A

1.
HAZOP WORKSHEET FOR TANK AND COMPRESSER
Mobile vessel to fixed vessel (TK-101)

Intention- to increase the gas pressure to 2 bar
Unlined
Intention- transfer of ethane gas from road tanker/pipeline to storage tank (TK-101)
Guide word deviation Cause Consequences Safeguard Recommendation
No/none Flow -Master valve failed to - Delay in dispatch of

open material
-Blockage in master valve - Evaporation of gas from
fixed tank
More flow - Leakage of pipe joints - Wastage of raw material
Reverse Flow - High pressure at mobile -Pipe joints leakage

vessel
Other than Static electricity - Road tanker not earthed -Fire or explosion break out
from ignition of flammable
- Escape of gas through vapour
crack of pipe joints
Vessel (TK-102) - Pump (P-102)

Intention- to increase gas pressure
Line 14
Intention- transfer of sodium hydroxide gas from the storage tank (TK-102) to centrifugal pump (P-102)
No/none flow -Failure of pump system - Production delayed

- Blockage of pump - Wastage occurs from
unused raw material after
expiry date
- Pump malfunction
More flow - Deviation and error of -Higher pressure

Pump system
-Centrifugal pump heats and
up and possible explosion
Reverse flow - High pressure in storage - Leakage of pipe joints

tank
Less flow - Blockage of pipelines - Less production per hour

- Deviation and error of - possible backflow
pump system
Distillation column (T-104) - Vessel (TK-104)

Intention-To increase the pressure of the gas to 32.90 bar
Line 27
Intention- transfer the methane gas from the demethanizer distillation column to storage tank (TK-104)
No/none flow - Accumulation of - Production delayed/stopped

methane gas at distillation
column
Less flow - Blockage of pipeline - Lesser production due to

imbalance flow affecting
- System deviation overall production process
More flow - Distillation column - more weight travelling in

control malfunction the pipe causing pipe rupture
- High pressure
Reverse flow - Backflow from the - mixing of fresh product

distillation column with old product
Distillation column (T-106) - Vessel (TK-103)

Intention-to increase the gas pressure to 32.90 bar
Line 34
Intention- transfer ethylene gas from the C2 splitter distillation column (T-106) to storage tank (TK-103)
No/none flow - Accumulation of - Production delayed/stopped

ethylene gas at distillation
column
Less flow - Blockage of pipeline - Lesser production due to

imbalance flow affecting
- System deviation overall production process
More flow - Distillation column - more weight travelling in

control malfunction the pipe causing pipe rupture
- High pressure
Reverse flow - Backflow from the - mixing of fresh product

distillation column with old product
2. HAZOP WORKSHEET FOR HEAT EXCHANGER
Vessel – Heat Exchanger

Intention: To decrease the gas temperature from 850 ˚C to 300 ˚C
Line no. 6
Intention: Transfer the mixed gas from furnace H-102 to Heat Exchanger E-101
None No flow 1. Blockage in -Loss of flow to E-101, no

stream no.6. reaction due to control response.
-Malfunction of heat exchanger
E-101
2. Valve fails closed -As for (1)

or blocks.
-Overpressure in line 6 before
valve leading to rupture.
3. Leak or drain left As for (1) and (2)
open.
-Potential damage to surrounding.
4. Failure of inlet -Process fluid temperature is not

cooling water lowered accordingly.
valve to open
-Cooling water service failure.
-Controller fails and close valve.
CONTAMINAT Process fluid line 1. Leakage of tube As (4)

ION contamination and cooling water
goes in. -Outlet (stream no. 7)
temperature is too low
CORROSION Corrosion of 1. Hardness of -Less cooling and crack of tube

tube cooling water.
HIGH High cooling 1. Failure of cooling -Process fluid temperature is not

flow water valve. lowered accordingly.
-Controller fails.
High 1. The temperature of - Process gas temperature is not

temperature furnace outlet to lowered accordingly.
high
LOW Low cooling 1. Pipe blockage -Temperature of process gas

flow 2. Lower flow rate remains constant.
Low pressure 1. Lower pressure -Less flow in production line

Low temperature 1. Too high cooling - Temperature produce in stream
flow to exchanger E- no. 7 is too low
101
REVERSE Reverse process 1. Failure of process -Malfunction of heat exchanger

gas flow gas inlet valve

Intention: To decrease the gas temperature from 300 ˚C to 25 ˚C
Line no. 6
Intention: Transfer the mixed gas from Heat Exchanger E-101 to Quenching tower T-101
1. Failure of heat -malfunction of quenching tower

NONE No flow exchanger
controller
HIGH Pressure 1. Failure of process - Bursting of tube
fluid valve
Temperature 2. Low flow rate of - Temperature of gas
cooling water constant
Intention: To decrease the gas temperature from 8372.74 ˚C to -7.10 ˚C
Line no. 21
Intention: Transfer the mixed gas from compressor C-104 to Heat Exchanger E-102

stream no.21. reaction due to control response.
E-102

or blocks.

open.
-Potential damage to surrounding.
8. Failure of inlet -Process fluid temperature is not

cooling water lowered accordingly.
valve to open
-Controller fails and close valve.
CONTAMINAT Process fluid line 2. Leakage of tube As (4)

ION contamination and cooling water
goes in. -Outlet (stream no. 22)
temperature is too low
CORROSION Corrosion of 2. Hardness of -Less cooling and crack of tube

tube cooling water.
HIGH High cooling 2. Failure of cooling -Process fluid temperature is not

flow water valve. lowered accordingly.
-Controller fails.
High 2. The temperature of - Process gas temperature is not

C-104 outlet to
temperature high lowered accordingly.
LOW Low cooling 3. Pipe blockage -Temperature of process gas

flow 4. Lower flow rate remains constant.
Low temperature 1. Too high cooling - Temperature produce in stream

flow to exchanger E- no. 22 is too low
102


Intention: The temperature constant -7.10˚C
Line no. 22
Intention: Transfer the mixed gas from Heat Exchanger E-102 to Refrigerator cool box E-103
2. Failure of heat -malfunction of quenching tower

NONE No flow exchanger
controller
fluid valve
Intention: To decrease the gas temperature from 2 ˚C to 39.98 ˚C
Line no. 28
Intention: Transfer the mixed gas from Demethanizer distillation column T-104 to Heat Exchanger E-104

stream no.28. reaction due to control
response.
E-104

or blocks.

open.
-Potential damage to
surrounding.
4. Failure of inlet -Process fluid temperature is

steam water valve not increase accordingly.
to open
-Steam water service failure.
-Controller fails and close
valve.
CONTAMINATIO Process fluid 1. Leakage of tube As (4)

N line and steam water
contamination goes in. -Outlet (stream no. 29)
temperature is too high
HIGH High steam flow 1 .Failure of steam -Process fluid temperature is

water valve. not increased accordingly.
-Controller fails.
High 1. The temperature - Process gas temperature is not

temperature of T-104 outlet to lowered accordingly.
high
LOW Low steam flow 5. Pipe blockage -Temperature of process gas

6. Lower flow rate remains constant.
Low 1. Too high cooling - Temperature produce in

temperature flow to exchanger E- stream no. 28 is too low
104


Intention: The temperature change from 39.98 to 2.84˚C
Line no. 29
Intention: Transfer the mixed gas from Heat Exchanger E-104 to Deethanizer distillation column T-102
3. Failure of heat -malfunction of quenching

NONE No flow exchanger tower
controller
fluid valve
Intention: To decrease the gas temperature from 2 ˚C to 39.98 ˚C
Line no. 28
Intention: Transfer the mixed gas from Demethanizer distillation column T-104 to Heat Exchanger E-104

stream no.28. reaction due to control
response.
E-104

or blocks.

open.
-Potential damage to
surrounding.
8. Failure of inlet -Process fluid temperature is

steam water valve not increase accordingly.
to open
-Controller fails and close
valve.
CONTAMINATIO Process fluid 2. Leakage of tube As (4)

N line and steam water
contamination goes in. -Outlet (stream no. 29)
temperature is too high
HIGH High steam flow 2 .Failure of steam -Process fluid temperature is

water valve. not increased accordingly.
-Controller fails.
High 4. The temperature - Process gas temperature is not

temperature of T-104 outlet to lowered accordingly.
high
LOW Low steam flow 7. Pipe blockage -Temperature of process gas

8. Lower flow rate remains constant.
Low 1. Too high cooling - Temperature produce in

temperature flow to exchanger E- stream no. 28 is too low
104


Intention: The temperature change from 39.98 to 2.84˚C
Line no. 29
Intention: Transfer the mixed gas from Heat Exchanger E-104 to Deethanizer distillation column T-102
4. Failure of heat -malfunction of quenching

NONE No flow exchanger tower
controller
fluid valve
3. HAZOP WORKSHEET FOR SCRUBBER
GW Deviation Possible causes Possible consequences Safeguard Recommendation
NO No flow of NaOH 1. Valve partly or -No conversion of gas

completely closed CO2 and H2S
2. Level of NaOH in
storage tank lower -Hazardous to
3. Human error environment
4. Pump fail
-Business loss
No flow of inlet 1. Valve partly or -

from stream no.13 completely closed
2. Human error
HIGH High flow of 1. Shut down the -Hazardous
contaminant gas trapping of gas in the -Contaminant product
scrubber
High flow of NaOH 1. The pump failure -high cost
-The NaOH tank
empty
LOW Low flow of NaOH 1. The pump failure -The contaminant gas
does not fully convert
4. HAZOP WORKSHEET FOR MIXER (M-101)
Part Considered : Gas Mixer
No. Study Note Process Guideword Possible Causes Consequences Safeguard Recommendation
Parameter
1 Stream 1 Flow No  Valve Fully closed  A complete mixing

 Valve Malfunction between Feed Ethane
(feed stream)
 No Ethane in the tank (S1), Steam (S3) and
 Pipe Ruptures Recycle Ethane (S4)
 Fan ID Malfunction will not achieved
 Fan ID is off
More  Valve are fully open  Overflow will occur in
 Valve malfunction the vessel which causes
inefficient cracking
process in the furnaces
Less  Valve Partially Open  Amount of Ethane does
 Leakage in the Pipeline not correlate with
production targeted
2 Stream 3 Flow No  Valve fully closed  A complete mixing
 Valve malfunction ratio between ethane
(Boiler)
 Pipeline is ruptured and steam will not
achieved which can
causes the efficiency of
the cracking process
Less  Valve Partially Open  A complete mixing
 Leakage in the Pipeline ratio between ethane
and steam will not
achieved which can
3 Stream 2 Flow No  Valve fully closed  A complete mixing
 Valve malfunction ratio between ethane
(Ethane
 Pipeline is ruptured and steam will not
recycle) achieved which can
Less  Valve Partially Open  Amount of Ethane does
 Valve malfunction not correlate with
 Leakage in the Pipeline production targeted
5. HAZOP WORKSHEET FOR FURNACES
Part Considered : Furnaces
Parameter
1 Reaction Flow No  Valve Fully closed  Ethane cracking

 Valve malfunction process does not accord
Vessel (H-
 No Ethane in the tank
102)
 Pipe Ruptures

Less  Valve Partially Open  Ethane is over-cracking
 Leakage in the Pipeline due to high retention
time ethane inside the
furnace which cause
increase production of
by-product such tar and
coke
Temperature High  Poor Insulation  Possible of explosion
 Uncontrolled of and rupture on reactor
exothermic reaction  Overheating at the wall
 Control system of reactor
malfunction  More heat loss to the
surrounding
 Ethane is over-cracking
due to high temperature
inside the furnace
which cause increase
production of by-
product such tar and
coke
Low  Furnace malfunction  No or less reaction
 Control system happen in the reactor
malfunction which decrease the
efficiency of the
process
6. HAZOP WORKSHEET FOR HYDROGEN REACTOR
Part Considered : Hydrogenation Reactor
Parameter
1 Reaction Flow No  Valve Fully closed  Acetylenes

 Valve malfunction hydrogenation process
Vessel (R-
 Pipe Ruptures does not occur
101)

inefficient
hydrogenation process
in the reactor
Less  Valve Partially Open  Hydrogenation in
 Leakage in the Pipeline Ethylene will occur
which causes increase
production of by-
product ethane
Temperature High  Poor Insulation  Possible of explosion
 Uncontrolled of and rupture on reactor
exothermic reaction  Overheating at the wall
 Control system of reactor
malfunction  More heat loss to the
surrounding
Low  Furnace malfunction  No or less reaction

 Control system happen in the reactor
malfunction which decrease the
efficiency of the
process
7. HAZOP WORKSHEET FOR DISTILLATION COLUMN
Vessel – Distillation Column (T-104)

Intention – to separate methane (CH4) as overhead product and carbon 2 (C2) as bottom product.
Guide Deviation Causes Consequences Safeguards Recommendations

Word
(GW)
No Flow 1. Pipe blockage at the 1. Separation process in T-

outlet T-103. 104 is affected.
2. Control valve shut at 2. Unable to separate
the outlet T-103. hydrocarbons
3. Pump failure of efficiently.
outlet T-103. 3. Separation efficiency
decrease.
Less 1. Pipe blockage at the 1. Feed composition does
outlet T-103. not enough for
separation process.
2. Low in product purity.
More 1. Control valve of 1. Flooding in the column.
outlet T-103 fail 2. Decrease in temperature
closed. of T-104.
2. Increase in pumping 3. Rise in bottom liquid
capacity. level.
Reverse 1. High pressure inside 1. Back flow of material to
T-104. outlet T-103.
Low Temperature 1. Heat loss (steam 1. Changes in pressure
leakage in reboiler). inside column.
2. Less steam flow in 2. Major product loss lead
reboiler. to low in product purity.
High 1. Heat exchanger 1. Changes in pressure
failure. inside column.
2. More hydrocarbons 2. Low in product purity.
flow. 3. Separation occur
3. Reboiler control insufficiently.
failure.
Low Pressure 1. Low vapour flow 1. Weeping or dumping
inside T-104. occur.
2. Reduce separation
efficiency.
High 1. High vapour 1. Entrainment or flooding
pressure. occur.
2. Pressure indicator 2. Reduce separation
failure. efficiency.
Low Level 1. Blockage at the inlet 1. Insufficient distillate
of T-104 and reflux purity.
drum. 2. Decrease in reflux ratio.
2. Pump failure at the 3. Reflux drum runs dry.
outlet T-103.
High 1. Control valve failure. 1. Excessive flooding
occurs inside T-104.
2. Condensate overflows in
the reflux drum.
3. Changes in reflux ratio
as well as distillate
purity.
Intention – to separate carbon 2 hydrocarbons (C2H6, C2H4 and C2H2) and, carbon 3 hydrocarbons and above (C3H6, C3H8 and
C4H8).

Word
(GW)

outlet E-104. 105 is affected.
the outlet E-104. hydrocarbons
outlet E-104. 3. Separation efficiency
decrease.
outlet E-104. not enough for
separation process.
outlet E-104 fail 2. Decrease in temperature
closed. of T-105.
capacity. level.
T-105. outlet E-104.
failure.
inside T-105. occur.
efficiency.
pressure. occur.
outlet E-104.
the reflux drum.
purity.
Intention – to separate between ethylene (C2H4) and ethane (C2H6).

Word
(GW)

outlet E-105. 106 is affected.
the outlet E-105. hydrocarbons
outlet E-105. 3. Separation efficiency
decrease.
outlet E-105. not enough for
separation process.
outlet E-105 fail 2. Decrease in temperature
closed. of T-106.
capacity. level.
T-106. outlet E-105.
failure.
inside T-106. occurs.
efficiency.
pressure. occurs.
outlet E-105.
the reflux drum.
purity.
8. HAZOP WORKSHEET FOR QUENCHING
Vessel – Quenching Tower (T-101)

Intention – to cool or reduce the temperature of hot vapour at 25°C and remove tar and coke.
Guide Word Deviation Causes Consequences Safeguards Recommendations

(GW)
No Flow 1. Pipe blockage at the 1. Hot vapour of

outlet E-101. hydrocarbons cannot
2. Control valve shut at be cool down at
the outlet E-101. 102°C.
3. Pump failure of 2. Process disruption.
outlet E-101 and P- 3. Impurities (tar and
101. coke) cannot be
removed.
Less 1. Pipe blockage at the 1. Low in product purity.
outlet E-101 and P- 2. Desired temperature
101. cannot be achieved.
More 1. Control valve failure 1. Low in product purity.
at the outlet E-101.
2. Pump failure at the
outlet P-101.
Low Temperature - -
High 1. Heat exchanger (E- 1. Changes in desired

101) failure. temperature at top
2. Temperature control outlet T-101.
failure.
Low Pressure 1. Pump failure at the 1. Insufficient water to
outlet P-101. reduce the
2. Low vapour flow temperature.
inside T-101. 2. Less product at the
top outlet T-101.
4. Insufficiently separate
impurities from
hydrocarbon.
High 1. High vapour 1. Lead to high
pressure. temperature at the top
2. Pressure indicator outlet T-101.
failure.
9. HAZOP WORKSHEET FOR QUENCHING
Vessel – Dehumidifier (H-103)

Intention – to eliminated water from mixed gas.

Word
(GW)
No Flow  The outlet pipe line  Equipment damage.

is block
 The valve on
humidifier is close.
Less 2. Valve on 4. Cause pressure in the
stream to decrease.
dehumidifier partly
5. The mixed gas
closed transferred to the
compressor will be
3. Leaking in the pipe
decrease.
line.
More  High pressure in  The pipe may rupture.
the stream.
 Overflow in T-
102.
Low Temperature  Leakage in the  Slow the reaction in

pipeline the vessel.
High  Equipment mal  Can cause damage to
function. the equipment.
Low Pressure  Leakage in the  Increase in

pipeline. temperature.
 Equipment damaged.
High 3. Low 4. Hazardous gasses will
leaked to the
temperature in
surrounding air
the feed 5. The pipeline may
rupture.
stream.
10. HAZOP WORKSHEET FOR REFREGERATOR
Vessel – Refrigerator (E-103)

Intention – to eliminated water from mixed gas.

Word
(GW)
No Flow  The outlet pipe line  Equipment damage.

is block
 The valve on
humidifier is close.
Less 6. Valve on 8. Cause pressure in the
stream to decrease.
dehumidifier partly
9. The mixed gas
closed transferred to the
compressor will be
7. Leaking in the pipe
decrease.
line.
More  High pressure in  The pipe may rupture.
the stream.
 Overflow in T-
102.
High Temperature  Equipment mal  Slow the reaction in

function. the vessel.
 Leakage in the  Can cause damage to
pipeline. the equipment.
Low Pressure  Leakage in the  Increase in
pipeline. temperature.
 Equipment damaged.
High 6. Low 7. Hazardous gasses will
leaked to the
temperature in
surrounding air
the feed 8. The pipeline may
rupture.
stream.
9. The reaction in reactor
R-101 may not occur.

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1.

HAZOP WORKSHEET FOR TANK AND COMPRESSER

Mobile vessel to fixed vessel (TK-101)

Guide word deviation Cause Consequences Safeguard Recommendation

No/none Flow -Master valve failed to - Delay in dispatch of

More flow - Leakage of pipe joints - Wastage of raw material

Reverse Flow - High pressure at mobile -Pipe joints leakage

Vessel (TK-102) - Pump (P-102)

Guide word deviation Cause Consequences Safeguard Recommendation

No/none flow -Failure of pump system - Production delayed

More flow - Deviation and error of -Higher pressure

Reverse flow - High pressure in storage - Leakage of pipe joints

Less flow - Blockage of pipelines - Less production per hour

Distillation column (T-104) - Vessel (TK-104)

No/none flow - Accumulation of - Production delayed/stopped

Less flow - Blockage of pipeline - Lesser production due to

More flow - Distillation column - more weight travelling in

Reverse flow - Backflow from the - mixing of fresh product

Distillation column (T-106) - Vessel (TK-103)

Guide word deviation Cause Consequences Safeguard Recommendation

No/none flow - Accumulation of - Production delayed/stopped

Less flow - Blockage of pipeline - Lesser production due to

More flow - Distillation column - more weight travelling in

Reverse flow - Backflow from the - mixing of fresh product

2. HAZOP WORKSHEET FOR HEAT EXCHANGER

Vessel – Heat Exchanger

Guide word deviation Cause Consequences Safeguard Recommendation

None No flow 1. Blockage in -Loss of flow to E-101, no

2. Valve fails closed -As for (1)

4. Failure of inlet -Process fluid temperature is not

CONTAMINAT Process fluid line 1. Leakage of tube As (4)

CORROSION Corrosion of 1. Hardness of -Less cooling and crack of tube

HIGH High cooling 1. Failure of cooling -Process fluid temperature is not

High 1. The temperature of - Process gas temperature is not

LOW Low cooling 1. Pipe blockage -Temperature of process gas

Low pressure 1. Lower pressure -Less flow in production line

REVERSE Reverse process 1. Failure of process -Malfunction of heat exchanger

Vessel – Heat Exchanger

1. Failure of heat -malfunction of quenching tower

Guide word deviation Cause Consequences Safeguard Recommendation

None No flow 5. Blockage in -Loss of flow to E-102, no

6. Valve fails closed -As for (1)

7. Leak or drain left As for (1) and (2)

8. Failure of inlet -Process fluid temperature is not

CONTAMINAT Process fluid line 2. Leakage of tube As (4)

CORROSION Corrosion of 2. Hardness of -Less cooling and crack of tube

HIGH High cooling 2. Failure of cooling -Process fluid temperature is not

High 2. The temperature of - Process gas temperature is not

LOW Low cooling 3. Pipe blockage -Temperature of process gas

Low pressure 2. Lower pressure -Less flow in production line

Low temperature 1. Too high cooling - Temperature produce in stream

REVERSE Reverse process 2. Failure of process -Malfunction of heat exchanger

Vessel – Heat Exchanger

2. Failure of heat -malfunction of quenching tower

None No flow 1. Blockage in -Loss of flow to E-104, no

2. Valve fails closed -As for (1)

3. Leak or drain left As for (1) and (2)

4. Failure of inlet -Process fluid temperature is

CONTAMINATIO Process fluid 1. Leakage of tube As (4)

HIGH High steam flow 1 .Failure of steam -Process fluid temperature is

High 1. The temperature - Process gas temperature is not

LOW Low steam flow 5. Pipe blockage -Temperature of process gas

Low pressure 3. Lower pressure -Less flow in production line