the flash separator Vessel (K200)

Look for problems related to the level of solution inside the flash

Recycle pump (J300) racing

Low Flow

Low level in flash separator (K200)

SAFEGUARDS

ACTION


DEVIATION Low Flow

CAUSE Recycle pump (J300) failure related to poor suction conditions

High concentration of salt due to low level inside the flash or errors related to the concentration of salt given by the dosing tank Valve V205 malfunction, half or completely opened when it shouldn’t be Drain leaking

No Flow

Valve V302, V304 or V204 jammed and not opening at all Gas locking due to presence of gas if the vortex breaker doesn’t work properly Heat exchanger (H300) leaking all the fluid outside the system

EFFECT

SAFEGUARDS

ACTION

As for (5); cavitation; low flow into the heat exchanger (H300) may lead to a solution overheated, which can rise the pressure in the flash vessel (K200); cavitation inside the recycle pump (J300) As for (5); blockage of pump and/or valves; low flow into the heat exchanger (H300) may lead to a solution overheated, which can rise the pressure in the flash vessel (K200) Less volume of heated solution into the flash vessel can lead to an inefficient separation of MEG/water from salt As for (5); low flow into the heat exchanger (H300) may lead to a solution overheated, which can rise the pressure in the flash vessel (K200); Failure of all the heating system of the flash (13)




Maintenance of the system and attention to the concentration of salt measured in the bottom part of the flash separator

Level controller LTC200 and level recorder LR200 (12)

Maintenance and if it is necessary, fix the valve

Flow control instruments FT302, DIR302, FIR302, TIR323

Check valves V303 and V305

As for (11)

As for (13)

As for (11)

Change or maintenance of the valve V302 Maintenance of the vortex breaker

As for (13)

As for (12)

Fix or change the heat exchanger (H300)

DEVIATION Reverse Flow High Pressure

CAUSE Recycle pump (J300) reversed High temperature

EFFECT

SAFEGUARDS

As for (13)

As for (12)

Rise of pressure in the flash separator (K200)


ACTION Maintenance of the plant Use valve V222 and check possible problems in the plant that led to high temperature



Drawing No./Procedure 26164_P&ID_001 Subject From the Separation Column (E200) to the Bleed Down (R403) and the Sampling Receiver (R404)

DEVIATION

CAUSE

EFFECT

SAFEGUARDS

ACTION

Temperature sensors (TE306,TE308,TE310,TE312); high temperature alarms (TZAH306,TZAH308,TZAH310, 312) Temperature sensors (TE306,308,310,312); sampling receiver (R404)

Decrease the temperature by less steam input on heat exchanger H300

High temperature

Overheat in the flash separator

Change in solution and salt crystals properties; MEG degradation

Low temperature

Flash separator temperature under set point

Inefficient MEG separation; lower salt concentration due to the higher presence of MEG

Blockage in separation column due to incrustation and/or salt accumulation Failure in vacuum pump (J200); failure in valves V409 and/or V411

Flooding; corrosion; erosion; break of salt loop operation.

Bleed down (R403); high level alarms (LZAH300, LZAH301,LZAH302,LZAH303)

No testing (no sample collection due to the lack of pressure difference). The separation column (E200) will be at the same pressure as the bleed down (R403) and the sampling receiver (R404) Motor temperature rise; vortex formation

Pressure indicators (PI400,PI401,PI402,PI403).

High level

High pressure testing

High speed

Motor malfunction (M300,301,302,303) (1)

Temperature controllers (TIC305,307,309,311); hand switches (HS300,HS301,HS302,HS303)

Increase the temperature by more steam input on heat exchanger H300 Regular maintenance of the separation column (E200) Install high pressure alarms; vacuum pump (J200) regular maintenance; valves V409 and V411 regular maintenance Motor (M300,M301,M302, M303) regular maintenance (2)

DEVIATION Low speed

CAUSE As for (1)

EFFECT Insufficient wash of the MEG residue from the salts

SAFEGUARDS Conductivity transmitters (CT300,CT301,CT302, CT303,CT304); sampling receiver (R404) to analyse MEG concentration

ACTION As for (2)



Drawing No./Procedure 26164_P&ID_001 Subject Salt loop (from R400 to R401 and back to R400)

DEVIATION No Flow

CAUSE

EFFECT

SAFEGUARDS

No feed to salt tank

No production of brine (1); column full of salt

Conductivity control in the column

Pump J401 failure

As for (1)

Speed frequency control, temperature control and pressure control in the pump Flow rate transmitters (FT400,401,402)

No water feed into the brine tank; valve V428 closed in error Line blockage/closed valve Line fracture High Flow

Pump J401 racing

Low Flow

Pump J401 failure

ACTION Install level alarm on R400 (2)

As for (2); regular maintenance in the pump As for (1); Regular maintenance high salt concentration in the in the valve (3); stream install level alarm on R401; composition transmitter in pipelines As for (1); Temperature sensor (TE403); Regular maintenance overload of the pump J401 FT400,FT401,FT402 in the valves As for (1); FT400,FT401,FT402 Regular inspection in leakage the lines Low level of salt tank; high Speed frequency control, Regular maintenance pressure stream in brine tank; temperature control and in the pump (4); low pressure in salt tank; pump pressure control in the pump; open valves V416, temperature rise manual drain; V419 or V420 FT400,FT401,FT402 Low production of brine (5) Speed frequency control, As for (4) temperature control, pressure control in the pump; FT400,FT401,FT402

DEVIATION

CAUSE

Low Flow

Sedimentation of salts in pipes

High Concentration Low Concentration

High Level (R400)

High Level (R401)

EFFECT

SAFEGUARDS

As for (5); line blockage; change in desired fluid properties and concentration As for (5)

FT400,FT401,FT402

As for (5)

FT402

High water feed to R401 J401 failure

Change in desired fluid properties (6) As for (5); as for (6)

FT402

High feed to R400 from the column

Flooding in R400 (7)

High feed from brine tank J401 failure

As for (7)

Line blockage

As for (7)

High water feed

Flooding in R401 and change in brine composition (9)

Low water influx to R401 Low water feed to R401

As for (7)

Flow transmitter (FT402)

Speed frequency control; temperature control; pressure control in the pump Conductivity control in the column; manual drain point (V416) FT400; Manual drain point (V416) Speed frequency control, temperature control and pressure control in the pump; manual drain point (V416 and V419) FT400,FT401,FT402; manual drain point (V416, V419 and V420) FT402; manual drain point (V425); valves V428 and V429

ACTION Regular inspection in the lines; install composition transmitter in pipelines Increase water feed Increase water feed; install composition transmitter in pipelines Decrease water feed As for (4) Install high level alarm in R400 (8); open drain point As for (8); open drain point As for (4); as for (8); open drain point As for (8); regular inspection in the lines; open drain point Install high level alarm in R401 (10); open drain point; close V428 or V429

DEVIATION

CAUSE

EFFECT

High Level (R401)

High feed from salt tank (J401 racing)

As for (9); pump temperature rise

Low Level (R400)

Low feed from the column

Change in brine composition (11)

Low feed from brine tank J401 racing

As for (11)

Low water feed

As for (11); accumulation of salt in pipelines As for (11)

Low Level (R401)

Low feed from salt tank (J401 failure)

As for (11); pump temperature rise

SAFEGUARDS

ACTION

Speed frequency control, temperature control, pressure control in the pump; manual drain point (V425); valve V417 Conductivity control in the column; level switches in column FT400

As for (4); as for (10); close V417; open drain point

Speed frequency control, temperature control, pressure control in the pump FT402

As for (12)

Speed frequency control, temperature control and pressure control in the pump

As for (12); regular maintenance in the pump

Install low level alarm in R400 (12) As for (12)

As for (12); increase water feed

HAZOP RECORD FORM Facility/Project MEG Reclamation Pilot Plant Drawing No./Procedure 26164_P&ID_001 Subject From the Flash Separator (K200), to the Condensate Separator Tank (K300) passing through condenser C201 and sub-cooler C301

DEVIATION


CAUSE

High Flow

Pump (J200) racing

Low Flow

Pump (J200) failure

High Temperature

Low/no flow of chilled water input on condenser C201 and sub-cooler C301; valves jammed (V221 and V306)

Low temperature

High flow of chilled water input on condenser C201 and sub-cooler C301

EFFECT Inefficient process of condensation in condenser C201 and sub-cooler C301 (1); leak in condenser C201 and sub-cooler C301; flash separator (K200) pressure loss Flash separator (K200) pressure gain; cavitation in pipelines; presence of foreign body from corrosion; sedimentation; leak in condenser C201 and subcooler C301 As for (1); change in solution properties (4)

As for (4)

SAFEGUARDS

ACTION

Hand switch (HS200); vacuum control valve PCV203 (2)

Install a speed frequency controller in pump J200 and a flow transmitter (3)

As for (2)

As for (3); regular maintenance of condensers

Flow indicators (FI202,301); temperature sensors (TE204,205,316,317), transmitters (TT204,205,316,317) and indicators & recorders (TIR204,205,316,317) (5) As for (5)

Install a flow controller in the chilled water feed associated with the temperature indicators & recorders (TIR204,316) (6) As for (6)

DEVIATION

CAUSE

High Pressure

Failure of condenser C201 and/or sub-cooler C301 in cooling the solution of MEG/water

EFFECT Insufficient MEG/water solution recovered; high pressure in condensate separator tank (K300)

SAFEGUARDS No safeguards

ACTION Install a high pressure alarm; install a pressure indicator on K300

HAZOP RECORD FORM Facility/Project MEG Reclamation Pilot Plant Drawing No./Procedure 26164_P&ID_001 Subject From Condenser 201 to Storage Tank (R500), passing through Vacuum Trap (K201), Vacuum Receiver (K202) and Condensate Separator Tank (K300)

DEVIATION High Temperature

Low Temperature High Pressure


CAUSE

EFFECT

SAFEGUARDS

ACTION

Ventilated place without hot surfaces for the J200 pump work Ventilated place without hot surfaces for the J400 pump work Temperature indicators TW318, TE318, TT318, TIR318, valve V431 Presence of vacuum trap K200 and receiver K201

Install temperature indicator in the pump (2) As for (2)

No ventilation around the J200 pump

Pump damage and/or malfunction (1)

No ventilation around the J400 pump

As for (1)

Failure of sub-cooler C301, leading J400 pump to heat Cold fluid entrance in J200 pump

As for (1)

Obstruction in the line connected to the J200 pump

Pump damage; failure of J200 Valves V213 and V214,; to provide vacuum vacuum trap K200 and receiver K201 (3)

Liquid entrance in the J200 Water vapour entrance above J200 pump capacity Obstruction in the line connected to the J400 pump

J200 pump damage, lubrication oil compromised Condensing fluid dissolves in pump oil; pump corrosion

J200 pump damage, condensing fluid


Pump damage; failure of J400 No safeguards to drive the MEG/water liquid mixture

Regular maintenance of sub-cooler C301 Temperature control of the air entering the pump Install relief valve downstream from the pump (4) Install extra pressure indicator/controller No action As for (4)

DEVIATION Low Pressure

Failure of Vent Failure of Power

Failure of Vacuum

Reverse Flow

CAUSE

SAFEGUARDS

ACTION

Low flow and poor efficiency of J200 Risk of J400 pump to air suction; cavitation

Vacuum control valve PCV203

Correct dimensioned pipes Regular maintenance (5)

Rise in J200 pump temperature and pressure Failure of J200 to provide vacuum and drive the MEG/water mixture (6)

Vent to a safe location

As for (5)

Computer monitoring of the hand switch

Electrical failure of hand switch HS400

Failure of J400 to drive the MEG/water mixture (7)

Computer monitoring of the hand switch

Internal/component problem of J200 pump

As for (6)

Obstruction in line near J200 pump

As for (6)

Respect the working conditions, lifetime and lubrication of the pump No safeguards

Install backup generator; check the connection between the switch and the J200 pump Install backup generator; check the connection between the switch and the J400 pump Regular maintenance, testing and lubrication As for (4)

Failure of valves V411 or V409

Failure of J200 to provide vacuum to bleed down R403 and sampling receiver R404 As for (7)

Narrow diameter pipes High flow in J400 pump, stoking so fast that the fluid can’t be pulled or sucked into the chamber as fast as the diaphragm is withdrawing, lowering pressure Failure of vent to drive the output of J200 pump Electrical failure of hand switch HS200

Failure of J400 diaphragm pump internal check valves

EFFECT

Hand switch HS400

Pressure indicators PI400, PI401, PI402, PI403

As for (5)

No safeguards

Install check valve before the entrance of the J400 pump

DEVIATION

CAUSE

Reverse Flow

Sudden power cut to J200 pump leads to low inertial force of rotating parts, that can’t overcome system head (blowback) Overpressure in pipeline; failure of vacuum Line blockage near J200 pump Line blockage near J400 pump

No Flow

High Flow

Low Flow

Vapour appearance near J400 pump, cavitation Failure of valve V222 Failure of vacuum control valve PCV203 Failure of speed indicator controller SIC400 Partial blockage near J200 pump J200 pump malfunction Partial blockage near J400 pump J400 pump malfunction Failure of speed indicator controller SIC400 (jammed low)

EFFECT

SAFEGUARDS

ACTION

As for (6)

No safeguards

Install check valve before the entrance of J200

As for (6)

As for (3)

Install extra pressure indicator/controller

As for (6)

As for (3)

As for (4)

Danger to the process No safeguards stability and continuation, as it stops the MEG/water drive Pump damage, stop to the Speed indicator controller process SIC400 (8)

As for (4)

Vacuum control valve PCV203 won’t control the adequate level of vacuum (9) As for (9)

Hand switch HS200 (10) As for (10)

Install flow rate controller/transmitter (11) As for (11)

Risk of J400 pump to air suction, cavitation

Hand switch HS400

As for (5)

As for (6)

Vacuum control valve PCV203

As for (11)


Vacuum control valve PCV203 As (8)


As for (7) Low J400 pump efficiency

As (8) No safeguards


Install temperature indicator

DEVIATION

CAUSE

Contaminants

Failure of sintered filter Z203, allowing contaminated air to enter the vacuum system Water or any other liquid entering the pump J200 Contaminant in the oil lubricant of the J200 pump

As for (1)

Valve V205

As for (5)

As for (1)

As for (3)

As for (5)

As for (1)

Check lubricant and clean filters regularly, replace when necessary

As for (5)

Contaminant in the oil lubricant of the J400 pump Corrosion of vessels or instrument near J400 pump, contaminating fluid Condenser C201, flash separator K200 or mixing tank F101 failure

As for (1)

Check oil level and clean filters regularly, replace when necessary Valve V205

As for (5)

Temperature indicators and transmitters in the condenser C201 and flash separator K200 (12) As for (12)

As for (5)

Valve V205; vacuum control valve PCV203 (13)

Install level indicator (14)

As for (13)

As for (14)

Valves V408 and V433

As for (14)

High Concentration

Low Concentration

Condenser C201, flash separator K200 or mixing tank F101 failure

High Level

Failure of valve V213 to open Failure of valve V214 to open Failure of valve V412 to open

EFFECT

As for (1)

High concentration of MEG/water vapour (>90%) causes J200 pump to fail to drive the mixture Low concentration of MEG/water vapour (<20%) causes J200 pump to fail to drive the mixture High level of liquid in K201 vacuum trap, danger to J200 pump High level of liquid in K202 vacuum receiver, danger to J200 pump High level in R403 bleed down, unable to take sample

SAFEGUARDS

ACTION

As for (5)

As for (5)

DEVIATION

CAUSE

High Level

Failure of valve V413 to open Failure of speed indicator controller SIC400, lowering speed of J400 pump Failure of discharge valve after storage tank R500

EFFECT

SAFEGUARDS

ACTION

High level in R404 sampling receiver unable to take sample High level in condensate separator tank K300


As for (14)

Valve V307; level indicators LSL305 and LSL306

As for (5)

High level in storage tank R500


As for (14)

HAZOP

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