HAZOP

HAZOP RECORD FORM Facility/Project MEG Reclamation Pilot Plant

Drawing No./Procedure 26164_P&ID_001

Subject From Chemical Dosing Tank (F100) to the Flash Separator (K200), passing through Pump J100

DEVIATION

CAUSE EFFECT SAFEGUARDS ACTION

High Mixing

Agitator failure (1)

Temperature rise; salt’s properties alteration; vortex formation; paddle stirrers corrosion and/or erosion

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

Send a specialist to fix the motor in order to control the agitator’s velocity (3)

Low Mixing

As for (1); paddle stirrers corrosion and/or erosion

Desired homogeneity not achieved; pump’s erosion

As for (2) As for (3)

High Level

High feed rate to dosing tank (F100)

Flooding; pressure surges (4) Level transmitter (L100); manual drain connected to a valve (V100) (5)

Install a high level alarm; automatic switch of valve (V100) connected to level transmitter (L100)

Pump (J100) or valve (V101) failure

As for (4) As for (5); Flow controller (FC102); hand switch (HS102) (6)

Pump and valve regular maintenance; install a speed frequency controller (7)

Low Level

Low feed rate to dosing tank (F100)

Paddle stirrers corrosion; sludge formation (8)

Level transmitter (L100) Install a low level alarm

Pump (J100) racing As for (8) As for (6) As for (7)

High Flow

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)

Install a flow transmitter (9); pump regular maintenance (10)

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.

DEVIATION


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 (6) As for (9); as for (10)

Manual drain point failure (valve V100 failure : opened all time);

As for (11) As for (6) As for (9); valve regular maintenance (12)

Valve (V101,V102,NRV201) failure: obstructed route

As for (11) As for (6) As for (9); as for (12)

No Flow Pump (J100) failure As for (11); As for (6); manual drain point from valve (V100) (13)

As for (9);

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

Chemical dosing tank mixing motor controller (SIC100)

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

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

Contaminate the solution; change solution’s properties;

No safeguards As for (14)



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

DEVIATION


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

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)

Install a level transmitter; install a high level alarm on the feed tank F101 (3); pump regular maintenance (4)

Pump (J101) or valve (V108) failure

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

As for (3); install an automatic switch of valve (V107,V109) connected to level transmitter; as for (4); valve regular maintenance (5)

Low Level 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)

As for (1); level switch indicating the feed tank F101 low level (LSL101) (7)

Increase the inlet flow of reagents (8)

Pump J101 failure As for (6) As for (7); feed pump (J101) over temperature; feed pump (J101) motor controller

As for (8)

Date 10/12/2014


DEVIATION


High Flow Pump (J100) racing Feed tank (F101) pressure gain; high level on feed tank (F101); pump (J101) cavitation

As for (1); manual drain connected to a valve (V107); manual drain connected to a valve (V109);

Install a flow transmitter

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

Feed tank (F101) pressure lost; low level on feed tank (F101) (9)

As for (1); Level switch indicating the feed tank F101 low level (LSL101) (10)

Pump and valve regular maintenance (11)

No Flow Pump (J100) failure; closed valve

As for (9) As for (10) As for (11)

High Concentration Pump J100 racing (12) Flash separator inefficiency (13)

Valve V103 and flow controller FC102 (14)

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

Low Concentration

As for (12) As for (13) As for (14) 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




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

DEVIATION


High Flow 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) 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 (3); valve regular maintenance (6)

Low Flow Pump (J101) racing; pump (J101) cavitation

Decrease in the recycle flow (6)


Valve (V111, V112) failure: obstructed route


No Flow Pump (J101) or valve (V111,V112) failure

No recycle loop back to the feed tank (F101)

As for (2); as for (5)

Pump and valve maintenance (7)

Date 10/12/2014


DEVIATION


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

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


Contaminants Pump (J101) corrosion; pump (J101) erosion; valve (V111,V112) corrosion due mechanical friction

Contaminate the solution; change in solution’s properties




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

DEVIATION


High Flow Pump (J101) racing 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)

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

Valve (V113, NRV200) failure: opened route

As for (1) No safeguards Install a flow controller; install a flow transmitter; valve regular maintenance (4)

Low Flow 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)


Valve (V113, NRV200) failure: obstructed route

As for (7) No safeguards As for (4)

No Flow Pump (J101) failure As for (7) As for (2) As for (3)

Valve (V113,NRV200) failure

As for (7) No safeguards As for (4)

Date 10/12/2014




Subject From Storage Tank (R500) to the Feed Tank (F101)

DEVIATION


High Level (R500) Failure of pump J400 Flooding; high pressure on storage tank (R500)

Valve leaving the storage tank Install a level transmitter and controller on storage tank (R500), connected to pump J500

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 Install a level transmitter and controller on feed tank (F101), connected to pump J500 as a second alternative

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)

Regular maintenance of the pump (3)

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)


Date 10/12/2014


DEVIATION


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

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

Regular maintenance of the valves and the pump



Subject From the Flash Separator (K200) to Valves V200, V201 and V203

DEVIATION


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

Change in solution and salt crystals properties; MEG degradation

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

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

Low Temperature

As for (1); heat exchanger (H300) and/or HS204, TE211, TT211, TIR211, TE212, TSH212, TZAH212 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

Instruments HS204, TT211, TIR211, TSH212; temperature sensors (TE211,TE212) and communication between controllers of the flash separator with controllers of the heat exchanger (H300)

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

Date 10/12/2014


DEVIATION


High Pressure 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)

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)

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

High Level As for (2); as for (3)

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

Maintenance of the valves of the MEG Rig plant

Low Level

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

Vortex breaker connected with valve V202 may not deliver the correct amount and concentration of solution for the heating recycle flow; corrosion of equipment

As for (4); flow transmitter FT200 and controller FCT200

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

DEVIATION


Static Build-up Presence of salts and variations in pressure, temperature and composition of liquid/gas

Source of ignition Instruments CT200, TI200, TIR200, CI200, CIR200

Correct concentration of salts into the solution

High Mixing Vortex formation due to vortex breaker malfunction

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

Vortex breaker located inside the Flash Separator (K200)

Maintenance and fixing of the vortex breaker



Subject From the Valve V202 to the Heat Exchanger (H300)

DEVIATION


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)

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)

The overheat in flash separator (K200) leads to a high temperature liquid arriving into the recycle pump

As for (2) Temperature Instruments TE315, TSH315 and high temperature alarm (TZAH315)

As for (3)

Recycle pump (J300) racing (4)

High flow of a liquid with higher temperature

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

Fix the recycle pump

Date 10/12/2014


DEVIATION


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


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


High Flow As for (4) High flow into the heat exchanger (H300) may lead to an insufficient heating of the solution

Flow control instruments SIC300, SIR300, HS304, FT302, DIR302, FIR302, TIR323 (6); valves V303, V305 (leading to a manual drain point)

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

Low Flow

Low Level in Flash Separator (K200)

Pump failure As for (6); level controllers connected to the flash separator vessel (K200)

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

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)

As for (6) Maintenance and fixing of the pump, the last one only if it’s necessary

Drain leaking; valve jammed

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

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

DEVIATION


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

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)

As for (6) Maintenance of the system and attention to the concentration of salt measured in the bottom part of the flash separator

No Flow Recycle pump (J300) failure

Failure of all the heating system of the flash

As for (6) Fix the pump

Valve V302 jammed and not opening at all


As for (6) Change or maintenance of the valve V302

Gas locking due to presence of gas if the vortex breaker doesn’t work properly

Heating system inefficient As for (6) Maintenance of the vortex breaker

Reverse Flow Recycle pump (J300) failure (pump reversed)


As for (6) Fix the recycle pump (J300)



Subject From the Heat Exchanger (H300) to the Flash Separator (K200)

DEVIATION


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

Date 10/12/2014


DEVIATION


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)

Temperature controller TDCR321, temperature instruments TIR320, TDIR321, TIR322, TW320, TE320, TW319, TE319, TSH319 (6); high temperature alarm TZAH319 (7); valve V205 (8)

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

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

As for (5) As for (6); as for (8)

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

Low Temperature

As for (4) If the fluid is not hot enough, the flash separator (K200) may not be efficient to vaporize the MEG/water mixture (9)

Temperature instruments TW322, TE322, TIR320, TDIR321, TIR322, TW320, TE320, TW319, TE319, temperature controllers TDCR321 (10)

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

Failure (not closing) of valves V311, V312 and V313

As for (9) As for (10) Maintenance and if it is necessary, change of fix the valves

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) As for (10); pressure indicator PI204

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

DEVIATION


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

Solution overheated, composition changed, ingress of steam can lead to presence of contaminants that can react with the solution or equipment, damaging the operation

Pressure indicator PI204; speed viewing device SG301; temperature instruments TE320, TW320, TW319, TE319, TSH319; high temperature alarm TZAH319; valve V205

Fix the heat exchanger

Recycle pump (J300) racing

As for (9); high flow into the heat exchanger (H300) may lead to an insufficient heating of the solution

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)


Low Flow

Low level in flash separator (K200)

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

DEVIATION


Low Flow Recycle pump (J300) failure related to poor suction conditions

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)



High concentration of salt due to low level inside the flash or errors related to the concentration of salt given by the dosing tank

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)


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

Valve V205 malfunction, half or completely opened when it shouldn’t be

Less volume of heated solution into the flash vessel can lead to an inefficient separation of MEG/water from salt

Level controller LTC200 and level recorder LR200 (12)

Maintenance and if it is necessary, fix the valve

Drain leaking

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);

Flow control instruments FT302, DIR302, FIR302, TIR323

Check valves V303 and V305

No Flow Valve V302, V304 or V204 jammed and not opening at all

Failure of all the heating system of the flash (13)

As for (11) Change or maintenance of the valve V302

Gas locking due to presence of gas if the vortex breaker doesn’t work properly

As for (13) As for (11) Maintenance of the vortex breaker

Heat exchanger (H300) leaking all the fluid outside the system

As for (13) As for (12) Fix or change the heat exchanger (H300)

DEVIATION


Reverse Flow

Recycle pump (J300) reversed

As for (13) As for (12) Maintenance of the plant

High Pressure

High temperature Rise of pressure in the flash separator (K200)


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



Subject From the Separation Column (E200) to the Bleed Down (R403) and the Sampling Receiver (R404)

DEVIATION


High temperature Overheat in the flash separator

Change in solution and salt crystals properties; MEG degradation

Temperature sensors (TE306,TE308,TE310,TE312); high temperature alarms (TZAH306,TZAH308,TZAH310, 312)

Decrease the temperature by less steam input on heat exchanger H300

Low temperature Flash separator temperature under set point

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

Temperature sensors (TE306,308,310,312); sampling receiver (R404)

Increase the temperature by more steam input on heat exchanger H300

High level Blockage in separation column due to incrustation and/or salt accumulation

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

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

Regular maintenance of the separation column (E200)

High pressure testing Failure in vacuum pump (J200); failure in valves V409 and/or V411

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)

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

Install high pressure alarms; vacuum pump (J200) regular maintenance; valves V409 and V411 regular maintenance

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

Motor temperature rise; vortex formation

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

Motor (M300,M301,M302, M303) regular maintenance (2)

Date 10/12/2014


DEVIATION


Low speed As for (1) Insufficient wash of the MEG residue from the salts

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

As for (2)



Subject Salt loop (from R400 to R401 and back to R400)

DEVIATION


No Flow No feed to salt tank

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

Conductivity control in the column

Install level alarm on R400 (2)

Pump J401 failure

As for (1)

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

As for (2); regular maintenance in the pump

No water feed into the brine tank; valve V428 closed in error

As for (1); high salt concentration in the stream

Flow rate transmitters (FT400,401,402)

Regular maintenance in the valve (3); install level alarm on R401; composition transmitter in pipelines

Line blockage/closed valve

As for (1); overload of the pump J401

Temperature sensor (TE403); FT400,FT401,FT402

Regular maintenance in the valves

Line fracture As for (1); leakage

FT400,FT401,FT402 Regular inspection in the lines

High Flow Pump J401 racing Low level of salt tank; high pressure stream in brine tank; low pressure in salt tank; pump temperature rise

Speed frequency control, temperature control and pressure control in the pump; manual drain; FT400,FT401,FT402

Regular maintenance in the pump (4); open valves V416, V419 or V420

Low Flow Pump J401 failure

Low production of brine (5)

Speed frequency control, temperature control, pressure control in the pump; FT400,FT401,FT402

As for (4)

Date 10/12/2014


DEVIATION


Low Flow Sedimentation of salts in pipes

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

FT400,FT401,FT402 Regular inspection in the lines; install composition transmitter in pipelines

Low water influx to R401

As for (5) Flow transmitter (FT402) Increase water feed

High Concentration Low water feed to R401

As for (5) FT402 Increase water feed; install composition transmitter in pipelines

Low Concentration High water feed to R401

Change in desired fluid properties (6)

FT402 Decrease water feed

J401 failure

As for (5); as for (6)

Speed frequency control; temperature control; pressure control in the pump

As for (4)

High Level (R400) High feed to R400 from the column

Flooding in R400 (7) Conductivity control in the column; manual drain point (V416)

Install high level alarm in R400 (8); open drain point

High feed from brine tank

As for (7)

FT400; Manual drain point (V416)

As for (8); open drain point

J401 failure

As for (7)

Speed frequency control, temperature control and pressure control in the pump; manual drain point (V416 and V419)

As for (4); as for (8); open drain point

Line blockage As for (7) FT400,FT401,FT402; manual drain point (V416, V419 and V420)

As for (8); regular inspection in the lines; open drain point

High Level (R401)

High water feed

Flooding in R401 and change in brine composition (9)

FT402; manual drain point (V425); valves V428 and V429

Install high level alarm in R401 (10); open drain point; close V428 or V429

DEVIATION


High Level (R401) High feed from salt tank (J401 racing)

As for (9); pump temperature rise

Speed frequency control, temperature control, pressure control in the pump; manual drain point (V425); valve V417

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

Low Level (R400) Low feed from the column

Change in brine composition (11)

Conductivity control in the column; level switches in column

Install low level alarm in R400 (12)

Low feed from brine tank

As for (11)

FT400

As for (12)

J401 racing

As for (11); pump temperature rise

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

As for (12)

Low Level (R401) Low water feed

As for (11); accumulation of salt in pipelines

FT402

As for (12); increase water feed

Low feed from salt tank (J401 failure)

As for (11) Speed frequency control, temperature control and pressure control in the pump

As for (12); regular maintenance in the pump



Subject From the Flash Separator (K200), to the Condensate Separator Tank (K300) passing through condenser C201 and sub-cooler C301

DEVIATION


High Flow

Pump (J200) racing 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

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

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

Low Flow Pump (J200) failure Flash separator (K200) pressure gain; cavitation in pipelines; presence of foreign body from corrosion; sedimentation; leak in condenser C201 and sub-cooler C301

As for (2) As for (3); regular maintenance of condensers

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

As for (1); change in solution properties (4)

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

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

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


As for (6)

Date 10/12/2014


DEVIATION


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

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

No safeguards Install a high pressure alarm; install a pressure indicator on K300



Subject From Condenser 201 to Storage Tank (R500), passing through Vacuum Trap (K201), Vacuum Receiver (K202) and Condensate Separator Tank (K300)

DEVIATION


High Temperature No ventilation around the J200 pump

Pump damage and/or malfunction (1)

Ventilated place without hot surfaces for the J200 pump work

Install temperature indicator in the pump (2)

No ventilation around the J400 pump

As for (1) Ventilated place without hot surfaces for the J400 pump work

As for (2)

Failure of sub-cooler C301, leading J400 pump to heat

As for (1) Temperature indicators TW318, TE318, TT318, TIR318, valve V431

Regular maintenance of sub-cooler C301

Low Temperature Cold fluid entrance in J200 pump

J200 pump damage, condensing fluid

Presence of vacuum trap K200 and receiver K201

Temperature control of the air entering the pump

High Pressure Obstruction in the line connected to the J200 pump

Pump damage; failure of J200 to provide vacuum

Valves V213 and V214,; vacuum trap K200 and receiver K201 (3)

Install relief valve downstream from the pump (4)

Liquid entrance in the J200

J200 pump damage, lubrication oil compromised

As for (3) Install extra pressure indicator/controller

Water vapour entrance above J200 pump capacity

Condensing fluid dissolves in pump oil; pump corrosion

As for (3) No action

Obstruction in the line connected to the J400 pump

Pump damage; failure of J400 to drive the MEG/water liquid mixture

No safeguards

As for (4)

Date 10/12/2014


DEVIATION


Low Pressure

Narrow diameter pipes Low flow and poor efficiency of J200

Vacuum control valve PCV203 Correct dimensioned 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

Risk of J400 pump to air suction; cavitation

Hand switch HS400 Regular maintenance (5)

Failure of Vent Failure of vent to drive the output of J200 pump

Rise in J200 pump temperature and pressure

Vent to a safe location As for (5)

Failure of Power Electrical failure of hand switch HS200

Failure of J200 to provide vacuum and drive the MEG/water mixture (6)

Computer monitoring of the hand switch

Install backup generator; check the connection between the switch and the J200 pump

Electrical failure of hand switch HS400

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

Computer monitoring of the hand switch

Install backup generator; check the connection between the switch and the J400 pump

Failure of Vacuum Internal/component problem of J200 pump

As for (6) Respect the working conditions, lifetime and lubrication of the pump

Regular maintenance, testing and lubrication

Obstruction in line near J200 pump

As for (6) No safeguards

As for (4)

Failure of valves V411 or V409

Failure of J200 to provide vacuum to bleed down R403 and sampling receiver R404

Pressure indicators PI400, PI401, PI402, PI403

As for (5)

Reverse Flow

Failure of J400 diaphragm pump internal check valves

As for (7)

No safeguards Install check valve before the entrance of the J400 pump

DEVIATION


Reverse Flow Sudden power cut to J200 pump leads to low inertial force of rotating parts, that can’t overcome system head (blowback)

As for (6)

No safeguards Install check valve before the entrance of J200

No Flow Overpressure in pipeline; failure of vacuum

As for (6) As for (3) Install extra pressure indicator/controller

Line blockage near J200 pump


Line blockage near J400 pump

Danger to the process stability and continuation, as it stops the MEG/water drive


Vapour appearance near J400 pump, cavitation

Pump damage, stop to the process

Speed indicator controller SIC400 (8)

Install temperature indicator

High Flow Failure of valve V222 Vacuum control valve PCV203 won’t control the adequate level of vacuum (9)

Hand switch HS200 (10) Install flow rate controller/transmitter (11)

Failure of vacuum control valve PCV203


Failure of speed indicator controller SIC400

Risk of J400 pump to air suction, cavitation

Hand switch HS400 As for (5)

Low Flow Partial blockage near J200 pump

As for (6) Vacuum control valve PCV203 As for (11)

J200 pump malfunction As for (6) Vacuum control valve PCV203 As for (11)

Partial blockage near J400 pump

As for (7) As (8) As for (5)

J400 pump malfunction As for (7) As (8) As for (5)

Failure of speed indicator controller SIC400 (jammed low)

Low J400 pump efficiency No safeguards As for (5)

DEVIATION CAUSE EFFECT SAFEGUARDS ACTION

Contaminants Failure of sintered filter Z203, allowing contaminated air to enter the vacuum system

As for (1)

Valve V205

As for (5)

Water or any other liquid entering the pump J200


Contaminant in the oil lubricant of the J200 pump

As for (1) Check lubricant and clean filters regularly, replace when necessary

As for (5)

Contaminant in the oil lubricant of the J400 pump

As for (1) Check oil level and clean filters regularly, replace when necessary

As for (5)

Corrosion of vessels or instrument near J400 pump, contaminating fluid

As for (1)

Valve V205

As for (5)

High Concentration Condenser C201, flash separator K200 or mixing tank F101 failure

High concentration of MEG/water vapour (>90%) causes J200 pump to fail to drive the mixture

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

As for (5)

Low Concentration Condenser C201, flash separator K200 or mixing tank F101 failure

Low concentration of MEG/water vapour (<20%) causes J200 pump to fail to drive the mixture


High Level Failure of valve V213 to open

High level of liquid in K201 vacuum trap, danger to J200 pump

Valve V205; vacuum control valve PCV203 (13)

Install level indicator (14)

Failure of valve V214 to open

High level of liquid in K202 vacuum receiver, danger to J200 pump


Failure of valve V412 to open

High level in R403 bleed down, unable to take sample

Valves V408 and V433 As for (14)

DEVIATION


High Level Failure of valve V413 to open

High level in R404 sampling receiver unable to take sample


Failure of speed indicator controller SIC400, lowering speed of J400 pump

High level in condensate separator tank K300

Valve V307; level indicators LSL305 and LSL306

As for (5)

Failure of discharge valve after storage tank R500

High level in storage tank R500


HAZOP

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