Shift Convertors Hazard and Operability Study

Prepared By WSA/AFN

HAZOP study of High Pressure Unit System at Synthesis Loop Valves carried out by selecting different node points and parameters deviation
from their normal value.
1) Temperature
2) Pressure
3) Concentration

Risk assessment criteria for HAZOP study is explained in the following tables:

Severity Score (S)

S-Score Definition
0 No Production loss, equipment damage
1 Production loss
2 Equipment damage
3 Personnel safety+ Production loss + Equipment damage

Likelihood (L)

L-Score Definition
0 Unlikely, very low probability (Could not happen any time in a year)
1 Likely, low probability (Can happen in 1-5 years)
2 Very likely, very high probability (Can happen any time in a year)

HAZOP Study Ammonia Unit

 RISK LEVEL (R=S+L)

R-Score Definition
0 (Negligible) Negligible risk, related activities may proceed with existing controls
1 (Tolerable) Risk that has been reduced to a level that can be endured
2 (Moderate) Risk that requires further control and improvement
3 (Substantial) Risk that is not acceptable in the medium term but activities may still be
carried out under special control
4 (Intolerable) Risk that is not acceptable, relative activities must be stopped
5 (Extreme) Risk that threatens the survival and continuation in its present form

HAZOP Study Ammonia Unit

 Node: HTSC (R-204) Inlet
R-204 Design Temperature: 465oC

Deviation: Temperature

GUIDE RESIDUAL
DEVIATION CAUSES CONSEQUENCES S L R EXISTING SAFEGUARDS RECOMMENDATION
WORD RISK
1. Alarms at 02-TRC-19T &
02-TI-1.50 in DCS
2. R-203 outlet, 02-TI-1.39
1. 02-TRC-19V malfunctioning (full & TR-14.6 high
open) 1. Damage to R-204 temperature alarms
High 2. R-203 outlet high temperature shell 2 1 3 configured in DCS 1
3. Fouling at E-208A/B tubes 2. Damage to catalyst 3. Steam drum low level
4. Dry-out of E-208A/B trip security in I-1
4. Round the clock
monitoring of relevant
parameters
1. Alarms at 02-TRC-19T &
Handjack may be provided
Temperature 02-TI-1.50
at 02-TRC-19V.
2. R-203 outlet, 02-TI-1.39
& TR-14.6 low
1. 02-TRC-19V malfunctioning
temperature alarms
(closure during start-
1. CO slip from R-204 configured in DCS
up/shutdown)
2. Damage to catalyst 3. E-208A outlet TH-11/12
Low 2. E-208A/B tube leakage 2 1 3 1
due to alarms are configured in
3. Lower temperature at R-203
condensation DCS
outlet
4. Round the clock
4. Passing in MS to R-204 I/Vs’
monitoring of relevant
parameters
5. Double block & bleed at
MS line to R-204

Node: HTSC (R-204) Inlet

HAZOP Study Ammonia Unit
 R-204 Design Pressure: 34kg/cm2
Deviation: Pressure
GUIDE RESIDUAL
DEVIATION CAUSES CONSEQUENCES S L R EXISTING SAFEGUARDS RECOMMENDATION
WORD RISK
1. 02-PRC-22T high pressure
alarms configured in DCS
2. Pressure control on auto, 02-
1. E-208A/B tube leakage
PRC-22V
2. Increase in system pressure 02-PSV-10 is installed on
3. Local PI gauge at R-204 inlet
(i.e. 02-MOV-8/9 closure, I-6 inlet line bleed, to be
4. 02-PSV-22A/B/C
actuation, TK-431 trip) installed as per original
Damage to R-204 and 5. 02-PSV-10 (thermal PSV)
High 3. Abnormal increase in inlet 2 1 3 1 P&ID without isolation.
associated piping 6. PMP of PSVs & Control Valves
gas/steam/air flow New off-take may be
7. Gas/Air/Steam flow
4. Increase in bed temperature provided for PSV
controller with alarms on DCS
due to catalyst oxidation in installation.
8. E-208A/B outlet temp. alarms
isolated condition
are configured in DCS
Pressure 9. Round the clock monitoring
of relevant parameters
1. Isolations of 02-PRC-22V and
02-PSV-22A/B/C are present
1. 02-PRC-22V opening due to
2. 02-PRC-22 transmitter /
inadvertent signal from DCS
control valve & 02-PSV-
or control valve /
22A/B/C are part of PMP
transmitter malfunctioning
Low Production loss 1 1 2 3. 02-PRC-22T low pressure 0
2. Popping of 02-PSV-22A/B/C
alarm is configured in DCS
3. Abnormal decrease in inlet
4. Local PI gauge at R-204 inlet
gas/steam/air flow
5. Gas/Air/Steam flow
4. Decrease in system pressure
controller with alarms on DCS
6. Round the clock monitoring

Node: HTSC (R-204) Inlet

Deviation: Flow

HAZOP Study Ammonia Unit

GUIDE RESIDUAL
DEVIATION CAUSES CONSEQUENCES S L R EXISTING SAFEGUARDS RECOMMENDATION
WORD RISK
1. 02-DPI-20T for monitoring
∆P across R-204 with high
value alarm configured in
DCS
2. 02-PRC-22V & 02-PSV-
22A/B/C are present to
1. E-208A/B tube leakage
1. Increase in CO slip vent excess flow
2. Decrease in system pressure
2. Damage to R-204 3. PMP of PSVs & Control
(i.e. opening of process gas
High catalyst bottom 2 1 3 Valves 1
vents)
grid & downstream 4. Gas/Air/Steam flow
3. Abnormal increase in inlet
equipment controller with alarms on
gas/steam/air flow
DCS
5. E-208A/B outlet temp.
alarms are configured in
DCS
Flow 1. Round the clock monitoring
of relevant parameters
1. Isolations of 02-PRC-22V
and 02-PSV-22A/B/C are
present
2. 02-PRC-22 transmitter /
1. 02-PRC-22V opening due to
control valve & 02-PSV-
inadvertent signal from DCS
22A/B/C are part of PMP
or control valve /
3. 02-PRC-22T low pressure
Low transmitter malfunctioning Production loss 1 1 2 0
alarm is configured in DCS
2. Popping of 02-PSV-22A/B/C
4. Local PI gauge at R-204
3. Abnormal decrease in inlet
inlet
gas/steam/air flow
5. Gas/Air/Steam flow
controller with alarms on
DCS
6. Round the clock monitoring

HAZOP Study Ammonia Unit

 Node: HTSC (R-204) Inlet
Deviation: CO Concentration
GUIDE RESIDUAL
DEVIATION CAUSES CONSEQUENCES S L R EXISTING SAFEGUARDS RECOMMENDATION
WORD RISK
1. R-204 bed Temp. & ∆T In view of frequent variation in
indication with alarms on NG analysis due to depleting
DCS reservoir, online analyzer may
1. Increase in ∆T across 2. S/C indication with alarm be provided for NG
1. Low S/C R-204 on DCS composition monitoring. Same
More CO 2. R-203 outlet High Temp. 2. Increase in R-204 CO 0 1 1 3. Process Gas/Steam flow 0 will also make F.E load
3. Increase in CO2 in NG slip transmitters are part of indication reliable and help to
3. Increase in R-205 ∆T PMP take prompt action in case of
4. Gas analysis twice a week change in NG composition. SR
5. Round the clock previously initiated but closed
monitoring by PEMM.

Deviation: Oxygen Concentration

GUIDE RESIDUAL
DEVIATION CAUSES CONSEQUENCES S L R EXISTING SAFEGUARDS RECOMMENDATION
WORD RISK
1. Trip interlock on low Gas
/ Air ratio (I-3)
2. Process Gas/Air flow
transmitters are part of
1. Increase in catalyst bed PMP
temperature due to oxidation 3. Bed temperature
1. Low Gas/Air
2. Increase in CO slip from R- indication with alarm on
More Oxygen 2. Oxygen slip from 1 1 2 0
204 due to deteriorated DCS
R-203 in start-up
performance of catalyst 4. R-204 outlet analysis
3. Increase in R-205 ∆T twice a week
5. SOPs are in place for
start-up
6. Round the clock
monitoring

HAZOP Study Ammonia Unit

 Deviation: Steam

GUIDE RESIDUAL
DEVIATION CAUSES CONSEQUENCES S L R EXISTING SAFEGUARDS RECOMMENDATION
WORD RISK
1. S/C indication with
alarm on DCS
1. Increase in CO 2. Process Gas/Steam
Less 1. Low S/C slippage from R-204 1 1 2 flow transmitters are 0
2. Increase in R-205 ∆T part of PMP
3. Round the clock
monitoring
1. S/C indication with
alarm on DCS
Steam 2. Process Gas/Steam
flow transmitters are
part of PMP
1. High S/C
Damage to catalyst 3. E-208A/B outlet temp.
More 2. E-208A/B tube leakage 2 1 3 1
due to condensate alarms are configured
3. Passing in MS to R-204 isolations
in DCS
4. Double block & bleed
at MS line to R-204
5. Round the clock
monitoring

HAZOP Study Ammonia Unit

 Node: HTSC (R-204) Outlet
Deviation: Temperature

GUIDE RESIDUAL
DEVIATION CAUSES CONSEQUENCES S L R EXISTING SAFEGUARDS RECOMMENDATION
WORD RISK
1. Alarms at 02-TRC-19T & 02-
TI-1.50
1. Increase in catalyst bed 2. Alarms at 02-TI-18.3
temperature due to 3. Trip interlock on low Gas / Air
oxidation & CO slip due to ratio (I-3)
deteriorated catalyst 4. Process Gas/Air flow
performance transmitters are part of PMP
1. Higher inlet temperature
2. Increase in CO slip due to 5. Bed temperature indication
2. Oxygen slip from R-203
High increase in outlet 2 1 3 with alarm on DCS 0
3. Increase in CO in R-203
temperature 6. R-311 inlet temperature
outlet gas
3. Increase in E-209 shell side indication and alarms are
outlet temperature available
Temperature 4. Increase in R-204/R-205 7. E-209 tube side inlet and
∆T in case of higher CO in bypass are available
inlet gas 8. R-204 outlet analysis twice a
week
9. Round the clock monitoring
1. Alarms at 02-TRC-19T & 02-
TI-1.50
2. Alarms at 02-TI-18.3
1. Lower inlet temperature 1. Decrease in R-204 ∆T
3. 02-DPI-20T indication with
Low 2. Channeling in catalyst 2. Higher CO slip at R-204 0 1 1 0
alarms on DCS
bed outlet
4. R-204 outlet analysis twice a
week
5. Round the clock monitoring

HAZOP Study Ammonia Unit

 Node: HTSC (R-204) Outlet
Deviation: CO Concentration
GUIDE RESIDUAL
DEVIATION CAUSES CONSEQUENCES S L R EXISTING SAFEGUARDS RECOMMENDATION
WORD RISK
1. S/C and process
Gas/Steam flow
transmitters indications
1. Low S/C with alarms available on
2. Channeling / caking in DCS, also part of PMP
catalyst bed 1. Increase in R-204 CO 2. R-204 bed Temp.
More CO 3. Poor performance of slip 0 1 1 indication with alarms on 0
catalyst due to aging 2. Increase in R-205 ∆T DCS
4. R-203 outlet High Temp. 3. 02-DPI-20T indication with
5. Increase in CO2 in NG alarms on DCS
4. Gas analysis twice a week
5. Round the clock
monitoring

HAZOP Study Ammonia Unit

 Node: LTSC (R-205) Inlet
R-205 Design Temperature: 300oC

Deviation: Temperature

GUIDE Residual
DEVIATION CAUSES CONSEQUENCES S L R EXISTING SAFEGUARDS Risk RECOMMENDATION
WORD
1. Alarms at 02-TRC-20T & 02-
TI-18.5 in DCS
1. 02-TRC-20V malfunctioning
2. Cat-tracker installed at R-
(full open)
205 and alarms configured
2. 02-TRC-20V opening due to 1. Damage to R-205
in DCS
inadvertent signal from DCS or shell and other d/s
High 2 1 3 3. Handjack is available on 02- 1
control valve / transmitter equipment
TRC-20V
malfunctioning 2. Damage to catalyst
4. Manual BFW bypass of E-
3. BFW bypass of E-211 opening
211
is higher
5. Round the clock monitoring
of relevant parameters
1. Hot shot, 02-TRC-20V
available to control R-205
Temperature inlet temp on Auto
1. Lower temp if
2. Alarms at 02-TRC-20T and
approaches dew
02-TI-18.5 in DCS
point of gas stream,
3. Manual BFW bypass of E-
1. E-210 / E-211 tube leakage steam condensation
211
2. BFW bypass of E-211 opening occurs which causes 1. R-205 ∆P indication
4. R-205 ∆P indication in field
Low is lower caking of catalyst 3 1 4 1 may be provided at
5. 02-HIC-4V isolations
3. E-209 tube leakage 2. CO slip increases if DCS
available
4. 02-HIC-4V open / passing reaction front
6. CO analyzer available at DCS
exceeds catalyst bed,
and alarms configured
results in production
7. Lab analysis twice a week
loss
8. R-311 ∆T indication at DCS
9. Round the clock monitoring
of relevant parameters

HAZOP Study Ammonia Unit

 Node: LTSC (R-205) Inlet
R-205 Design Pressure: 33kg/cm2

Deviation: Pressure

GUIDE Residual
DEVIATION CAUSES CONSEQUENCES S L R EXISTING SAFEGUARDS Risk RECOMMENDATION
WORD
Pressure 1. 02-PRC-41T high pressure
alarms configured in DCS
2. Pressure control on auto, 02-
PRC-41V
3. 03-PSV-15A/B/C at R-205
1. E-210 / E-211 tube leakage
outlet
2. Increase in system pressure
4. 02-PRC-22T high pressure
(i.e. 02-MOV-8/9 closure, I-6
alarms configured in DCS
actuation, TK-431 trip) 1. Damage to R-205 1. R-205 ∆P indication
5. Pressure control on auto, 02-
High 3. Abnormal increase in inlet and associated 2 1 3 1 may be provided at
PRC-22V
gas/steam/air flow piping DCS
6. Local PI gauge at R-205 inlet
4. Increase in bed temperature
7. 02-PSV-22A/B/C
due to catalyst oxidation in
8. 02-PSV-9 (thermal PSV)
isolated condition
9. PMP of PSVs & Control Valves
10. Gas/Air/Steam flow controller
with alarms on DCS
11. Round the clock monitoring of
relevant parameters
Low 1. 02-PRC-22V or 02-PRC-41V 1. Production loss 1 1 2 1. Isolations of 02-PRC-41V1 / V2 0
opening due to inadvertent and 02-PRC-22V are present
signal from DCS or control 2. Alarms at 02-PRC-41T
valve / transmitter 3. Handjack are available on 02-
malfunctioning PRC-41 V1 / V2 and 02-PRC-
2. E-209 tube leakage 22V
3. Passing of 02-MOV-10V 4. R-311 ∆T indication at DCS
4. Leakage from R-205 inlet piping and alarms configured
/ flange 5. Handjack is available on 02-
5. Abnormal decrease in inlet MOV-10V

HAZOP Study Ammonia Unit

 6. PMP of PSVs & Control Valves
7. Gas/Air/Steam flow controller
gas/steam/air flow
with alarms on DCS
6. Decrease in system pressure
8. Round the clock monitoring of
relevant parameters

HAZOP Study Ammonia Unit

 Node: LTSC (R-205) Inlet
Deviation: Flow
GUIDE RESIDUAL
DEVIATION CAUSES CONSEQUENCES S L R EXISTING SAFEGUARDS RISK RECOMMENDATION
WORD
1. Local ∆P indication in field
across R-205
1. E-210 / 211 tube leakage
1. Increase in CO slip 2. R-311 ∆T indication at DCS
2. Decrease in system pressure
3. Damage to R-205 3. Gas/Air/Steam flow controller
(i.e. opening of process gas 1. R-205 ∆P indication may
High catalyst bottom 2 1 3 with alarms on DCS 1
vents) be provided at DCS
grid & downstream 4. E-210 / E-211 outlet temp.
3. Abnormal increase in inlet
equipment alarms are configured in DCS
gas/steam/air flow
5. Round the clock monitoring of
relevant parameters
Flow
1. 02-PRC-22V opening due to 1. Isolations of 02-PRC-22V and
inadvertent signal from DCS 02-PSV-22A/B/C are present
or control valve / 2. 02-PRC-22 transmitter / control
transmitter malfunctioning valve & 02-PSV-22A/B/C are
Low 2. Leakage from R-205 inlet Production loss 1 1 2 part of PMP 0
piping / flange 3. Local PI gauge at R-205 inlet
3. Popping of 02-PSV-22A/B/C 4. Gas/Air/Steam flow controller
4. Abnormal decrease in inlet with alarms on DCS
gas/steam/air flow 5. Round the clock monitoring

HAZOP Study Ammonia Unit

 Node: LTSC (R-205) Inlet
Deviation: CO Concentration
GUIDE RESIDUAL
DEVIATION CAUSES CONSEQUENCES S L R EXISTING SAFEGUARDS RISK RECOMMENDATION
WORD
1. S/C indication with alarm on
DCS
2. R-205 bed Temp. & ∆T
indication with alarms on DCS
1. Increase in ∆T across
3. Process Gas/Steam flow
R-205
1. Low S/C transmitters are part of PMP
More CO 2. Increase in R-205 CO 0 1 1 0
2. High CO slip from R-204 4. R-311 ∆T indication at DCS
slip
and alarms configured
3. Increase in R-311 ∆T
5. Online CO analyzer at R-205
outlet
6. Gas analysis twice a week
7. Round the clock monitoring

Deviation: Steam

GUIDE RESIDUAL
DEVIATION CAUSES CONSEQUENCES S L R EXISTING SAFEGUARDS RISK RECOMMENDATION
WORD
Less Steam 1. Low S/C 1. Increase in CO 1 1 2 1. S/C indication with alarm 0
slippage from R- on DCS
205 2. Process Gas/Steam flow
2. Increase in R-205 transmitters are part of
R-311 ∆T PMP
3. R-311 ∆T indication at DCS
and alarms configured
4. Online CO analyzer at R-
205 outlet
5. Gas analysis twice a week
6. Round the clock monitoring

HAZOP Study Ammonia Unit

 1. S/C indication with alarm
on DCS
2. Process Gas/Steam flow
transmitters are part of
PMP
3. E-210 / E-211 outlet temp.
alarms are configured in
1. High S/C
Damage to catalyst DCS
More 2. E-210 / 211 tube leakage 2 1 3 1
due to condensate 4. Hot shot, 02-TRC-20V
3. Passing in MS to R-205 isolations
available to control R-205
inlet temperature and
configured with alarms at
DCS
5. Double block & bleed at
MS line to R-205
6. Round the clock monitoring

HAZOP Study Ammonia Unit

 Node: LTSC (R-205) Outlet
Deviation: Temperature

GUIDE RESIDUAL
DEVIATION CAUSES CONSEQUENCES S L R EXISTING SAFEGUARDS RISK RECOMMENDATION
WORD
1. Increase in R-205 shell
1. Alarms are available at 02-TI-18-4
temperature
and alarms configured at DCS
2. Very high temp may
1. Higher inlet temperature 2. Online CO analyzer available and
damage reactor shell and
High 2. Higher CO slippage from 2 1 3 alarms configured at DCS 0
deteriorate catalyst
R-204 3. R-204 outlet analysis twice a
3. Increase in CO slip due to
week
increase in outlet
Temperature 4. Round the clock monitoring
temperature

1. Alarms at 02-TI-18-4
1. Lower inlet temperature
1. Decrease in R-205 ∆T 2. Local DPI indication in field
2. 02-MOV-10V passing DPI indicator may be
Low 2. Higher CO slip at R-205 0 1 1 3. R-205 outlet analysis twice a 0
3. Channeling in catalyst provided at DCS
outlet week
bed
4. Round the clock monitoring

HAZOP Study Ammonia Unit

 Node: LTSC (R-205) Outlet
Deviation: CO Concentration
GUIDE RESIDUAL
DEVIATION CAUSES CONSEQUENCES S L R EXISTING SAFEGUARDS RECOMMENDATION
WORD RISK
1. S/C and process
Gas/Steam flow
transmitters indications
with alarms available on
DCS, also part of PMP
1. Low S/C
2. R-205 bed Temp.
2. Channeling / caking in 1. Increase in R-311 ΔT
indication with alarms on
catalyst bed and bed
More CO 0 1 1 DCS 0
3. Poor performance of temperatures
3. R-311 bed Temp.
catalyst due to aging 2. Production Loss
indication with alarms on
4. 02-MOV-10V passing
DCS
4. Local dpi indication in field
5. Gas analysis twice a week
6. Round the clock
monitoring

HAZOP Study Ammonia Unit