HAZOP STUDY RECORD SHEET

SYSTEM: MIXING POINT PROJECT: FORMALDEHYDE PRODUCTION PLANT ZONE TOTAL PAGES:
LINE: STREAM 1, 2 and 34
Parameter Guide Deviation Causes Consequences Action Safeguard Recommendations
Word
- - - - -
- - - - -
- - - - -
- - - - -
- - - - -
- - - - -
HAZOP STUDY RECORD SHEET Risk
SYSTEM: HE-01 PROJECT: FORMALDEHYDE PRODUCTION PLANT ZONE A TOTAL PAGES: 7 Assessment
LINE: STREAM 3 and 4
Parameter Guide Deviation Causes Consequences Action Safeguard Recommendations R P C
Word
Flow None No flow at stream - ST-01 is - Damage done - Fill up the - Install a - Regular - - -
3 empty to HE-01 storage tank to flow maintenance of
- Blockage in - No flow to the initiate the indicator pipelines,
stream 3 rest of the process - Install a equipment and
- Valve plant hence no - Clear the temperature indicators
malfunctions production rate blockage of indicator - Regulate the
or closed pipeline - Pipeline design of HE-01
- Breakage in - Repair the monitoring
pipeline pipeline
system and
valves
- Rectify the
damage done
to HE-01
No flow at stream - Blockage in - Pressure build - Clear the - Install a - Regular - - -
4 stream 4 up in HE-01 blockage of flow maintenance of
- Valve - Risk of pipeline indicator pipelines,
malfunctions explosion - Repair - Install a equipment and
or closed pipeline pressure indicators
- Breakage in system and and - Regulate the
pipeline valves temperature design of HE-01
- Rectify indicator
damage done - Pipeline
to HE-01 monitoring
No flow for utility - Blockage in - No heat - Clear blockage - Install a - Regular - - -
stream utility stream transfer of pipeline flow maintenance of
pipeline process take - Repair indicator pipelines,
- Breakage in place pipeline - Pipeline indicators and
pipeline - Process stream system and indicator equipment
is not valve
vaporized
 - Valve
malfunctions
or closed
Less Less flow rate at - Leakage in - Outlet stream - Repair - Install a - Regular - - -
stream 3 pipeline has higher pipeline flow maintenance of
- Partial temperature system indicator pipelines,
blocking than expected - Disassemble - Install a equipment and
occurs in value HE-01 to temperature indicators
stream 3 - More heat remove indicator - Regulate the
- Corrosion in accumulated in deposited solid - Install a design of HE-01
pipeline HE-01 - Clear blockage level
system - Deposition of in pipeline indicator
- Control solids inside of - Rectify - Pipeline
failure HE-01 damage done monitoring
- Fouling in - Damage done to HE-01
pipeline to HE-01
Less flow rate at - Leakage in - Less efficient - Repair - Install a - Regular - - -
stream 4 pipeline heat transfer pipeline flow maintenance of
- Fouling in - Liquid stream system indicator equipment,
heat is not - Dismantle HE- - Install a pipelines and
exchanger vaporized 01 to remove temperature indicators
- Partial completely any deposited indicator - Regular clean-
blocking - Deposition of solids and - Install a up of HE-01
occurs in solids inside of blockage level - Regulate the
stream 4 HE-01 - Clear blockage indicator design of HE-01
- Corrosion in - Decrease in in stream - Pipeline
pipeline production rate monitoring
system from expected
value
Less flow for - Partial - Less efficient - Clear blockage - Install a - Regular - - -
utility stream blockage at heat transfer of pipeline flow maintenance of
utility stream - Liquid is not - Repair indicator pipelines,
- Leakage in completely pipeline - Pipeline indicators and
pipeline vaporized system monitoring equipment
 - Decreased in
production rate
More More flow rate at - Faulty valves - Outlet stream - Repair or - Install a - Regular valve - - -
stream 3 will have replace valves flow maintenance
lower indicator
temperature
than required
More flow for - Faulty valves - Outlet stream - Repair or - Install a - Regular valve - - -
utility stream has higher replace valves flow maintenance
temperature indicator
than required
value
Pressure Less Low pressure of - Inlet valve - Less flow rate - Repair piping - Install a - Regular - - -
stream 3 malfunction into HE-01 system flow equipment and
- Pipeline - Outlet stream - Remove indicator piping system
leakage in for HE-01 blockage in - Install a maintenance
stream 3 have higher pipeline pressure - Frequent
- Pipeline temperature - Repair or indicator monitoring on
blockage in than required replace valve - Install a indicators
stream 1 and value pressure
2 alarm
Low pressure of - Outlet valve - No flow in - Close the inlet - Install a - Regular - - -
stream 4 malfunction stream 4 stream to HE- flow equipment and
- Pipeline - Pressure will 01 indicator piping system
leakage in build up in - Repair piping - Install a maintenance
stream 4 HE-01 system pressure - Regulate the
- Blockage in - Repair or indicator design of HE-01
process replace valve - Install a
stream tube - Disassemble pressure
site of HE-01 HE-01 to alarm
remove
blockage
Low pressure of - Inlet valve - Inefficient heat - Repair or - Install a - Regular - - -
utility stream malfunction transfer replace valve flow equipment and
indicator piping system
maintenance
 - Outlet valve - Outlet stream - Stop the plant - Install a - Frequent
malfunction is not momentarily pressure monitoring on
completely while fixing indicator indicators
vaporized the issue - Install a
- Reaction rate pressure
is less alarm
favourable
Low pressure in - Low inlet - Low inlet flow - Repair piping - Install a - Regular - - -
HE-01 flows into HE-01 system pressure equipment and
- Inlet and - Temperature - Close opened indicator piping system
outlet pipe of HE-01 pressure - Install a maintenance
leakage drops release valve flow - Frequent
- Pressure - Replace or indicator monitoring on
release valve repair faulty indicators
is left open valves
More High pressure of - Fouling in - Pressure build - Disassemble - Install a - Regular - - -
stream 4 heat up in HE-01 heat exchanger flow equipment and
exchanger and damages it to remove indicator piping system
- Pipeline fouling - Install a maintenance
blockage in - Remove pressure - Install backup
stream 4 blockage in indicator pipelines for
piping - Install a HE-01
pressure - Install a vent or
alarm bypass pipeline
- Install an for HE-01
emergency
relief valve
at HE-01
High pressure in - Inlet valve - Temperature is - Replace or - Install a - Regular - - -
HE-01 for utility or lower than repair faulty pressure equipment and
process required value valves indicator piping system
stream in outlet - Install a maintenance
malfunctions stream flow - Frequent
- Outlet valve - Reaction rate indicator monitoring on
for utility or is less indicators
process desirable
 stream
malfunctions
Temperature Less Low temperature - Inefficient - Output stream - Repair the - Install a - Install a - - -
of stream 4 heat transfer is not equipment temperature thermostat
process completely used to heat up indicator controller
- Less flow vaporized utility stream - Install flow - Frequent
rate of utility indicator monitoring on
stream - Install indicators
- Too many pressure - Regular
flow rate indicator equipment and
from stream piping system
3 to HE-01 maintenance
- Loss of heat - Good insulator
to materials is used
surrounding to build HE-01
Low temperature - Equipment - Output stream - Repair the - Install a - Install a - - -
of utility stream used to heat is not equipment temperature thermostat
up utility completely used to heat up indicator controller
steam vaporized utility stream - Frequent
malfunctions monitoring on
indicators
- Regular
equipment and
piping system
maintenance
Low temperature - Equipment - Output stream - Repair the - Install a - Install a - - -
of HE-01 used to heat is not equipment temperature thermostat
up utility completely used to heat up indicator controller
steam vaporized utility stream - Frequent
malfunctions - Repair or monitoring on
- No or less replace faulty indicators
inlet flow of valves - Regular
heating duty equipment and
- High flow piping system
rate of inlet maintenance
 process
stream
- Inlet valve
malfunction
More High temperature - Damage to - Overall - Disassemble - Install a - Install a - - -
of stream 4 HE-01 reaction is HE-01 to temperature thermostat
- Partial affected due to remove indicator controller
blockage to some fouling and - Install flow - Frequent
stream 3 unwanted blockage indicator monitoring on
- Leakage in reactions that - Remove - Install indicators
pipeline of favours high blockage and pressure - Regular
stream 3 temperature repair pipeline indicator equipment and
- Higher flow system piping system
of heating maintenance
duty than
required
value
- Fouling in
HE-01
High temperature - Equipment - Outlet stream - Disassemble - Install a - Install a - - -
of utility stream used to heat has higher HE-01 to temperature thermostat
up utility temperature remove indicator controller
steam than required fouling and - Install flow - Frequent
malfunctions value blockage indicator monitoring on
- Blockage in - Overall - Remove - Install indicators
HE-01 reaction is blockage and pressure - Regular
affected due to repair pipeline indicator equipment and
some system piping system
unwanted - Repair the maintenance
reactions that equipment
favours high used to heat up
temperature utility stream
High temperature - Heating duty - Outlet stream - Repair the - Install a - Install a - - -
of HE-01 overflow has higher equipment temperature thermostat
- Equipment temperature used to heat up indicator controller
used to heat utility stream
 up utility than required - Repair or - Install flow - Frequent
steam value replace faulty indicator monitoring on
malfunctions - Overall valves indicators
- Utility reaction is - Regular
stream inlet affected due to equipment and
valve some piping system
malfunctions unwanted maintenance
reactions that
favours high
temperature
HAZOP STUDY RECORD SHEET Risk
SYSTEM: HE-02 PROJECT: FORMALDEHYDE PRODUCTION PLANT ZONE A TOTAL PAGES: 7 Assessment
LINE: STREAM 6 and 7
Parameter Guide Deviation Causes Consequences Action Safeguard Recommendations R P C
Word
Flow None No flow at stream - No air enters - Damage done - Rectify the - Install a - Regular - - -
6 from air inlet to HE-01 issues from air flow maintenance of
- Blockage in - No flow to the inlet indicator pipelines,
stream 6 rest of the - Clear the - Install a equipment and
- Valve plant hence no blockage of temperature indicators
malfunctions production rate pipeline indicator - Regulate the
or closed - Repair the - Pipeline design of HE-02
- Breakage in pipeline monitoring
pipeline system and
valves
- Rectify the
damage done
to HE-02
No flow at stream - Blockage in - Pressure build - Clear the - Install a - Regular - - -
7 stream 7 up in HE-02 blockage of flow maintenance of
- Valve - Risk of pipeline indicator pipelines,
malfunctions explosion - Repair - Install a equipment and
or closed pipeline pressure indicators
- Breakage in system and and - Regulate the
pipeline valves temperature design of HE-02
- Rectify indicator
damage done - Pipeline
to HE-02 monitoring
No flow for utility - Blockage in - No heat - Clear blockage - Install a - Regular - - -
stream utility stream transfer of pipeline flow maintenance of
pipeline process take - Repair indicator pipelines,
- Breakage in place pipeline - Pipeline indicators and
pipeline system and indicator equipment
- Valve valve
malfunctions
or closed
Less Less flow rate at - Leakage in - Outlet stream - Repair - Install a - Regular - - -
stream 6 pipeline has higher pipeline flow maintenance of
- Partial temperature system indicator pipelines,
blocking than expected - Disassemble - Install a equipment and
occurs in value HE-02 to temperature indicators
stream 6 - More heat remove indicator - Regulate the
- Corrosion in accumulated in deposited solid - Install a design of HE-02
pipeline HE-02 - Clear blockage level
system - Deposition of in pipeline indicator
- Control solids inside of - Rectify - Pipeline
failure HE-02 damage done monitoring
- Fouling in - Damage done to HE-02
pipeline to HE-02
Less flow rate at - Leakage in - Less efficient - Repair - Install a - Regular - - -
stream 7 pipeline heat transfer pipeline flow maintenance of
- Fouling in - Deposition of system indicator equipment,
heat solids inside of - Dismantle HE- - Install a pipelines and
exchanger HE-02 02 to remove temperature indicators
- Partial - Decrease in any deposited indicator - Regular clean-
blocking production rate solids and - Install a up of HE-02
occurs in from expected blockage level - Regulate the
stream 7 value - Clear blockage indicator design of HE-02
- Corrosion in in stream - Pipeline
pipeline monitoring
system
Less flow for - Partial - Less efficient - Clear blockage - Install a - Regular - - -
utility stream blockage at heat transfer of pipeline flow maintenance of
utility stream - Liquid is not - Repair indicator pipelines,
- Leakage in completely pipeline - Pipeline indicators and
pipeline vaporized system monitoring equipment
- Decreased in
production rate
More More flow rate at - Faulty valves - Outlet stream - Repair or - Install a - Regular valve - - -
stream 6 will have replace valves flow maintenance
lower indicator
 temperature
than required
More flow for - Faulty valves - Outlet stream - Repair or - Install a - Regular valve - - -
utility stream has higher replace valves flow maintenance
temperature indicator
than required
value
Pressure Less Low pressure of - Inlet valve - No flow rate - Repair piping - Install a - Regular - - -
stream 6 malfunction into HE-02 system flow equipment and
- Pipeline due to vacuum - Remove indicator piping system
leakage in circumstances blockage in - Install a maintenance
stream 6 pipeline pressure - Frequent
- Repair or indicator monitoring on
replace valve - Install a indicators
pressure
alarm
Low pressure of - Outlet valve - No flow in - Close the inlet - Install a - Regular - - -
stream 7 malfunction stream 7 stream to HE- flow equipment and
- Pipeline - Pressure will 02 indicator piping system
leakage in build up in - Repair piping - Install a maintenance
stream 4 HE-02 system pressure - Regulate the
- Blockage in - Repair or indicator design of HE-02
process replace valve - Install a - Install a vent or
stream tube - Disassemble pressure bypass pipeline
site of HE-01 HE-02 to alarm for HE-02
remove - Install an
blockage emergency
relief valve
Low pressure of - Inlet valve - Inefficient heat - Repair or - Install a - Regular - - -
utility stream malfunction transfer replace valve flow equipment and
- Outlet valve - Reaction rate - Stop the plant indicator piping system
malfunction is less momentarily - Install a maintenance
favourable while fixing pressure - Frequent
the issue indicator monitoring on
indicators
 - Install a
pressure
alarm
Low pressure in - Low inlet - Low inlet flow - Repair piping - Install a - Regular - - -
HE-02 flows into HE-02 system pressure equipment and
- Inlet and - Temperature - Close opened indicator piping system
outlet pipe of HE-02 pressure - Install a maintenance
leakage drops release valve flow - Frequent
- Pressure - Replace or indicator monitoring on
release valve repair faulty indicators
is left open valves
More High pressure of - Fouling in - Pressure build - Disassemble - Install a - Regular - - -
stream 7 heat up in HE-02 heat exchanger flow equipment and
exchanger and damages it to remove indicator piping system
- Pipeline fouling - Install a maintenance
blockage in - Remove pressure - Install backup
stream 7 blockage in indicator pipelines for
piping - Install a HE-02
pressure - Install a vent or
alarm bypass pipeline
- Install an for HE-02
emergency
relief valve
High pressure in - Inlet valve - Temperature is - Replace or - Install a - Regular - - -
HE-02 for utility or lower than repair faulty pressure equipment and
process required value valves indicator piping system
stream in outlet - Install a maintenance
malfunctions stream flow - Frequent
- Outlet valve - Reaction rate indicator monitoring on
for utility or is less indicators
process desirable
stream
malfunctions
Temperature Less Low temperature - Inefficient - Output - Repair the - Install a - Install a - - -
of stream 4 heat transfer temperature is equipment temperature thermostat
process indicator controller
 - Less flow less than used to heat up - Install flow - Frequent
rate of utility required value utility stream indicator monitoring on
stream - Install indicators
- Too many pressure - Regular
flow rate indicator equipment and
from stream piping system
3 to HE-01 maintenance
- Loss of heat - Good insulator
to materials is used
surrounding to build HE-02
Low temperature - Equipment - Output - Repair the - Install a - Install a - - -
of utility stream used to heat temperature is equipment temperature thermostat
up utility less than used to heat up indicator controller
steam required value utility stream - Frequent
malfunctions monitoring on
indicators
- Regular
equipment and
piping system
maintenance
Low temperature - Equipment - Output - Repair the - Install a - Install a - - -
of HE-02 used to heat temperature is equipment temperature thermostat
up utility less than used to heat up indicator controller
steam required value utility stream - Frequent
malfunctions - Repair or monitoring on
- No or less replace faulty indicators
inlet flow of valves - Regular
heating duty equipment and
- High flow piping system
rate of inlet maintenance
process
stream
- Inlet valve
malfunction
More High temperature - Damage to - Overall - Disassemble - Install a - Install a - - -
of stream 4 HE-01 reaction is HE-01 to temperature thermostat
- Partial affected due to remove indicator controller
blockage to some fouling and - Install flow - Frequent
stream 3 unwanted blockage indicator monitoring on
- Leakage in reactions that - Remove - Install indicators
pipeline of favours high blockage and pressure - Regular
stream 3 temperature repair pipeline indicator equipment and
- Higher flow system piping system
of heating maintenance
duty than
required
value
- Fouling in
HE-01
High temperature - Equipment - Outlet stream - Disassemble - Install a - Install a - - -
of utility stream used to heat has higher HE-01 to temperature thermostat
up utility temperature remove indicator controller
steam than required fouling and - Install flow - Frequent
malfunctions value blockage indicator monitoring on
- Blockage in - Overall - Remove - Install indicators
HE-01 reaction is blockage and pressure - Regular
affected due to repair pipeline indicator equipment and
some system piping system
unwanted - Repair the maintenance
reactions that equipment
favours high used to heat up
temperature utility stream
High temperature - Heating duty - Outlet stream - Repair the - Install a - Install a - - -
of HE-02 overflow has higher equipment temperature thermostat
- Equipment temperature used to heat up indicator controller
used to heat than required utility stream - Install flow - Frequent
up utility value - Repair or indicator monitoring on
steam replace faulty indicators
malfunctions valves - Regular
equipment and
- Utility piping system
stream inlet maintenance
valve
malfunctions
HAZOP STUDY RECORD SHEET Risk
SYSTEM: HE-03 PROJECT: FORMALDEHYDE PRODUCTION PLANT ZONE C TOTAL PAGES: 6 Assessment
LINE: STREAM 17 and 18
Parameter Guide Deviation Causes Consequences Action Safeguard Recommendations R P C
Word
Flow None No flow at stream - ST-03 is - Damage done - Fill up the - Install a - Regular - - -
17 empty to HE-03 storage tank to flow maintenance of
- Blockage in - No flow to the initiate the indicator pipelines,
stream 17 rest of the process - Install a equipment and
- Valve plant hence no - Clear the temperature indicators
malfunctions production rate blockage of indicator - Regulate the
or closed pipeline - Pipeline design of HE-03
- Breakage in - Repair the monitoring
pipeline pipeline
system and
valves
- Rectify the
damage done
to HE-03
No flow at stream - Blockage in - Pressure build - Clear the - Install a - Regular - - -
18 stream 18 up in HE-03 blockage of flow maintenance of
- Valve - Risk of pipeline indicator pipelines,
malfunctions explosion - Repair - Install a equipment and
or closed pipeline pressure indicators
- Breakage in system and and - Regulate the
pipeline valves temperature design of HE-03
- Rectify indicator
damage done - Pipeline
to HE-03 monitoring
No flow for utility - Blockage in - No heat - Clear blockage - Install a - Regular - - -
stream utility stream transfer of pipeline flow maintenance of
pipeline process take - Repair indicator pipelines,
- Breakage in place pipeline - Pipeline indicators and
pipeline - Process stream system and indicator equipment
is not valve
vaporized
 - Valve
malfunctions
or closed
Less Less flow rate at - Leakage in - Outlet stream - Repair - Install a - Regular - - -
stream 17 pipeline has higher pipeline flow maintenance of
- Partial temperature system indicator pipelines,
blocking than expected - Disassemble - Install a equipment and
occurs in value HE-03 to temperature indicators
stream 17 - More heat remove indicator - Regulate the
- Corrosion in accumulated in deposited solid - Install a design of HE-03
pipeline HE-03 - Clear blockage level
system - Deposition of in pipeline indicator
- Control solids inside of - Rectify - Pipeline
failure HE-03 damage done monitoring
- Fouling in - Damage done to HE-03
pipeline to HE-03
Less flow rate at - Leakage in - Less efficient - Repair - Install a - Regular - - -
stream 18 pipeline heat transfer pipeline flow maintenance of
- Fouling in - Liquid stream system indicator equipment,
heat is not - Dismantle HE- - Install a pipelines and
exchanger vaporized 03 to remove temperature indicators
- Partial completely any deposited indicator - Regular clean-
blocking - Deposition of solids and - Install a up of HE-03
occurs in solids inside of blockage level - Regulate the
stream 18 HE-03 - Clear blockage indicator design of HE-03
- Corrosion in - Decrease in in stream - Pipeline
pipeline production rate monitoring
system from expected
value
Less flow for - Partial - Less efficient - Clear blockage - Install a - Regular - - -
utility stream blockage at heat transfer of pipeline flow maintenance of
utility stream - Output - Repair indicator pipelines,
- Leakage in temperature is pipeline - Pipeline indicators and
pipeline less than system monitoring equipment
required value
 Decreased in
production rate
More More flow rate at - Faulty valves - Outlet stream - Repair or - Install a - Regular valve - - -
stream 17 will have replace valves flow maintenance
lower indicator
temperature
than required
More flow for - Faulty valves - Outlet stream - Repair or - Install a - Regular valve - - -
utility stream has higher replace valves flow maintenance
temperature indicator
than required
value
Pressure Less Low pressure of - Inlet valve - Less flow rate - Repair piping - Install a - Regular - - -
stream 17 malfunction into HE-03 system flow equipment and
- Pipeline - Outlet stream - Remove indicator piping system
leakage in for HE-03 blockage in - Install a maintenance
stream 3 have higher pipeline pressure - Frequent
- Pipeline temperature - Repair or indicator monitoring on
blockage in than required replace valve - Install a indicators
stream 16 value pressure
and 17 alarm
Low pressure of - Outlet valve - Less flow in - Repair piping - Install a - Regular - - -
stream 18 malfunction stream 4 system flow equipment and
- Pipeline - Outlet stream - Repair or indicator piping system
leakage in for HE-03 will replace valve - Install a maintenance
stream 4 have higher - Disassemble pressure - Regulate the
- Blockage in temperature HE-03 to indicator design of HE-03
process than required remove - Install a - Frequent
stream tube value blockage pressure monitoring on
site of HE-01 - Less amount alarm indicators
of DME is
absorbed
Low pressure of - Inlet valve - Inefficient heat - Repair or - Install a - Regular - - -
utility stream malfunction transfer replace valve flow equipment and
- Outlet valve - Output - Stop the plant indicator piping system
malfunction temperature is momentarily maintenance
 less than while fixing - Install a - Frequent
required value the issue pressure monitoring on
- DME indicator indicators
absorption is - Install a
less effective pressure
alarm
Low pressure of - Low inlet - Low inlet flow - Repair piping - Install a - Regular - - -
HE-03 flows into HE-03 system pressure equipment and
- Inlet and - Temperature - Close opened indicator piping system
outlet pipe of HE-03 pressure - Install a maintenance
leakage drops release valve flow - Frequent
- Pressure - DME - Replace or indicator monitoring on
release valve absorption is repair faulty indicators
is left open less effective valves
More High pressure of - Fouling in - Pressure build - Disassemble - Install a - Regular - - -
stream 18 heat up in HE-03 heat exchanger flow equipment and
exchanger and damages it to remove indicator piping system
- Pipeline fouling - Install a maintenance
blockage in - Remove pressure - Install backup
stream 18 blockage in indicator pipelines for
piping - Install a HE-03
pressure - Install a vent or
alarm bypass pipeline
- Install an for HE-03
emergency
relief valve
High pressure of - Inlet valve - Temperature is - Replace or - Install a - Regular - - -
HE-03 for utility or lower than repair faulty pressure equipment and
process required value valves indicator piping system
stream in outlet - Install a maintenance
malfunctions stream flow - Frequent
- Outlet valve indicator monitoring on
for utility or indicators
process
stream
malfunctions
Temperature Less Low temperature - Inefficient - Output - Repair the - Install a - Install a - - -
of stream 18 heat transfer temperature is equipment temperature thermostat
process less than used to heat up indicator controller
- Less flow required value utility stream - Install flow - Frequent
rate of utility indicator monitoring on
stream - Install indicators
- Too many pressure - Regular
flow rate indicator equipment and
from stream piping system
18 to HE-03 maintenance
- Loss of heat - Good insulator
to materials is used
surrounding to build HE-03
Low temperature - Equipment - Output - Repair the - Install a - Install a - - -
of utility stream used to heat temperature is equipment temperature thermostat
up utility less than used to heat up indicator controller
steam required value utility stream - Frequent
malfunctions monitoring on
indicators
- Regular
equipment and
piping system
maintenance
Low temperature - Equipment - Output - Repair the - Install a - Install a - - -
of HE-03 used to heat temperature is equipment temperature thermostat
up utility less than used to heat up indicator controller
steam required value utility stream - Frequent
malfunctions - Repair or monitoring on
- No or less replace faulty indicators
inlet flow of valves - Regular
heating duty equipment and
- High flow piping system
rate of inlet maintenance
process
stream
 - Inlet valves
malfunction
More High temperature - Equipment - Outlet stream - Disassemble - Install a - Install a - - -
of utility stream used to heat has higher HE-03 to temperature thermostat
up utility temperature remove indicator controller
steam than required fouling and - Install flow - Frequent
malfunctions value blockage indicator monitoring on
- Blockage in - Remove - Install indicators
HE-01 blockage and pressure - Regular
repair pipeline indicator equipment and
system piping system
- Repair the maintenance
equipment
used to heat up
utility stream
High temperature - Heating duty - Outlet stream - Repair the - Install a - Install a - - -
of HE-03 overflow has higher equipment temperature thermostat
- Equipment temperature used to heat up indicator controller
used to heat than required utility stream - Install flow - Frequent
up utility value - Repair or indicator monitoring on
steam replace faulty indicators
malfunctions valves - Regular
- Utility equipment and
stream inlet piping system
valve maintenance
malfunctions
HAZOP STUDY RECORD SHEET Risk
SYSTEM: HE-04 PROJECT: FORMALDEHYDE PRODUCTION PLANT ZONE E TOTAL PAGES: 7 Assessment
LINE: STREAM 25 and 26
Parameter Guide Deviation Causes Consequences Action Safeguard Recommendations R P C
Word
Flow None No flow at stream - Blockage in - Damage done - Fill up the - Install a - Regular - - -
25 stream 25 to HE-04 storage tank to flow maintenance of
- Valve - No flow to the initiate the indicator pipelines,
malfunctions rest of the process - Install a equipment and
or closed plant hence no - Clear the temperature indicators
- Breakage in final blockage of indicator - Regulate the
pipeline production rate pipeline - Pipeline design of HE-04
- Repair the monitoring
pipeline
system and
valves
- Rectify the
damage done
to HE-04
No flow at stream - Blockage in - Pressure build - Clear the - Install a - Regular - - -
26 stream 26 up in HE-04 blockage of flow maintenance of
- Valve - Risk of pipeline indicator pipelines,
malfunctions explosion - Repair - Install a equipment and
or closed pipeline pressure indicators
- Breakage in system and and - Regulate the
pipeline valves temperature design of HE-04
- Rectify indicator
damage done - Pipeline
to HE-04 monitoring
No flow for utility - Blockage in - No heat - Clear blockage - Install a - Regular - - -
stream utility stream transfer of pipeline flow maintenance of
pipeline process take - Repair indicator pipelines,
- Breakage in place pipeline - Pipeline indicators and
pipeline - Process stream system and indicator equipment
is not valve
vaporized
 - Valve
malfunctions
or closed
Less Less flow rate at - Leakage in - Output - Repair - Install a - Regular - - -
stream 25 pipeline temperature is pipeline flow maintenance of
- Partial less than system indicator pipelines,
blocking required value - Disassemble - Install a equipment and
occurs in - More heat HE-04 to temperature indicators
stream 25 accumulated in remove indicator - Regulate the
- Corrosion in HE-04 deposited solid - Install a design of HE-04
pipeline - Deposition of - Clear blockage level
system solids inside of in pipeline indicator
- Control HE-04 - Rectify - Pipeline
failure - Damage done damage done monitoring
- Fouling in to HE-04 to HE-04
pipeline
Less flow rate at - Leakage in - Less efficient - Repair - Install a - Regular - - -
stream 26 pipeline heat transfer pipeline flow maintenance of
- Fouling in - Output system indicator equipment,
heat temperature is - Dismantle HE- - Install a pipelines and
exchanger less than 04 to remove temperature indicators
- Partial required value any deposited indicator - Regular clean-
blocking Deposition of solids and - Install a up of HE-04
occurs in solids inside of blockage level - Regulate the
stream 26 HE-04 - Clear blockage indicator design of HE-04
- Corrosion in - Decrease in in stream - Pipeline
pipeline production rate monitoring
system from expected
value
Less flow for - Partial - Less efficient - Clear blockage - Install a - Regular - - -
utility stream blockage at heat transfer of pipeline flow maintenance of
utility stream - Output - Repair indicator pipelines,
- Leakage in temperature is pipeline - Pipeline indicators and
pipeline less than system monitoring equipment
required value
 - Decreased in
production rate
More More flow rate at - Faulty valves - Output - Repair or - Install a - Regular valve - - -
stream 25 temperature is replace valves flow maintenance
less than indicator
required value
More flow for - Faulty valves - Output - Repair or - Install a - Regular valve - - -
utility stream temperature is replace valves flow maintenance
higher than indicator
required value
Pressure Less Low pressure of - Inlet valve - Less flow rate - Repair piping - Install a - Regular - - -
stream 25 malfunction into HE-01 system flow equipment and
- Pipeline - Output - Remove indicator piping system
leakage in temperature is blockage in - Install a maintenance
stream 3 higher than pipeline pressure - Frequent
- Pipeline required value - Repair or indicator monitoring on
blockage in replace valve - Install a indicators
stream 1 and pressure
2 alarm
Low pressure of - Outlet valve - No flow in - Close the inlet - Install a - Regular - - -
stream 26 malfunction stream 26 stream to HE- flow equipment and
- Pipeline - Pressure will 04 indicator piping system
leakage in build up in - Repair piping - Install a maintenance
stream 4 HE-01 system pressure - Regulate the
- Blockage in - Repair or indicator design of HE-04
process replace valve - Install a
stream tube - Disassemble pressure
site of HE-01 HE-04 to alarm
remove
blockage
Low pressure of - Inlet valve - Inefficient heat - Repair or - Install a - Regular - - -
utility stream malfunction transfer replace valve flow equipment and
- Outlet valve - Output - Stop the plant indicator piping system
malfunction temperature is momentarily maintenance
 less than while fixing - Install a - Frequent
required value the issue pressure monitoring on
indicator indicators
Low pressure of - Low inlet - Low inlet flow - Repair piping - Install a - Regular - - -
HE-04 flows into HE-04 system pressure equipment and
- Inlet and - Temperature - Close opened indicator piping system
outlet pipe of HE-04 pressure - Install a maintenance
leakage drops release valve flow - Frequent
- Pressure - Replace or indicator monitoring on
release valve repair faulty indicators
is left open valves
More High pressure of - Fouling in - Pressure build - Disassemble - Install a - Regular - - -
stream 26 heat up in HE-04 heat exchanger flow equipment and
exchanger and damages it to remove indicator piping system
- Pipeline fouling - Install a maintenance
blockage in - Remove pressure - Install backup
stream 26 blockage in indicator pipelines for
piping - Install a HE-04
pressure - Install a vent or
alarm bypass pipeline
- Install an for HE-04
emergency
relief valve
at HE-04
High pressure of - Inlet valve - Temperature is - Replace or - Install a - Regular - - -
HE-04 for utility or lower than repair faulty pressure equipment and
process required value valves indicator piping system
stream in outlet - Install a maintenance
malfunctions stream flow - Frequent
- Outlet valve indicator monitoring on
for utility or indicators
process
stream
malfunctions
Temperature Less Low temperature - Inefficient - Output - Repair the - Install a - Install a - - -
of stream 26 heat transfer temperature is equipment temperature thermostat
process less than used to heat up indicator controller
- Less flow required value utility stream - Install flow - Frequent
rate of utility indicator monitoring on
stream - Install indicators
- Too many pressure - Regular
flow rate indicator equipment and
from stream piping system
25 to HE-04 maintenance
- Loss of heat - Good insulator
to materials is used
surrounding to build HE-04
Low temperature - Equipment - Output - Repair the - Install a - Install a - - -
of utility stream used to heat temperature is equipment temperature thermostat
up utility less than used to heat up indicator controller
steam required value utility stream - Frequent
malfunctions monitoring on
indicators
- Regular
equipment and
piping system
maintenance
Low temperature - Equipment - Output - Repair the - Install a - Install a - - -
of HE-04 used to heat temperature is equipment temperature thermostat
up utility less than used to heat up indicator controller
steam required value utility stream - Frequent
malfunctions - Repair or monitoring on
- No or less replace faulty indicators
inlet flow of valves - Regular
heating duty equipment and
- High flow piping system
rate of inlet maintenance
process
stream
 - Inlet valves
malfunction
More High temperature - Damage to - Output - Disassemble - Install a - Install a - - -
of stream 25 HE-04 temperature is HE-04 to temperature thermostat
- Partial more than remove indicator controller
blockage to required value fouling and - Install flow - Frequent
stream 3 blockage indicator monitoring on
- Leakage in - Remove - Install indicators
pipeline of blockage and pressure - Regular
stream 4 repair pipeline indicator equipment and
- Higher flow system piping system
of heating maintenance
duty than
required
value
- Fouling in
HE-04
High temperature - Equipment - Outlet stream - Disassemble - Install a - Install a - - -
of utility stream used to heat has higher HE-04 to temperature thermostat
up utility temperature remove indicator controller
steam than required fouling and - Install flow - Frequent
malfunctions value blockage indicator monitoring on
- Blockage in - Remove - Install indicators
HE-04 blockage and pressure - Regular
repair pipeline indicator equipment and
system piping system
- Repair the maintenance
equipment
used to heat up
utility stream
High temperature - Heating duty - Outlet stream - Repair the - Install a - Install a - - -
of HE-04 overflow has higher equipment temperature thermostat
- Equipment temperature used to heat up indicator controller
used to heat than required utility stream - Install flow - Frequent
up utility value indicator monitoring on
indicators
 steam - Repair or - Regular
malfunctions replace faulty equipment and
- Utility valves piping system
stream inlet maintenance
valve
malfunctions
HAZOP STUDY RECORD SHEET Risk
SYSTEM: AB-01 PROJECT: FORMALDEHYDE PRODUCTION PLANT ZONE B TOTAL PAGES: Assessment
LINE: STREAM 10, 12, 13 and 24
Parameter Guide Deviation Causes Consequences Action Safeguard Recommendations R P C
Word
Flow No No flow at stream - Inlet valve - No production - Replace or - Install flow - Regular - - -
10 malfunctions rate of repair faulty sensor equipment and
or closed formaldehyde valves - Install a piping system
- Pipeline or DME - Open shut flow maintenance
blockage valves regulation - Frequent
- Pipeline - Repair system monitoring
breakage pipeline
system
- Remove
blockage in
pipeline
No flow at stream - Inlet valve - Feed stream - Replace or - Install flow - Regular - - -
12 malfunctions will exit AB- repair faulty sensor equipment and
or closed 01 from top as valves - Install a piping system
- Pipeline gas without - Open shut flow maintenance
blockage being absorbed valves regulation - Frequent
- Pipeline - Repair system monitoring
breakage pipeline
- ST-02 is system
empty - Remove
blockage in
pipeline
- Fill up ST-02
to initiate
process
No flow at stream - Outlet valve - Pressure will - Replace or - Install a - Regular - - -
13 malfunctions build-up in repair faulty flow equipment and
or closed AB-01 valves indicator piping system
- Pipeline - Open shut - Install a maintenance
blockage valves pressure
 - Pipeline - Temperature - Repair indicator - Frequent
breakage will build-up pipeline and a monitoring
in AB-01 system pressure - Install a
- No production - Remove alarm thermostat
rate of DME blockage in - Install a controller for
pipeline temperature AB-01
indicator
No flow at stream - Outlet valve - Pressure will - Replace or - Install a - Regular - - -
24 malfunctions build-up in repair faulty flow equipment and
or closed AB-01 valves indicator piping system
- Pipeline - Temperature - Open shut - Install a maintenance
blockage will build-up valves pressure - Frequent
- Pipeline in AB-01 - Repair indicator monitoring
breakage - No production pipeline and a - Install a
rate of system pressure thermostat
formaldehyde - Remove alarm controller for
blockage in - Install a AB-01
pipeline temperature
indicator
Less Less flow at - Partial - Less - Replace or - Install flow - Regular - - -
stream 10 blockage in production rate repair faulty sensor equipment and
pipeline in DME and valves - Install a piping system
- Leakage in formaldehyde - Repair flow maintenance
pipeline pipeline regulation - Frequent
- Valve system system monitoring
malfunctions - Remove
blockage in
pipeline
Less flow at - Partial - Less - Replace or - Install flow - Regular - - -
stream 12 blockage in production rate repair faulty sensor equipment and
pipeline for valves - Install a piping system
- Leakage in formaldehyde - Repair flow maintenance
pipeline - Most pipeline regulation - Frequent
- Valve formaldehyde system system monitoring
malfunctions will exits at
top of AB-01
 - Remove
blockage in
pipeline
Less flow at - Outlet valve - Pressure will - Replace or - Install a - Regular - - -
stream 13 malfunction build-up in repair faulty flow equipment and
- Pipeline AB-01 valves indicator piping system
blockage - Temperature - Repair - Install a maintenance
- Pipeline will build-up pipeline pressure - Frequent
breakage in AB-01 system indicator monitoring
- Less - Remove and a - Install a
production rate blockage in pressure thermostat
of DME pipeline alarm controller for
- Install a AB-01
temperature
indicator
Less flow at - Outlet valve - Pressure will - Replace or - Install a - Regular - - -
stream 24 malfunction build-up in repair faulty flow equipment and
- Pipeline AB-01 valves indicator piping system
blockage - Temperature - Repair - Install a maintenance
- Pipeline will build-up pipeline pressure - Frequent
breakage in AB-01 system indicator monitoring
- Less - Remove and a - Install a
production rate blockage in pressure thermostat
of pipeline alarm controller for
formaldehyde - Install a AB-01
temperature
indicator
More More flow at - Valve - Absorption - Repair or - Install a - Regular - - -
stream 10 malfunctions rate of replace faulty flow equipment and
formaldehyde valves indicator piping system
decreased maintenance
- Overflowing - Frequent
AB-01 monitoring
More flow at - Valve - Formaldehyde - Repair or - Install a - Regular - - -
stream 12 malfunctions weight content replace faulty flow equipment and
in final valves indicator
 product piping system
decreased to maintenance
less optimal - Frequent
value monitoring
- Overflowing
AB-01
More flow at - Valve - Absorption - Repair or - Install a - Regular - - -
stream 13 malfunctions rate is replace faulty flow equipment and
- AB-01 decreased to valves indicator piping system
overflows less than maintenance
optimal value - Frequent
monitoring
More flow at - Valve - Absorption - Repair or - Install a - Regular - - -
stream 24 malfunctions rate is replace faulty flow equipment and
- AB-01 decreased to valves indicator piping system
overflows less than maintenance
optimal value - Frequent
monitoring
Pressure Less Low pressure at - Pipe leakage - Empty flow of - Replace or - Install a - Regular - - -
stream 10 - Valve bottom inlet repair faulty flow equipment and
malfunction into AB-01 valves indicator piping system
- Absorption - Repair - Install a maintenance
rate is non- pipeline pressure - Frequent
existent system indicator monitoring
Low pressure at - Pipe leakage - Less absorbent - Replace or - Install a - Regular - - -
stream 12 - Valve stream into repair faulty flow equipment and
malfunction AB-01 valves indicator piping system
- Absorption - Repair - Install a maintenance
rate is less pipeline pressure - Frequent
than optimal system indicator monitoring
Low pressure at - Pipe leakage - Gas phase - Replace or - Install a - Regular - - -
stream 13 - Valve components repair faulty flow equipment and
malfunction cannot leave valves indicator piping system
AB-01 - Repair - Install a maintenance
pipeline pressure - Frequent
system indicator monitoring
 - Pressure - Open a - Install a - Install a vent or
accumulates in pressure relief pressure bypass pipeline
AB-01 valve relief valve in AB-01
Low pressure at - Pipe leakage - Less flow rate - Replace or - Install a - Regular - - -
stream 24 - Valve exits AB-01 repair faulty flow equipment and
malfunction valves indicator piping system
- Repair - Install a maintenance
pipeline pressure - Frequent
system indicator monitoring
- Open a - Install a
pressure relief pressure
valve relief valve
Low pressure - Low inlet - Low bottom - Replace or - Install a - Regular - - -
inside absorber flows exit flow from repair faulty flow equipment and
- Inlet and AB-01 valves indicator piping system
outlet pipe - Gas phase - Repair - Install a maintenance
leakage might not exit pipeline pressure - Frequent
- Pressure AB-01 system indicator monitoring
release valve - Pressure can - Open a - Install a - Install a vent or
is left open potentially pressure relief pressure bypass pipeline
accumulates valve relief valve in AB-01
More High pressure at - Valve - Absorption - Replace or - Install a - Regular - - -
stream 10 malfunctions rate is repair faulty flow equipment and
- Inlet pipe decreased valves indicator piping system
fitting to AB- - Repair - Install a maintenance
01 is blocked pipeline pressure - Frequent
system indicator monitoring
- Install a - Install a vent or
pressure bypass pipeline
relief valve in AB-01
High pressure at - Valve - Absorption - Replace or - Install a - Regular - - -
stream 12 malfunctions rate is repair faulty flow equipment and
- Inlet pipe decreased valves indicator piping system
fitting to AB- - Repair - Install a maintenance
01 is blocked pipeline pressure - Frequent
system indicator monitoring
 - Install a - Install a vent or
pressure bypass pipeline
relief valve in AB-01
High pressure at - Outlet valve - Absorption - Replace or - Install a - Regular - - -
stream 13 malfunctions rate is repair faulty flow equipment and
decreased valves indicator piping system
- Repair - Install a maintenance
pipeline pressure - Frequent
system indicator monitoring
- Install a - Install a vent or
pressure bypass pipeline
relief valve in AB-01
High pressure at - Outlet valve - Absorption - Replace or - Install a - Regular - - -
stream 24 malfunctions rate is repair faulty flow equipment and
decreased valves indicator piping system
- Repair - Install a maintenance
pipeline pressure - Frequent
system indicator monitoring
- Install a - Install a vent or
pressure bypass pipeline
relief valve in AB-01
High pressure - Inlet flow - Potential - Repair any - Install a - Regular - - -
inside absorber increased damage done pipeline flow equipment and
- Outlet pipe to inlet valves problems indicator piping system
blockage - Backflow from - Remove - Install a maintenance
- Outlet valve AB-01 to inlet blockage in pressure - Frequent
malfunctions streams pipe fittings indicator monitoring
and pipelines - Install a - Install a vent or
- Repair or pressure bypass pipeline
replace faulty relief valve in AB-01
valves
Temperature High High temperature - CE-01 - More cooling - Stop the - Install a - Frequent - - -
at stream 13 malfunctions duty required production temperature monitoring
- Reaction for CE-02 process and indicator - Regular
occurs in rectify the equipment and
AB-01 issues
 - Absorption - Repair or - Install a piping system
rate is higher replace CE-01 cooling maintenance
than required jacket
value and too
much heat of
absorption is
released
High temperature - ST-02 is - More cooling - Stop - Install a - Frequent - - -
at stream 24 exposed to duty required production temperature monitoring
heat for CE-02 process and indicator
- Reaction rectify the - Install a
occurs in issues cooling
AB-01 - Evacuate jacket
- Absorption content of ST-
rate is higher 02
than required - Identify the
value and too heat source
much heat of and eliminate
absorption is it
released
High temperature - Inlet stream - Outlet - Stop the - Install a - Frequent - - -
inside absorber has higher temperature production temperature monitoring
temperature will increase process to indicator - Regular
than required - More cooling rectify the - Install a equipment and
value duty for CE-02 issues cooling piping system
- Reaction is required - Repair heat jacket maintenance
occurs in exchangers
AB-01 presented
- Absorption before inlets
rate is higher
than required
value and too
much heat of
absorption is
released
HAZOP STUDY RECORD SHEET Risk
SYSTEM: AB-02 PROJECT: FORMALDEHYDE PRODUCTION PLANT ZONE C TOTAL PAGES: Assessment
LINE: STREAM 15, 18, 19 and 20
Parameter Guide Deviation Causes Consequences Action Safeguard Recommendations R P C
Word
Flow No No flow at stream - Inlet valve - DME is not - Replace or - Install flow - Regular - - -
15 malfunctions absorbed repair faulty sensor equipment and
or closed valves - Install a piping system
- Pipeline - Open shut flow maintenance
blockage valves regulation - Frequent
- Pipeline - Repair system monitoring
breakage pipeline
system
- Remove
blockage in
pipeline
No flow at stream - Inlet valve - Feed stream - Replace or - Install flow - Regular - - -
18 malfunctions will exit AB- repair faulty sensor equipment and
or closed 02 from top as valves - Install a piping system
- Pipeline flue gas - Open shut flow maintenance
blockage without being valves regulation - Frequent
- Pipeline absorbed - Repair system monitoring
breakage pipeline
- ST-03 is system
empty - Remove
blockage in
pipeline
- Fill up ST-03
to initiate
process
No flow at stream - Outlet valve - Pressure will - Replace or - Install a - Regular - - -
19 malfunctions build-up in repair faulty flow equipment and
or closed AB-02 valves indicator piping system
- Pipeline - Open shut - Install a maintenance
blockage valves pressure
 - Pipeline - Temperature - Repair indicator - Frequent
breakage will build-up pipeline and a monitoring
in AB-02 system pressure - Install a
- No production - Remove alarm thermostat
rate of DME blockage in - Install a controller for
pipeline temperature AB-02
indicator
No flow at stream - Outlet valve - Pressure will - Replace or - Install a - Regular - - -
20 malfunctions build-up in repair faulty flow equipment and
or closed AB-02 valves indicator piping system
- Pipeline - Temperature - Open shut - Install a maintenance
blockage will build-up valves pressure - Frequent
- Pipeline in AB-02 - Repair indicator monitoring
breakage - No production pipeline and a - Install a
rate of system pressure thermostat
formaldehyde - Remove alarm controller for
blockage in - Install a AB-02
pipeline temperature
indicator
Less Less flow at - Partial - Less - Replace or - Install flow - Regular - - -
stream 15 blockage in production rate repair faulty sensor equipment and
pipeline in DME valves - Install a piping system
- Leakage in - Repair flow maintenance
pipeline pipeline regulation - Frequent
- Valve system system monitoring
malfunctions - Remove
blockage in
pipeline
Less flow at - Partial - Less - Replace or - Install flow - Regular - - -
stream 18 blockage in production rate repair faulty sensor equipment and
pipeline for DME valves - Install a piping system
- Leakage in - Most DME - Repair flow maintenance
pipeline will exits at pipeline regulation - Frequent
- Valve top of AB-02 system system monitoring
malfunctions
 - Remove
blockage in
pipeline
Less flow at - Outlet valve - Pressure will - Replace or - Install a - Regular - - -
stream 19 malfunction build-up in repair faulty flow equipment and
- Pipeline AB-02 valves indicator piping system
blockage - Temperature - Repair - Install a maintenance
- Pipeline will build-up pipeline pressure - Frequent
breakage in AB-02 system indicator monitoring
- Remove and a - Install a
blockage in pressure thermostat
pipeline alarm controller for
- Install a AB-02
temperature
indicator
Less flow at - Outlet valve - Pressure will - Replace or - Install a - Regular - - -
stream 20 malfunction build-up in repair faulty flow equipment and
- Pipeline AB-02 valves indicator piping system
blockage - Temperature - Repair - Install a maintenance
- Pipeline will build-up pipeline pressure - Frequent
breakage in AB-02 system indicator monitoring
- Less - Remove and a - Install a
production rate blockage in pressure thermostat
of DME pipeline alarm controller for
- Install a AB-02
temperature
indicator
More More flow at - Valve - Absorption - Repair or - Install a - Regular - - -
stream 15 malfunctions rate of replace faulty flow equipment and
formaldehyde valves indicator piping system
decreased maintenance
- Overflowing - Frequent
AB-02 monitoring
More flow at - Valve - Formaldehyde - Repair or - Install a - Regular - - -
stream 18 malfunctions weight content replace faulty flow equipment and
in final valves indicator
 product piping system
decreased to maintenance
less optimal - Frequent
value monitoring
- Overflowing
AB-01
More flow at - Valve - Absorption - Repair or - Install a - Regular - - -
stream 19 malfunctions rate is replace faulty flow equipment and
- AB-01 decreased to valves indicator piping system
overflows less than maintenance
optimal value - Frequent
monitoring
More flow at - Valve - Absorption - Repair or - Install a - Regular - - -
stream 20 malfunctions rate is replace faulty flow equipment and
- AB-01 decreased to valves indicator piping system
overflows less than maintenance
optimal value - Frequent
monitoring
Pressure Less Low pressure at - Pipe leakage - Empty flow of - Replace or - Install a - Regular - - -
stream 15 - Valve bottom inlet repair faulty flow equipment and
malfunction into AB-02 valves indicator piping system
- Absorption - Repair - Install a maintenance
rate is non- pipeline pressure - Frequent
existent system indicator monitoring
Low pressure at - Pipe leakage - Less absorbent - Replace or - Install a - Regular - - -
stream 18 - Valve stream into repair faulty flow equipment and
malfunction AB-02 valves indicator piping system
- Absorption - Repair - Install a maintenance
rate is less pipeline pressure - Frequent
than optimal system indicator monitoring
Low pressure at - Pipe leakage - Gas phase - Replace or - Install a - Regular - - -
stream 19 - Valve components repair faulty flow equipment and
malfunction cannot leave valves indicator piping system
AB-02 - Repair - Install a maintenance
pipeline pressure - Frequent
system indicator monitoring
 - Pressure - Open a - Install a - Install a vent or
accumulates in pressure relief pressure bypass pipeline
AB-02 valve relief valve in AB-02
Low pressure at - Pipe leakage - Less flow rate - Replace or - Install a - Regular - - -
stream 20 - Valve exits AB-02 repair faulty flow equipment and
malfunction valves indicator piping system
- Repair - Install a maintenance
pipeline pressure - Frequent
system indicator monitoring
- Open a - Install a
pressure relief pressure
valve relief valve
Low pressure - Low inlet - Low bottom - Replace or - Install a - Regular - - -
inside absorber flows exit flow from repair faulty flow equipment and
- Inlet and AB-02 valves indicator piping system
outlet pipe - Gas phase - Repair - Install a maintenance
leakage might not exit pipeline pressure - Frequent
- Pressure AB-02 system indicator monitoring
release valve - Pressure can - Open a - Install a - Install a vent or
is left open potentially pressure relief pressure bypass pipeline
accumulates valve relief valve in AB-02
More High pressure at - Valve - Absorption - Replace or - Install a - Regular - - -
stream 15 malfunctions rate is repair faulty flow equipment and
- Inlet pipe decreased valves indicator piping system
fitting to AB- - Repair - Install a maintenance
02 is blocked pipeline pressure - Frequent
system indicator monitoring
- Install a - Install a vent or
pressure bypass pipeline
relief valve in AB-02
High pressure at - Valve - Absorption - Replace or - Install a - Regular - - -
stream 18 malfunctions rate is repair faulty flow equipment and
- Inlet pipe decreased valves indicator piping system
fitting to AB- - Repair - Install a maintenance
02 is blocked pipeline pressure - Frequent
system indicator monitoring
 - Install a - Install a vent or
pressure bypass pipeline
relief valve in AB-02
High pressure at - Outlet valve - Absorption - Replace or - Install a - Regular - - -
stream 19 malfunctions rate is repair faulty flow equipment and
decreased valves indicator piping system
- Repair - Install a maintenance
pipeline pressure - Frequent
system indicator monitoring
- Install a - Install a vent or
pressure bypass pipeline
relief valve in AB-02
High pressure at - Outlet valve - Absorption - Replace or - Install a - Regular - - -
stream 20 malfunctions rate is repair faulty flow equipment and
decreased valves indicator piping system
- Repair - Install a maintenance
pipeline pressure - Frequent
system indicator monitoring
- Install a - Install a vent or
pressure bypass pipeline
relief valve in AB-02
High pressure - Inlet flow - Potential - Repair any - Install a - Regular - - -
inside absorber increased damage done pipeline flow equipment and
- Outlet pipe to inlet valves problems indicator piping system
blockage - Backflow from - Remove - Install a maintenance
- Outlet valve AB-01 to inlet blockage in pressure - Frequent
malfunctions streams pipe fittings indicator monitoring
and pipelines - Install a - Install a vent or
- Repair or pressure bypass pipeline
replace faulty relief valve in AB-02
valves
Temperature High High temperature - CE-02 - Low to zero - Stop the - Install a - Frequent - - -
at stream 15 malfunctions absorption rate production temperature monitoring
- Absorption for DME in process and indicator - Regular
rate is higher water rectify the equipment and
than required issues
 value and too - Repair or - Install a piping system
much heat of replace CE-02 cooling maintenance
absorption is jacket
released
High temperature - ST-03 is - Low to zero - Stop - Install a - Frequent - - -
at stream 18 exposed to absorption rate production temperature monitoring
heat for DME in process and indicator
- Reaction water rectify the - Install a
occurs in issues cooling
AB-02 - Evacuate jacket
- Absorption content of ST-
rate is higher 03
than required - Identify the
value and too heat source
much heat of and eliminate
absorption is it
released
High temperature - Inlet stream - Outlet - Stop the - Install a - Frequent - - -
inside absorber has higher temperature production temperature monitoring
temperature will increase process to indicator - Regular
than required - Low to zero rectify the - Install a equipment and
value absorption rate issues cooling piping system
- Absorption for DME in - Repair heat jacket maintenance
rate is higher water exchangers
than required presented
value and too before inlets
much heat of
absorption is
released