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; salts

properties alteration; vortex
formation; paddle stirrers
corrosion and/or erosion
Desired homogeneity not
achieved; pumps 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 agitators
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 (9);
as for (12)
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 solutions properties;
SAFEGUARDS
No safeguards
ACTION
Install a motor
controller on pump
J100;
pump and valve
regular maintenance
(14)
As for (14)
HAZOP RECORD FORM

Facility/Project
Date
10/12/2014
26164_P&ID_001
Team Members
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);
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
lost; low level on feed tank
(F101) (9)
SAFEGUARDS
ACTION
Install a flow
transmitter
As for (9)
As for (1);
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
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

change solutions properties
No safeguards
As for (11)
Pump and valve

regular maintenance
(11)
As for (11)
HAZOP RECORD FORM

Facility/Project
Date
10/12/2014
26164_P&ID_001
Team Members
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;

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)

As for (6)
As for (5)
As for (4)
As for (2);
as for (5)
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
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)

No safeguards
change in solutions properties
ACTION
As for (7)
As for (7)
HAZOP RECORD FORM

Facility/Project
Date
10/12/2014
26164_P&ID_001
Team Members
Subject
Feed line from the Pump (J101) up to the Flash
Separator (K200)
DEVIATION
High Flow
CAUSE
Pump (J101) racing
No Flow
SAFEGUARDS
ACTION

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;


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)

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)
HAZOP RECORD FORM

Facility/Project
Date
10/12/2014
Team Members
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 wont 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
HAZOP RECORD FORM

Facility/Project
Date
10/12/2014
Team Members
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);
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
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
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
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
HAZOP RECORD FORM

Facility/Project
Date
10/12/2014
Team Members
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:
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

degradation (2)
Valve V204; hand switch

HS204; temperature
instruments TT211, TIR211,
TSH212; temperature
sensors (TE211,TE212);
the heat exchanger (H300);
(TZAH212)
Decrease the
temperature by less
heat exchanger
(H300); maintenance
(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);
TT211, TIR211, TE212,
TSH212 malfunction;
malfunction of valves
V309 and/or V310,
PCV300

containing the valve V203 with
less salt than expected for the
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)
Increase the
temperature by more
steam input on heat
exchanger H300;
maintenance and, if
of the pipelines
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 its
necessary
As for (6)
Maintenance of the
pipeline, paying
special attention to the
valves V303 and V305,
that shouldnt be
always opened, and
the valve V302 that
mustnt 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
a solution overheated;
pump (J300)
Drain leaking; valve

jammed
ACTION
Look for problems

related to the level of
solution inside the
flash
one only if its
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
a solution overheated;
pump (J300)
Failure of all the heating
system of the flash
system of the flash
As for (6)
Gas locking due to

presence of gas if the
vortex breaker doesnt
work properly
Recycle pump (J300)
failure (pump reversed)
Heating system inefficient
As for (6)

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)
HAZOP RECORD FORM

Facility/Project
Date
10/12/2014
Team Members
26164_P&ID_001
Subject
From the Heat Exchanger (H300) to the Flash
Separator (K200)
DEVIATION
CAUSE
EFFECT
SAFEGUARDS
ACTION
High Temperature

separator due to:
TT211, TIR211, TE212,
TSH212, TZAH212
malfunction

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);
(TZAH212);
the heat exchanger (H300)
(2)
temperature instruments
TE315, TSH315, TW322,
TE322, TIR320, TDIR321,
TIR322, TW320, TE320,
TW319, TE319, TSH319 and
temperature controller
TDCR321 (3);
TZAH315; high temperature
alarm TZAH319; valve V205
Decrease the
temperature by less
heat exchanger
(H300); maintenance
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
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);
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
necessary, change of
fix the valves
fix the controllers
necessary, change of
fix the valves
fix the controllers and
valves
DEVIATION
CAUSE
EFFECT
Low Temperature
Heat exchanger (H300)

TT211, TIR211, TE212,
TSH212, TZAH212
malfunction
As for (1);
as for (2);
as for (3)
Increase the
temperature by more
steam input on heat
exchanger H300;
maintenance and, if
of the pipelines
High Flow
Leak in heat exchanger

(H300), promoting
steam and solution
mixture

containing the valve V203 with
less salt than expected for the
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
an insufficient heating of the
solution
Pressure indicator PI204;

speed viewing device
SG301; temperature
instruments TE320, TW320,
TW319, TE319, TSH319;
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

one only if its
necessary
DEVIATION
Low Flow
CAUSE
Recycle pump (J300)
failure related to poor
suction conditions
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
shouldnt 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 doesnt
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);
pump (J300)
As for (5);
blockage of pump and/or
valves; low flow into the heat
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
a solution overheated, which
can rise the pressure in the
flash vessel (K200);
system of the flash (13)
As for (6);
as for (7);
as for (11)

one only if its
necessary
As for (6);
as for (7);
as for (11)
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)
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)
As for (6);
as for (7);
as for (8)
ACTION
Maintenance of the
plant
Use valve V222 and
check possible
problems in the plant
that led to high
temperature
HAZOP RECORD FORM

Facility/Project
Date
10/12/2014
Team Members
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

separator

degradation
Low temperature
Flash separator
temperature under set
point

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)
HAZOP RECORD FORM

Facility/Project
Date
10/12/2014
Team Members
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
Regular maintenance
pressure stream in brine tank;
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)
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
column; manual drain point
(V416)
FT400;
Manual drain point (V416)
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
Increase water feed
Increase water feed;
install composition
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

control in the pump; manual
drain point (V425); valve
V417
column; level switches in
column
FT400
As for (4);
as for (10);
close V417; open drain
point

control in the pump
FT402
As for (12)

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
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
Date
10/12/2014
Team Members
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
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
Date
10/12/2014
Team Members
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
As for (3)
As for (3)
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 cant 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 cant
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
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 wont 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)
As for (11)
As for (6)
As for (7)

As (8)
As for (11)
As for (5)
As for (7)
Low J400 pump efficiency
As (8)
No safeguards
As for (5)
As for (5)
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
open
open
EFFECT
As for (1)
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

open
Failure of speed
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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HAZOP RECORD FORM

Agitator failure (1)

Temperature rise; salts

Speed indicator (SIC100);

Flooding; pressure surges (4)

Level transmitter (L100);

Pump (J100) or valve

Low feed rate to dosing

Paddle stirrers corrosion;

Level transmitter (L100)

Pump (J100) racing

Dosing tank (F100) pressure

Pump (J100) racing;

High level on dosing

Manual drain point

Dosing tank (F100) mixing

Contaminate the solution;

HAZOP RECORD FORM

Increase in the input

Flooding; pressure surges

Hand switch on pump J100

Pump (J101) or valve

Flooding; pressure surges

Low feed rate on the

Process inefficiency since the

Pump J101 failure

Pump (J100) racing

Pump (J100) racing;

Pump (J100) failure;

Pump J100 racing (12)

Flash separator inefficiency

Valve V103 and flow controller

Pump (J100,J101) failure;

Feed pump (J101) over

Pump (J100) corrosion;

Contaminate the solution;

Pump and valve

HAZOP RECORD FORM

Pump (J101) racing

Increase in the recycle flow (1) Feed pump (J101) over

Pump (J101) racing;

Decrease in the recycle flow

The valve type can be

Valve (V111, V112)

Pump and valve

Pump (J101) or valve No recycle loop back to the

Contaminate the solution;

HAZOP RECORD FORM

Feed tank (F101) pressure

Feed pump (J101) over

Pump (J101) racing;

Feed tank (F101) pressure

Valve (V113, NRV200)

Pump (J101) failure

Valve (V113, NRV200)

HAZOP RECORD FORM

High Level (R500)

Failure of pump J400

Valve leaving the storage tank

Low Level (F101)