HAZOP Worksheets XYZ BLOCK X-YZ FIELD DEVELOPMENT, Central Processing Platform Date:

Node Function: Describe its Function/Design Intent. Review in association with the layout or location of equipment Identify any novel or first of its kind or innovative solution.

PFD Nos: P&ID Nos:

Oper/ Design Press, barg / Oper/ Design Temp, ºC / Remarks:
Causes are within nodes; consequences can be elsewhere. For vessel outlet causes are pressure issues

Node: 1 Describe the Node

Deviation Possible Causes Potential Consequences Safeguards & Procedures Recommendations Rank

No / Less Flow Spec blind/ manual valve

/SDV/MOV closed
Choke/ FCV/ PCV/ High pressure in LP system
TCV/LCV/HCV fails closed
Line/ filter plugged/ blocked Fine Print
Wax/ hydrate blockage Educational/ Training Material
Stuck Pig Issued as a service to the
Low or incorrect ∆P
industry
Supply tank/ Suction Vessel
empty
for Free Distribution
Upstream line rupture
Operator routes wrongly or
Cross connection
PCV/BDV/PSV leaks High backpressure on RD and over Pressure indicator and alarm provided
RD upstream of PSV leaks pressurisation of the protected vessel. [25a] downstream of RD; PSV/BDV tail pipe
sweating
Pump fails/ cavitates/ Power
failure, Engine failure, Drive shaft
broken
Pump stroke adjusted wrongly
NPSH not adequate for starting Inability to start a stand-by pump or switch off Suction line and electrical system sized to
standby pump. duty pump. run N+1 pumps

REPORT NUMBER: REV: C 22 MAY 2010 PAGE 1 OF 16

HAZOP Worksheets XYZ BLOCK X-YZ FIELD DEVELOPMENT, Central Processing Platform Date:

Node: 1 Describe the Node

Deviation Possible Causes Potential Consequences Safeguards & Procedures Recommendations Rank
Low fluid density/ High viscosity Oil: Water emulsion; Unable to pump, as
required head is high
Viscosity/ Density Low Unable to pump, as developed head is low
HX: Hot side fluid not flowing If the other fluid is too cold, may lead to low Entire HX train in cold service is specified for
during start-up tube metal temperature and brittle failure material suitable for the coldest fluid.
releasing HC. Explosion. [4b]
Flow maldistribution amongst May lead to overheating, tube rupture and Individual pass flow controllers and proper
passes in a fired heater fire. [6a] monitoring during plant start up and
operation
More Flow Choke/FCV/PCV/TCV/LCV/HCV
fails open
Control valve bypass open
Gas blowby in liquid outlet High press and or low temp downstream.
High ∆P/ Upstream pressure
high/ downstream pressure low
Cross connection
HX or downstream pipe rupture
Pigging bringing in more liquids Liquid overflows into vapour outlet; loss of 5% bypass pigs to avoid picking full hold up
liquid level control
Draining under pressure Icing; blockage; damage to LP Drain
System;
Pump stroke adjusted wrongly
Pump or compressor racing; low
∆P
Extra Pump or Compressor
started
Higher fluid density. More Mass
Supply tank/ Suction vessel
overflow
Storage tank filled too fast with Tank pressurised and blew its top during Vent size bigger than any inlet size;
firewater for its air vent to cope hydrotest. [3a] Operating procedures in place.
up with. Vent covered with
plastic bag.
Firewater/Seawater/ Cooling Low pressure switch may start the standby/ Study how the seawater/
Water line ruptures water pumps. The resultant massive flow of firewater/ cooling water piping is

REPORT NUMBER: REV:C 22 MAY 2010 PAGE 2 OF 16

HAZOP Worksheets XYZ BLOCK X-YZ FIELD DEVELOPMENT,
Node: 1
Deviation Possible Causes
Relief & Pressure Control Valve
dump gas to flare at a high
velocity.
HC liquid product pumped into a
floating roof tank at a high rate
Liquid carry over with high
velocity gas
Loss of instrument air supply
resulting in opening of all deluge
valves, increasing FW demand
Erosion @ bends after Cavitation downstream of
LCV flashing control valves
Erosion @ bends after Piping downstream of water
Water / Steam Injn injection points is prone to
erosion-corrosion as the liquid
travels at gas velocity.
Reverse Flow Line rupture upstream
Upstream vent/ BDV opened
Pump failure or reversal
REPORT NUMBER:
Describe the Node
Potential Consequences
water may flood the FSO/ FPSO/ semisub,
sinking it. [3i]
Resulting vibrations in piping may rupture tail
pipe or flare header.
Static electricity generated resulting in tank
explosion
Flare KOD internal may break off, rupture
flare header releasing flared gas locally
leading to a fire [1g]
May lead to metal loss ("thinning") in the
downstream piping. High liquid velocities in
the two phase flow downstream of LCV can
cause additional erosion affecting piping
integrity. The thinned metal wall will give
away as a result of erosion caused by solids
like proppant and/or the usual wellmuds /
sands that flow with liquid. Leads to line
rupture releasing large hydrocarbon. [31a]
Erosion - Corrosion of bend downstream of a
water injection point leads to HC release,
vapour cloud explosion, fire and damage to a
refinery [31g]
REV:C 22 MAY 2010
Central Processing Platform Date:
Safeguards & Procedures Recommendations Rank
routed, should there be a rupture
how the high water flow will be
drained off at any point and the
effect of automatic start of large
water pumps in case of water
piping rupture.
Proper pipe routing and supports. Conduct AIV/FIV study.
Consider providing second
check valve (of different type for
reliability) in series in instrument
air line to deluge valve.
It is recommended to have a straight run of
twenty (20) diameters before a bend in
piping downstream of such LCV as such
bends are vulnerable.
For liquid injection, use spray nozzles,
employing part of the gas as an atomising
fluid
Locate injection points well ahead of bends.
During plant operation, routinely check the
piping downstream of such injection points
specially bends for thinning.
PAGE 3 OF 16
HAZOP Worksheets XYZ BLOCK X-YZ FIELD DEVELOPMENT,
Node: 1
Deviation Possible Causes
Check valve/ block valve leaks
Two way flow
HC leak in vertical piperuns with
large oil inventory
Reaction/ high downstream
pressure / high backpressure
Oil well converted to Water Injn
Thermal inbreathing/
outbreathing
Mis-directed flow Operator routes wrongly
Where else it can flow External leakage; drain/ vent
valve open/ leaks
PSV on N2 cylinder leaks
Small bore piping.
Riser rupture
Other flow issues Liquid condenses in vapour line
Liquid carry over to compressor
Sand/ debris/ solids in liquid or
vapour line
Contaminants Gas/ Air/ water/ steam /HC ingress
Liquid/ Solid Corrosion products
Liquid carry over into vapor line;
Condensation in vapor line
Leaking HC gets into FD fan
intake
Air used to pneumatic-testing of
piping enters connected tank
thru leaking block valves.
Water ingress into hotoil circuit
REPORT NUMBER:
Central Processing Platform Date:
Describe the Node
Potential Consequences Safeguards & Procedures Recommendations Rank
The entire contents of the downstream piping Check valve?
will empty, even after closing SDV upstream.
HC spill when ‘water piping’ broken for Add Caution in P&IDs/ Op
maintenance Manual
Top of diesel storage tank corroded by water
in air ingress
No backup N2 Provide load cells to +ively identify inventory
½" SS Glycol tubing parts from a fitting.
Glycol, condensate, and gas sprayed onto
the glycol reboiler and ignited. [31h]
Resultant HC release in seawater reduces
the buoyancy of FSO/FPSO and topples it.
Liquid travels at high velocity; erosion.
Compressor blades damage; production loss
High erosion in piping; HC release and Consider target ‘T’ instead of sharp bends
explosion
Boiler/ Fired Heater firebox explosion. [6b] HC detectors in plant; FD fan intake x m
[86a] above ground
Tank lift off its foundation. [3h] Vessel isolation pieces like spectacle blinds,
drop-off spool pieces and/or double block
and bleed can prevent leakage thru corroded
valves
Violent boil off, rupture, fire & explosion [1a] Oil used as hydrotest medium; low point
drains provided.
REV:C 22 MAY 2010 PAGE 4 OF 16
HAZOP Worksheets XYZ BLOCK X-YZ FIELD DEVELOPMENT, Central Processing Platform Date:

Node: 1 Describe the Node

Deviation Possible Causes
Water ingress into a vessel that
was supposed to be isolated.
Fugitive water into the reactor.
Water introduced into spent mol.
Sieve.
Mercury in process fluid, sand
Contaminant sent back in tote
tank; LPG cylinders
heat exchanger/ isolation valve
leaks
Slurries settle down
Compatibility Wax/low temp; acid/alkali
Potential Consequences
Water may react with the stored chemical,
releasing poisonous gas (MIC) killing many.
[3g]
Flixborough: Plant blows up. 31p
Steam ingress via leaking valve leads to
decomposition of residual material into
unstable chemicals, blowing off column top
Violent reaction releasing absorbed
hydrocarbon and toxic gases. May lead to
fire and explosion. Death or injury if
personnel are not wearing masks.
Metal embrittlement Aluminium, if present
[15b]
Safeguards & Procedures Recommendations Rank
Vessel isolation pieces like spectacle blinds,
drop-off spool pieces and/or double block
and bleed can prevent leakage thru corroded
valves.
Vessel isolation procedures and swinging of
spectacle blinds avoids such incident. [2c]
Avoid aluminium as MOC, specially in cold
boxes

Toxic Components Toxic chemicals handled Personnel injury Double block & bleed / spool piece isolation
provided
High Temperature Burner/ heating / heat tracing/
cooling failure
Hot oil system: Start up warm up boils of trapped water and loosens mill scale Slow warm up + Loading on filters
Trapped fluid cooked by
refractory heat in WHRU/ heater
External fire/ internal heater fire
Reactions, HX scaling
HX tube leak/ rupture
FD/ID fan failure
Refrigerant warms to ambient
Ambient temperature high

REPORT NUMBER: REV:C 22 MAY 2010 PAGE 5 OF 16

HAZOP Worksheets XYZ BLOCK X-YZ FIELD DEVELOPMENT, Central Processing Platform Date:

Node: 1 Describe the Node

Deviation Possible Causes Potential Consequences Safeguards & Procedures Recommendations Rank
Solar/ flare radiation heat Design temperature exceeded
Hot engine casing; uninsulated
regenerator vessel wall
Stack oxygen analyzers operate Furnace damaged. Note: Flame arrestor
above auto-ignition temperature provided on the probe may degrade in
of fuel service. [6f]
Flare radiation Flare piping instrument not specified for Consider Thermally Sprayed
equilibrium temp Aluminium (TSA) coating
High temperature in reboiler
affects condensate quality
Less Flow
Low Temperature Flashing/ chilling due to JT
Gas blowby & chilling due to JT Low temp gases lead to brittle fracture of d/s
piping. Result in a fire. [25e]
Cold creep upstream of JT valve
System blowndown
Heater/ boiler shutdown
Reactions, HX scaling
Fired heater/ reboiler control or
control valve failure
FD/ID fan failure
Flare KOD heater failure Low temp gases lead to brittle fracture of Suitable temperature alarms and protection,
flare piping, releasing the flared gas within such as SS piping for a distance are good
the plant. Result in a fire. [25e] measures
Ambient cool Cold hydrotest water may lead to vessel Hydrotest water used in cold countries is
rupture [2a] above 16°C or 10°C above the impact test
temperature of the metal.
HX: Hot side fluid flow loss May lead to low tube metal temperature if the Entire HX train in cold service is specified for
other fluid is too cold and brittle failure of material suitable for the coldest fluid.
tubes, HC release and explosion. [4b]
More cooling medium or Cooling
medium leak or heat exchanger
tube rupture
Insulation/ Heat Tracing failure High pressure in LP piping
resulting in fluid gels/ blocks

REPORT NUMBER: REV:C 22 MAY 2010 PAGE 6 OF 16

HAZOP Worksheets XYZ BLOCK X-YZ FIELD DEVELOPMENT, Central Processing Platform Date:

Node: 1 Describe the Node

Deviation Possible Causes Potential Consequences Safeguards & Procedures Recommendations Rank
Level bridles blocked by wax Incorrect level reading
Corrosion under insulation. LPG sphere topples; Hydrocarbon leakage Inspection windows provided in insulation.
Support legs corroded under fire- [3c] Intumescent epoxy coating used. Operating
proofing concrete procedure calls for inspection of vessel,
appurtenances and supporting structures
before hydrotesting.
Tracing control failure Design temperature exceeded
More flow
Transient Temperature Starting-up refrigerant / LT units Heat exchanger leaks; Brittle failure/ fracture
Large user (GT) trips Transient changes resulting it spurious Consider time averaged (20 sec) inputs
TAHH/TALL
High Pressure External fire/ High Temperature/
Thermal
Blocked outlet - Spec blind/
valve /MOV/SDV closed
Upstream Choke/
FCV/PCV/TCV fails open
Downstream
FCV/PCV/TCV/LCV/HCV fails
closed
Operator routes wrongly or
Cross connection
Gas blowby
Compressor/ Pump speeds up.
PD Pump blocked
Downstream Line/ Filter
plugged/ blocked.. Hydrate, Wax
Bigger impeller in pump
Pump has no min flow control
2” manual vent opened If upstream pressure is more than 35 bar, Full rating of tail piping; RO provided in the
resultant press in tail pipe may exceed 150# vent line to reduce flow and tail pipe
rating if system can pass >100 MMscfd. pressure.
Start-up pressure equalisation High velocity flow, damaging d/s piping AIV/FIV studies
Large user (GT) trips Transient changes resulting it spurious Consider time averaged (20 sec) inputs;
PAHH/PALL dump PCV

REPORT NUMBER: REV:C 22 MAY 2010 PAGE 7 OF 16

HAZOP Worksheets XYZ BLOCK X-YZ FIELD DEVELOPMENT, Central Processing Platform Date:

Node: 1 Describe the Node

Deviation Possible Causes Potential Consequences Safeguards & Procedures Recommendations Rank
Start-up surge GRE pipe breaks
Water hammer
High backpressure
Flaring introduces high RD fails to open when demanded Two RDs in series are provided; the second
backpressure on RD one protects against backpressure.
HX scaling/ leaks/ rupture
Rupture disk leaks May lead to high backpressure on RD and Pressure indicator and alarm provided
overpressurisation of the protected unit. [25a] downstream of RD
Heating / cooling failure
Solar/ flare radiation heat inflow
Refrigerant warms to ambient
Boiling, reaction, ambient warms
Implosion
Reaction
Less Pressure/ Condensation/ freezing/ cooling
Vacuum Ambient cools
Downstream
FCV/PCV/TCV/LCV/HCV fails
open
Operator routes wrongly or
Cross connection
Backpress PCV or BDV opens
Emptying vessels
Cool down: hot vapour/ steaming
Liquid leg drained to atmosphere
Vessel drained creating vacuum Vacuum in tank when drained out after a Tank's vent acts as its relief valve and
/ Vent line closed . Storage tank hydrotest and collapses [3d] deserves as much attention and inspection
vent covered with plastic bag, as a PSV. Vent should be inspected and
honeybee nest, wax or rusted checked before filling and emptying a tank.
flame arrestor.
Upstream pressure falls
Compressor/ pumps slows
Smaller impeller in pump

REPORT NUMBER: REV:C 22 MAY 2010 PAGE 8 OF 16

HAZOP Worksheets XYZ BLOCK X-YZ FIELD DEVELOPMENT, Central Processing Platform Date:

Node: 1 Describe the Node

Deviation Possible Causes Potential Consequences Safeguards & Procedures Recommendations Rank
High velocity in transfer line Liquid atomises and unable to separate in
downstream column
Safety shower provided on the Pressure requirement as per ANSI Z358.1
same deck on which the supply not met at the safety shower/eyewash unit
water tank (gravity flow) is and the adequate flow is not available during
located emergency
Soda lime solution type CO2 Pulls in vacuum in the tank during pump out, (1) Use Soda lime solution type
absorber at DM water storage damaging tank damage. CO2 absorber with caution
tank breather line solidifies due (2) Provide PVRV on tanks
to lack of supervision.
High Level Liquid outlet blocked; plugged,
Strainer blocked
LCV /SDV fails closed
Surge / Slug/ Gush of inflow
Pigging brings in more liquid
Column trays plugged with mud
Pump failure
Flow meter malfunction
Faulty level instrumentation. Tank overflows resulting in a massive fire Hydrocarbon detection and shutdown Tank level control LT and trip LT
Tank over flow and explosion. [3e] systems around tank farm. In the case of should track each other and
volatile and flammable liquids, bunds around provide discrepancy alarm. Tank
tanks are of lesser value, as the vapour flow meters should track level
quickly overflows the bund wall. Level readings and provide
inferred in DCS in addition to LAHH discrepancy alarm.
Liquid level balances out when
tank inlet valves of 2 parallel
tanks for same products are
opened simultaneously by
mistake (Operational issue)
Uneven level Long vessel with internal waves Transient changes resulting it spurious Consider time averaged (20 sec) inputs;
LAHH/LALL
FPSO motion

Low / No Level/ Empty LCV fails open; bypass open or Gas blowby [1i, 1h] Downstream equipment PSV sized for gas Check if time available is
passes blowby via failed LCV and its bypass adequate for LALL to close SDV

REPORT NUMBER: REV:C 22 MAY 2010 PAGE 9 OF 16

HAZOP Worksheets XYZ BLOCK X-YZ FIELD DEVELOPMENT, Central Processing Platform Date:

Node: 1 Describe the Node

Deviation Possible Causes Potential Consequences Safeguards & Procedures Recommendations Rank
Less inflow/ source empty
Pyrophoric components exposed Fire, Personnel Injury, plant damage [2b] Wet spent metallic parts during replacement
to reduce risk of metal fires.
Vessel heating element exposed Hydrocarbon heated above auto-ignition Have control level transmitter track trip level
temperature transmitter for descrepancy
Chemical Reaction/ Injection/ Addition
Less residence time
More residence time

More Concentration More of one reactant charged Run away reaction, HC release and
explosion [5b]
Burner in a boiler or fired heater Each failed attempt leads to hydrocarbon Operating practice to lockout third ignition
fails to light after 2 attempts. accumulation and explosive mixture in the unless firebox is purged.
firebox. [6b]
Poor mixing
Solvent flashes off
Less Concentration More/ less residence times
Less of one reactant charged;
run away reaction
During fuel switch over from gas Furnace starved of air, based on stack Operating practice: to increase the air to
to oil or vice versa, total fuel fired oxygen reading, during fuel switch over may compensate for the momentary additional
may be higher than air available. explode. [6e] firing and then cut it back after switchover.
Competing reactions, Bhopal
Decomposition
Incorrect Chemical Wrong valve opened
Solvent flushing
More/ Less/ Wrong/ Valve leaks/open: Reactant
As-Well-As Reaction back flows into another line
Fast/ Runaway Slow/
Unwanted Reaction

Stirrer/ Agitator Failure Batch processing

More/ Less Mixing

REPORT NUMBER: REV:C 22 MAY 2010 PAGE 10 OF 16

HAZOP Worksheets XYZ BLOCK X-YZ FIELD DEVELOPMENT, Central Processing Platform Date:

Node: 1 Describe the Node

Deviation Possible Causes Potential Consequences Safeguards & Procedures Recommendations Rank
Sequence Step
Skipped
Wrong sequence
Extra Actions
Chem injn points are Negates each other
close together
Instruments – None / Instruments redundancy
too many/ insufficient
FO/ FC/ FL positions
Instrt Response Time
Interlocks
Piping Class Rating Check spec breaks
Operable/ Maintainable Access/ egress
Sampling
Venting/ Draining/ Purging
Swinging blinds, spades
Fouling/ Plugging of filters
Changing filter elements Quick opening doors can fail and kill [1d]
Leak detection & isolation
Dip legs, level measurement Operator has to walk on corroded tank roof
Drip pans
Utility connection without a Vessel contents spray on operators when Depressurization before draining or purging
check valve attempting to purge vessel under pressure is a MUST.
[31e]
Leaking steam hose May lead to fire if hydrocarbon backs into it.

Isolation, spools, DBB

Too many 2” tap-offs for DBB Potential leak sources Check if bleeds in pressure instruments are
acceptable and relocate PTs if possible.

Overview

REPORT NUMBER: REV:C 22 MAY 2010 PAGE 11 OF 16

HAZOP Worksheets
Deviation Possible Causes
Product RVP not met Reboiler fouling/ inability to clean
reboiler as only one provided
Product spec not met Start-up/ fouled catalyst
Material Selection CS tubes used in a fired heater
heating sulphur bearing streams.
Corrosion/ Erosion Seawater on the shell side of
HX.
Material Identification Maintenance crew wrongly
inserted a carbon steel elbow,
instead of alloy steel elbow in a
high-pressure, high-temperature
hydrogen line.
LPG handling Propane leakage
Old style vent stack Hydrocarbon spill over/ spewing
out of top
Commissioning Preparation, testing, verification
how will it be done Debris, construction material
Sequence
Water, Hydrotesting
Initial fill
Test runs
Hydrotest
Start-up First Start/ Black Start
Next Starts
Out of sequence /Missed out
step
HP valve/ bypass SDV opened
High inlet pipeline pressure
Low outlet pipeline pressure
REPORT NUMBER:
XYZ BLOCK X-YZ FIELD DEVELOPMENT, Central Processing Platform Date:
Potential Consequences Safeguards & Procedures Recommendations Rank
Loss of production A standby reboiler provided
Inability to dispose off offspec products
May lead to rapid corrosion and rupture of Consider 5Cr½Mo tubes instead of CS.
carbon steel tubes [6d]
Leads to corrosion of CS tube sheets behind It is recommended to have seawater on tube
titanium cladding on the shell side + side.
hydrocarbon release and explosion. [4a]
High temperature hydrogen attack (HTHA) Positive alloy verification is a
may rupture the elbow; H2 release ignited. must. We need to identify
[31i] materials used in our projects
and strictly follow company’s
alloy verification procedures.
Piping engineers may design out
the possibility of incompatible
components being interchanged.
Explosion/ BLVE [1e]
HC ignition and explosion. 2d
Dirty to clean system
Damage to compressors, filters, meters
Static load of water in steam or gas pipes
High velocity/ vibration damage in d/s pipes
Rapid pressurization; vibration; JT cooling
Hi velocity, JT cooling – PL MDMT exceeded
REV:C 22 MAY 2010 PAGE 12 OF 16
HAZOP Worksheets XYZ BLOCK X-YZ FIELD DEVELOPMENT, Central Processing Platform Date:

Overview
Deviation Possible Causes Potential Consequences Safeguards & Procedures Recommendations Rank
Sudden vaporization of water Pressure surge may destroy reformer tubes. Gradual warming and steaming out the
trapped in a furnace coil [6g] requires attention
Drain/ flare connecting part of
the plant running; others under
maintenance or not yet started
Shutdown
Planned Work permits, safety clearance
procedures, confined space
entry, isolation, blowdown,
purging, ESDs
Emergency
Temporary trailer parking lot. Workers will be caught unaware if there is
any incident in the plant. [2d]
Thermally reactive chemicals in Nitrogen purging may not remove it. Water washing and draining may help but Avoid such low points in piping
piping low point. Subsequent steaming may lead to explosion. will generate a significant quantity of waste for such services. Add a warning
31j liquid to be treated. in operating manual & PIDs,
"Warning: Process fluid may
decompose and explode on
heating during steaming the
piping. Ensure fluid is completely
drained by opening low point
drains before steaming”

Vessel Entry HC trapped in sand/ silica gel
H2S trapped in Mol Sieve
Pig got stuck in the neck of a
receiver.
Entry into Gas Turbine Water mist/ steam mist/ halogen
Enclosure
Fire & Explosion [1f, 1c]
On opening the door, residual pressure
trapped behind the pig may blow it off. [35a]
May lead to asphyxiation, scalding; temp
may be as high as 100°C. [9b]
Orient pig trap doors away from plant,
towards sea.
Lockout mist discharge when the hood door
is opened and provide status alarm.

Testing/ calibration Trip testing method and

frequency

Noise Rotating machinery, acoustically

induced vibration, flares etc.

REPORT NUMBER: REV:C 22 MAY 2010 PAGE 13 OF 16

HAZOP Worksheets XYZ BLOCK X-YZ FIELD DEVELOPMENT, Central Processing Platform Date:

Overview
Deviation Possible Causes Potential Consequences Safeguards & Procedures Recommendations Rank
Sources Vibration Mitigation
Power Failure
Utility Failure - Inst Air,
Plant Air, Hydraulic
Fluid, Steam, Nitrogen,
Cooling Water,
Process Water, DM
Water, Hot Oil, Fuel
Oil, Fuel Gas, Vacuum
& Vents
DCS Failure Redundancy
Telecommunication / MMI
Telemetry Failure
Redundancy
Electrical–HAC/
isolation/ earth
Emissions Gas/ Dust/ Liquid/ Waste
Disposal
Ground seepage
Dust Explosion
Relief valve discharges
Reaction in drains
Treatment and disposal methods
Open drain tank Heavy rains HC leakage to sea in unmanned facilities Provide covers/lids on open drain points, to
overflows be closed before demanning.
Bunding Storm Water/ Firewater
containment - Hazardous wastes
bag filter failure
Materials handling
Handling Toxic Wastes Handling mercury waste Personnel injury
Handling pyrophoric waste Fire, Personnel Injury, plant damage [2b] Wet spent metallic parts during replacement
to reduce risk of metal fires.
Radioactive materials,
biologically active materials

REPORT NUMBER: REV:C 22 MAY 2010 PAGE 14 OF 16

HAZOP Worksheets XYZ BLOCK X-YZ FIELD DEVELOPMENT, Central Processing Platform Date:

Overview
Deviation Possible Causes
Removing old catalysts/ adding
new catalysts
Emergency Evacuation
Earthquake, Flooding,
Bushfire
Fire & Explosion Protection; Prevention
Detection/ mitigation Gas / fire detectors
Shut-off valves and controls
Deluge systems, extinguisher
Training
Escape routes, Steam / water
curtain, safety shower
Location of Safety Equipment
Pipe rack structure not fire
proofed.
Dropped Object, Vehicle impact
Collision
Potential Consequences Safeguards & Procedures Recommendations Rank
Personnel Injury; Dust damage to
instruments
Nearby community, police, hospital kept
informed of chemicals handled, hazards and
treatment
Structure may fail, rupture additional pipes
and feed a fire. [51a]
Piping/ drain valve ripping off leading to spill, Avoid small bore piping on
fire and explosion. [31d] vessels with large flammable
liquid inventory and/or locate
them downstream of a SDV.
Mark on P&ID such vulnerable
piping.
During 3D Model review, check if
they are protected. This check
needs to be repeated by
construction and commissioning
team to filter out any missed
item.
Mark physically on plant floor
designated and prohibited
vehicle access ways.
Remote isolation valves and
control room stopping of a
pumps is a must while handling
large inventory of flammable

REPORT NUMBER: REV:C 22 MAY 2010 PAGE 15 OF 16

HAZOP Worksheets XYZ BLOCK X-YZ FIELD DEVELOPMENT, Central Processing Platform Date:

Overview
Deviation Possible Causes Potential Consequences Safeguards & Procedures Recommendations Rank
liquids.
Suitable hydrocarbon leak
detection and shutdown system
is a must.
Human Factors

Alarms Too many alarms. Fatigue. Excessive alarm and warning systems cause Conduct an Alarm
workers to become desensitized. [15c] Rationalization Study. Consider
start/ stop of pumps and other
events without initiating an
alarm. Alarms should activate
when the event fails to initiate.

Take along
1. Methane Phase Diagarm to determine likely low temp on pressure reduction. Roughly 0.5°C per 1 bar drop; 0.5°F per 10 psi drop
2. Flange rating chart
3. Piping Spec with temperature limits
4. Condensed API 14 C

REPORT NUMBER: REV:C 22 MAY 2010 PAGE 16 OF 16