Hazop Report

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HAZARD AND OPERABILITY STUDY REPORT P2B – 10 – 02 – HZ – 0001 – R
FOR AMMONIA UNIT DATE BY CHKD APVD
17 Jul 14 ALI MRI/ ER HH
TABLE OF CONTENTS
HAZOP STUDY REPORT – SUMMARY ...................................................................... 4
1. INTRODUCTION .................................................................................................... 5
2. OBJECTIVES ......................................................................................................... 5
3. SCOPE & BASIS .................................................................................................... 5
3.1 SCOPE OF STUDY ................................................................................................... 5
3.2 BASIS OF STUDY ..................................................................................................... 6
4. HAZOP SESSION .................................................................................................. 6
5. METHODOLOGY ................................................................................................... 6
6. NODES ................................................................................................................... 9
7. GUIDEWORDS ....................................................................................................... 9
8. EXECUTION ......................................................................................................... 10
9. ASSUMPTIONS FOR THE STUDY ...................................................................... 10
10. WORKSHEETS RECORDING ............................................................................. 12
11. CONCLUSION ...................................................................................................... 12
12. FOLLOW UP ACTIONS ....................................................................................... 12
13. REFERENCE ........................................................................................................ 12
APPENDIX
Appendix–1 : Drawing List
Appendix–2 : Node List
Appendix–3 : HAZOP Worksheets
Appendix–4 : Recommendation List
Appendix–5 : Attendance Sheets
Appendix–6 : HAZOP Follow up Action Sheets
Appendix–7 : Master P&IDs
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HAZOP STUDY REPORT – SUMMARY
Title Description
Study Hazard and Operability (HAZOP) Study

Project PUSRI-IIB
Project Location Palembang, South Sumatera, Indonesia
Owner PT Pupuk Sriwidjaja Palembang
Contractor Consortium of PT Rekayasa Industri – Toyo Engineering
Corporation
3rd Party HSE Consultant IRESC
Session Days 14 (between 09 and 20 December 2013 and between 06

and 09 January 2014)
Study Location PT Rekayasa Industri Head Office
Participation PT Pupuk Sriwidjaja, PT Rekayasa Industri, IRESC
No. of P&IDs 98
No. of Nodes 27
No. of Recommendations
218 2
Recording Software PHA Pro 8
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1. INTRODUCTION
PT Rekayasa Industri (Rekayasa) has been awarded the Engineering Procurement and
Construction (EPC) Contract for the PUSRI-IIB Project. The plant is located in Palembang,
South Sumatera, Indonesia and is owned by PT Pupuk Sriwidjaja Palembang.
Rekayasa engaged IRESC as a 3 rd Party Consultant to perform HAZOP study for the Ammonia
Unit of the PUSRI-IIB Project. This report presents the details of the HAZOP study pertaining to
the Ammonia Unit. HAZOP study sessions were conducted for 14 days in two sessions, between
9th and 20th December 2013 and between 6th and 9th January 2014 at PT Rekayasa
Engineering Head Office, Jakarta, Indonesia.
2. OBJECTIVES
The prime objective of Hazard and Operability (HAZOP) study is identification of Hazards and
Operability issues that could have a significant impact on the design and operation of the plant,
if there is a process deviation away from the safe operating envelope.
A few key objectives are listed as below:
 To identify/ analyze potential hazards and operability issues due to deviations from normal
process or operating conditions or intended design;
 To evaluate the adequacy of the existing safeguards with respect to safety and operations;
 To identify additional safeguards required for the system under study to address the
causes and minimize the consequences of deviation; and
 To recommend ways to mitigate the consequences of deviations and return to normal and
safe operations.
3. SCOPE & BASIS

3.1 SCOPE OF STUDY
The scope of HAZOP study included the facilities related to the Ammonia Unit for the PUSRI-IIB
Project which were covered in 98 P&IDs.
A listing of drawings studied in the HAZOP study is provided in Appendix 1 – Drawing List.
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3.2 BASIS OF STUDY

The HAZOP Study was based on the P&IDs that were Issued for Approval status during the
EPC stage of the project. The nodes covered in the HAZOP Study were identified and marked-
up on the Master P&IDs.
The detail description and contents of each Node analyzed during the study are provided in
Appendix 2 – Node List. All the master P&IDs used during the study are attached in Appendix 7
– Master P&IDs, for record purposes.
Apart from the P&IDs, following documents were used as reference:

 Process Flow Diagrams (PFDs);
 Heat & Material Balance;
 Basic Engineering Design Data (BEDD);
 Equipment and Instrument data sheets (for major equipment, control valve);
 Pressure relief load summary;
 Safety valve data sheets or basis;
 Cause & Effect Diagrams and/or Interlock Description;
 Plot Plans; and
 Material Safety Data Sheets (MSDS);
 Process Description.
4. HAZOP SESSION
The HAZOP study was held in PT Rekayasa Industri Head Office, Jakarta, Indonesia. The
P&IDs were divided into 27 Nodes and the review of these nodes was completed over a period
of 14 days in two sessions with first session from 9th to 20th December 2013 and second
session from 6th to 9th January 2014.
The HAZOP worksheets and recommendations generated during the workshop were in
agreement of all the participants. The detailed list of participants is attached in Appendix 5 –
Attendance Sheets.
5. METHODOLOGY
The HAZOP Study Methodology is the step by step qualitative analysis of various logically divided
sections of a Process Plant to identify potential hazards and operability issues associated with it. This
approach is a workshop based group activity comprising of a multidisciplinary team,
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which systematically reviews process drawing details, to determine significant issues which are
likely during the event of deviations from the normal design intention.
The guideword approach emphasizes on various causes which can result in process deviation
away from its normal operating envelope. The resulting consequences are the anticipated
response of the facility to that particular deviation. This plant behavior is verified against the
preventive and/or mitigation measures already available in the design. In case of insufficient
preventive and/or mitigation measures and to limit the overall risk imposed, recommendations
may be provided by the HAZOP team to eliminate or reduce the risks.
HAZOP is an identification technique and is not necessarily intended as a means of solving

problems. While recommendations are proposed during the meeting, these shall be taken for
further review and analysis outside the session. It is not intended as a substitute for initial design
and the proper application of safety codes. The application of the HAZOP technique is illustrated
in Figure 5.1.
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Figure 5.1: HAZOP Methodology
Select a System/ Unit
Select a Node From the chosen

System/ Unit (e.g. feed to a
vessel)
Brief the design intention
Apply a Parameter
Apply a Guideword
Deviation
Examine Possible Causes
Examine Consequences
Assess Safeguards
Decide on any Required Actions
Repeat for Other

Yes Guidewords
No
Repeat for Other
Yes Property Words
No
Repeat for all

Yes Sub-systems
No
HAZOP Completed
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6. NODES
The facility was divided into a number of sub-systems, known as nodes, based on system
design. This sectionalized analysis enables the team to comprehend the analysis in a very
effective manner. During the analysis, the cause of deviation is always from within the node,
however the associated consequence can be anywhere across the process facility.
The detailed description, equipment list and associated drawings of each node analyzed during
the study are provided in Appendix 2 – Node List.
7. GUIDEWORDS
Guidewords combined with the process Parameters generates a list of Deviations that are
utilized for HAZOP analysis. These guidewords and parameters are listed in Table 7.1.
Applicable deviations are applied on each node to identify any safety or operability issues
associated with the process.
Table 7.1 HAZOP Guidewords/ Parameters

Deviation. Guidewords Parameter Description
No/ Low Flow No/ Low Flow
More/ High flow More/ High Flow
Reverse/ Reverse/ Flow
Misdirected flow Misdirected
More/ High More/ High Pressure
pressure
Low pressure Low Pressure Includes vacuum
More/ High More/ High Temperature
temperature
Low Low Temperature Includes cryogenic conditions
temperature
High level More Level Includes high interface level
Low level Low Level Includes low interface level
Start-up/ Others Start-up/ Shutdown/ Maintenance
Shutdown/ covers issues such as isolation,

Maintenance drain, purge, reduced throughput,
emergency shutdown and
commissioning
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Deviation. Guidewords Parameter Description

Composition As well as/ Other Composition/
change/ than/ Part of Phase
Contamination/
Additional
Phase/ Loss of
Phase
Utility failure Others Utility failure: cooling water, power,
etc.
Others Others Others include tube failure,
corrosion, emergency isolation,
blowdown, layout issues, etc.
8. EXECUTION
The key steps in execution of HAZOP Study are listed below:
 Identify the purpose and operation of the equipment/ process;

 Understand the normal operating condition, various mode and associated process
conditions;
 Review relevant information to assist in the identification of possible problems;
 Identify potential hazards or operability issues and possible consequences utilizing the
guide word approach; and
 Review if identified hazards and issues can be prevented, lowered or mitigated by
safeguards already incorporated in design.
General procedure:
 All recording are done by the HAZOP secretary or scribe on a PHA Pro 8 enabled laptop
which is projected to enable the entire team to review, endorse and comment, if required;
 Project members from disciplines which do not require continuous participation were called
on need basis; and
 Draft worksheet was submitted after the session day for Team member to review and
suggest any corrections required in the next session.
9. ASSUMPTIONS FOR THE STUDY

HAZOP study assumptions are required to ensure the study remains focused to identify hazards
and operability issues under certain rules and guidelines. These assumptions are based on
engineering practices and commonly used across various Process Plants. The list of
assumptions as agreed by the team is provided below:
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Design Assumptions:
 Equipment designed for the facility is suitable for the subjected process operating and
design condition.
 The facility will be subjected to overall fire/ gas leak scenario (e.g. emergency isolation),
but any catastrophic rupture of equipment will not be considered except for tube rupture/
seal leak.
 Pressure safety valves, rupture discs, mechanical stops etc. type of mechanical protection
devices are expected to be available, when on demand.
 Overpressure protection due to reverse pressure against a check valve, pressure relief
devices shall be assessed in accordance with project specifications or design codes.
However, single check valve is adequate for reverse flow or excessive temperature unless
special circumstances exist.
 Non-return valves for clean fluids and subjected to frequent demand are considered less
prone to failure.
 Instrumentation layer of protection like interlock/ shutdown system/ trip/ HIPPS (High
Integrity Pressure Protective System) are deemed as protection/ safeguard and are
considered adequate.
 Car sealed open/ car sealed close valve (CSO/ CSC) are considered to hold.
Study Philosophy:
 The facility under design or operation will be well maintained;
 Events like natural calamity (e.g. earthquake, flooding etc.), dropped objects, terrorism or
sabotage are not considered;
 Double jeopardy or simultaneous occurrence of two independent failures is not considered
except in special cases where the consequence is severe and hence the risks may be
significant;
 Environmental impact due to gas dispersion will not be part of HAZOP as it is handled by
an independent study;
 Loss of production is a consequence of any shutdown. Hence not mentioned explicitly for
each consequence;
 To avoid duplication, similar process system/ equipment which are parallel (including spare
equipment, parallel trains) will not be covered. However, all actions recorded during the
HAZOP are applicable to all such systems/ equipment. Also, simultaneous operation of
parallel systems and related interconnection issues will be reviewed, as necessary;
 HAZOP is a qualitative study and no quantitative analysis will be performed in the session;
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 Recommendations proposed are for further review and analysis outside the session.
However, HAZOP is only for identifying and recording issues.
10. WORKSHEETS RECORDING

The session proceedings were recorded on the worksheet, using PHA Pro 8 software and the
completed worksheets are included in Appendix 3 – HAZOP Worksheets.
11. CONCLUSION
2
The HAZOP study has generated a total of 218 recommendations/ action items. A list of
recommendation is provided in Appendix 4 – Recommendation List.
The recommendations raised by the HAZOP team include items for further review discussions and/
or changes to the current design, which will improve the safety or the operability of the facility. These
recommendations are by agreement of the team and follow-up/ close out of each will be carried out
by the responsible parties separately. Changes proposed as a result of HAZOP review will be
discussed and agreed by PT Pupuk Sriwidjaja/ Rekayasa.
12. FOLLOW UP ACTIONS

Proper follow-up and close-out of all recommendations will be monitored through the HAZOP Study
Action Sheets by the party identified as responsible for the action/ changes proposed as a result of
HAZOP review, will be discussed and agreed by PT Pupuk Sriwidjaja/ Rekayasa.
Individual follow-up forms for all HAZOP recommendations are attached in Appendix – 6. Report on
closing out of HAZOP Action Sheets will be submitted separately in the other document by PT
Rekayasa.
13. REFERENCE
• Dyadem International Ltd PHA-Pro 8, HAZOP Recording Software
• P2B-00-81-GP-0004-C, HAZOP Study Procedure
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APPENDIX 1 – DRAWING LIST

Appendix 1 – Drawing List
No. Drawing No./ Revision Document Name Place(s) Used Comment
1 P2B-10-02-EF-62D001-R/ Rev 2 General Notes For reference only
2 P2B-10-02-EF-62D002-R/ Rev 2 Piping Symbols For reference only
3 P2B-10-02-EF-62D003-R/ Rev 2 Instrument Symbology For reference only
4 P2B-10-02-EF-62D004-R/ Rev 2 Drawing Index For reference only
5 P2B-10-02-EF-62D005-R/ Rev 2 Equipment Index For reference only
6 P2B-10-02-EF-62D101-R/ Rev 2 Air Compressor (Stage 1 to 2) Nodes: 10
7 P2B-10-02-EF-62D101A-R/ Rev 2 Air Compressor (Stage 3 to 4) Nodes: 10
8 P2B-10-02-EF-62D101B-R/ Rev 2 Gas Turbine for Air Compressor Nodes: 10
9 P2B-10-02-EF-62D102-R/ Rev 2 Feed gas Compressor KO Drum Nodes: 1, 15
10 P2B-10-02-EF-62D102A-R/ Rev 2 LTS Reduction Nodes: 19
11 P2B-10-02-EF-62D102B-R/ Rev 2 Feed Gas Compressor Nodes: 1, 2
12 P2B-10-02-EF-62D103-R/ Rev 2 Desulfurization Nodes: 2
13 P2B-10-02-EF-62D103A-R/ Rev 2 Mixed Feed to Primary Reformer Nodes: 1, 3
14 P2B-10-02-EF-62D104-R/ Rev 2 Induced Draft Fan Nodes: 11
15 P2B-10-02-EF-62D104A-R/ Rev 2 Forced Draft Fan Nodes: 11
16 P2B-10-02-EF-62D105-R/ Rev 2 Primary Reformer- Convection Coils Nodes: 2, 10, 11
17 P2B-10-02-EF-62D106-R/ Rev 2 Primary Reformer- Radiant section and Nodes: 3, 10, 11
Convection Coils
18 P2B-10-02-EF-62D107-R/ Rev 2 Secondary Reformer Nodes: 3, 10, 24
19 P2B-10-02-EF-62D108-R/ Rev 2 HT Shift Converter Nodes: 4, 24
20 P2B-10-02-EF-62D108A-R/ Rev 2 LT Shift Converter Nodes: 4
21 P2B-10-02-EF-62D109-R/ Rev 2 LT Effluent Cooling Nodes: 5, 8, 24
22 P2B-10-02-EF-62D110-R/ Rev 2 CO2 Absorber Nodes: 1, 5, 6, 7, 9
23 P2B-10-02-EF-62D111-R/ Rev A Methanator Nodes: 12, 24
24 P2B-10-02-EF-62D111A-R/ Rev 2 Methanator Effluent Nodes: 12
25 P2B-10-02-EF-62D112-R/ Rev 2 Synthesis Gas Dryers Nodes: 13, 14
26 P2B-10-02-EF-62D112A-R/ Rev 2 Purifier Feed/ Effluent Nodes: 13
27 P2B-10-02-EF-62D112B-R/ Rev 2 Purifier Rectifier Nodes: 13
28 P2B-10-02-EF-62D112C-R/ Rev 2 Purifier Expander Nodes: 13
29 P2B-10-02-EF-62D113-R/ Rev 2 Synthesis Gas Compressors Nodes: 15, 16
30 P2B-10-02-EF-62D114-R/ Rev 2 Ammonia Converter Feed/ Effluent Nodes: 15, 16, 17,
Exchangers 24
31 P2B-10-02-EF-62D115-R/ Rev 2 Ammonia Synthesis Converter Nodes: 15, 16
32 P2B-10-02-EF-62D116-R/ Rev 2 Unitized Chiller (120-CF3 and 120-CF4) Nodes: 16, 17
33 P2B-10-02-EF-62D116A-R/ Rev 2 Unitized Chiller (120-CF1 and 120-CF2) Nodes: 16, 17
34 P2B-10-02-EF-62D117-R/ Rev 2 Ammonia Refrigerant Compressor Nodes: 17
35 P2B-10-02-EF-62D118-R/ Rev 2 Ammonia Refrigerant Nodes: 17
36 P2B-10-02-EF-62D118A-R/ Rev 2 Warm Ammonia Product Pumps Nodes: 17
37 P2B-10-02-EF-62D118B-R/ Rev 2 Cold Ammonia Pumps Nodes: 17
38 P2B-10-02-EF-62D119-R/ Rev 2 Ammonia Separation Nodes: 16, 17
39 P2B-10-02-EF-62D119A-R/ Rev 2 Process Condensate pumps Nodes: 9
40 P2B-10-02-EF-62D120-R/ Rev 2 HP Condensate Stripper Nodes: 3, 9
41 P2B-10-02-EF-62D120A-R/ Rev 2 Hydraulic Turbine Nodes: 6, 8
42 P2B-10-02-EF-62D120B-R/ Rev 2 HP and LP Flash Column Nodes: 5, 6, 7, 8,
21
1 of 3
43 P2B-10-02-EF-62D121-R/ Rev 2 LP Flash Overhead Nodes: 7
44 P2B-10-02-EF-62D121A-R/ Rev 2 CO2 Stripper Nodes: 8
45 P2B-10-02-EF-62D122-R/ Rev 2 Semi-lean Solution Circulating Pumps Nodes: 8, 20, 21
46 P2B-10-02-EF-62D122A-R/ Rev 2 Lean Solution pumps Nodes: 7, 8, 21
47 P2B-10-02-EF-62D123-R/ Rev 2 Lean Solution Exchangers Nodes: 8, 24
48 P2B-10-02-EF-62D124-R/ Rev 2 OASE Solution Storage Tank Nodes: 20
49 P2B-10-02-EF-62D125-R/ Rev 2 OASE Sump Nodes: 20
50 P2B-10-02-EF-62D126-R/ Rev 2 Semi-lean Solution Pumps Nodes: 6, 8
51 P2B-10-02-EF-62D127-R/ Rev 2 Ammonia Absorber Nodes: 16, 18
52 P2B-10-02-EF-62D128-R/ Rev 2 Ammonia Rectifier Nodes: 17, 18
53 P2B-10-02-EF-62D130-R/ Rev 2 Molecular Sieve Regen Heater Nodes: 14
54 P2B-10-02-EF-63D101-R/ Rev 2 Chemical Injection Nodes: 21
55 P2B-10-02-EF-63D103-R/ Rev 2 Sample Cooler Details For reference only
56 P2B-10-02-EF-63D105-R/ Rev 2 Hot Vent Header For reference only
57 P2B-10-02-EF-63D105A-R/ Rev 2 NH3 Flare Header For reference only
58 P2B-10-02-EF-63D105B-R/ Rev 2 Cold Vent header For reference only
59 P2B-10-02-EF-63D106-R/ Rev 2 Plant Air, Instrument Air & Nitrogen For reference only
Distribution
60 P2B-10-02-EF-64D101-R/ Rev 2 HP Steam Generation Nodes: 24
61 P2B-10-02-EF-64D102-R/ Rev 2 HP Steam distribution Nodes: 24
62 P2B-10-02-EF-64D103-R/ Rev 2 MP Steam distribution Nodes: 24
63 P2B-10-02-EF-64D104-R/ Rev 2 LP Steam distribution Nodes: 24
64 P2B-10-02-EF-64D105-R/ Rev 2 103-JTC Surface Condenser Nodes: 24
65 P2B-10-02-EF-64D105A-R/ Rev 2 103-JTC Surface Condenser Pumps Nodes: 22
66 P2B-10-02-EF-64D105B-R/ Rev 2 101-JTC Surface Condenser Nodes: 24
67 P2B-10-02-EF-64D105C-R/ Rev 2 101-JTC Surface Condenser Pumps Nodes: 22
68 P2B-10-02-EF-64D105D-R/ Rev 2 102-JTC Surface Condenser Nodes: 22
69 P2B-10-02-EF-64D105E-R/ Rev 2 102-JTC Surface Condenser Pumps Nodes: 22
70 P2B-10-02-EF-64D105F-R/ Rev 2 Demin Water Distribution Nodes: 22, 24
71 P2B-10-02-EF-64D106-R/ Rev 2 Deaerator Nodes: 14, 18, 21,
24
72 P2B-10-02-EF-64D106A-R/ Rev 2 HP BFW Pumps Nodes: 18, 24
73 P2B-10-02-EF-64D107-R/ Rev 2 Steam Turbine Details (103-JT) Nodes: 24
74 P2B-10-02-EF-64D108-R/ Rev 2 Steam Turbine Details (105-JT) Nodes: 24
75 P2B-10-02-EF-64D108A-R/ Rev 2 Steam Turbine Details (104-JT) Nodes: 24 Refer to
"Comment"
Column on Node
List - Node 24
76 P2B-10-02-EF-64D108B-R/ Rev 2 Steam Turbine Details (101-JT) Nodes: 24
77 P2B-10-02-EF-64D108C-R/ Rev 2 Steam Turbine Details (101-BJT and Nodes: 24 Refer to
101-BJAT) "Comment"
Column on Node
List - Node 24
78 P2B-10-02-EF-64D108D-R/ Rev 2 Steam Turbine Details (101-BJ1T and Nodes: 24
101-BJ1AT)
79 P2B-10-02-EF-64D108E-R/ Rev 2 Steam Turbine Details (107-JBT) Nodes: 24 Refer to
"Comment"
Column on Node
List - Node 24
80 P2B-10-02-EF-64D108F-R/ Rev 2 Steam Turbine Details (108-JT) Nodes: 24 Refer to
2 of 3
"Comment"
Column on Node
List - Node 24
81 P2B-10-02-EF-64D108G-R/ Rev 2 Steam Turbine Details (101-JLOT) Nodes: 24 Refer to
"Comment"
Column on Node
List - Node 24
82 P2B-10-02-EF-64D108H-R/ Rev 2 Steam Turbine Details (103-JLOT) Nodes: 24 Refer to
"Comment"
Column on Node
List - Node 24
83 P2B-10-02-EF-64D108I-R/ Rev 2 Steam Turbine Details (102-JT) Nodes: 24 Refer to
"Comment"
Column on Node
List - Node 24
84 P2B-10-02-EF-64D109-R/ Rev 2 Water Jacket Details Nodes: 22
85 P2B-10-02-EF-64D109A-R/ Rev 2 Water Jacket Overflow Recovery Nodes: 25
System
86 P2B-10-02-EF-64D110-R/ Rev 2 Cooling water distribution For reference only
87 P2B-10-02-EF-64D111-R/ Rev 2 Fuel Gas Distribution Nodes: 23
88 P2B-10-02-EF-64D112-R/ Rev 2 Fuel Gas Arch Burners Nodes: 23
89 P2B-10-02-EF-64D113-R/ Rev 2 Start-up Heater Burner Nodes: 15
90 P2B-10-02-EF-64D114-R/ Rev 2 Fuel Gas Tunnel Burner Nodes: 23
91 P2B-10-02-EF-64D115-R/ Rev 2 Fuel Gas Superheat Burners Nodes: 23
92 P2B-10-02-EF-64D116-R/ Rev 2 Flare System For reference only
93 P2B-10-02-EF-64D119-R/ Rev 2 Condensate Header For reference only
94 P2B-10-02-EF-64D120-R/ Rev 2 Potable water and water header For reference only
distribution
95 P2B-10-02-EF-64D121-R/ Rev 2 OASE Sewer system and chemical Nodes: 27
drain system
96 P2B-10-02-EF-64D122-R/ Rev 2 Oily drain system Nodes: 26
97 P2B-10-02-EF-64D123-R/ Rev 2 General process fluid for ammonia For reference only
98 P2B-10-02-EF-64D124-R/ Rev 2 Waste water header For reference only
3 of 3
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APPENDIX 2 – NODE LIST

Appendix 2 – Node List
Node Design Intent Equipment Details Drawings / References Comment
1. Feed Gas Natural gas for the ammonia plant feed and fuel is supplied from the battery limit at a Feed Gas KO Drum, 174-D P2B-10-02-EF-62D102-R/
from Battery temperature of 30 degC and pressure of 15 kg/cm2a minimum to the Feed Gas KO Des./ Oper. Temp.: 100/ 30 degC Rev 2
2
Limit to Feed Drum, 174-D to remove any liquid and solid content in the gas. Part of the NG is then Des./ Oper. Press.: 27.5/ 14 kg/cm G
P2B-10-02-EF-62D102B-
Gas Knockout sent to Primary Reformer Furnace as fuel and rest of it is compressed in the Feed Gas
Drum and to Compressor, 102-J to 53 kg/cm2a. 102-J is provided with Feed Gas Compressor Kick Feed Gas Compressor, 102-J R/ Rev 2
Feed Gas Back Cooler, 143-C which allows part of the discharge gas to be recycled back to the Nor. Press. (suction/ discharge): 11.5/ P2B-10-02-EF-62D103A-
2
Compressor Feed Gas KO Drum during start-up and plant turndown. The cooler is also used for 50 kg/cm G R/ Rev 2
cooling the recirculating NG used for heat-up of desulfurization section during start-up. Nor. Temp. (suction/ discharge): 30/
Recycle Hydrogen from the upstream of Molecular Sieve Dryer joins at the outlet of 145.4 degC P2B-10-02-EF-62D110-R/
the Feed Gas KO Drum. Feed Gas Compressor Kick Back Rev 2
Cooler, 143-C
Des./ Oper. Temp. (shell & tube): 405/
152 & 80/ 43 degC
Des./ Oper. Press. (shell & tube): 27/
2
14.3 & 8/ FV/ 4.5 kg/cm G
2. Feed Gas The natural gas contains total sulfur of max. 15 ppmv and average 8 ppmv as H2S. Hydrotreater, 101-D P2B-10-02-EF-62D102B-
from Sulphur is a poison to most catalysts used in the downstream process and must be Des./ Oper. Temp.: 401/ 371 degC R/ Rev 2
Compressor removed. The natural gas feed, is first mixed with a recycle stream of hydrogen-rich Des./ Oper. Press.: 58.3/ 50.44
to Feed synthesis gas from the purge gas ammonia recovery system, the overhead of the HP 2
G P2B-10-02-EF-62D103-R/
kg/cm
Rev 2
Preheat Coil Ammonia Scrubber, producing a mixture containing about 2.0 mol% hydrogen. When
and then to the Scrubber is offline the hydrogen is supplied from upstream of Molecular Sieve Desulfurizer, 108-DA/DB P2B-10-02-EF-62D105-R/
Hydrotreater Dryers. The feed gas is then heated to 371 degC in the Feed Preheat Coils located in Des./ Oper. Temp.: 405/ 371 degC
2 Rev 2
and the convection section of the Primary Reformer, 101-B, prior to desulfurization. Des./ Oper. Press.: 27.5/ 14 kg/cm G
Desulfurizer The desulfurization of the feed gas is accomplished in two separate steps. In the first
including H2 Feed Preheat Coil, 101-BCF
make-up step, the heated gas is passed through a single Hydrotreater vessel, 101-D, which Des./ Oper. Temp.: 447/ 371 degC
2
contains hydrogenation catalyst, cobalt/ molybdenum oxide (CoMox) which react with Des./ Oper. Press.: 58.3/ 52 kg/cm G
the organic sulfur compounds like mercaptan, carbonyl sulphide present in the feed
gas to form hydrogen sulphide.
In the second step, the process gas is passed through two Desulfurizer vessels, 108-
DB/DC, each containing two beds of zinc oxide catalyst. The hydrogen sulphide in the
gas reacts with ZnO catalyst and is retained in the bed. The effluent stream coming
out of the Desulfurizer beds contains less than 0.1 ppmv sulfur.
3. Feed Gas The desulfurized feed gas is mixed with medium pressure steam prior to reforming. Mixed Feed Preheat Coil, 101-BCX P2B-10-02-EF-62D103A-
from Process steam is added to achieve a 2.7 steam to carbon molar ratio in the mixed Des. Temp.: 53 degC R/ Rev 2
2
Desulfurizer feed gas. The mixture is preheated to around 488 degC in the convection section of Des. Press.: 56/ Hold kg/cm G
P2B-10-02-EF-62D106-R/
to Primary the Primary Reformer, 101-B, and the hot mixed feed is distributed to the Primary
Reformer and Reformer catalyst tubes, which are suspended in the radiant section of the furnace Mixed Feed Preheat Coil, 101-BCX Rev 2
Secondary and packed with nickel based reforming catalysts. As the mixed feed flows down over Des. Temp.: 530 degC P2B-10-02-EF-62D107-R/
2
Reformer the reforming catalyst, steam reforming and water gas shift reactions take place, Des. Press.: 56 kg/cm G Rev 2
including forming hydrogen, carbon monoxide and carbon dioxide. The reactions are
Mixed Feed endothermic overall and the required heat duty is supplied by fuel gas being fired in Primary Reformer, 101-B P2B-10-02-EF-62D120-R/
Preheat Coil burners located in the Arch of the radiant section of 101-B and between the rows of Des. Temp.: 53 degC Rev 2
catalyst tubes. 2
Des. Press.: 41.7 kg/cm G
1 of 18
Primary Reformer Effluent Transfer
The process gas leaving Primary Reformer contains about 52.7 % hydrogen and 28.5 Line, 107-D
% methane on dry basis. This is fed to the Secondary Reformer, 103-D via Primary Des. Temp.: 205 (-12) degC
2
Reformer Effluent Transfer Line, 107-D. In Secondary Reformer, the quantity of air is Des. Press.: 44 kg/cm G
controlled to produce a three-to-one molar ratio of hydrogen to nitrogen in the
synthesis gas. The preheated process air from the Air Preheat Coils enters 103-D Secondary Reformer, 103-D
from the top. During secondary reforming the oxygen in the air combusts part of the Des./ Oper. Temp.: 506 (upp)/ 204
process gas from the Primary Reformer, leading to a high temperature (approx. 1349 (low)/ 497 degC
2
degC) in a special mixing and combustion chamber above the catalyst bed. The hot Des./ Oper. Press.: 44.4/ 39.9 kg/cm G
gas from this combustion passes down through a bed of nickel reforming catalyst
where it reacts to produce more hydrogen in a similar manner to the Primary Secondary Reformer Waste Heater
Reformer, but without outside heat transfer. Due to the overall endothermic nature of Boiler, 101-C
the reforming reaction, the gas temperature leaving the Secondary Reformer is Des./ Oper. Temp. (shell & tube):
reduced to approximately 898 degC. 358/328 & 400/897/898 degC
Des./ Oper. Press. (shell & tube):
2
Heat recovery is achieved by Secondary Reformer Waste Heat Boiler, 101-C, where 142/FV/126.5 & 43.3/39.9 kg/cm G
HP steam is generated. The partially cooled gas then goes to a HP Steam
Superheater, 102-C, where it is cooled to HTS inlet temperature of 371 degC. HP Steam Superheater, 102-C
Des./ Oper. Temp. (shell & tube):
410/371 & 420/-12/338 degC
2
42.8/38.4 & 139.9/FV/ 123 kg/cm G
4. HT Shift In the shift conversion step, carbon monoxide reacts with steam to form equivalent High Temperature Shift Converter, 104- P2B-10-02-EF-62D108-R/
Converter amounts of hydrogen and carbon dioxide by the shift reaction which is reversible and D1 Rev 2
effluent to exothermic. The CO shift reaction rate is favoured by high temperature, but the Des./ Oper. Temp.: 475/ 431 degC 2
G P2B-10-02-EF-62D108A-
HTS Effluent equilibrium conversion of CO to CO2 is favoured by low temperature. Therefore, shift Des./ Oper. Press.: 42.8/ 32.8 kg/cm
R/ Rev 2
Steam conversion is carried out in two stages, High Temperature Shift Converter (HTSC) and
Generator Low Temperature Shift Converter (LTSC) with interstage cooling. HTS Effluent Steam Generator, 103-C1
and HTS The High Temperature Shift Converter, 104-D1 is operated at higher temperature with Des./ Oper. Temp. (shell & tube):
Effluent BFW 475/0/431 & 410/ 0 degC
Preheater and the reactor inlet temperature of about 371 degC. It contains iron oxide catalyst and Des./ Oper. Press. (shell & tube):
2
then to LT produces the bulk of the shift conversion, and CO content at the exiting stream 4142.5/ FV/ 126.57 kg/cm G
Shift reduced to about 3.34 mol% CO on dry basis. Due to the low steam to gas ratio in the
Converter plant, HTS also consists of a copper promoter to prevent unwanted side reactions that HTS Effluent BFW Preheater, 103-C2
could harm the catalyst. The gas leaving the HTS Converter is cooled by generating Des./ Oper. Temp. (shell & tube): 343/
steam and preheating boiler feed water in the HTS Effluent/ Steam Generator & BFW 286.4 & 358/ 257.8 degC
Preheater, 103-C1/C2. Des./ Oper. Press. (shell & tube): 42.8/
The Low Temperature Shift Converter, 104-D2 is operated at lower temperature with 2
38.2 & 125/ FV/ 126.57 kg/cm G
the reactor inlet temperature of about 205 degC. The LTS contains copper based Low Temperature Shift Converter, 104-
catalyst and the gas leaving the LTS Converter has a residual carbon monoxide D2
content of about 0.30 mol% on dry basis. The LTSC consists of two vessels Des./ Oper. Temp.: 270/ 205 degC
104D2A/D2B to allow catalyst replacement during normal operation. 2
Des./ Oper. Press.: 42.8/ 37.6 kg/cm G
2 of 18
5. LTSC Heat is recovered from the LTS effluent gas in three exchangers is used for pre- LTS Effluent/ BFW Preheater, 131-C P2B-10-02-EF-62D109-R/
effluent to heating the BFW in LTS Effluent/ BFW Preheater, 131-C, providing reboiling for CO2 Des./ Oper. Temp. (shell & tube): 275/ Rev 2
LTS Effluent/ Stripper in CO2 Stripper Reboiler, 105-C and pre-heating Demin water in LTS Effluent/ 279.8 & 250/ 174.75 degC
BFW Demin Water Exchanger, 106-C. The gas exiting the heat exchangers is at 70 degC Des./ Oper. Press. (shell & tube): 42.8/ P2B -10-02-EF-62D110-R/
2
Preheater, and is sent to the Raw Gas Separator, 142-D1 for removal of any entrained liquid in 37.3 & 171/ 140.25 kg/cm G Rev 2
CO2 Stripper the process gas and then sent to CO2 Absorber, 121-D. P2B-10-02-EF-62D120B-
Reboiler and The CO2 contained in the shifted process gas is reduced to 500 ppmv by washing in a CO2 Stripper Reboiler, 105-C R/ Rev 2
LTS Effluent/ Des./ Oper. Temp. (shell & tube): 160/ -
Demin Water two stage activated amine based system. The process gas from 142-D1 first enters 12/ 126 & 200/ -12/ 167 degC
Exchanger the bottom section of the CO2 Absorber which contains two beds of high performance Des./ Oper. Press. (shell & tube): 5/ FV/
2
and the packing, and the gas flows upward contact with downward flow of semi-lean OASE 3.5 & 42.8/ 37.21 kg/cm G
cooled gas to solution. Bulk of its CO2 content in the gas is removed by absorption into the semi-
Raw Gas lean OASE solution. The gas containing 0.05 mol% of CO2 then flows further up to the LTS Effluent/ Demin Water Exchanger,
Separator and top section of the Absorber where most of the remaining CO2 is removed by 106-C
CO2 Absorber absorption into the downward flow lean solution. Des./ Oper. Temp. (shell & tube): 150/ -
and then to The Purified gas is then water washed and passed through a demister at the top of the 12/ 120 & 80/ -12/ 136 degC
CO2 Absorber Des./ Oper. Press. (shell & tube): 10.1/
2
Overhead absorber and then sent to the CO2 Absorber Overhead KO Drum to remove any FV/ 8.7 & 42.8/ 37 kg/cm G
Knockout traces of entrained OASE solution.
drum Raw Gas Separator, 142-D1
Des./ Oper. Temp.: 100/ 70 degC
2
CO2 Absorber Overhead Knockout
Drum, 142-D2
2
Des./ Oper. Press.: 41/ 36.5 kg/cm G
CO2 Absorber, 121-D
Des./ Oper. Temp.: 120/ -12/ 70 degC
2
6. Rich amine Rich Amine from CO2 Absorber, 121-D bottom is passed through Hydraulic Turbine Hydraulic Turbine for 107-JA, 107-JAHT P2B-10-02-EF-62D110-R/
and Semi- for Semi-Lean Solution Pump, 107-JAHT, where power is recovered by letting down Normal Temp. (suction/ discharge): 85/ Rev 2
lean amine the high pressure solution. The solution is then sent to HP Flash Column, 163-D, 85 degC
circuit which allows partial disengagement of gas from solution. The solution from bottom of Normal Press. (suction/ discharge): P2B-10-02-EF-62D120A-
2
163-D is sent under level control to LP Flash Column, 122-D1 where it is flashed to 36.16/ 9.03 kg/cm G R/ Rev 2
about 2 kg/cm2a. Most of the semi-lean solution from 122-D1 is pumped back to CO2 P2B-10-02-EF-62D120B-
Absorber by Semi-lean Solution Pumps, 107-JA/JB/JC. Part of the semi-lean solution HP Flash Column, 163-D R/ Rev 2
is sent to CO2 Stripper, 122-D2 through Solution Circulating Pump, 117-J/JA. Des./ Oper. Temp.: 120/ 85 degC
2
Des./ Oper. Press.: 37.6/ 63 kg/cm G P2B-10-02-EF-62D126-R/
LP Flash Column, 122-D1 Rev 2

Des./ Oper. Press.: 4/ -0.527/ 1.02
2
kg/cm G
Semi-lean OASE Solution Pumps, 107-
JA/JB/JC
3
Design Capacity: 1784.4 m /h
2
Suct./ Disch.: 4.13/ 41.3 kg/cm G
3 of 18
7. CO2 The CO2 stream exiting the overhead of LP Flash Column and CO2 Stripper is CO2 Stripper Overhead Condenser, P2B-10-02-EF-62D110-R/
product washed with wash water and sent to CO2 Stripper Reflux Condenser, 110-C, where it 110-C Rev 2
system is cooled to 38 degC. The cooled gas is then sent to CO2 Stripper Reflux Drum, 153-D Des./ Oper. Temp. (shell & tube): 130/ -
P2B-10-02-EF-62D120B-
to remove any liquid and then sent to battery limit. 12/ 77.3 & 80/ -12/ 45 degC
Des./ Oper. Press. (shell & tube): 5/ FV/ R/ Rev 2
2
3.5 & 42.8/ 37.21 kg/cm G P2B-10-02-EF-62D121-R/
CO2 Stripper Reflux Drum, 153-D Rev 2
Des./ Oper. Temp.: 80/ -12/ 38 degC P2B-10-02-EF-62D122A-
Des./ Oper. Press.: 4 (50% vacuum)/ R/ Rev 2
2
0.8 kg/cm G
CO2 LP Flash Reflux Pumps, 110-J/JA
3
2
Start-up Vent Silencer, SP-155
Des./ Oper. Temp.: 3.5 degC
2
Des./ Oper. Press.: 110 kg/cm G
8. Lean The part of semi-lean solution from LP Flash Column is pumped by Semi-lean CO2 Stripper, 122-D2 P2B-10-02-EF-62D120A-
Amine circuit Solution Circulating Pumps, 117-J/JA through the Lean/ Semi-lean Exchangers, 112- Des./ Oper. Temp.: 160/ 126 degC R/ Rev 2
C/CA where it is heated to about 115 degC (max) and then sent to top of CO2 Des./ Oper. Press.:4/ -0.527/ 1.12
Stripper, 122-D2. A slip stream of semi-lean solution is routed back to LP Flash 2
G P2B-10-02-EF-62D120B-
kg/cm
R/ Rev 2
Column through a mechanical filter.
Heat for stripping is provided by CO2 Stripper Reboiler, 105-C. The stripped OASE Semi-Lean Solution Circulating Pumps, P2B-10-02-EF-62D122-R/
117-J/JA
solution is cooled by heat exchange with Lean Semi-Lean Solution Exchanger, 112- 3
Rev 2
2
C/CA and then with DM water in Lean Solution Demin Water Preheater, 109-C and Suct./ Disch.: 4.06/ 7.21 kg/cm G P2B-10-02-EF-62D123-R/
Lean Solution Water Cooler, 108-C/CA. The cooled lean solution is then pumped back Rev 2
to CO2 Absorber by Lean Solution Pump, 108-J/JA. OASE Solution Filter, 104-L
Des./ Oper. Temp.: 130/ -12/ 78.3 degC P2B-10-02-EF-62D122A-
2G R/ Rev 2
Des./ Oper. Press.: 12/ 7 kg/cm
Lean OASE Solution Pumps, 108-J/JA P2B-10-02-EF-62D121A-
3 R/ Rev 2
2 P2B-10-02-EF-62D126-R/
Lean Semi-Lean Solution Exchanger, Rev 2
112-C/CA P2B -10-02-EF-62D109-R/

Des./ Oper. Temp. (shell & tube): 160/ Rev 2
126 & 150/ 99 degC
Des./ Oper. Press. (shell & tube): 5.3/
2
0.5 FV/ 1.02 & 12/ 0.5FV/ 6.3 kg/cm G
Lean Solution Demin Water Preheater,
109-C
88.3 & 80/ 50.5 degC
2
FV/ 1.25 & 15.5/ FV/ 7 kg/cm G
4 of 18
Lean Solution Water Cooler, 108-C/CA

88.3 & 80/ 45 degC
2
FV/ 1.25 & 8/ FV/ 7 kg/cm G
Semi-Lean OASE Solution Pumps, 107-
JA/JB/JC
3
2
9. Process The process condensate from the Raw Gas Separator, 142-D1 is combined with Raw Gas Separator, 142-D1 P2B-10-02-EF-62D110-R/
condensate condensate from Methanator Effluent Separator, 144-D. The condensate is preheated Des./ Oper. Temp.: 100/70 degC Rev 2
2
from Raw Gas by Stripper effluent in the Condensate Stripper Feed Effluent Exchanger, 188- Des./ Oper. Press.: 42.8/36.7 kg/cm G
P2B-10-02-EF-62D119A-
Separator to C1/C2/C3 and then sent to the Process Condensate Stripper, 130-D where dissolved
Process CO2, methanol and ammonia are stripped with process steam. MP steam from MP Process Condensate Pump for 142-D1, R/ Rev 2
Condensate steam header under flow control, is used to strip the process condensate. The stripped 121-J/JA P2B-10-02-EF-62D120-R/
3
Stripper and condensate leaving the bottom of the Stripper is further cooled to about 39 degC by Design Capacity: 99.82 m /h
2 Rev 2
steam from cooling water in the Stripped Condensate Cooler, 174-C1/C2. The cooled, stripped Suct./ Disch.: 33.51/ 52.4 kg/cm G
overhead of condensate is exported to the offsite for treatment in polisher unit.
Stripper to Condensate Stripper Feed Effluent
Primary Exchanger, 188-C1/C2/C3
Reformer and Des./ Oper. Temp. (shell & tube): 300/-
treated 12/259 & 300/-12/243 degC
condensate to Des./ Oper. Press. (shell & tube):53/
utility unit. 2
FV/ 45.17 & 53/ FV/ 49.58 kg/cm G
Process Condensate Stripper, 130-D
Des./ Oper. Press.: 52/ FV/ 46.07
2
kg/cm G
Stripped Condensate Cooler, 174-
C1/C2
Des./ Oper. Temp. (shell & tube): 240/-
12/ 81 & 80/ 43 degC
Des./ Oper. Press. (shell & tube):9.1/
2
FV/ 4.6 & 8/ FV/ 4.53 kg/cm G
5 of 18
10. Process The Process Air Compressor, 101-J delivers process air for the Secondary Reformer Air filter for 101-J/ 101-J Package, 101- P2B-10-02-EF-62D101-R/ Refer Vendor
Air plus the instrument and plant air for both the ammonia and urea units as well as urea L Rev 2 HAZOP.
Compressor plant passivation air. Des./ Oper. Temp.: Hold/ 36 degC 2
G P2B-10-02-EF-62D101A-
and air supply Des./ Oper. Press.: Hold/ Atm kg/cm
Process Air Compressor is a four stage centrifugal compressor is controlled to R/ Rev 2
to Secondary
Reformer maintain a constant pressure drop across the process air control valve. Air is filtered Process Air Compressor, 101-J P2B-10-02-EF-62D101B-
including Hot and compressed in the Compressor to the discharge pressure out of the last stage at Norm. Press. (suction/ Discharge): 0/
2 R/ Rev 2
and Cold about 44.5 kg/cm2a. Inter-stage cooling and condensate separation is provided. The 43.5 kg/cm G
Process air compressed process air from discharge of the Compressor is then heated in the air Norm. Temp. (suction/ Discharge): 36/ P2B-10-02-EF-62D105-R/
coil. preheat coils to about 497 degC before going to the Secondary Reformer. 165.4 Rev 2
During turndown operation, compressed air is vented to maintain minimum load on the 101-J Stage-1 Intercooler, 101-JC1 P2B-10-02-EF-62D106-R/
Compressor. A small amount of MP steam is injected upstream of the preheat coils to Des./ Oper. Temp. (shell & tube): 210/ Rev 2
protect the coil from overheating during start-up shutdown. 154 & 80/ 43 degC P2B-10-02-EF-62D107-R/
2 Rev 2
1.39 & 8/ FV/ 4.5 kg/cm G
Separator for 101-JC1, 101-JD1
2
101-J Stage-2 Intercooler, 101-JC2
164 & 80/ 43 degC
2
5.5 & 8/ FV/ 4.5 kg/cm G
2
101-J Stage-3 Intercooler, 101-JC3
157 & 80/ 43 degC
Des./ Oper. Press. (shell & tube):23/ 16
2
& 8/ FV/ 4.5 kg/cm G
2
Des./ Oper. Press.: 23/ 16 kg/cm G
Air Compressor Vent Silencer, SP-151

Des./ Oper. Temp.: 190/ Hold degC
2
Des./ Oper. Press.: 10/ Hold kg/cm G
Cold Process Air Coil, 101-BCA1

2
6 of 18
Hot Process Air Coil, 101-BHPA
2
11. Primary The Induced Draft Fans, 101-BJ/BJA which operate in parallel are provided to Air Filter for 101-BJ1/BJ1A, 101- P2B-10-02-EF-62D104-R/
Reformer maintain negative draft (static pressure inlet -281 mmH2O and outlet 0 mmH2O at BJL/BJLA Rev 2
Forced Draft normal condition) in the Primary Reformer to suck the flue gases to the stack. Two
Combustion Air Preheater Coil, 101-BC P2B-10-02-EF-62D104A-
Fan and Forced Draft Fans, 101-BJ1/BJ1A are also provided to supply combustion air which is
Induced Draft preheated using flue gases and sent to the Arch Burners, 101-BBA, Superheat Steam Turbine Driver for 101- R/ Rev 2
Fan Burners, 101-BBS/BBSA and Tunnel Burners, 101-BBT. P2B-10-02-EF-62D105-R/
BJ1/BJ1A, 101-BJ1T/BJ1AT Rev 2
Forced Draft Fan, 101-BJ1/BJ1A P2B-10-02-EF-62D106-R/
Norm. Press. (suction/ Discharge): 539/ Rev 2
2
181 kg/cm G
Norm. Temp. (suction/ Discharge): 35/
20
Steam Turbine Driver for 101-BJ/BJA,
101-BJT/BJAT
DT: 420 degC
2
DP: 52 kg/cm G
Induced Draft Fan, 101-BJ/BJA
Reformer Furnace Stack, 101-BL
12. The overhead gas from CO2 Absorber is preheated in the Methanator Feed Effluent Methanator Feed Effluent Exchanger, P2B-10-02-EF-62D111-R/
Methanator Exchanger, 114-C and Methanator Start-up Heater, 172-C. The gas then flows to the 114-C Rev A
system Methanator, 106-D, where the remaining carbon oxides combine with hydrogen over a Des./ Oper. Temp. (shell & tube): 457/
P2B-10-02-EF-62D111A-
nickel catalyst to form water and methane. 344.4 & 457/ 310 degC
Des./ Oper. Press. (shell & tube): 39.22/ R/ Rev 2
2
The Methanator effluent is cooled by heat exchange with Methanator feed and cooling 35.8 & 39.93/ 36.4 kg/cm G
water and then further cooled by ammonia refrigerant to about 4 degC. The
condensate is separated in Methanator Effluent Separator, 144-D and then pumped to Methanator Start-up Heater, 172-C
Raw Gas Separator, 142-D1. The gas from overhead of separator is sent to Molecular Des./ Oper. Temp. (shell & tube): 346/ -
Sieve Dryer, 109-DA/DB, and a slip stream is sent as recycle hydrogen under flow 12/ 316 & 530/ -12/ 328 degC
control to Feed Gas Compressor, 102-J. Des./ Oper. Press. (shell & tube): 39.7/
2
36 & 136.4/ 126.57 kg/cm G
Methanator, 106-D
Des./ Oper. Temp.: 457/ 344.4 degC
2
Methanator Effluent Cooler, 115-C
Des./ Oper. Temp. (shell & tube): 200/ -
12/ 84 & 80/ -12/ 43 degC
2
35.8 & 8/ FV/ 4.5 kg/cm G
7 of 18
Methanator Effluent Chiller, 130-C1/C2

28/ 17 & 100/ -12/ 37.2 degC
2
6.5 & 39.8/ 35.3 kg/cm G
Methanator Effluent Separator, 144-D
2
Des./ Oper. Press.: 38.8/ 35 kg/cm G
Process Condensate Pump for 144-D,
122-J/JA
3
Des. Capacity: 3.6+MF m /h
2
13. Molecular The chilled gas from the Methanator Effluent Separator, 144-D flows to the Molecular Molecular Sieve Dryer, 109-DA/DB P2B-10-02-EF-62D112-R/
Sieve Dryer Sieve Dryer, 109-DA/DB containing solid desiccants. Exiting these Dryers the total of Des./ Oper. Temp.: 279/ 245 (Regen.) Rev 2
and water CO2 and NH3 content is reduced to less than 1.0 ppmv, i.e. 0.5 ppmv, 0.3 degC
Cryogenic ppmv, and 0.2 ppmv respectively. Molecular Sieve Dryer Filters, 154-LA/LB are Des./ Oper. Press.: 38.5/ 35/ 1.44 P2B-10-02-EF-62D112A-
2
Purification provided at the Dryer outlets. (Regen.) kg/cm G R/ Rev 2
system Dried raw synthesis gas is cooled to about minus 129 degC in the cryogenic Purifier by Molecular Sieve Dryer Filter, 154-LA/LB P2B-10-02-EF-62D112B-
R/ Rev 2
heat exchanger with make-up syngas and with Purifier vent gas in the upper section of Des./ Oper. Temp.: 275/ -12/ 4 - 245
the plate fin exchanger, 132-C. The gas then flows through a turbo expander, 131-JX, degC P2B-10-02-EF-62D112C-
where energy is removed to develop the net refrigeration required to the Purifier. Des./ Oper. Press.: 38.7/ 24.73 R/ Rev 2
Expander energy is recovered by generating electricity in 131-JG, which will be 2
kg/cm G
connected to 2.4 kV MCC 61A. The expander effluent is further cooled to about minus Purifier Feed Cold Box Package, 137-L
173 degC and partially condensed in the lower section of 132-C and then enters the
Purifier Rectifier column, 137-D. Liquid from the bottom of the rectifier is partially Purifier Feed/ Effluent Exchanger, 132-
evaporated at reduced pressure in the shell side of the Rectifier Overhead Condenser, C
134-C. This cools the rectifier overhead and generates reflux for the rectifier. The
rectifier bottoms contain the excess nitrogen, all of the methane and about 60 percent Purifier Rectifier, 137-D
of inlet flowrate of the argon. The partially evaporated liquid leaving the shell side of Des./ Oper. Temp.: 65/ -195/ Hold degC
2
the rectifier overhead condenser is reheated and vaporised by exchange with the Des./ Oper. Press.: 38.7/ Hold g/cm G
Purifier feed and then leaves the Purifier as waste gas. Purifier Rectifier Condenser (Integral
The make-up syngas from the top of the rectifier overhead condenser is reheated by
with 137-D), 134-C
exchange with Purifier feed to about 1.8 degC and sent to the Syngas Compressor. Purifier Expander/ Generator, 131-
As this Node contains a package Purifier Feed Cold Box Package (137-L) (including
JX/JG
2
expander 131-JX), detail HAZOP can be carried out with the package Vendor Suct./ Disch.: 34.42/ 32. 62 kg/cm G
representative only. Nor. Temp.: Hold
8 of 18
14. Dryer The regeneration facilities are designed for about 20-hour cycle to provide a Molecular Sieve Dryer, 109-DA/DB P2B-10-02-EF-62D112-R/
Regeneration comfortable safety margin as the drying cycle works on a 24 hour cycle basis. Des./ Oper. Temp.: 279/ 245 (Regen.) Rev 2
System Regeneration and cooling of the Dryers are done with dry vent gas from the Purifier, degC
heated to 245 degC in the syngas Dryer Regeneration Heater, 183-C by MP steam. Des./ Oper. Press.: 38.5/ 35/ 1.44 P2B -10-02-EF-62D130-R/
2G Rev 2
(Regen.) kg/cm
During startup or when waste gas from Purifier is unavailable, a 2-3% side stream of
P2B-10-02-EF-64D106-R/
the fresh makeup gas is used for the regeneration of the molecular sieve. Purifier Waste Gas Filter, 144-L Rev 2
Des./ Oper. Temp.: 275/ -12/ 1.8 - 80
The waste gas is used to regenerate the Syngas Dryers and then burned as fuel in the degC
Primary Reformer. 2
Mol Sieve Regeneration Heater, 183-C
12/ 245 & 420/ -12/ 386 degC
2
1.87 & 51.6/ FV/ 46.9 kg/cm G
15. Synthesis The purified syngas from Purifier Feed/ Effluent Exchanger, 132-C is compressed in Synthesis Gas Compressor, 103-J P2B-10-02-EF-62D113-R/
Gas two stages in the Syngas Compressor, 103-J to about 150 kg/cm2a. Recycle gas is Stage 1 Rev 2
Compressor added to the syngas before the last wheel of the second stage and the combined flow Nor. Press. (Suct./ Disch.): 31.52/ 82. 3
system and leaves the Compressor at about 158 kg/cm2a. 2
G P2B-10-02-EF-62D114-R/
kg/cm
Rev 2
Ammonia Make up and recycle gases from the Syngas Compressor are preheated by exchange Nor. Temp. (Suct./ Disch.): 1.9/ 111
Synthesis degC P2B-10-02-EF-62D115-R/
Converter with the Converter effluent in the Feed/ Effluent Exchanger, 121-C. Syngas Stage 2 Rev 2
Compressor discharge flows to the fixed-bed, horizontal Converter, 105-D. Ammonia Nor. Press. (Suct./ Disch.): 82/ 149.1
2
concentration in the feed to the Converter is about 1.8 mole percent. The effluent from kg/cm G P2B-10-02-EF-64D113-R/
the first bed containing about 10.8 percent ammonia is cooled by heat exchange with Nor. Temp. (Suct./ Disch.): 38/ 113 Rev 2
the feed from the Converter annulus. Heat is recovered from the second bed effluent degC
P2B-10-02-EF-62D102-R/
by preheating the remaining feed to the first bed. Ammonia concentration in the Stage 3
effluent form the second bed is about 16.2 mol percent. Final ammonia concentration Nor. Press. (Suct./ Disch.): 149.1/ 156.9 Rev 2
2
leaving the Converter is about 19.9 percent. kg/cm G
Gas-fired Start-up Heater 102-B is provided for activating a fresh charge of catalyst in Nor. Temp. (Suct./ Disch.): 59/ 65.7
degC
the ammonia Converter and for heating the catalyst up to the temperature at which
reaction is self-sustaining during start-up of the plant. Syn Gas Compressor Interstage Cooler,
116-C
12/ -90 & 80/ 43 degC
2
69.4 & 8/ FV/ 4.53 kg/cm G
Ammonia Converter Feed/ Effluent
Exchanger, 121-C
197 & 210/ 176 degC
2
152.7 & 170/ 156.7 kg/cm G
Ammonia Synthesis Converter, 105-D
2
9 of 18
Ammonia Conv. Bed 1 Interchanger,
122-C1
Ammonia Conv. Bed 2 Interchanger,
122-C2
Start-up Heater 102-B

Des./ Oper. Press.: 152.7/ 156.4
2
kg/cm G
16. Unitized The effluent from the Converter is cooled in Ammonia Converter Effluent/ Steam Ammonia Converter Effluent/ Steam P2B-10-02-EF-62D113-R/
Chiller system Generator, 123-C1 and Ammonia Converter Effluent/ BFW Preheater, 123-C2. It is Generator, 123-C1 Rev 2
then cooled by exchange with fresh make up syngas from the Syngas Compressor Des./ Oper. Temp. (shell & tube): 400/ -
P2B-10-02-EF-62D114-R/
discharge in Feed/ Effluent Exchanger, 121-C. The Converter effluent gas is further 12/ 446 & 358/ -12/ 328 degC
cooled in Ammonia Converter Effluent Cooler, 124-C1/C2 and further cooled and Des./ Oper. Press. (shell & tube): 170/ Rev 2
2
condensed in the Ammonia Unitized Chiller, 120-C. The condensed gas exit 153.6 & 142.5/ FV/ 126.5 kg/cm G P2B-10-02-EF-62D115-R/
temperature of the Unitized Chiller is minus 17.8 degC, with the liquid ammonia Rev 2
product disengaged from the synthesis gas in Ammonia Separator, 146-D immediately Ammonia Converter Effluent/ BFW
downstream of the exchanger. Preheater, 123-C2. P2B-10-02-EF-62D116A-
Recycle vapor from the ammonia separator, containing about 2.63 mole percent Des./ Oper. Temp. (shell & tube): 358/ - R/ Rev 2
12/ 292 & 370/ -12/ 344 degC
ammonia is reheated in the Unitized Chiller. The reheated recycle vapor is directed to Des./ Oper. Press. (shell & tube): 142.5/ P2B -10-02-EF-62D116-R/
2
the synthesis gas Compressor and recirculated for reuse as feed to the Converter. FV/ 125.62 & 170/ 153.26 kg/cm G Rev 2
The purge gas stream from Ammonia Separator, 146-D flows to the HP Ammonia P2B-10-02-EF-62D119-R/
Scrubber, 124-D, for recovery and removal of the ammonia. Feed/ Effluent Exchanger, 121-C Rev 2
197 & 210/ 176 degC P2B-10-02-EF-62D127-R/
Des./ Oper. Press. (shell & tube): 142.5/ Rev 2
2
FV/ 125.62 & 170/ 153.26 kg/cm G
Ammonia Converter Effluent Cooler,
124-C1/C2
12/ 89 & 80/ -12/ 43 degC
2
153.16 & 8/ FV/ 4.53 kg/cm G
Ammonia Unitized Chiller, 120-C
40/ 33 & 65/ -28/ 38/ 17.8 degC
2
6.32 & 170/ 149.1 kg/cm G
Synthesis Gas Compressor, 103-J
Stage 3
Nor. Press. (Suct./ Disch.): 149.1/ 156.9
2
kg/cm G
Nor. Temp. (Suct./ Disch.): 59/ 65.7
degC
10 of 18
Ammonia Separator, 146-D
Des./ Oper. Temp.: 65/ -33/ -18 degC
2
17. Ammonia Ammonia is condensed from the converter effluent stream by chilling with ammonia Ammonia Unitized Chiller, 120-C P2B-10-02-EF-62D114-R/
Refrigeration refrigerant at four levels in Ammonia Unitized Chiller, 120-C. The ammonia vapours Des./ Oper. Temp. (shell & tube): 65/ - Rev 2
system from the four refrigeration levels are routed to Ammonia Refrigerant Compressor, 105- 40/ 33 & 65/ -28/ 38/ 17.8 degC
J. The Refrigerant Compressor also processes the ammonia vapor from the Des./ Oper. Press. (shell & tube): 15.8/ P2B -10-02-EF-62D116-R/
2
Methanator Effluent Chiller, 130-C1/C2. The ammonia vapor is ultimately compressed 6.32 & 170/ 149.1 kg/cm G Rev 2
and condensed in a CW cooled Ammonia Condenser, 127-C, and goes to the warm P2B-10-02-EF-62D116A-
section of the Refrigerant Receiver, 149-D. 1st Stage Refrigerant Flash Drum, 120- R/ Rev 2
CF1
The small amount of non-condensable gas from the Refrigerant Receiver, 149-D goes
Des./ Oper. Temp.: 65/ (-40)/ -33.3 P2B-10-02-EF-62D117-R/
to the LP Scrubber in the ammonia recovery system, where ammonia is washed out degC Rev 2
2
with water. The liquid ammonia from the cold section of the Refrigerant Receiver, 149- Des./ Oper. Press.: 15.8/ 0.00 kg/cm G
P2B-10-02-EF-62D118-R/
D is used as refrigerant. The cold ammonia product is drawn from the cold section of
the unitized exchanger and is sent to ammonia storage via the Cold Ammonia Product 2nd Stage Refrigerant Flash Drum, 120- Rev 2
Pump, 124-J/JA. The warm ammonia product is drawn from the warm section of 149- CF2 P2B-10-02-EF-62D118A-
D and pumped via the Warm Ammonia Product Pump, 113-J/JA to the battery limit for Des./ Oper. Temp.: 65/ (-29)/ -18.5 R/ Rev 2
urea production. degC
Liquid ammonia from 146-D is depressurized and flashed to a pressure of 19 kg/cm2a 2 P2B-10-02-EF-62D118B-
R/ Rev 2
in the Ammonia Letdown Drum, 147-D. The flashed vapor, primary dissolved 3rd Stage Refrigerant Flash Drum, 120-
synthesis gas, is mixed with the refrigeration system purge gas and sent to the LP CF3 P2B -10-02-EF-62D119-R/
Ammonia Scrubber, 123-D. The remaining ammonia product is then split into streams Des./ Oper. Temp.: 65/ (-29)/ -4.5 degC Rev 2
2
leading to the ammonia refrigeration system Unitized Chiller 120-C, and the ammonia Des./ Oper. Press.: 15.8/ 2.66 kg/cm G P2B-10-02-EF-62D128-R/
Refrigerant Receiver, 149-D. The washed gas stream exit 123-D is sent to the fuel Rev 2
system. 4th Stage Refrigerant Flash Drum, 120-
CF4
Des./ Oper. Temp.: 65/ (-29)/ 14.7 degC
2
Ammonia Refrigerant Compressor, 105-
J
Nor. Press. (Suct./ Disch.): 0/ 15.7
2
kg/cm G
Nor. Temp. (Suct./ Disch.): -33/ 99
degC
Refrigerant Compressor 3rd Stage
Intercooler, 128-C
12/ 88 & 80/ -12/ 43 degC
2
6.68 & 8/ FV/ 4.53 kg/cm G
Ammonia Injection Pump, 120-J
3
2
Suct./ Disch.: 15.55/ 111.68 kg/cm G
11 of 18
Refrigerant Condenser, 127-C

29/ 99 & 80 / 35 degC
2
15.2 & 8/ FV/ 4.53 kg/cm G
Refrigerant Receiver, 149-D
Des./ Oper. Temp.: 100/ -33/ -17 to 38
degC
2
Warm Ammonia Product Pump, 113-
J/JA
3
2
Cold Ammonia Product Pump, 124-J/JA
3
2
Ammonia Letdown Drum, 147-D
Des./ Oper. Temp.: 65/ -33/ -17.2 degC
2
18. Loop HP purge gas stream from synthesis loop is fed to the HP Ammonia Scrubber, 124-D HP Ammonia Scrubber, 124-D P2B-10-02-EF-62D127-R/
Purge and LP flash gas stream is fed to a separate LP Ammonia Scrubber, 123-D. In 123-D Des./ Oper. Temp.: 70/ -33/ 18 (top)/ 6 Rev 2
Ammonia and 124-D, ammonia in the gas streams is recovered as an aqueous ammonia (bottom) degC
Recovery solution. The combined aqua solution from both columns is fed to the Ammonia 2
G P2B-10-02-EF-62D128-R/
Des./ Oper. Press.: 94.8/ 85.9 kg/cm
Rev 2
system Distillation Column, 125-D, which is reboiled by MP steam. The recovered overhead
including ammonia vapour is combined with the main refrigerant ammonia stream going to the LP Ammonia Scrubber, 123-D P2B-10-02-EF-64D106-R/
Ammonia Ammonia Condenser, 127-C. The reflux for distillation column, 125-D is taken from the Des./ Oper. Temp.: 90/ -33/ 60/ -17.2 Rev 2
Distillation discharge of Warm Ammonia Product Pump, 113-J/JA. degC
2
Column Des./ Oper. Press.: 17.5/ 14 kg/cm G P2B-10-02-EF-64D106A-
Warm Ammonia Product Pump, 160- R/ Rev 2
J/JA
3
2
Ammonia Distillation Column, 125-D
Des./ Oper. Temp.: 260/ 65 (top)/ 211
(bottom) degC
Des./ Oper. Press.: 22.4/ FV/ 18.9
2
kg/cm G
Ammonia Distillation Column Reboiler,
160-C
122/ 386 & 260/ -122/ 211 degC
12 of 18
2
FV/ 45.4 & 24/ FV/ 19 kg/cm G
Ammonia Distillation Column Feed/
Effluent Exchanger, 161-C1/C2
161.3 & 241.1/ 213.7 degC
2
FV/ 22 & 21/ FV/ 20 kg/cm G
HP Ammonia Scrubber Feed Pumps,
161-J/JA
Design Capacity: 1.23 (min)/ 1.48 (max)
3
m /h
2
19. LTS Reduction of LTS is accomplished using hydrogen rich gas from 142-D1/D2 mixed in a LTS Start-up Heater, 175-C P2B-10-02-EF-62D102A-
Reduction nitrogen carrier gas using LTS Start-up Heater, 175-C for temperature control and LTS Des./ Oper. Temp. (shell & tube): 275/ - R/ Rev 2
system Start-up Blower, 173-J for closed loop circulation. 12/ 205 & 420/ -12/ 386 degC
2
The reduction as well as heating of LTS can be carried out with both the reactors in 4.22 & 52/ FV/ 45.97 kg/cm G
line or individually also. LTS Start-up Blower, 173-J
The carrier gas and hydrogen flows through the LTS with the temperature, pressure
Nor. Press. (Suct./ Disch.): 5.97/ 7.27
2
and mass spectrometer analyzer available. The gas exiting is directed to LTS Start-up kg/cm G
Cooler, 173-C, where it is cooled with cooling water. The flow is then directed to LTS Nor. Temp. (Suct./ Disch.): 40/ 73 degC
Reduction System K. O. Drum, 173-D, where water that was condensed will be
knocked out. 173-D exit will direct the gas to LTS Start-up Blower, 173-J. This motor- LTS Start-up Cooler, 173-C
driven circulator provides the circulation for LTS reduction. The circulator cooling is Des./ Oper. Temp. (shell & tube): 275/ -
done against cooling water. 12/ 235 & 80/ 43 degC
Des./ Oper. Press. (shell & tube): 11/ 4
2
& 8/ FV/ 4.5 kg/cm G
LTS Reduction System K. O. Drum,
173-D
2
Des./ Oper. Press.: 8.4/ 4 kg/cm G
20. OASE OASE solution is poured manually into OASE Solution Sump Tank, 115-F. DM water OASE Solution Sump Tank, 115-F P2B-10-02-EF-62D124-R/
solution connection as well as OASE Solution Mixer, 110-L are available for dilution. The Des./ Oper. Temp.: 100/ 35 degC Rev 2
storage/ sump diluted OASE solution is pumped by OASE Sump Pump, 115-J through OASE Sump Des./ Oper. Press.: ATM/ ATM
P2B-10-02-EF-62D125-R/
system Filter, 115-L to OASE Solution Storage Tank, 114-F.
OASE Sump Pump, 115-J Rev 2
3
114-F is a nitrogen blanketed tank and releases nitrogen to atmosphere (to safe Design Capacity: 20 m /h P2B-10-02-EF-62D122-R/
2
location). From this tank, the diluted OASE solution is pumped by OASE Solution Suct./ Disch.: -0.08/ 2.88 kg/cm G Rev 2
Transfer Pump, 111-J to the upstream of OASE Solution Filter, 104-L. This tank is
also used for draining the OASE solution from the system during shutdown. The OASE Solution Mixer, 110-L
solution being drained from the system during shutdown may contain some traces of Des./ Oper. Temp.: 100/ 20-100 degC
hydrogen. To avoid possible formation of explosive mixture inside 114-F (which is a Des./ Oper. Press.: ATM/ ATM
very big tank), it is blanketed with nitrogen. OASE Solution Storage Tank, 114-F
This system is generally used only for making up the OASE solution. Also, this is a Des./ Oper. Temp.: 100/ 20-45 degC
13 of 18
manually supervised operation. Des./ Oper. Press.: ATM/ ATM

OASE Solution Transfer Pump, 111-J
3
Design Capacity: 60 m /h
2
Suct./ Disch.: -0.16/ 6.2 kg/cm G
OASE Sump Filter, 115-L
2
21. Chemical All the injection systems are very similar. Every system is having a tank floating with OASE Antiform Injection Pump, 109- P2B-10-02-EF-63D101-R/
Injection atmosphere (high point vent routed to safe location). OASE Antifoam Injection Tank is LJ/LJA Rev 2
3
system provided with OASE lean solution for dilution and the other tanks are provided with DM Design Capacity: 5 m /h 2 P2B-10-02-EF-62D120B-
(OASE water connection for dilution. The tanks are provided with local level gauges. From the Suct./ Disch.: Hold/ 7.24 kg/cm G
R/ Rev 2
Antifoam tank, solution is pumped by metering pumps to unit. PRVs are provided at the pump
injection, discharges and routed to the suction of the pump. All the discharge lines are provided Antifoam Injection Tank, 109-LF P2B-10-02-EF-62D122-R/
Phosphate with NRV at the joining point in the unit. Rev 2
injection, Agitator for 109-LF, 109-LL
All the injection systems are Vendor package items.
Ammonia P2B-10-02-EF-62D122A-
injection, pH Control Injection Pump, 107-LJ/LJA R/ Rev 2
3
Oxygen Design Capacity: 35 m /h
Scavenger 2
G P2B-10-02-EF-64D106-R/
Suct./ Disch.: Hold/ 7.5 kg/cm
injection) Rev 2
pH Control Injection Tank, 107-LF
Phosphate Injection Pump, 108-LJ/LJA
3
2
Suct./ Disch.: Hold/ 145 kg/cm G
Phosphate Injection Tank, 108-LF
2
Des./ Oper. Press.: Hold kg/cm G
Agitator for 108-LF, 108-LL
Oxygen Scavenger Injection Pump,
106-LJ/LJA
3
2
Suct./ Disch.: Hold/ 7.5 kg/cm G
Oxygen Scavenger Tank, 106-LF
22. Water Condensate from 102-JTC is pumped by Condensate Pump for 102-JTC, 119-J/JA Condensate Pump for 103-JTC, 123- P2B-10-02-EF-64D105A-
Jackets for under level control of the condenser boot. To this line, condensate from Condensate J/JA R/ Rev 2
3
Primary Pump for 103-JTC, 123-J/JA and Condensate Pump for 101-JTC, 118-J/JA also joins. Design Capacity: 30 m /h
Reformer The combined flow pass through Condensate Filter, 112-L, and then part of it flows to 2
G P2B-10-02-EF-64D105C-
Suct./ Disch.: -0.614/ 8 kg/cm
R/ Rev 2
(107-D) Secondary Reformer (Water Jacket), 103-D under level control. The other part flows to
effluent the Primary Reformer Effluent Transfer Line (Water Jacket), 107-D under level control. Condensate Pump for 101-JTC, 118- P2B-10-02-EF-64D105D-
transfer line J/JA
3 R/ Rev 2
and The jackets are generally in filled condition. The loss due to vaporization is made up Design Capacity: 134.34 m /h
Secondary 2 P2B-10-02-EF-64D105E-
Suct./ Disch.: -0.628/ 8 kg/cm G
14 of 18
Reformer under level control. R/ Rev 2
(103-D) Surface Condenser for 102-J and 104-
P2B-10-02-EF-64D105F-
JTC, 102-JTC
Des./ Oper. Temp. (shell & tube): 150/ R/ Rev 2
49.4 & 80/ 42.3 degC P2B-10-02-EF-64D109-R/
Des./ Oper. Press. (shell & tube): 811.7/ Rev 2
FV/ -671.73 & 5902.9/ FV/ 2043.9
mmHg
Condensate Pump for 102-JTC, 119-
J/JA
3
2
Condensate Filter, 122-L
3
2
Primary Reformer Effluent Transfer Line
(Water Jacket), 107-D
Des./ Oper. Press.: 44.4/ 39.77
2
kg/cm G
Secondary Reformer (Water Jacket),
103-D
Des./ Oper. Temp.: 516 (upper)/ 205
(lower) degC
Des./ Oper. Press.: Full Water/ Full
Water
23. Fuel gas Waste gases from Purifier, LP/ HP Ammonia Scrubber (under PV-1038A/ FV-1029 Arch Burners, 101-BBA P2B-10-02-EF-64D111-R/
system to control), HP Flash Column (under PV-1039B control) flows into header. From this Tunnel Burners, 101-BBT Rev 2
Primary header, waste gases flow to the Arch Burners, 101-BBA.
P2B-10-02-EF-64D112-R/
Reformer
Arch Burners Fuel gas from Feed Gas KO Drum, under PV-1001A/B control, and further controlled Superheat Burners, 101-BBS/BBSA Rev 2
(101-BBA), by PV-1002B/A flows to the Arch Burners, 101-BBA with individual HVs for each P2B-10-02-EF-64D114-R/
Primary Burner. Rev 2
Reformer
Fuel gas from Feed Gas KO Drum, under PV-1001A/B control, and further controlled
Tunnel P2B-10-02-EF-64D115-R/
Burners (101- by PV-4143 flows to the Tunnel Burners, 101-BBT. Rev 2
BBT) and Fuel gas from Feed Gas KO Drum, under PV-1001A/B control, and further controlled
Primary
Reformer by TV-1005 flows to the Superheat Burners, 101-BBS/BBSA.
Superheat From the upstream of TV-1005, fuel gas flows to the pilot burners of the Superheat
Burners (101-
BBS/BBSA) Burners under pressure control.
15 of 18
24. Steam Condensate from the turbine flows to Lean Solution/ Demin Water Preheater, 109-C, Lean Solution/ Demin Water Preheater, P2B-10-02-EF-62D123-R/ All surface
system where it is getting heated up by lean solution and then flows to LTS Effluent/ Demin 109-C Rev 2 condensers are
Water Exchanger, 106-C, where it is heated up by LTS effluent and then flows to Des./ Oper. Temp. (shell & tube): 120/ similar in design and
P2B-10-02-EF-62D109-R/
Deaerator, 101-U. DM water is also flowing from battery limit under the level control of 88.3 & 80/ 50.5 degC control. HAZOP on
Deaerator. This line joins at the upstream of Lean Solution/ Demin Water Preheater, Des./ Oper. Press. (shell & tube): 5.3/ Rev 2 Surface Condenser
2
109-C. FV/ 1.25 & 15.5/ FV/ 7 kg/cm G P2B-10-02-EF-64D106-R/ for 103-JT, 103-JTC
Rev 2 is done. Hence this is
There is a LP Steam line joining to Deaerator under pressure control of the Deaerator. LTS Effluent/ Demin Water Exchanger, applicable for all other
Oxygen scavenger is also added to Deaerator. 106-C P2B-10-02-EF-64D106A- Surface Condensers.
The deaerated water from Deaerator is pumped by HP BFW Pump, 104-J/JA to LTS Des./ Oper. Temp. (shell & tube): 150/ - R/ Rev 2 101-JT, 104-JT, 102-
12/ 120 & 80/ -12/ 136 degC
Effluent/ BFW Preheater, 131-C (tube side), where it is heated up by LTS effluent. Part Des./ Oper. Press. (shell & tube): 10.1/ P2B -10-02-EF-62D114-R/ JT are all of
2
of the outlet from 131-C flows to Ammonia Converter Effluent/ BFW Preheater FV/ 8.7 & 42.8/ 37 kg/cm G Rev 2 condensing type
Exchanger, 123-C2 and Ammonia Converter Effluent/ Steam Generator, 123-C1 in P2B-10-02-EF-62D108-R/ turbines, hence
series, where it is heated up by ammonia converter effluent, and flows to Steam Drum, Deaerator, 101-U Rev 2 HAZOP carried out
141-D. The other part of the outlet from 131-C flows to HTS Effluent BFW Preheater, Des./ Oper. Temp.: 260/ 130.1 degC for 101-JT is
103-C2 and HTS Effluent Steam Generator, 103-C1 and then it flows to Steam Drum, Des./ Oper. Press.: 4/ FV/ 4/ 1.73 P2B-10-02-EF-64D101-R/ applicable for 104-JT
141-D. 2 Rev 2 and 102-JT also.
kg/cm G
Steam Drum has the facility for blowdown through Blowdown Cooler and Blowdown HP BFW Pump, 104-J/JA P2B -10-02-EF-62D107-R/ 101-BJ1T HAZOP is
3
Drum. From the Blowdown Drum, 186-D, LP steam generated flows to the LP steam Design Capacity: 470.12 m /h Rev 2 carried out. This is
2
header and the water flows under level control through Blowdown Cooler, 191-C to Suct./ Disch.: 2.93/ 132.5 kg/cm G P2B-10-02-EF-64D102-R/ similar to 101-BJT,
cooling tower basin, or to check pit through WW header. Rev 2 107-JBT, 108-JT,
LTS Effluent/ BFW Preheater, 131-C 101-JLT and 103-JLT.
Steam from the Steam Drum flows to HP Steam Superheater, 102-C, where it is Des./ Oper. Temp. (shell & tube): 275/ P2B-10-02-EF-62D111-R/ Hence HAZOP
heated by the effluent from the Secondary Reformer. The heated steam from 102-C 279.8 & 250/ 174.75 degC Rev A carried out for 101-
flows to Superheater SSH Coil, 101-BCS1. The outlet from the coil is desuperheated Des./ Oper. Press. (shell & tube): 42.8/ BJ1T is applicable to
(whenever required, however a small flow is kept always) by the water pumped from
2
37.3 & 171/ 140.25 kg/cm G P2B -10-02-EF-64D108-R/ these turbines also.
Deaerator, 101-U by HP BFW Pump, 104-J/JA under temperature control (TV-1553). Rev 2
The desuperheated steam is further heated in Hot Steam Superheat Coil, 101-BCS2 Ammonia Converter Effluent/ BFW P2B-10-02-EF-64D107-R/
and flows to Steam Turbine for 105-J, 105-JT and Steam Turbine for 103-J, 103-JT. Preheater Exchanger, 123-C2 Rev 2
Whenever required, the steam from the header is desuperheated with the same Des./ Oper. Temp. (shell & tube): 358/ -
deaerated water pumped by 104-J/JA to make MP steam and flows to the MP steam 12/ 292 & 370/ -12/ 344 degC P2B-10-02-EF-64D105-R/
header. Des./ Oper. Press. (shell & tube): 142.5/ Rev 2
2
Steam flows to 105-JT, which then flows to the MP steam header. Leakage from the FV/ 125.62 & 170/ 153.26 kg/cm G P2B -10-02-EF-64D103-R/
turbine flows to LP steam header. Ammonia Converter Effluent/ Steam Rev 2
Steam from the outlet of 103-JT flows to Surface Condenser for 103-JT, 103-JTC, Generator, 123-C1 P2B-10-02-EF-64D104-R/
where it is cooled by cooling water. The condensate from the boot of Surface 12/ 446 & 358/ -12/ 328 degC Rev 2
Condenser is pumped by Condensate Pump, 123- J/JA under level control of the boot Des./ Oper. Press. (shell & tube): 170/ P2B-10-02-EF-64D105B-
2
to Condensate Filter, 112-L, and then to 109-C as described in the first paragraph. MP 153.6 & 142.5/ FV/ 126.5 kg/cm G R/ Rev 2
steam from 103-JT flows to the MP steam header. This 103-JT is an extraction cum
condensation type turbine. LP steam from the header flows to the turbine condensers Steam Drum, 141-D P2B-10-02-EF-64D105F-
ejectors (101-JTC, 103-JTC, 102-JTC, 6209-JTC). Des./ Oper. Temp.: 358/ -12/ 328 degC R/ Rev 2
Des./ Oper. Press.: 139.9/ FV/ 126.5 P2B-10-02-EF-64D108B-
2
From MP steam header, steam flows to 101-JT, 104-JT, 102-JT and 6209-JAT/JBT kg/cm G
(CW Turbine), and also to Process Condensate Stripper, 130-D. The condensate from R/ Rev 2
the turbines flows to individual condensers, and the condensate is pumped by P2B-10-02-EF-64D108A-
dedicated condensate pumps to Condensate Filter, 112-L or to water treatment unit. R/ Rev 2
16 of 18
From the same MP steam header, number of backpressure turbines (101- HTS Effluent BFW Preheater, 103-C2 P2B-10-02-EF-64D108C-
BJ1T/BJ1AT, 101-BJT/BJAT, 107-JBT, 108-JT, 101-JLT, 103-JLT) are operating and Des./ Oper. Temp. (shell & tube): 343/ R/ Rev 2
the LP steam from the turbines join the LP steam header. Excess LP steam is injected 286.4 & 358/ 257.8 degC
to 101-JT. Des./ Oper. Press. (shell & tube): 42.8/ P2B-10-02-EF-64D108D-
Similar to 103-JT, condensate from 101-JT and 105-JT are also cooled and the 2 R/ Rev 2
38.2 & 125/ FV/ 126.57 kg/cm G
P2B-10-02-EF-64D108E-
condensates are also pumped to the Condensate Filter, 112-L. HTS Effluent Steam Generator, 103-C1
MP steam from header flows to Steam Turbine for 101-J, 101-JT. LP steam from Des./ Oper. Temp. (shell & tube): R/ Rev 2
475/0/431 & 410/ 0 degC P2B-10-02-EF-64D108F-
header is also sent to the turbine through a flow element. The condensate from the Des./ Oper. Press. (shell & tube):
2 R/ Rev 2
turbine flows to Surface Condenser for 101-JT, 101-JTC. The Condenser is also 4142.5/ FV/ 126.57 kg/cm G
provided with Vacuum Jets & Inter/ After Condenser for 101-JTC, 101-JCC. From the P2B-10-02-EF-64D108G-
boot of the Condenser, the condensate is pumped by Condensate Pump for 101-JTC, HP Steam Blowdown Drum, 186-D R/ Rev 2
118-J/JA to the Condensate Filter, 122-L/ Deaerator, 101-U. Des./ Oper. Temp.: 220/ 149.3 degC
Des./ Oper. Press.: 5.5/ FV/ 3.73 P2B -10-02-EF-64D108I-R/
2
G Rev 2
kg/cm
Blowdown Cooler, 191-C P2B-10-02-EF-64D108H-
R/ Rev 2
12/ 149.3 & 75/ -12/ 43 degC
Des./ Oper. Press. (shell & tube): 7/ FV/
2
3.76 & 8/ FV/ 4.5 kg/cm G
HP Steam Superheater, 102-C
Des./ Oper. Temp. (shell & tube):
410/371 & 420/-12/338 degC
2
42.8/38.4 & 139.9/FV/ 123 kg/cm G
Superheater SSH Coil, 101-BCS1
Des./ Oper. Press.: 139.9/ Hold
2
kg/cm G
Hot Steam Superheat Coil, 101-BCS2
Des./ Oper. Press.: 139.9/ Hold
2
kg/cm G
Steam Turbine for 103-J, 103-JT
Des./ Oper. Temp.: 136.4/ 123.1 degC
2
Des./ Oper. Press.: 510 kg/cm G
Des./ Oper. Press.: 136.4/ 123.1
2
kg/cm G
Des./ Oper. Temp.: 410/ 387.9 degC
2
17 of 18
Surface Condenser for 103-JT, 103-JTC

69.1 & 80/ 42.3 degC
FV/ -535 & 5902.9/ FV/ 2043.9 mmHg
Surface Condenser for 101-JT, 101-JTC

49.5 & 80/ 42.3 degC
FV/ -669.53 & 5902.9/ FV/ 2043.9
mmHg
Vacuum Jets & Inter/ After Condenser
for 101-JTC, 101-JCC

Condensate Pump for 101-JTC, 118-
J/JA
3
2
25. Water Condensate from the jackets is drained to a drain header and flows to the Water Water Jacket Overflow Recovery Pit, P2B-10-02-EF-64D109A-
Jacket Jacket Overflow Recovery Pit, 1001-AD, which is covered and below the ground. From 1001-AD R/ Rev 2
Overflow this pit, condensate is pumped by Condensate Jacket Overflow Pump, 1001-J/JA to Des./ Oper. Temp.: 130/ 100 degC
Recovery Ammonia Cooling Tower Basin. These pumps are provided with autostart/ autostop Des./ Oper. Press.: Full liquid/ ATM
system facility on high level/ low level of the Recovery Pit. Condensate Jacket Overflow Pump,
1001-J/JA
3
2
Suct./ Disch.: 0/ 3.57 kg/cm G
26. Oily Drain Oily drains from unit flows to Oily Drain Drain Pit, 1002-AD, which is covered and sited Oily Drain Drain Pit, 1002-AD P2B-10-02-EF-64D122-R/
system below the ground. It has a compartment to separate the oil and water. From this pit, Des./ Oper. Temp.: 70/ 30 degC Rev 2
oily water is pumped by Oily Water Pump, 1002-J to waste water header. The pump is Des./ Oper. Press.: Full liquid/ ATM
provided with autostart/ autostop facility on high level/ low level of the Oily Drain Pit. Oily Water Pump, 1002-J
3
From the Oily Drain Pit, oil overflows to the oily compartment, where from it is Design Capacity: 5 m /h
collected in drums using a portable pump. 2
27. Chemical Chemical drains/ OASE spill from the unit flows by gravity to OASE Chemical Waste OASE Chemical Waste Pit, 1003-AD P2B-10-02-EF-64D121-R/
Waste/ OASE Pit, 1003-AD, which is covered and sited partially below the ground. From this pit, it is Des./ Oper. Temp.: 70/ 30 degC Rev 2
Spill system pumped by OASE Chemical Waste Pump, 1003-J/JA to waste water header. The Des./ Oper. Press.: Full liquid/ ATM
pump is provided with autostart/ autostop facility on high level/ low level of the OASE OASE Chemical Waste Pump, 1003-
Chemical Waste Pit.
J/JA
3
2
18 of 18
JOB NO. : 12-1812/ BA1066 REV
DOC. NO. : 2
APPENDIX 3 – HAZOP WORKSHEET

Appendix 3 – HAZOP Worksheets
Unit: Pusri-IIB Project
Node: 1. Feed Gas from Battery Limit to Feed Gas Knockout Drum and to Feed Gas Compressor
Drawing: P2B-10-02-EF-62D102-R/ Rev 2; P2B-10-02-EF-62D102B-R/ Rev 2; P2B-10-02-EF-62D103A-R/ Rev 2; P2B-10-02-EF-62D110-R/ Rev 2
Deviation Causes Consequences Safeguards Recommendations Responsibility
1. No/ Low Flow 1. No Flow of NG supply 1.1. Potential loss of suction to Feed Gas 1.1.1. FIC-1130A (surge control) provided to 1. Review the requirement of Rekayasa/
from B/L to Feed Gas K. O. Compressor (102-J) leading to possible open FV-1130 to maintain the flow to the Feed providing a low pressure alarm Compressor
Drum (174-D) surging and consequential damage. Gas Compressor (102-J) through Kickback with low low pressure interlock at Vendor
Cooler (143-C). However, as gas will be going to suction of Feed Gas Compressor
the fuel gas header, this will result in loss of (102-J) to trip the Feed Gas
suction to the machine and damage. Compressor.
1.1.2. PT-6171 is provided on the suction of
Feed Gas Compressor (102-J).
1.2. Loss of supply of NG to Desulfurizer 1.2.1. FIC-1130A (surge control) provided to 216. Consider the closure of FV- Rekayasa/
(108-DA/DB) and Reformers (101-B/103-D). open FV-1130 to maintain the flow to the Feed 1703 and FV-1022 in the event of Compressor
Potential overheating and damage of Gas Compressor (102-J) through Kickback FSLL-1201 initiation from the Vendor
Reformer tubes. Cooler (143-C). However, as gas will be going to interlock.
the fuel gas header, this will result in loss of
Refer to Node 23 for impact on Burners. suction to the machine and damage.
1.2.2. Steam flow to the reformer tubes
continues and hence no damage is expected.
1.2.3. FSLL-1201 (2oo3) (mixed feed) is
provided on the NG feed line to reformer with
interlock I-101J bring the reformer to minimum
firing.
2. Less flow of fuel gas to 2.1. Potential loss of suction to Feed Gas 2.1.1. FIC-1130A (surge control) provided to 1. Review the requirement of Rekayasa/
Feed Gas K. O. Drum Compressor (102-J) leading to possible open FV-1130 to maintain the flow to the Feed providing a low pressure alarm Compressor
(174-D) from B/L or surging and consequential damage. Gas Compressor (102-J) through Kickback with low low pressure interlock at Vendor
plugging of suction strainer Cooler (143-C). However, as gas will be going to suction of Feed Gas Compressor
of Compressor the fuel gas header, this will result in loss of (102-J) to trip the Feed Gas
suction to the machine and damage. Compressor.
2.1.2. PT-6171 is provided on the suction of
Feed Gas Compressor (102-J).
2.2. Loss of supply of NG to Desulfurizer 2.2.1. FIC-1130A (surge control) provided to 1. Review the requirement of Rekayasa/
(108-DA/DB) and Reformers (101-B/103-D). open FV-1130 to maintain the flow to the Feed providing a low pressure alarm Compressor
Potential overheating and damage of Gas Compressor (102-J) through Kickback with low low pressure interlock at Vendor
Reformer tubes. Cooler (143-C). However, as gas will be going to suction of Feed Gas Compressor
the fuel gas header, this will result in loss of (102-J) to trip the Feed Gas
Refer to Node 23 for impact on Burners. suction to the machine and damage. Compressor.
2.2.2. Steam flow to the reformer tubes continue
and hence no damage is expected.
3. Feed Gas Compressor 3.1. Loss of supply of NG to Desulfurizer 3.1.1. Loss of NG to reformer will lead to 1. Review the requirement of Rekayasa/
1 of 151
(102-J) trip (108-DA/DB) and Reformers (101-B/103-D). reformer going to minimum firing. providing a low pressure alarm Compressor
Potential overheating of Reformer tubes and with low low pressure interlock at Vendor
3.1.2. I-102J interlock, on trip of Compressor will
Feed Gas Pre-heater leading to damage. suction of Feed Gas Compressor
close XV-1201 on feed gas line to Primary (102-J) to trip the Feed Gas
Reformer (101-B) and XV-1212 on process air Compressor.
line to Secondary Reformer (103-D)
3.2. Potential high pressure on the feed gas 3.2.1. NG supply line and Feed Gas K. O. Drum
supply line and Feed Gas K. O. Drum (174- (174-D) are designed for 27.5 kg/cm2G and
D) upstream pressure is not expected to exceed
27.5 kg/cm2G since PRV-4001 (set at 27.5
kg/cm2G) is provided upstream of the NG supply
line.
4. FIC-1130 malfunctions 4.1. Possible damage to the Compressor 2. Compressor Vendor to suggest Rekayasa/
and closes FV-1130 on suitable safeguard (such as Compressor
Compressor kickback line vibration switch and trip) for the Vendor
when required malfunction of the kickback valve
for Feed Gas Compressor (102-J)
when required.
5. No flow of condensate 5.1. Potential overfilling of the Feed Gas KO 5.1.1. LSHH-1227 (2oo3) is provided pn the
from Feed Gas K. O. Drum Drum and possible liquid carryover to Feed Gas KO Drum with interlock I-102J to trip
(174-D) due to LIC-1002 Compressor suction and damage of the Compressor.
malfunctions and closes Compressor.
5.1.2. Suitable filter is provided at upstream of
LV-1002 on condensate
line or solids carryover the Feed Gas KO Drum 174-D to arrest the
from upstream and choking particles carried over to the KO Drum.
the drain line from KO
drum
6. Plugging of demister in 6.1. Potential loss of suction to Feed Gas 1. Review the requirement of Rekayasa/
Feed Gas K. O. Drum Compressor (102-J) leading to possible providing a low pressure alarm Compressor
(174-D) surging and consequential damage. with low low pressure interlock at Vendor
suction of Feed Gas Compressor
(102-J) to trip the Feed Gas
Compressor.
6.2. Potential high pressure in the feed gas 6.2.1. Gas supply line and Feed Gas K. O. Drum
supply line including Feed Gas K. O. Drum are designed for 27.5 kg/cm2G and upstream
pressure is not likely to exceed 27.5 kg/cm2G
since the upstream is provided with PRV-4001
set at 27.5 kg/cm2G.
7. FIC-1703 malfunctions 7.1. Potential loss of hydrogen to 7.1.1. AAH-1107 (sulfur analyzer) is provided on
and closes FV-1703 on desulfurizers resulting in higher sulfur the outlet of desulfurizer.
recycle Hydrogen line to leakage to the reformer.
suction of Feed Gas
2 of 151
Compressor during start-up

2. More/ High 1. More flow of NG to Feed 1.1. Potential increase in feed gas supply to 1.1.1. FIC-1001/ FV-1001 on the NG feed gas
Flow Gas K. O. Drum (174-D) Compressor suction and downstream line will maintain the required flowrate to
from upstream due to any leading to decrease in steam to carbon ratio. reformer.
reason
1.1.2. FFAL-1001 (steam/carbon ratio) is
provided on the NG feed line to reformer.
1.1.3. FFSLL-1201 (steam to carbon ratio) is
provided with interlock I-101 to close XV-1212 on
process air line.
2. More flow of condensate 2.1. Potential overfilling of the Feed Gas KO 2.1.1. LSHH-1227 (2oo3) is provided on the
in the feed gas Drum and possible liquid carryover to Feed Gas K. O. Drum with interlock I-102J to trip
Compressor suction and damage of the Compressor.
Compressor.
3. More flow of condensate 3.1. Potential loss of suction to Feed Gas 1. Review the requirement of Rekayasa/
from Feed Gas K. O. Drum Compressor (102-J) leading to possible providing a low pressure alarm Compressor
(174-D) due to LIC-1002 surging and consequential damage. No with low low pressure interlock at Vendor
malfunctions and opens consequence in the existing burning pit due suction of Feed Gas Compressor
LV-1002 fully on to more flow. (102-J) to trip the Feed Gas
condensate line of KO Compressor.
drum
4. FIC-1703 malfunctions 4.1. Potential increase in recycle hydrogen 4.1.1. PIC-1007 is provided at outlet of
and opens more than supply to Compressor suction resulting in Desulfurizers to maintain the speed of steam
required FV-1703 on lower molecular weight gas to Compressor. turbine.
recycle Hydrogen line to Possible less discharge pressure from
suction of Feed Gas Compressor which in turn will lead to lower
Compressor. capacity for operation of reformer.
Hydrogen line from OEP is
joining recycle hydrogen

line upstream of FV-1703.
5. FIC-1130 malfunctions 5.1. Potential overpressurization of Feed 4. Review the requirement of Rekayasa
and opens FV-1130 more Gas K. O. Drum leading to damage. overpressure protection for the
than required on Feed Gas Knockout Drum (174-
Compressor kickback line D) considering the FV-1130 full
open scenario.
3. Reverse/ 1. Feed Gas Compressor 1.1. FIC-1130/ FV-1130 on the spill back line 3. Check that the increase in Rekayasa
Misdirected (102-J) trip will open and the Compressor will suction pressure of the Feed Gas
Flow experience settle out pressure. As the spill Compressor (102-J) in the event
back is connected to feed gas drum, the of Compressor trip does not
drum will be subjected to settle out pressure exceed the design pressure (27.5
3 of 151
which is higher than design pressure of the kg/cm2G) of the Compressor
feed gas drum. Potential damage the feed suction system (including Feed
gas drum. Gas K. O. Drum).
In the case the suction system
pressure exceeds 27.5 kg/cm2G,

suitable safeguards to be
provided.
2. Reverse flow of feed gas 2.1. Potential overpressurization of nitrogen 2.1.1. Single check valve and one isolation valve
from Compressor header. (normally closed) is provided on the nitrogen line
discharge to nitrogen joining to Compressor discharge. This line is
header used during purging only.
4. More/ High 1. No new issue identified
Pressure
5. Low Pressure 1. No new issue identified
6. More/ High 1. Cooling water failure in 1.1. Potential increase in temperature of 1.1.1. TI-6172A is provided on the discharge of 5. Review the requirement of high Rekayasa/
Temperature Feed Gas Kickback Cooler feed gas to suction of Compressor and in the Compressor. temperature alarm and high high Compressor
(143-C) turn higher temperature in the discharge. temperature interlock to trip Feed Vendor
Possible damage to the compressor. Gas Compressor (102-J) in
However, the severity is expected to be less consultation with the Vendor.
than that of surging.
7. Low 1. No issue identified
Temperature
8. High Level 1. No new issue identified.
Refer No/ Low flow
scenario.
9. Low Level 1. No new issue identified.
Refer to more flow
scenario.
10. Start-up/ 1. Requirement of running 1.1. Potential issues in operation of Feed 1.1.1. Feed Gas Compressor is designed for
Shutdown/ the Compressor with Gas Compressor. running with nitrogen during start-up.
Maintenance nitrogen during start-up for
heating up of front-end
section
2. Maintenance 2.1. Difficulty in draining when one drain 127. Consider to provide two Rekayasa
requirement of control valve is given for FC type. drain valves at the upstream and
valves downstream for control valves of
FC type and one drain valve for
control valve of FO type as
advised by KBR.
4 of 151
This is a global recommendation.
11. Composition 1. Change in the NG 1.1. Potential issues in operation of Feed 1.1.1. Feed Gas Compressor is designed for
change/ composition from upstream Gas Compressor (102-J). maximum CO2 case.
Contamination/ with reference to more
Additional CO2 and less CH4
Phase/ Loss
Phase
12. Utility failure 1. IA failure 1.1. Control valves will go to fail safe
position.
2. Steam failure 2.1. Compressor trip. Refer to No/ Low flow
scenario.
13. Others 1. Tube leak in Feed Gas 1.1. Potential leakage of feed gas into 1.1.1. RD-143C is provided on cooling water
Compressor Kickback cooling water side leading to return line to release the pressure.
Cooler (143-C) overpressurization and damage.
2. High pressure hydrogen 2.1. Possible overpressurization of SG-1500- 147. Review the tie-in connection Rekayasa
from OEP to Feed Gas 2"-B1A2R of hydrogen from OEP (Class D)
Compressor (102-J) to the outlet of Feed Gas K.O
suction through FV-1703 Drum (174-D) (Class B) with
reference to pressurization of the
line.
Node: 2. Feed Gas from Compressor to Feed Preheat Coil and then to Hydrotreater and Desulfurizer including H2 make-up
Drawing: P2B-10-02-EF-62D102B-R/ Rev 2; P2B-10-02-EF-62D103-R/ Rev 2; P2B-10-02-EF-62D105-R/ Rev 2

1. No/ Low Flow 1. No flow of gas from 1.1. No consequence envisaged on the
upstream (e.g. Feed gas Hydrotreater (101-D) and Desulfurizer (108-
Compressor trip) DA/DB).
Impact on Primary Reformer will be studied
in Node 3.
1.2. Potential overheating and damage of 1.2.1. Steam flow to the reformer tubes continue
Reformer tubes. and hence no damage is expected.
2. FIC-1022 malfunctions 2.1. Improper removal of sulfur in 2.1.1. AAH-1004A1/A2 (sulfur analyzer) is
and closes FV-1022 on the Hydrotreater (101-D) and Desulfurizer (108- provided at the outlet of Hydrotreater (101-D).
recycle hydrogen line to the DA/DB) resulting in sulfur break through to
2.1.2. AAH-1107 (sulfur analyzer) is provided at
5 of 151
inlet of Hydrotreater (101- Primary Reformer (101-B) and potential for the outlet of Desulfurizer (108-DA/DB).
D) sulfur and carbon lay down. Potential for
catalyst poisoning.
3. FIC-1001 malfunctions 3.1. Compressor downstream section 3.1.1. FIC-1130A (surge control) provided to
and closes FV-1001 on the including hydrotreater and desulfurizer will open FV1130 at discharge of Feed Gas
feed gas line to Primary be subjected to Compressor shut-off Compressor (102-J) through Kickback Cooler
Reformer (101-B) condition. (143-C).
firing.
3.1.3. PRV-102J (set at 58.3 kg/cm2G) is
provided at the Compressor discharge.
3.1.4. Compressor downstream system is
designed for 58.3 kg/cm2G.
3.2. Potential overheating and damage of 3.2.1. Steam flow to the reformer tubes continue
Reformer tubes. and hence no damage is expected.
3.2.2. FAL-1201A/B/C are available.
firing.
2. More/ High 1. More flow of feed gas 1.1. Improper removal of sulfur in 1.1.1. AAH-1004A1/A2 (sulfur analyzer) is
Flow from the Feed Gas Hydrotreater (101-D) and Desulfurizer (108- provided at the outlet of Hydrotreater 101-D
Compressor (102-J) due to DA/DB) resulting in sulfur break through to
malfunction and opening of Primary Reformer (101-B) and potential for
FV-1001 on NG feed to sulfur and carbon lay down. Potential for the outlet of Desulfurizer (108-DA/DB).
Primary Reformer catalyst poisoning.
2. FIC-1022 malfunctions 2.1. No consequence foreseen for the
and opens FV-1022 more Desulfurizer.
than required on the
2.2. Possible overpressurization of the feed 2.2.1. PRV-SG1014 (set at 58.3 kg/cm2G) is
hydrogen line to the inlet of
Hydrotreater (101-D) gas line to hydrotreater. provided on the recycle hydrogen line.
3. Reverse/ 1. HIC-1107 malfunction 1.1. Potential less flow of feed gas to 1.1.1. FAL-1201A/B/C are available.
Misdirected and opens HV-1107 during reformer leading to damage.
1.1.2. FSLL-1201 (mixed feed) (2oo3) is
Flow normal operation
firing.
6 of 151
1.1.3. FFSHH-1203 (proc. air to feed gas ratio)

(2oo3) is provided with interlock I-101J to bring
reformer to minimum firing.
4. More/ High 1. Plugging of catalyst bed 1.1. Potential higher differential pressure 1.1.1. PDAH-1105A is provided across the
Pressure in Hydrotreater (101-D) leading to less flow of feed gas to hydrotreater.
downstream.
1.1.2. AAH-1004A1/A2 (sulfur analyzer) is
It is possible to run the hydrotreater with provided at the outlet of Hydrotreater (101-D)
high differential pressure as long as the 1.1.3. AAH-1107 (sulfur analyzer) is provided at
sulfur in the outlet of hydrotreater is under the outlet of Desulfurizer (108-DA/DB).
control.
2. Plugging of catalyst bed 2.1. Potential higher differential pressure 2.1.1. PDAH-1105B/C is provided across the
in Desulfurizer (108- leading to less flow of feed gas to Desulfurizer.
DA/DB) downstream.
2.1.2. One Desulfurizer can take the full load
while other is under maintenance.
3. High discharge pressure 3.1. Higher pressure of feed gas to 3.1.1. PRV-102J (set at 58.3 kg/cm2G) is
from the Compressor due downstream. provided at the Compressor discharge.
to malfunction of turbine
speed control
6. More/ High 1. TIC-1305 malfunctions 1.1. Potential high temperature of feed gas 1.1.1. TAH-1323 is provided at the outlet of
Temperature and closes TV-1305 on the to Hydrotreater and Desulfurizer leading to Hydrotreater.
bypass line of Feed damage Hydrotreater and Desulfurizer.
1.1.2. TAH-1307 is provided on the feed gas line
Preheat Coil (101-BCF)
to Primary Reformer (101-B).
7. Low 1. TIC-1305 malfunctions 1.1. Improper removal of sulfur in 1.1.1. AAH-1004A1/A2 (sulfur analyzer) is
Temperature and opens TV-1305 more Hydrotreater (101-D) and Desulfurizer (108- provided at the outlet of Hydrotreater 101-D
than required on the DA/DB) resulting in sulfur break through to
bypass line of Feed Primary Reformer (101-B) and potential for
Preheat Coil (101-BCF) sulfur and carbon lay down. Potential for the outlet of Desulfurizer (108-DA/DB).
catalyst poisoning. 1.1.3. TAL-1307 is provided at the Feed gas line
to Primary Reformer.
8. High Level 1. Not applicable
9. Low Level 1. Not applicable
10. Start-up/ 1. No issue identified
Shutdown/
Maintenance
11. Composition 1. High sulfur content in the 1.1. Potential increase in load to catalyst in 1.1.1. AAH-1004A1/A2 (sulfur analyzer) is 6. Catalyst Vendor of Rekayasa/
7 of 151
change/ feed gas desulfurizer leading to reduced lifecycle of provided at the outlet of Hydrotreater (101-D) Hydrotreater (101-D) and Catalyst
Contamination/ the catalyst. Desulfurizer (108-DA/DB) to Vendor
1.1.2. AAH-1107 (Sulfur analyzers) is provided
Additional confirm that the catalyst will work
Phase/ Loss at the outlet of Desulfurizer (108-DA/DB). to give the required output of
Phase sulfur (0.1 ppmv) under reduced
lifecycle conditions due to
increase in sulfur content of more
that 15 ppmv in the feed.
12. Utility 1. IA failure 1.1. Control valves will go to fail safe
Failure condition.
13. Others 1. Disposal of used catalyst 1.1. Potential environmental issue if not 7. Catalyst Vendor to suggest Rekayasa/
disposed of in safe manner. appropriate procedure to unload Catalyst
and dispose the used catalyst of Vendor
Desulfurizer (108-DA/DB).
This is applicable for all the
catalysts in this plant.

2. Leakage of Feed 2.1. Potential increase in furnace pressure in 2.1.1. PAH-1059A/B/C are provided in the
Preheat Coil (101-BCF) Primary Reformer (101-B). Primary Reformer.
2.1.2. PAH-1058A is provided in the Primary
Reformer.
2.1.3. PSHH-1059 (2oo3) are provided in
Primary Reformer with interlock I-101B with
following actions:
a) Close XV-1222A/B Sec. Gas to Arch Burners
b) Open XV-1222C Arch Sec. Gas Bleed valve
c) Trip superheat and tunnel burners.
d) Initiate interlock I-101 after 15 secs to stop air
flow.
2.2. Potential increase in unburnt 2.2.1. Sample point is provided at the stack for
hydrocarbon in the flue gas. monitoring flue gas composition.
Node: 3. Feed Gas from Desulfurizer to Primary Reformer and Secondary Reformer including Mixed Feed Preheat Coil
Drawing: P2B-10-02-EF-62D103A-R/ Rev 2; P2B-10-02-EF-62D106-R/ Rev 2; P2B-10-02-EF-62D107-R/ Rev 2; P2B-10-02-EF-62D120-R/ Rev 2

1. No/ Low Flow 1. No flow of feed gas from 1.1. Potential overheating of Primary 1.1.1. Steam flow to the reformer tubes
upstream to Primary Reformer tubes leading to damage of continues and hence no damage is expected.
8 of 151
Reformer (101-B) due to catalyst. 1.1.2. FAL-1201A/B/C are available.
any reason (e.g.: Feed Gas
Compressor trip, 1.1.3. FSLL-1201 (2oo3) (mixed feed) is
malfunction and closure of provided on the NG feed line to reformer with
FV-1001/ XV-1201, etc.) interlock I-101J bring the reformer to minimum
firing.
1.1.4. FFSHH-1203 (2oo3) (proc. air to feed gas
ratio) is provided with interlock I-101J to bring
reformer to minimum firing, and air will be cut off
to the Secondary Reformer (103-D).
1.1.5. Multiple TIs with high alarm are provided
on the harp of Primary Reformer.
1.2. Potential overheating of Feed Preheat 1.2.1. I-102J through XS-1129 ramps PIC-1002 218. Change 4”manual globe 2
Coil convection section (101-BCF) leading to to minimum firing valve on line V-1090-4’’-D1A2R-
damage. H100 to HV so that operator in
DCS can maintain flow in 101-
BCF to remove heat.
2. FIC-1025 malfunctions 2.1. No consequence foreseen as this is 138. Review the requirement of Rekayasa
and closes FV-1025 on only an added facility. KBR confirms that the recycle hydrogen line joining
recycle hydrogen line to Primary Reformer (101-B) will work without at the inlet of Primary Reformer
feed gas recycle hydrogen supply (line joining at the (101-B).
inlet of Primary Reformer).
3. Less flow of process 3.1. Potential carbon lay down on the 3.1.1. FFSLL-1201 (steam to carbon ratio)
steam due to any reason reformer catalyst leading to inactive (2oo3) is provided with interlock I-101 to ramp
(e.g.: FV-1002 on MS condition of the catalyst. the Primary Reformer to minimum firing through
header malfunctions) PIC-1002 and closes XV-1201 and FV-1001 on
the feed gas line to Primary Reformer (101-B).
3.2. Potential overheating of Primary 3.2.1. Steam flow to the reformer tubes 8. KBR recommends to have 2 x Rekayasa
Reformer (101-B) tubes leading to damage continues and hence no damage is expected. 100% capacity control valves
of catalyst tubes which in turn leads to (currently FV-1002) for MP steam
3.2.2. FAL-1201A/B/C are available.
leakage in the tubes. supply to Primary Reformer (101-
3.2.3. FSLL-1201 (2oo3) is provided on the NG B) as per KBR basic engineering
feed line to reformer with interlock I-101J bring package. This is to avoid damage
the reformer to minimum firing. to reformer tubes as the reformer
is operated at high temperature.
on the harp of Primary Reformer.
4. Loss of air supply to 4.1. Potential overheating of the Cold 4.1.1. TAH-1325 is provided at the cold process 9. Ensure that gases from Hot Rekayasa
Secondary Reformer (103- Process Air Coil (101-BCA1) inside the air coil outlet. Vent Header which are currently
D) (e.g.: Process air Primary Reformer (101-B) leading to routed to atmosphere do not
4.1.2. TAH-1312 is provided at the Primary
9 of 151
Compressor trip) damage. Reformer. result in flammable mixture
(LFL/UFL) at ground level.
4.1.3. FSLL-1203 (process air) (2oo3) is
provided on the process air line with interlock I- This is a global recommendation.
101J will do the following actions:
a) Opens FV-1044 to allow MP steam into the
coil.
b) Ramps the Primary Reformer to minimum
firing through PIC-1002 (Arch burners)
c) Feed gas forced into auto mode to ramp
minimum firing through FIC-1001
d) Trip of Superheater Main Burners and Tunnel
Burners
e) MOV-1011/XV-1211 provided on the inlet to
Methanator will close which increases the
pressure in upstream leading to opening of PV-
1005 will vent the off-spec product from
Secondary Reformer to hot vent header through
106-D.
f) MOV-1007 and MOV-1008 are closed and
MOV-1009 is opened to bypass the LTS
Converters through I-104D2
4.2. Potential reduction in Secondary 4.2.1. Same as above 4.1.3 9. Ensure that gases from Hot Rekayasa
Reformer (103-D) catalyst temperature Vent Header which are currently
leading to loss of combustion and reforming routed to atmosphere do not
reaction in the Secondary Reformer. result in flammable mixture
5. XV-1212 malfunctions 5.1. Potential overheating of the Cold 5.1.1. TAH-1325 is provided at the cold process
and closes on the process Process Air Coil (101-BCA1) inside the air coil outlet.
airline Primary Reformer (101-B) leading to
5.1.2. TAH-1312 is provided at the Primary
damage.
Reformer.
5.1.3. FSLL-1203 (process air) (2oo3) is
provided on the process air line with interlock I-
101J will do the following actions:
a) Opens FV-1044 to allow MP steam to the coil.
b) Ramps the Primary Reformer to minimum
firing through PIC-1002 (Arch burners)
Burners
10 of 151
106-D.
5.2. Blocked out condition at the discharge 5.2.1. Antisurge valve is provided for protection
of Air Compressor. of Air Compressor.
Further impact on this is addressed in Node
5.
6. Loss of BFW to 6.1. Potential high temperature of feed gas 6.1.1. TAH-1335 is provided at the outlet of the
Secondary Reformer to HT Shift Converter leading to sintering of Secondary Reformer Waste Heat Boiler (101-C).
Waste Heat Boiler (101-C) the catalyst in the HT Shift Converter.
6.1.2. LAL-1223A/B/C is available.
6.1.3. LSLL-1223 (HP Steam Drum low low
level) (2oo3) is provided on the HP Steam Drum
with interlock I-101 to trip the plant.
No purging of reformer is to be carried out till the
level is available in the Steam Drum.
6.2. Potential overheating and damage to 6.2.1. TAH-1335 is provided at the outlet of the
Secondary Reformer Waste Heat Boiler Secondary Reformer Waste Heat Boiler (101-C).
(101-C) as the same is not designed for dry
6.2.2. LAL-1223A/B/C is available.
run case. This may lead to leakage of
Secondary Reformer (103-D) effluent. 6.2.3. LSLL-1223 (HP Steam Drum low low
with interlock I-101 to trip the plant.
7. Loss of high pressure 7.1. This is not expected as the HP Steam
steam to HP Steam Drum is floating with the HP Steam
Superheater (102-C) due to Superheater.
non-availability of Steam
Drum (141-D)
2. More/ High 1. FIC-1001 malfunction 1.1. Potential decrease in steam to carbon 1.1.1. FFSLL-1201 (steam to carbon ratio) is
Flow and opens FV-1001 more ratio in the mixed feed to Primary Reformer provided with interlock I-101 with following
than required on the feed leading to carbon lay down on the catalyst. actions:
gas line to Primary a) Close XV-1212 on process air line;
Reformer (101-B) b) Ramps the Primary Reformer to minimum
firing;
c) Close XV-1201 on the mixed feed gas line.
11 of 151
2. FIC-1025 malfunctions 2.1. No consequence foreseen as this is 138. Review the requirement of Rekayasa
and opens FV-1025 more only an added facility. KBR confirms that the recycle hydrogen line joining
than required on recycle Primary Reformer (101-B) will work without at the inlet of Primary Reformer
hydrogen line to feed gas recycle hydrogen supply (line joining at the (101-B).
inlet of Primary Reformer).
3. FIC-1002 malfunctions 3.1. Potential chances of condensation in 10. Provide S/C ratio high alarm Rekayasa/
and opens FV-1002 more the LT shift converter leading to damage to on FFI-1001 on the process feed KBR
than required on MS the catalyst. gas line.
header
11. Ensure that operating Rekayasa/
instructions are provided for KBR
bypassing the Low Temperature
Shift Converter (LTSC) (104-
D2A/B) on S/C ratio high alarm.
3.2. Potential increase of HP steam 3.2.1. PIC-1036 with high alarm is provided on
generation leading to increase in HP steam the HP Steam Drum 141-D
header pressure.
3.2.2. PIC-1018 is provided on the HP steam
header to control the HP steam header pressure.
3.2.3. PRV-141D1/D2 are provided on the HP
Steam Drum.
3.3. Potential increase in the system 3.3.1. PRV-101C1/C2 are provided at the outlet
pressure. of HTS inlet.
3.4. Potential increase in pressure drop 3.4.1. PDAH is provided across the Primary
across catalyst bed in Primary Reformer Reformer, Secondary Reformer and HTSC.
(101-B), Secondary Reformer (103-D) and
HTSC.
3.5. Potential reduction in the Primary 3.5.1. TIC-1314 with low alarm is provided at the
Reformer (101-B) outlet temperature which outlet of Primary Reformer. This will try to
may affect the methane slip. increase fuel gas flow to burners.
3.5.2. AI-1001 (CH4 analyzer) with high and low
alarm is provided at the Primary Reformer outlet.
4. FIC-1003 malfunctions 4.1. Potential increase in temperature of 4.1.1. FFAH-1203 (proc. air to feed gas ratio) is
and increases the turbine process gas leading to damage to provided.
speed and thereby more Secondary Reformer catalyst.
4.1.2. FFSHH-1203 (proc. air to feed gas ratio)
flow of process air to
Secondary Reformer (103- (2oo3) is provided on the feed gas line with
D) interlock I-101J with following action:
a) Close XV-1212 on process air line
b) Brings the reformer to minimum
12 of 151
Burners
106-D.
in the Secondary Reformer.
4.1.4. Antisurge valve is provided for protection
of air Compressor.
3. Reverse/ 1. No issue identified
Misdirected
Flow
Pressure
6. More/ High 1. PIC-1002 malfunctions 1.1. Potential overfiring in the burners 1.1.1. Multiple TIs with high alarm are provided
Temperature and opens PV-1002 more leading to high temperature in the Primary in the radiant section of Primary Reformer.
on the fuel gas header to Reformer (101-B).
1.1.2. TAH-1314 is available at the reformer
burners
outlet line.
1.1.3. PSHH-1221 (2oo3) is provided on the fuel
gas header with interlock I-101B will initiate
following actions:
a) Close XV-1220A/B F.G to Arch Burners
b) Open XV-1220C Arch F.G Bleed valve
c) Close XV-1222A/B Sec. Gas to Arch Burners
d) Open XV-1222C Arch Sec. Gas Bleed valve
2. High temperature in
Secondary Reformer (103-
D) due to excess air. Refer
to More flow cause 4
above.
3. Failure of refractory in 3.1. Potential damage of the Secondary 3.1.1. Multiple skin TIs are provided on the
13 of 151
Secondary Reformer (103- Reformer shell. Potential hazardous Secondary Reformer shell.
D) scenario.
3.1.2. Water jacket with level control LIC-1142 is
provided for the Secondary Reformer shell.
7. Low 1. PIC-1002 malfunctions 1.1. Potential low temperature in the Primary 1.1.1. TIC-1314 with low alarm is provided at the
Temperature and closes PV-1002B/A on Reformer (101-B) leading to increase in outlet of Primary Reformer.
the fuel gas header to methane slip to downstream. Potential
1.1.2. AAH-1010/1021B (combustibles) are
burners release of unburnt hydrocarbon to flue gas.
provided in the flue gas from radiant section of
Primary Reformer.
1.1.3. AAH-1001 (CH4 analyzer) is provided at
the Primary Reformer outlet.
1.1.4. PSLL-1221 (2oo3) is provided on the fuel
gas header with interlock I-101B will initiate
following actions:
a) Close XV-1220A/B F.G to Arch Burners
b) Open XV-1220C Arch F.G Bleed valve
c) Close XV-1222A/B Sec. Gas to Arch Burners
d) Open XV-1222C Arch Sec. Gas Bleed valve
10. Start-up/ 1. Difficulty during start-up 1.1. 148. Consider to provide a Rekayasa
Shutdown/ to control the feed flow to a bypass valve for FV-1001
Maintenance lower level available on the line leading to
101-BCK, as per KBR basic
engineering package.
2. Injection of hydrogen for 2.1. Difficulty in performing catalyst 149. Consider to relocate the Rekayasa
the Primary Reformer (101- reduction of Primary Reformer since XV- hydrogen line from OEP joining
B) catalyst reduction 1201 will be in closed position. upstream of FV-1001 to the
upstream of FE-1201 downstream of XV-1201.
11. Composition 1. Change in the NG feed 1.1. Primary Reformer (101-B) is designed
change/ composition from upstream for feed composition range in design basis.
Contamination/ with reference to more Hence, no consequence expected.
Additional CO2 and less CH4
Phase/ Loss
Phase
12. Utility 1. IA failure 1.1. Control valves go to fail safe condition.
Failure
13. Others 1. Tube leak in Primary 1.1. Potential leakage of process gas and 1.1.1. Multiple TIs with high alarm are provided
burning inside the radian section of primary
14 of 151
Reformer (101-B) leading to high furnace draft and high radiant in the radiant section of Primary Reformer.
outlet temperature.
2. Leakage in Air Coils 2.1. Potential increase in furnace pressure in 2.1.1. PAH-1059A/B/C are provided in the
(101-BCA1/A2) Primary Reformer. Primary Reformer.
Reformer.
following actions:
flow.
2.2. Potential increase in oxygen content in 2.2.1. AAH-1484A (oxygen analyzer) is provided
flue gas. at the stack.
3. Leakage of Mixed Feed 3.1. Potential increase in furnace pressure in 3.1.1. PAH-1059A/B/C are provided in the
Preheat Coil (101-BCX) Primary Reformer (101-B). Primary Reformer.
Reformer.
following actions:
flow.
4. Tube leak in Secondary 4.1. Potential leakage of BFW into the
Reformer Waste Heat synthesis gas stream. Possible decrease in
Boiler (101-C) temperature of process gas and increase in
BFW consumption. However no major
consequence as BFW will be vaporized
along with process gas.
4.2. Potential increase in condensate level in 4.2.1. LIC-1003/ LV-1003 with high alarm is
Raw Gas Separator. provided on the Raw Gas Separator to maintain
the level.
5. Tube leak in HP Steam 5.1. Potential leakage of steam into the
synthesis gas stream. Possible decrease in
15 of 151
Superheater (102-C) temperature of process gas and increase in
steam consumption. However no major
consequence.
5.2. Potential increase in condensate level in 5.2.1. LIC-1003/ LV-1003 with high alarm is
Raw Gas Separator. provided on the Raw Gas Separator to maintain
the level.
Node: 4. HT Shift Converter effluent to HTS Effluent Steam Generator and HTS Effluent BFW Preheater and then to LT Shift Converter
Drawing: P2B-10-02-EF-62D108-R/ Rev 2; P2B-10-02-EF-62D108A-R/ Rev 2

1. No/ Low Flow 1. No flow of syngas to 1.1. No consequence foreseen for HTSC as
HTSC from upstream due this will lead to shutdown of plant.
to any reason
1.2. Potential less production of steam from
103-C1/C2. However, no major
consequence is envisaged.
2. No flow of BFW in HTS 2.1. Potential high temperature of process 2.1.1. TAH-1011 is provided on process gas line
Effluent/ Steam Generator gas going to LTSC leading to sintering of leading to LTSC.
& BFW Preheater (103- LTSC catalyst as well as CO slip. In adverse
C1/C2) (e.g.: Low level in case, possible leakage from the LTSC outlet
Deaerator leading to trip of piping. in the LTSC catalyst bed.
HP BFW pumps or FIC- Loss of MP steam may take place and in 2.1.3. LSLL-1223 (HP Steam Drum low low
1072/ FV-1072 level) (2oo3) is provided on the HP Steam Drum
malfunctions and closes) turn Syngas Compressor may trip. with interlock I-101 to trip the plant in adverse
In adverse case, Reformer will trip. case.
2.2. Potential more vaporization in 103- 2.2.1. FV-1072 is provided with minimum 99. High vaporization alarm shall Rekayasa
C2/C1 mechanical stop. be provided from UI-1001
available for HTS Effluent/ Steam
Generator & BFW Preheater
level) (2oo3) is provided on the HP Steam Drum (103-C1/C2).
with interlock I-101 to trip the plant in adverse
case.
3. Inadvertent closure of 3.1. Potential increase in system pressure 3.1.1. Open/ close indication is provided for
MOV-1008 on the syngas (upstream of LTSC). MOV-1008.
line to LTSC (104-D2A/B)
3.1.2. PIC-1032/ PV-1032 on the vent line will
maintain the pressure in the system.
3.1.3. PRV-101C1/C2 provided on the inlet of
16 of 151
HTSC.
4. Inadvertent closure of 4.1. Potential increase in system pressure 4.1.1. Open/ close indication is provided for
MOV-1007 on the outlet (upstream of LTSC). MOV-1007.
line from LTSC
4.1.2. PIC-1032/ PV-1032 on the vent line will
maintain the pressure in the system.
4.1.3. PRV-101C1/C2 (set pressure 42.8/ 44)
provided on the inlet of HTSC.
5. Non-opening of MOV- 5.1. Potential damage to the LTSC catalyst 5.1.1. As per trip logic, when MOV-1009 (bypass
1009 when required on the valve) is not opening, the inlet valve will not
bypass line of LTSC close.
2. More/ High 1. FIC-1072 malfunctions 1.1. Potential low temperature of process 1.1.1. TV-1011 is provided on the bypass line of
Flow and opens FV-1072 on the gas to LTSC resulting in condensation of 103-C2 to maintain the LTSC inlet temperature.
BFW supply line to HTS LTSC catalyst and eventual damage to
Effluent/ Steam Generator catalyst.
& BFW Preheater (103-
C1/C2)
2. More flow of syngas to 2.1. Possible increase in breakthrough of 2.1.1. AT-1011 (CO analyzer) is provided at the
HTSC from upstream due CO to downstream. However, Methanator outlet of HTSC for monitoring CO content.
to any reason and molecular sieve will take care of this
scenario. Hence no major consequence
expected.
2.2. More flow of syngas to LTSC. However
consequence is same as above.
3. Reverse/ 1. HIC-1049 malfunctions 1.1. Potential depressurization of HTSC and 1.1.1. Antisurge valve is provided for protection
Misdirected and opens HV-1049 on the downstream system leading to low suction of Syngas Compressor.
Flow vent line from HTSC when pressure for Syngas Compressor.
not required
2. PIC-1032 malfunctions 2.1. Potential depressurization of LTSC and 2.1.1. Antisurge valve is provided for protection
and opens PV-1032 on the downstream system leading to low suction of Syngas Compressor.
vent line from LTSC when pressure for Syngas Compressor.
not required
4. More/ High 1. Plugging of HTSC/ 1.1. Potential increase in differential 1.1.1. PDAH-1110 and PDAH-1037A/B are
Pressure LTSC catalyst bed pressure across the catalyst bed. However, provided for HTSC and LTSC respectively.
plugging is over a period.
6. More/ High 1. TIC-1010 malfunctions 1.1. Potential high temperature of process 1.1.1. TAH-1344A/B is provided in HTSC bed.
Temperature and opens the internal gas from 102-C to HTSC leading to sintering
damper in HP Steam
17 of 151
Superheater (102-C) of HTSC catalyst.
(process gas bypassing the
exchanger)
2. TIC-1011 malfunctions 2.1. Potential high temperature of process 2.1.1. Multiple TIs with high alarm are provided 204. Review the design Rekayasa
and opens TV-1011 on the gas going to LTSC leading to sintering of in the LTSC catalyst bed. temperature of LTSC (104-D2A
bypass of HTS Effluent LTSC catalyst. and B) as it has been made as
BFW Preheater (103-C2) 265 degC and 270 degC, where
as KBR basic engineering
package is specifying as 275
degC for both the reactors.
7. Low 1. TIC-1010 malfunctions 1.1. Potential low temperature of process 1.1.1. AT-1011 (CO analyzer) is provided at the
Temperature and closes the internal gas to HTSC leading to possible increase in outlet of HTSC for monitoring CO content.
damper in HP Steam breakthrough of CO to downstream LTSC.
Superheater (102-C) (all However, LTSC, Methanator and molecular
process gas going through sieve will take care of this scenario. Hence
the exchanger) no major consequence expected.
2. TIC-1011 malfunctions 2.1. Potential low temperature of process 2.1.1. Multiple TIs are provided in the LTSC
and closes TV-1011 on the gas to LTSC resulting in condensation of catalyst bed. However, required alarms can be
bypass of HTS Effluent LTSC catalyst and eventual damage to generated during commissioning.
BFW Preheater (103-C2) catalyst.
10. Start-up/ 1. Difficulty during start-up 1.1. 150. Consider to provide a Rekayasa
Shutdown/ to control the BFW flow to bypass valve for FV-1072
Maintenance HTS Effluent/ Steam available on the BFW line leading
Generator & BFW to HTS Effluent/ Steam Generator
Preheater (103-C1/C2) and & BFW Preheater (103-C1/C2),
Steam Drum (141-D) as per KBR basic engineering
package.
2. Difficulty to control the 2.1. Low temperature of LTS inlet gas 151. Consider to provide forcing Rekayasa
LTS inlet temperature leading to possible condensation in the valve at the inlet of HTS Effluent
during start-up LTSC. BFW Preheater (103-C2) on the
BFW line as per KBR basic
engineering package to control
the LTS inlet temperature.
11. Composition 1. No issue identified since
change/ the possible change of
Contamination/ CH4 content from the
Additional Secondary Reformer outlet
Phase/ Loss will not have any affect on
18 of 151
Phase LTSC and HTSC as the
same will be removed
downstream in Purifier
Failure condition.
13. Others 1. Tube leak in HTS 1.1. Potential leakage of BFW into the 1.1.1. TIC-1011 with low alarm is provided at the
Effluent Steam Generator synthesis gas stream leading to carryover to inlet to HTSC.
(103-C1)/ HTS Effluent LTSC. Potential damage to LTSC catalyst.
BFW Preheater (103-C2)
2. Difficulty to control the 2.1. 151. Consider to provide forcing Rekayasa
LTS inlet temperature valve at the inlet of HTS Effluent
during start-up BFW Preheater (103-C2) on the
BFW line as per KBR basic
engineering package to control
the LTS inlet temperature.

Node: 5. LTSC effluent to LTS Effluent/ BFW Preheater, CO2 Stripper Reboiler and LTS Effluent/ Demin Water Exchanger and the cooled gas to Raw Gas Separator and CO2 Absorber and then to CO2
Absorber Overhead Knockout drum
Drawing: P2B-10-02-EF-62D109-R/ Rev 2; P2B-10-02-EF-62D110-R/ Rev 2; P2B-10-02-EF-62D120B-R/ Rev 2
1. No/ Low Flow 1. No/ Low flow of syngas 1.1. No consequence expected for the LTS
from LTSC due to any effluent cooling equipment and CO2
reason (e.g.: MOV-1007 Absorber.
closes)
1.2. Potential low suction pressure for 1.2.1. Antisurge valve is provided for protection
Syngas Compressor leading to possible of Syngas Compressor.
damage.
2. No flow of BFW to LTS 2.1. Potential damage to the Preheater due 2.1.1. LTS Effluent/ BFW Preheater is designed
Effluent/ BFW Preheater to dry running. mechanically to take care of no flow of BFW.
(131-C)
2.1.2. Standby HP BFW pump is provided with
autostart facility.
with interlock I-101 to trip the plant in adverse
case.
2.2. Potential increase in process gas 139. Review the design Rekayasa
temperature leading to CO2 Stripper temperature of CO2 Stripper
19 of 151
Reboiler (105-C) Reboiler (105-C) as it is designed
from 200 degC, in light of no
BFW flow from upstream. (Design
temperature as per KBR basic
engineering package is 245
degC.)
3. No flow of Demin water 3.1. Potential increase in syngas 3.1.1. AAH-1023B (CO2 analyzer) is provided at 12. Provide high alarm from TI- Rekayasa
to LTS Effluent/ Demin temperature resulting in reduced absorption the outlet of CO2 Absorber Overhead KO Drum. 1352 on syngas outlet from LTS
Water Exchanger (106-C) in CO2 Absorber. In additional, increased Effluent/ Demin Water Exchanger
moisture content may cause dilution of MEA (106-C).
solution. This will aggravate the scenario, on the Methanator bed.
leading to possible increase of CO2 3.1.3. TSHH-1200/1201/1202/1203 (each 2oo3)
slippage. Eventually this may lead to are provided on the Methanator bed with
increase in Methanator bed temperature. interlock I-106D to close feed valve XV-1211 and
Possible vessel failure and damage to venting of syngas from upstream hot vent
header.
catalyst. Release of flammable/ toxic gases.
4. Inadvertent closure of 4.1. Potential increase in backpressure of 4.1.1. PIC-1040/ PV-1040 is provided on the 9. Ensure that gases from Hot Rekayasa
MOV-1005 on the feed to the system. vent of the process gas line to CO2 Absorber will Vent Header which are currently
the CO2 Absorber (121-D) open. routed to atmosphere do not
result in flammable mixture
5. No flow of condensate 5.1. Potential carryover of more condensate 5.1.1. AAH-1023B (CO2 analyzer) is provided at
from Raw Gas Separator with syngas to CO2 Absorber. This may lead the outlet of CO2 Absorber Overhead KO Drum.
(142-D1) due to to gradual dilution of MEA solution and make
malfunction of of LIC-1003 cause eventual CO2 slippage. (Inventory of
and closing of LV-1003A/B MEA solution in circulation is about 1000 on the Methanator bed.
m3.) Eventually this may lead to increase in 5.1.3. TSHH-1200/1201/1202/1203 (each 2oo3)
Methanator bed temperature. are provided on the Methanator bed with
Also, potential dilution of the rich amine interlock I-106D to close feed valve XV-1211 and
venting of syngas from upstream hot vent
solution in the CO2 Absorber bottom. header.
6. No flow of condensate 6.1. Potential carryover of liquid to 13. Provide LI with high alarm and Rekayasa
from CO2 Absorber Methanator, molecular sieve and Purifier. No high high level interlock on the
Overhead Knockout Drum major consequence on Methanator and CO2 Absorber Overhead
(142-D2) due to Molecular sieve. However, Purifier will be Knockout Drum (142-D2) to trip
malfunction and close of affected as it is operating in cryogenic the Methanator (106-D).
LIC-1005/ LV-1005 conditions.
7. FIC-1018 malfunctions 7.1. Loss of amine solution to the process
20 of 151
and closes FV-1018 on gas going to Methanator. However, the
condensate line to CO2 quantity is very small and no major
Absorber (121-D) consequence is expected.
8. FIC-1014 malfunctions 8.1. Potential loss of lean amine solution 8.1.1. AAH-1023B (CO2 analyzer) is provided at
and closes FV-1014 on resulting in inefficient absorption of CO2. the outlet of CO2 Absorber Overhead KO Drum.
lean amine solution line to Potential for high CO2 slippage from the
CO2 Absorber (121-D) absorber resulting in high temperature in the
Methanator. This may cause eventually on the Methanator bed.
runaway reaction and failure of equipment. 8.1.3. FSLL-1214 (2oo3) is provided on the lean
Potential release of high pressure and high amine solution line to CO2 Absorber with
temperature flammable/ toxic gas. interlock I-106D to trip the Methanator.
8.1.4. TSHH-1200/1201/1202/1203 (each 2oo3)
are provided on the Methanator bed with
interlock I-106D to close feed valve XV-1211 and
header.
8.2. Potential damage to lean suction pump 8.2.1. Adjustable mechanical stop is provided for
as it will experience shutoff condition. FV-1014.
9. FIC-1005 malfunctions 9.1. Potential loss of semi-lean amine 9.1.1. AAH-1023B (CO2 analyzer) is provided at
and closes FV-1005 on solution resulting in inefficient absorption of the outlet of CO2 Absorber Overhead KO Drum.
semi-lean amine solution CO2. Potential for high CO2 slippage from
line to CO2 Absorber (121- the absorber resulting in high temperature in
D) the Methanator. This may cause eventually on the Methanator bed.
runaway reaction and failure of equipment. 9.1.3. FSLL-1205 (2oo3) is provided on the
Potential release of high pressure and high semi-lean amine solution line to CO2 Absorber
temperature flammable/ toxic gas. with interlock I-106D to trip the Methanator.
9.1.4. TSHH-1200/1201/1202/1203 (each 2oo3)
header.
9.2. Potential damage to semi-lean suction 9.2.1. Adjustable mechanical stop is provided for
pump as it will experience shutoff condition. FV-1005.
10. No flow of rich amine 10.1. Potential loss of rich amine solution to 10.1.1. Turbine is provided with low speed 15. Provide high alarm from LT- Rekayasa
solution due to LIC-1004 hydraulic turbine and Stripper and in turn alarm. 1204 on CO2 Absorber (121-D).
malfunction and closure of increase in level in CO2 Absorber leading to
13. Provide LI with high alarm and Rekayasa
LV-1004A/B/C (in adverse possible carryover of liquid with gas to
case) on the rich amine Absorber Overhead KO Drum. high high level interlock on the
solution line from CO2 CO2 Absorber Overhead
Knockout Drum (142-D2) to trip
21 of 151
Absorber (121-D) the Methanator (106-D).

10.2. Potential reverse flow of rich amine 10.2.1. Inverted U seal and check valve is
into the feed line. provided on the process gas feed line to CO2
Absorber.
10.3. Potential loss of semi-lean amine 10.3.1. AAH-1023B (CO2 analyzer) is provided
solution resulting in inefficient absorption of at the outlet of CO2 Absorber Overhead KO
CO2. Potential for high CO2 slippage from Drum.
the absorber resulting in high temperature in
the Methanator. This may cause eventually
runaway reaction and failure of equipment. on the Methanator bed.
Potential release of high pressure and high 10.3.3. FSLL-1205 (2oo3) is provided on the
temperature flammable/ toxic gas. semi-lean amine solution line to CO2 Absorber
with interlock I-106D to trip the Methanator.
10.3.4. TSHH-1200/1201/1202/1203 (each 2oo3)
header.
11. Inadvertent closure of 11.1. Potential loss of rich amine solution to 11.1.1. Turbine is provided with low speed 13. Provide LI with high alarm and Rekayasa
XV-1052 on the rich amine hydraulic turbine and Stripper and in turn alarm. high high level interlock on the
line to hydraulic turbine increase in level in CO2 Absorber leading to CO2 Absorber Overhead
11.1.2. LIC-1004 with high alarm provided on the
possible carryover of liquid with gas to Knockout Drum (142-D2) to trip
absorber overhead KOD. CO2 Absorber. the Methanator (106-D).
2. More/ High 1. More flow of condensate 1.1. Potential low level in the Raw Gas 1.1.1. LSLL-1205 is provided on the Raw Gas
Flow from Raw Gas Separator Separator leading to possible gas Separator with interlock I-142D1 to trip the
(142-D1) due to LIC-1003 breakthrough to condensate pump. Pump process condensate pump 121-J/JA and close
malfunction and higher cavitation with potential for seal damage. LV-1003B.
opening of LV-1003A
1.2. Refer to Node 9 for impact of Process
Condensate Stripper.
2. More flow of condensate 2.1. Potential low level in the Raw Gas 2.1.1. LSLL-1205 is provided on the Raw Gas 14. Check the suitability of waste Rekayasa
from Raw Gas Separator Separator leading to possible gas Separator with interlock I-142D1 to trip the water header and check pit for the
(142-D1) due to LIC-1003 breakthrough to condensate pump and then process condensate pump 121-J/JA. gas breakthrough case from Raw
malfunction and higher to check pit through waste water header. Gas Separator (142-D1) in case
opening of LV-1003B This may lead to possible pressurization of of LIC-1003/ LV-1003B
waste water header and check pit as 142-D1 malfunctions and opens.
is operating at 36.7 kg/cm2G. Potential
damage and release of syngas. KBR recommends to have a
shutdown valve at the upstream
of LV-1003B to take care of gas
breakthrough scenario as per
22 of 151
KBR basic engineering package.

140. Interlock number shown as I- Rekayasa
130D against LV-1003B shall be
corrected as I-142D1.
141. As LV-1003B is closing on Rekayasa
interlock, this valve shall not be
provided with a bypass.
142. LV-1003B is indicated as FO Rekayasa
type, whereas it is of FC type.
143. I-142D1 on LSLL-1205 will Rekayasa/
be able to close LV-1003B even Pusri
though LIC-1003 malfunctions as
claimed by Rekayasa. However,
interlock acting on the same
malfunctioned element needs to
be reviewed and confirmed by
Owner, to ensure availability
when on demand.
3. More flow of condensate 3.1. Potential low level in CO2 Absorber 3.1.1. HP Flash column is designed for the
from CO2 Absorber Overhead KO Drum which may lead to gas operating conditions of the CO2 Absorber
Overhead Knockout Drum breakthrough to HP Flash Column (163-D). Overhead KO Drum. Also, PV-1039A/B is
(142-D2) due to available at the outlet of HP Flash Column to
malfunction and opening of release the pressure to hot vent header/ 101B
LIC-1005/ LV-1005 fuel.
3.2. Refer to Node 6 for impact on HP Flash
Column.
4. FIC-1018 malfunctions 4.1. Potential increase in condensate flow 4.1.1. PDAH-1042A is provided on the CO2 13. Provide LI with high alarm and Rekayasa
and opens FV-1018 more from CO2 LP Flash Reflux Pump (110-J/JA) Absorber. high high level interlock on the
than required on leading to increase in differential pressure in CO2 Absorber Overhead
4.1.2. LIC-1005 with high alarm will control the
condensate line to CO2 upper section of CO2 Absorber and increase Knockout Drum (142-D2) to trip
Absorber (121-D) in liquid carryover with the overhead gas to level in the Absorber Overhead KO Drum. the Methanator (106-D).
CO2 Absorber Overhead Knockout Drum
(142-D2).
4.2. Refer to Node 7 for impact on CO2
Stripper Reflux Drum.
5. FIC-1014 malfunctions 5.1. Potential increase in lean amine flow 5.1.1. PDAH-1042A is provided on the CO2 13. Provide LI with high alarm and Rekayasa
and opens FV-1014 more leading to increase in differential pressure in Absorber. high high level interlock on the
than required on lean upper section of CO2 Absorber and increase CO2 Absorber Overhead
5.1.2. LIC-1005 with high alarm will control the
amine solution line to CO2 in liquid carryover with the overhead gas to Knockout Drum (142-D2) to trip
23 of 151
Absorber (121-D) 142-D2. level in the Absorber Overhead KO Drum. the Methanator (106-D).
5.2. Potential loss of amine level in CO2 5.2.1. LSLL-1043 (2oo3) is available to trip the
Stripper (122-D2) leading to damage to Lean Lean OASE Solution Pump with interlock I-108J.
OASE Solution Pumps (108-J/JA).
6. FIC-1005 malfunctions 6.1. Potential increase in semi-lean amine 6.1.1. LIC-1005 with high alarm will control the 13. Provide LI with high alarm and Rekayasa
and opens FV-1005 more flow leading to increase in differential level in the Absorber Overhead KO Drum. high high level interlock on the
than required on semi-lean pressure in the CO2 Absorber and increase CO2 Absorber Overhead
amine solution line to CO2 in liquid carryover with the overhead gas to Knockout Drum (142-D2) to trip
Absorber (121-D) 142-D2. the Methanator (106-D).
6.2. Potential loss of lean amine level in LP 6.2.1. LALL-1045 (2oo3) is available to trip the 13. Provide LI with high alarm and Rekayasa
Flash Column (122-D1) leading to damage Lean Amine Solution Pump with interlock I-107J. high high level interlock on the
to semi-Lean Amine Solution Pump (107- CO2 Absorber Overhead
J/JA/JB). Knockout Drum (142-D2) to trip
the Methanator (106-D).
7. More flow of rich amine 7.1. Potential low level in CO2 Absorber 7.1.1. LSLL-1204 (2oo3) is provided with alarm
solution due to LIC-1004 bottom and possible gas breakthrough to on the CO2 Absorber outlet line with interlock I-
malfunction and opening of downstream. Possible release of hot 121D to close LV-1004C and XV-1052.
LV-1004C on the rich material containing flammable and toxic
amine solution line from (CO) gas.
CO2 Absorber (121-D)
7.2. Possible overspeeding of the hydraulic 7.2.1. Turbine is provided with overspeed safety
turbine 107-JAHT and in turn possible device SSH-1207A/B/C.
damage to 107-JA.
8. More flow of rich amine 8.1. Potential low level in CO2 Absorber 8.1.1. LSLL-1204 (2oo3) is provided with alarm
solution due to LIC-1004 bottom and possible gas breakthrough to on the CO2 Absorber outlet line with interlock I-
malfunction and opening of downstream. 121D to close LV-1004C and XV-1052.
LV-1004A/B on the rich
amine solution line from
3. Reverse/ 1. Inadvertent opening of 1.1. Potential increase in syngas 1.1.1. AAH-1023B (CO2 analyzer) is provided at 12. Provide high alarm from TI- Rekayasa
Misdirected HIC-1421/HV-1421 on the temperature resulting in carryover of more the outlet of CO2 Absorber Overhead KO Drum. 1352 on syngas outlet from LTS
Flow bypass line of CO2 Stripper moisture content to CO2 Absorber. This may Effluent/ Demin Water Exchanger
Reboiler (105-C) lead to inefficient absorption leading to (106-C).
possible increase of CO2 slippage. on the Methanator bed.
Eventually this may lead to increase in 1.1.3. TSHH-1200/1201/1202/1203 (each 2oo3)
Methanator bed temperature. are provided on the Methanator bed with
Possible vessel failure and damage to interlock I-106D to close feed valve XV-1211 and
catalyst. Release of flammable/ toxic gases. header.
Also, potential dilution of the rich amine
24 of 151
solution in the CO2 Absorber bottom.

1.2. Potential high temperature of syngas to 152. Review the design Rekayasa
LTS Effluent/Demin Water Exchanger (106- temperature of tube side (80
C) degC) of LTS Effluent/Demin
Water Exchanger (106-C) as per
KBR basic engineering package
(200 degC), since it will
experience high temperature in
case of full opening of HV-1421.
2. PIC-1040 malfunctions 2.1. Potential depressurization of the CO2
and opens PV-1040 on the Absorber system and loss of production due
feed line to CO2 Absorber to unloading of Synthesis Gas Compressor.
(121-D) when not required This may call for repressurization of the
plant. However, no major hazardous
situation.
3. Condensate supply 3.1. Potential reverse flow from CO2 3.1.1. Single check valve is provided on the 16. Review the requirement of Rekayasa
failure to CO2 Absorber Absorber which is operating at 36.7 condensate line. additional dissimilar check valve
(121-D) kg/cm2G and pressurization of the on the condensate line to CO2
condensate line from CO2 Stripper Reflux Absorber (121-D) as per KBR
drum. basic design package as the CO2
Stripper Reflux Drum (153-D) is
4. Condensate supply 4.1. Potential reverse flow from 142-D2 4.1.1. Single check valve is provided on the 153. Review the requirement of Rekayasa
failure to CO2 Absorber which is operating at 36.5 kg/cm2G and condensate line. additional dissimilar check valve
Overhead Knockout Drum pressurization of the condensate line from on the condensate line to CO2
(142-D2) CO2 Stripper Reflux drum. Absorber Overhead Knockout
Drum (142-D2) as per KBR basic
design package as the CO2
Stripper Reflux Drum (153-D) is
5. Lean amine supply 5.1. Potential reverse flow from CO2 5.1.1. Single check valve is provided on the lean 17. Review the requirement of Rekayasa
failure to CO2 Absorber Absorber which is operating at 36.7 amine solution line. additional dissimilar check valve
(121-D) kg/cm2G and pressurization of the lean- on the lean amine solution line to
amine line from CO2 Stripper (122-D2). CO2 Absorber (121-D) as per
KBR basic design package as the
CO2 Stripper (122-D2) is
designed for 4 kg/cm2G.
6. Semi-lean amine supply 6.1. Potential reverse flow from CO2 6.1.1. Single check valve is provided on the 18. Review the requirement of Rekayasa
failure to CO2 Absorber Absorber which is operating at 36.7 semi-lean amine line. additional dissimilar check valve
(121-D) kg/cm2G and pressurization of the lean- on the semi-lean solution line to
CO2 Absorber (121-D) as per
25 of 151
amine line from LP Flash Column (122-D1). KBR basic design package as the
LP Flash Column (122-D1) is
designed for 4 kg/cm2G.
4. More/ High 1. PIC-1040 malfunctions 1.1. Potential overpressurization of the 1.1.1. PRV-142-D1/121D are provided on the
Pressure and does not open PV- system leading to damage. feed gas line to CO2 Absorber.
1040 when required on the
feed line to CO2 Absorber
(121-D)
6. More/ High 1. TIC-1420 malfunctions 1.1. Potential increase in process gas
Temperature and opens TV-1420 on the temperature to Stripper reboiler resulting in
BFW bypass line to LTS higher reboiling. However, no mechanical
Effluent/ BFW Preheater damage is expected for reboiler as the
(131-C) design/ operating temperatures are within
range.
Refer to Node 8 for impact of higher
reboiling for CO2 Stripper.

1.2. Potential loss of preheating for BFW
resulting in lower HP steam generation.
However, no major consequence expected.
2. High temperature lean 2.1. Increase in lean amine solution 2.1.1. TAH-1672 is provided.
amine solution to CO2 temperature resulting in reduced absorption
2.1.2. AAH-1023B (CO2 analyzer) is provided at
Absorber (121-D) (e.g.: in CO2 Absorber.
loss of cooling in upstream) the outlet of CO2 Absorber Overhead KO Drum.
Possible vessel failure and damage to 2.1.3. Multiple TIs with high alarm are provided
catalyst. Release of flammable/ toxic gases. on the Methanator bed.
2.1.4. TSHH-1200/1201/1202/1203 (each 2oo3)
header.
7. Low 1. TIC-1420 malfunctions 1.1. Potential lower process gas temperature
Temperature and closes TV-1420 on the to Stripper Reboiler resulting in lower
BFW bypass line to LTS reboiling and thereby affecting the Stripper
Effluent/ BFW Preheater operation.
(131-C) Refer to Node 8 for impact of lower reboiling
for CO2 Stripper.

26 of 151
8. High Level 1. No new issue. Refer

More flow scenario.
9. Low Level 1. No new issue. Refer No/
Low flow scenario.
Shutdown/
Maintenance
11. Composition 1. Higher content of CO2 in 1.1. Potential increase in load to CO2 1.1.1. CO2 Absorber is designed for maximum
change/ syngas from the feed Absorber. CO2 case.
Contamination/
Additional
Phase/ Loss
Phase
Failure position.
13. Others 1. Tube leak in LTS 1.1. Potential leakage of BFW to syngas 1.1.1. Raw gas separator is provided to knock-
Effluent/ BFW Preheater resulting in carryover of liquid with process off the BFW from syngas.
(131-C) gas.
2. Tube leak in CO2 2.1. Potential leakage of syngas to Stripper 2.1.1. PRV-153D is provided on the CO2 20. Confirm that PRV-153D Rekayasa
Stripper Reboiler (105-C) and in turn overpressurization and damage Stripper Reflux Drum. provided on the CO2 Stripper
of the Stripper as the Stripper is designed for Reflux Drum (153-D) is sized to
4 kg/cm2G. take care of the syngas leakage
scenario to the CO2 Stripper
(122-D2).
2.2. Potential contamination of CO2 product 2.2.1. AI-1103 (Hydrogen analyzer) is provided 19. Provide high alarm from AI- Rekayasa
with hydrogen (from syngas) from CO2 on the CO2 line from CO2 Stripper Reflux Drum 1103 (Hydrogen analyzer) on the
Stripper Reflux Drum (153-D) to urea plant. 153-D to Urea plant CO2 line from CO2 Stripper
Reflux Drum (153-D) to Urea
Plant.
3. Tube leak in LTS 3.1. Potential leakage of syngas into Demin 3.1.1. RD-106C is provided on the Demin water 21. Confirm that PRV-101U Rekayasa
Effluent/ Demin Water water and overpressurization of Deaerator line from 106-C and set at 8 kg/cm2G. provided on the Deaerator (101-
Exchanger (106-C) system as it is designed for 4 kg/cm2G. U) is sized to take care of the
3.1.2. PRV-101U (set at 4 kg/cm2G) is provided
syngas leakage scenario to the
on the Deaerator. DM water line from LTS Effluent/
DM Water Exchanger (106-C).
27 of 151
Node: 6. Rich amine and Semi-lean amine circuit
Drawing: P2B-10-02-EF-62D110-R/ Rev 2; P2B-10-02-EF-62D120A-R/ Rev 2; P2B-10-02-EF-62D120B-R/ Rev 2; P2B-10-02-EF-62D126-R/ Rev 2
1. No/ Low Flow 1. XV-1052 malfunctions 1.1. Loss of rich amine solution to HP Flash 1.1.1. LAL-1041 is provided on the LP Flash 22. Ensure that operating Rekayasa
and closes on rich amine Column (163-D). This will lead to loss of Column. instructions are provided to stop
solution line to hydraulic feed to LP Flash Column (122-D1) as HP the Semi-lean Solution Circulating
1.1.2. LSLL-1045 (2oo3) is provided on the LP
turbine Flash Column is operated under level Pump (117-J/JA) on LALL-1045
control. Also, Loss of suction to Semi-lean Flash Column with interlock I-107J with following manually from the control room.
Solution Pump (107-JA/JAB/JC) and Semi- actions:
lean Solution Circulating Pump (117-J/JA) a) Close LV-1004C
Cavitation of pumps leading to possible seal b) Trip the hydraulic turbine 107-JAHT
damage. No toxic gas is present in the liquid c) Trip Semi-lean Solution Pump (107-
and only insignificant release of flammable JA/JAB/JC)
gas.
In adverse case, loss of suction to CO2
Compressor and damage.

1.2. For impact on CO2 Absorber, refer to
Node 5.
2. Inadvertent closure of 2.1. Potential loss of flow to turbine leading
MOV-1037 on rich amine to turbine trip and in turn tripping of 107-JA.
solution line to hydraulic However, rich solution can be let down to HP
turbine Flash Column (163-D) using LV-1004A/B on
the bypass line of the turbine. Also, autostart
facility is provided to start the standby pump
107-JC. Hence, no major consequence
foreseen.
3. LIC-1004 malfunctions 3.1. Same as 2.1 above. 39. Consider replacing LV-1004C Rekayasa
and closes LV-1004C on with HV-XXX as per KBR basic
rich amine solution line to engineering package.
hydraulic turbine
4. LIC-1004 malfunctions 4.1. No major consequence is expected as
and closes LV-1004A/B on the hydraulic turbine is designed for full flow
rich amine solution bypass capacity, it is possible to run the plant
line across hydraulic without any major upset.
turbine
5. Mechanical problem in 5.1. Potential loss of semi-lean solution flow 5.1.1. Turbine and pump running indications are
turbine and thereby Semi- to CO2 Absorber. provided in DCS.
lean OASE Solution Pump
5.1.2. FSL-1005 is provided to start the standby
(107-JA) stops
semi-lean solution pump 107-JC
6. Inadvertent closure of 6.1. The hydraulic turbine may be subjected 6.1.1. The line up to MOV-1038 is designed for 23. KBR recommends only a Rekayasa
MOV-1038 on the to high pressure due to blocked condition at CO2 Absorber pressure. manual isolation valve instead of
discharge of hydraulic the turbine discharge. Also, possible impact MOV-1038 at the Hydraulic
on the sealing system and damage. Turbine (107-JAHT) discharge in
28 of 151
turbine order to avoid hydraulic turbine
However, rich solution can be let down to HP being subjected to high pressure.
Flash Column (163-D) using LV-1004A/B on
the bypass line of the turbine.
7. No flow of solution from 7.1. Potential high level in the HP Flash 7.1.1. Standpipe is provided with LAHH-1048 for 24. KBR recommends to provide Rekayasa
HP Flash Column (163-D) Column and possible liquid carryover to the HP Flash Column. an interlock on LAHH-1048 with a
to LP Flash Column (122- downstream fuel gas system. This may lead shutdown valve on the outlet line
D1) due to malfunction and to hazardous scenario in the furnace. from HP Flash Column (163-D)
closure of LIC-1046/ LV- overhead leading to Primary
1046 Reformer (101-B) at upstream of
FT-1163 as per KBR basic
7.2. Potential loss of level in LP Flash 7.2.1. LAL-1041 is provided on the LP Flash 22. Ensure that operating Rekayasa
Column (122-D1). Also, loss of suction to Column. instructions are provided to stop
Semi-lean Solution Pump (107-JA/JAB/JC) the Semi-lean Solution Circulating
7.2.2. LSLL-1045 (2oo3) is provided on the LP
and Semi-lean Solution Circulating Pump Pump (117-J/JA) on LALL-1045
(117-J/JA). Cavitation of pumps leading to Flash Column with interlock I-107J with following manually from the control room.
possible seal damage. No toxic gas is actions:
present in the liquid and only insignificant a) Close LV-1004C
release of flammable gas. b) Trip the hydraulic turbine 107-JAHT
c) Trip Semi-lean Solution Pump (107-
In adverse case, loss of suction to CO2 JA/JAB/JC)
Compressor and damage.
8. No flow of anti-foam 8.1. As this is an intermittent flow, no serious 8.1.1. PDT-1042A/B with high alarm are
from upstream to CO2 consequences foreseen. available in the CO2 Absorber.
Absorber (121-D) due to
In case of requirement, if the antifoam 8.1.2. Operating instructions to be followed to
any reason
injection stops, possible upset in CO2 keep the antifoam injection system healthy.
Absorber due to higher delta P and in
adverse case carryover of OASE solution to
CO2 Absorber Overhead KO Drum and
Methanator. Possible increase of CO2
slippage from the Absorber.
9. No flow of anti-foam 9.1. As this is an intermittent flow, no serious 9.1.1. PDT-1043 with high alarm are available in
from upstream to LP Flash consequences foreseen. the LP Flash Column.
Column (122-D1) due to
any reason
injection stops, possible upset in LP Flash keep the antifoam injection system healthy.
Column due to higher delta P and in adverse
case carryover of OASE solution to CO2
Stripper Reflux Drum and in turn to CO2
Compressor.
29 of 151
10. Less flow of semi-lean 10.1. Potential loss of semi-lean amine 10.1.1. Pump running indication is provided in
amine solution from LP solution resulting in inefficient absorption of DCS.
Flash Column (122-D1) to CO2. Potential for high CO2 slippage from
10.1.2. FSL-1005 is provided to start the standby
CO2 Absorber due to the absorber resulting in high temperature in
tripping of Semi-lean the Methanator. This may cause eventually Semi-lean OASE Solution Pumps (107-JC)
OASE Solution Pump (107- runaway reaction and failure of equipment.
JB) Potential release of high pressure and high
temperature flammable/ toxic gas.
11. FIC-1005 malfunction 11.1. Potential damage to semi-lean suction 11.1.1. Adjustable mechanical stop is provided
and closes FV-1005 on pump as it will experience shutoff condition. for FV-1005.
semi-lean solution line to
11.2. Potential high level in LP Flash 11.2.1. LAH-1041 is provided on the LP Flash
Column which may lead to liquid carryover Column.
with the overhead gas.
11.2.2. CO2 Stripper overhead condenser and
Stripper reflux drum is provided to prevent liquid
carryover to CO2 Compressor.
12. FIC-1030 malfunctions 12.1. Potential entrainment of amine with
and closes FV-1030 on the overhead fuel gas going to vent and
wash water line to HP secondary fuel line to 101-B. However, no
Flash Column (163-D) serious consequence expected.
13. FIC-1016 malfunctions 13.1. Potential loss of wash water to LP
and closes FV-1016 on Flash Column resulting in entrainment of
wash water line to LP Flash amine with overhead CO2. However, no
Column (122-D1) major consequence foreseen as it is a
closed loop.
2. More/ High 1. LIC-1004 malfunctions 1.1. No consequence is foreseen as the
Flow and opens LV-1004C more turbine will take only a fixed flow of liquid.
than required on rich amine
solution line to hydraulic
turbine
2. LIC-1004 malfunctions 2.1. Potential high level in LP Flash Column 2.1.1. LAH-1041 is provided on the LP Flash
and opens LV-1004A/B (122-D1) which may lead to liquid carryover Column.
more than required on rich with the overhead gas.
2.1.2. CO2 Stripper Overhead Condenser and
amine solution bypass line
across hydraulic turbine CO2 Stripper Reflux Drum is provided to prevent
liquid carryover to CO2 Compressor.
2.2. Potential level decrease in CO2
Absorber. Refer to Node 5.
3. More flow of solution 3.1. Potential gas breakthrough from HP to 3.1.1. Gas content in HP Flash Column is very
from HP Flash Column LP Flash Column and in turn to CO2 low and the possibility of pressurization of LP
(163-D) to LP Flash Flash Column is very remote. However, PRV-
30 of 151
Column (122-D1) due to Stripper reflux drum. 153D is provided on the CO2 Stripper reflux
malfunctions and opens of drum.
LIC-1046/ LV-1046
3.2. Potential contamination of CO2 product 3.2.1. AI-1103 (Hydrogen analyzer) is provided 19. Provide high alarm from AI- Rekayasa
with hydrogen (from syngas) from CO2 on the CO2 line from CO2 Stripper Reflux Drum 1103 (Hydrogen analyzer) on the
Stripper Reflux Drum 153-D to urea plant. 153-D to Urea plant CO2 line from CO2 Stripper
Reflux Drum (153-D) to Urea
Plant.
4. FIC-1005 malfunction 4.1. Loss of lean amine level in LP Flash 4.1.1. LALL-1045 (2oo3) is available to trip the 13. Provide LI with high alarm and Rekayasa
and opens FV-1005 on Column (122-D1). Loss of suction to Semi- Lean Amine Solution Pump with interlock I-107J. high high level interlock on the
semi-lean solution line to lean Solution Pump (107-JA/JAB/JC) and CO2 Absorber Overhead
CO2 Absorber (121-D) Semi-lean Solution Circulating Pump (117- Knockout Drum (142-D2) to trip
J/JA). Cavitation of pumps leading to the Methanator (106-D).
possible seal damage. No toxic gas is
present in the liquid and only insignificant
release of flammable gas.
5. FIC-1030 malfunctions 5.1. Potential entrainment of wash water in
and opens FV-1030 more the vapor from overhead of HP Flash
than required on the wash Column to fuel/ hot vent header. However,
water line to HP Flash no serious consequence expected.
Column (163-D)
5.2. Potential high level in LP Flash Column 5.2.1. LAH-1041 is provided on the LP Flash
(122-D1) which may lead to liquid carryover Column.
with the overhead gas.
5.2.2. CO2 Stripper overhead condenser and
Stripper reflux drum is provided to prevent liquid
carryover to CO2 Compressor.
6. FIC-1016 malfunctions 6.1. Potential entrainment of wash water in
and opens FV-1016 more the vapor from overhead of LP Flash
than required on wash Column to CO2 Flash reflux drum. However,
water line to LP Flash no serious consequence expected.
Column (122-D1)
3. Reverse/ 1. Semi-lean OASE 1.1. Potential reverse flow scenario from 18. Review the requirement of Rekayasa
Misdirected Solution Pump (107-JA) discharge of the pump to suction leading to additional dissimilar check valve
Flow trips damage of the pump. Also, on the semi-lean solution line to
overpressurization of the LP Flash Column CO2 Absorber (121-D) as per
(122-D1) as check valve may pass and the KBR basic design package as the
gas may flow back from CO2 Absorber to LP LP Flash Column (122-D1) is
Flash Column. designed for 4 kg/cm2G.
4. More/ High 1. PIC-1039 malfunctions 1.1. No consequence foreseen as HP Flash
Pressure and closes PV-1039A/B Column (163-D) is designed for CO2
Absorber operating pressure.
31 of 151
5. Low Pressure 1. PIC-1039 malfunctions 1.1. Potential depressurization of the HP 1.1.1. LIC-1046 with high alarm is provided on
and opens PV-1039A/B Flash Column (163-D) which may affect the the HP Flash Column.
liquid circulation to LP Flash Column (122-
D1) resulting in high level in HP Flash
Column.
6. More/ High 1. Higher reboiling in CO2 1.1. Potential high temperature in LP Flash 1.1.1. AAH-1023B (CO2 analyzer) is provided at
Temperature Stripper (122-D2) Column (122-D1) leading to high the outlet of CO2 Absorber Overhead KO Drum.
temperature of semi-lean solution going to
CO2 Absorber. Potential reduction in
absorption capacity of semi-lean solution
resulting in increase in CO2 slippage from
Absorber.
7. Low 1. Lower reboiling in CO2 1.1. Potential low temperature in LP Flash 1.1.1. AAH-1023B (CO2 analyzer) is provided at
Temperature Stripper (122-D2) Column (122-D1) leading to high the outlet of CO2 Absorber Overhead KO Drum.
temperature of semi-lean solution going to
CO2 Absorber. Potential reduction in
absorption capacity of semi-lean solution
resulting in increase in CO2 slippage from
Absorber.
8. High Level 1. No new issue identified
9. Low Level 1. No new issue identified
Shutdown/
Maintenance
11. Composition 1. No issue identified
change/
Contamination/
Additional
Phase/ Loss
Phase
Failure position.
13. Others 1. Inadvertent closure of 1.1. Potential loss of suction to the semi- 25. Review the requirement of Rekayasa
MOV-1135/1137/1139 at lean solution pumps leading to damage of providing interlock to trip Semi-
suction of the semi-lean the pump. Potential seal failure. No toxic gas lean Solution Pumps (107-
solution pumps during is present in the liquid and only insignificant JA/JB/JC) in case of closure of
operation release of flammable gas. MOV-1135/1137/1139. Also,
consider providing start
permissive facility.
32 of 151
2. Inadvertent closure of 2.1. Potential damage to pump as they 26. Review the requirement of Rekayasa
MOV-1136/1138/1140 at might experience shut-off condition. Also, providing interlock to trip Semi-
discharge of the semi-lean the semi-lean amine solution is saturated lean Solution Pumps (107-
solution pumps during with CO2 and the CO2 in the solution may JA/JB/JC) in case of closure of
operation expand due to shut-off condition MOV-1136/1138/1140. Also,
temperatures leading to damage to seal and consider providing start
hazardous scenario. permissive facility.
3. HP Flash Column (163- 3.1. If this line is used during normal 155. Consider to reroute line Rekayasa
D) bottom is drained operation, possible flashing in the OASE MEA-1099-3" from the bottom of
accidentally to OASE Solution Storage Tank leading to HP Flash Column (163-D) to the
Solution Storage Tank overpressurization of the tank and damage. sump instead of OASE Solution
(114-F) during normal Storage Tank (114-F).
operation through MEA- Also provide spectacle blind on
1099-3"
the downstream of 3" valve
available on this line.
Node: 7. CO2 product system

Drawing: P2B-10-02-EF-62D110-R/ Rev 2; P2B-10-02-EF-62D120B-R/ Rev 2; P2B-10-02-EF-62D121-R/ Rev 2; P2B-10-02-EF-62D122A-R/ Rev 2

1. No/ Low Flow 1. Low flow of CO2 from LP 1.1. Potential low flow of CO2 to
Flash Column (122-D1) to downstream CO2 Compressor. Refer to
CO2 Stripper Reflux Drum Urea HAZOP.
(153-D) due to problem in
1.2. Potential low level in the reflux drum 1.2.1. FIC-1013 is provided to make-up the level
HP/LP Flash Column (163-
D/ 122-D) resulting in loss of suction and damage to with DM water.
CO2 LP Flash Reflux Pumps (110-J/JA).
1.2.2. LIC-1040 with low alarm is provided on the
reflux drum.
1.2.3. LSLL-1044 is provided on the reflux drum
with interlock I-110J to trip CO2 flash reflux
pumps.
2. FIC-1013 malfunctions 2.1. No significant consequence is expected
and closes FV-1013 on DM as the quantity of flow is very small.
water line
3. Inadvertent closure of 3.1. Potential overpressurization of the reflux 3.1.1. PV-1140A/B is provided on the CO2 line
MOV-1104 on CO2 line to drum. for venting.
CO2 Compressor
3.1.2. PRV-153D is provided on the CO2
33 of 151
Stripper Reflux Drum.

4. CO2 LP Flash Reflux 4.1. Potential loss of wash water to the 4.1.1. Pump running indication is provided in
Pump (110-J/JA) trips respective users. Discussed in respective DCS.
Nodes.
4.2. Potential high level in the reflux drum 4.2.1. Pump running indication is provided in
leading to liquid carryover with CO2 gas. DCS.
4.2.2. LIC-1040 with high alarm is provided on
the reflux drum.
4.2.3. LSH-1044 is provided on the reflux drum
to autostart the standby pump.
5. FIC-1016 malfunctions 5.1. Potential loss of wash water to LP Flash
and closes FV-1016 on Column. Refer to Node 5.
wash water line to LP Flash
Column (122-D)
2. More/ High 1. FIC-1013 malfunctions 1.1. Potential increase in dilution of the
Flow and opens FV-1013 more semi-lean amine solution in the system.
than required on DM water However no immediate consequences.
line
2. FIC-1016 malfunctions 2.1. Potential increase in wash water supply
and opens FV-1016 more to HP Flash Column (163-D). Refer to Node
than required on wash 5
water line to LP Flash
2.2. Potential loss of level in the reflux drum 2.2.1. LIC-1040 with low alarm is provided on the
Column (122-D)
resulting in loss of suction to the reflux reflux drum.
pump.
2.2.2. LSLL-1044 is provided on the reflux drum
with interlock I-110J to trip CO2 flash reflux
pumps.
3. Reverse/ 1. PIC-1104/ PV-1104A/B 1.1. Potential depressurization in the 1.1.1. Vent is routed to safe location.
Misdirected on the CO2 line to urea upstream system resulting in possible
Flow plant malfunctions and carryover of liquid with CO2 and venting of
opens CO2 to atmosphere.
1.2. Potential loss of CO2 supply to CO2
Compressor resulting in loss of suction.
Refer to Urea HAZOP.
4. More/ High 1. PIC-1104/ PV-1104A/B 1.1. Potential overpressurization of the reflux 1.1.1. PRV-153D is provided on the CO2
Pressure on the CO2 line to urea drum. Stripper Reflux Drum.
plant malfunctions and
does not open when
34 of 151
required
6. More/ High 1. Cooling water failure in 1.1. Potential high temperature CO2 to Urea 1.1.1. TAH-1406 is provided on the CO2 line to
Temperature CO2 Stripper Overhead plant. urea plant.
Condenser (110-C)
Temperature
Shutdown/
Maintenance
11. Composition 1. Upset in HP Flash 1.1. Possible contamination of CO2 with 19. Provide high alarm from AI- Rekayasa
change/ Column (163-D) hydrogen to CO2 Compressor. Potential 1103 (Hydrogen analyzer) on the
Contamination/ hazardous situation. CO2 line from CO2 Stripper
Additional Reflux Drum (153-D) to Urea
Phase/ Loss Plant.
Phase
Failure position.
13. Others 1. Tube leak in CO2 1.1. Potential leakage of cooling water to 1.1.1. LIC-1040 with high alarm is provided on
Stripper Overhead CO2 resulting in contamination of amine with the reflux drum.
Condenser (110-C) cooling water.
1.1.2. FIC-1016 with high alarm is provided at
pump discharge.

Node: 8. Lean Amine circuit
Drawing: P2B-10-02-EF-62D120A-R/ Rev 2; P2B-10-02-EF-62D120B-R/ Rev 2; P2B-10-02-EF-62D122-R/ Rev 2; P2B-10-02-EF-62D123-R/ Rev 2; P2B-10-02-EF-62D122A-R/ Rev
2; P2B-10-02-EF-62D121A-R/ Rev 2; P2B-10-02-EF-62D126-R/ Rev 2; P2B-10-02-EF-62D109-R/ Rev 2
1. No/ Low Flow 1. HV-1014/ HV-1016 1.1. Potential loss of suction to the semi- 27. Review the requirement of Rekayasa
closes on the suction of lean solution pumps leading to damage of providing interlock to trip Semi-
Semi-lean Circulating the pump. Potential seal failure. No toxic gas lean Solution Circulating Pumps
Pump (117-J/JA) is present in the liquid and only insignificant (117-J/JA) in case of closure of
release of flammable gas. HV-1014/1016 on the suction of
35 of 151
the pump. Also, consider
providing start permissive facility.
2. Semi-lean Circulating 2.1. Possible increase in level in LP Flash 2.1.1. Pump running indication is provided in
Pump (117-J/JA) trips Column (122-D1) (as the major part of flow DCS.
is going to 107-JA/JB/JC). In adverse
2.1.2. Standby pump is available which can be
scenario, liquid may carryover to CO2
Stripper Reflux Drum (153-D). started from the control room using HS-
1047/1048.
2.1.3. LAH-1041 is provided on the LP Flash
Column.
the CO2 Stripper reflux drum.
2.2. Potential loss of level in CO2 Stripper 2.2.1. Standby pump is available.
(122-D2) leading to loss of suction to Lean
2.2.2. Pump running indication is provided in
OASE Solution Pumps (108-J/JA) and
damage. Possible release of lean amine DCS.
solution. 2.2.3. LAL-1043A/B/C is provided on the CO2
This may lead to loss of amine to CO2 Stripper (122-D2)
Absorber. Refer to Node 5 for further 2.2.4. LSLL-1043 (2oo3) is provided with
discussion. interlock I-108J on the CO2 Stripper to trip Lean
OASE Solution Pumps (108-J/JA)
3. HV-1015/ HV-1017 3.1. Potential damage to pump as they 28. Review the requirement of Rekayasa
closes on the discharge of might experience shut-off condition. Also, providing interlock to trip Semi-
Semi-lean Circulating the semi-lean amine solution is saturated lean Solution Circulating Pumps
Pump (117-J/JA) with CO2 and the CO2 in the solution may (117-J/JA) in case of closure of
expand due to shut-off condition HV-1015/1017 available on the
temperatures leading to damage to seal and discharge of the pump. Also,
hazardous scenario. consider providing start
4. Plugging of OASE 4.1. Potential dirt accumulation in the amine 4.1.1. Backwash facility is provided to clean the
Solution Filter (104-L) solution in long run. filter during which the slip stream can be
stopped.
5. LIC-1042/ FIC-1017 5.1. Potential damage to semi-lean 5.1.1. FV-1017 is provided with minimum
malfunctions and closes circulating pump due to blocked condition at mechanical stop.
FV-1017 on the lean-amine discharge.
solution line to Lean Semi-
5.2. Potential loss of cooling for lean amine 5.2.1. LAL-1043A/B/C is provided on the CO2
Lean Solution Exchanger
(112-C) solution from CO2 Stripper (122-D2). Stripper (122-D2)
However, eventual loss of level in the
5.2.2. LSLL-1043 (2oo3) is provided on the CO2
Stripper, leading to loss of suction to Lean
36 of 151
OASE Solution Pumps (108-J/JA) and Stripper to trip Lean OASE Solution Pumps
damage. Possible release of lean amine (108-J/JA)
solution
This may lead to loss of amine to CO2
Absorber (121-D). Refer to Node 5 for

further discussion.
6. Plugging of strainer 6.1. Same as consequence 5.1 and 5.2 6.1.1. PDG-1062 is provided across the strainer.
SP/STR-112-C1/CA1 above. However, the severity of the
provided upstream of Lean consequence is lesser.
Semi-Lean Solution
Exchanger (112-C)
7. Plugging of the strainer 7.1. No immediate consequences foreseen 7.1.1. PDG-1061 is provided across the strainer.
SP/STR-112-C available as a part of the stream is flowing through
line to Lean Solution Lean Solution Water Cooler (108-C) and to
Demin Water Preheater the suction of Lean OASE Solution Pumps
(109-C) (108-J/JA).
8. No flow of DM water in 8.1. Potential loss of cooling of amine 8.1.1. TAH-1672 is provided on the amine
Lean Solution Demin solution in Lean Solution Demin Water solution line to Lean OASE Solution Pumps
Water Preheater (109-C) Preheater (109-C). However, the duty of this (108-J/JA).
exchanger is lower and major part of cooling
is done in Lean Solution Water Cooler (108-
C/CA). Hence, no major consequence
foreseen.
9. No flow of cooling water 9.1. Potential loss of cooling of amine 9.1.1. Lean Solution Pump (108-J/JA) is
in Lean Solution Water solution which may lead to high temperature designed for maximum lean amine temperature
Cooler (108-C/CA) of amine solution to Lean OASE Solution from upstream.
Pumps (108-J/JA) and eventually to CO2
9.1.2. TAH-1672 is provided on the amine
Absorber (121-D).
solution line to Lean OASE Solution Pumps
For impact on CO2 Absorber refer to Node (108-J/JA).
5.
10. Inadvertent closure of 10.1. Potential loss of suction to the lean 29. Review the requirement of Rekayasa
MOV-1264/1266 on the solution pumps leading to damage of the providing interlock to trip Lean
suction of Lean OASE pump. Potential seal failure. No toxic gas is OASE Solution Pumps (108-J/JA)
Solution Pumps (108-J/JA) present in the liquid and only insignificant in case of closure of MOV-
release of flammable gas. 1264/1266 on the suction of the
pump. Also, consider providing
start permissive facility.
11. Lean OASE Solution 11.1. Potential increase in level in CO2 11.1.1. Pump running indication is provided in
37 of 151
Pump (108-J/JA) trips Stripper (122-D2). DCS.
11.1.2. Standby pump is available.
Stripper which will control the amine flow to
absorber.
11.1.4. PSLL-1116 with alarm is provided in the
lean amine solution line with interlock I-1116 at
pump discharge to autostart the standby pump.
11.2. Potential loss of seal flushing solution 11.2.1. PAL-1117 provided on the seal flush line
to semi-lean solution pump, semi-lean at pump discharge will open XV-1117 to let in
circulating pump and lean amine pump. process condensate for seal flushing.
11.3. Potential loss of amine solution to CO2
Absorber (121-D). Refer to Node 5.
12. Inadvertent closure of 12.1. Potential damage to pump as they 30. Review the requirement of Rekayasa
MOV-1265/1267 on the might experience shut-off condition. Also, providing interlock to trip the Lean
discharge of Lean OASE the lean amine solution may contain small OASE Solution Pumps (108-J/JA)
Solution Pump (108-J/JA) amount of CO2 and the CO2 in the solution in case of closure of MOV-
may expand due to shut-off condition 1265/1267 on the discharge of
temperatures leading to damage to seal and the pump. Also, consider
hazardous scenario. providing start permissive facility.
13. FIC-1014 malfunctions 13.1. Potential damage to lean suction pump 13.1.1. Adjustable mechanical stop is provided
and closes FV-1014 on the as it will experience shutoff condition. for FV-1014.
lean amine solution line to
14. No flow of anti-foam 14.1. As this is an intermittent flow, no 14.1.1. PDT-1064 with high alarm are available
from upstream to CO2 serious consequences foreseen. in the CO2 Stripper.
Stripper (122-D2) due to
any reason
injection stops, possible upset in CO2 keep the antifoam injection system healthy.
Stripper due to higher delta P and in adverse
case carryover of OASE solution to LP Flash
Column (122-D1) and in turn to Urea Plant.
2. More/ High 1. LIC-1042/ FIC-1017 1.1. Potential more flow of lean-amine 1.1.1. PDAH-1064 is provided on the Stripper. 31. Provide high alarm from LI- Rekayasa
Flow malfunctions and opens solution to CO2 Stripper leading to high level 1043A/B/C on the CO2 Stripper
1.1.2. LIC-1042 with high alarm may be available
FV-1017 more than in CO2 Stripper. This may lead to flooding of (122-D2).
required on the lean-amine the Stripper column and inefficient stripping if it is not the cause of failure.
solution line to Lean Semi- of the solution. Potential for high differential 1.1.3. AAH-1023B (CO2 analyzer) is provided at
Lean Solution Exchanger pressure in the Stripper. Eventually, the outlet of CO2 Absorber Overhead KO Drum.
inefficient absorption of CO2 in CO2
38 of 151
(112-C) Absorber resulting in slippage of CO2.
1.2. Potential loss of level in LP Flash
Column. Refer to Node 6.
2. FIC-1014 malfunctions 2.1. Potential loss of level in CO2 Stripper 2.1.1. LAL-1043A/B/C is provided on the CO2
and opens FV-1014 more leading to loss of suction to Lean OASE Stripper (122-D2)
than required on the lean Solution Pumps (108-J/JA) and damage.
2.1.2. LSLL-1043 (2oo3) is provided with
amine solution line to CO2 Possible release of lean amine solution.
Absorber (121-D) interlock I-108J on the CO2 Stripper to trip Lean
This may lead to more flow of amine to CO2 OASE Solution Pumps (108-J/JA).
Absorber. Refer to Node 5 for further
discussion.
3. Reverse/ 1. No new issue identified
Misdirected
Flow
4. More/ High 1. Higher pressure due to 1.1. Potential overpressurization of LP Flash 1.1.1. PRV-153D is provided on the CO2
Pressure blockage of CO2 product in Column (122-D1), CO2 Stripper and CO2 Stripper Reflux Drum and sized for CO2
downstream Stripper reflux drum. blockage case.
5. Low Pressure 1. Higher suction of CO2 1.1. Potential lower pressure in the lean- 1.1.1. VRV-122D1 is provided on the LP Flash
Compressor amine/amine system which may result in Column.
vacuum condition.
1.1.2. LP Flash Column and Stripper are
designed for half vacuum condition.
2. Condensation of steam 2.1. Potential vacuum formation leading to 2.1.1. VRV-122D1 is provided on the LP Flash
in Stripper during damage. Column.
shutdown/ maintenance
2.1.2. Stripper is designed for half vacuum
condition.
6. More/ High 1. Higher reboiling 1.1. Potential high differential pressure in 1.1.1. PDAH-1064 is provided on the Stripper.
Temperature CO2 Stripper.
1.2. Potential high semi-lean solution
temperature. Refer to Node 6.
7. Low 1. Lower reboiling 1.1. Possible inefficient stripping of solution 1.1.1. AAH-1023B (CO2 analyzer) is provided at
Temperature in the CO2 Stripper going to CO2 Absorber. the outlet of CO2 Absorber Overhead KO Drum.
Eventually, inefficient absorption of CO2 in
1.1.2. Sample point S-1414 is available lean
CO2 Absorber resulting in slippage of CO2.
amine solution line at the outlet of 108-C/CA
39 of 151
10. Start-up/ 1. Positive isolation of 1.1. Potential for passing of HV- 32. Consider replacing the Rekayasa
Shutdown/ Semi-Lean Solution 1015/1017/1016/1014 as they are of butterfly butterfly valve with gate valve for
Maintenance Circulating Pumps (117- type. HV-1014/1015/1016/1017 at
J/JA) suction and discharge of Semi-
lean Solution Circulating Pump
(117-J/JA).
33. Consider providing MOV Rekayasa
instead of HV for HV-
1014/1015/1016/1017 at suction
and discharge of Semi-lean
Solution Circulating Pump (117-
J/JA).
11. Composition 1. No new issue identified
change/
Contamination/
Additional
Phase/ Loss
Phase
Failure position.
13. Others 1. No issue identified

Node: 9. Process condensate from Raw Gas Separator to Process Condensate Stripper and steam from overhead of Stripper to Primary Reformer and treated condensate to utility unit.
Drawing: P2B-10-02-EF-62D110-R/ Rev 2; P2B-10-02-EF-62D119A-R/ Rev 2; P2B-10-02-EF-62D120-R/ Rev 2
1. No/ Low Flow 1. Process Condensate 1.1. No consequence of loss of level in PC

Pump for 142-D1 (121- Stripper as the level control valve LIC-1025/
J/JA) trips LV-1025 will maintain the level.
1.2. Potential reverse flow of steam from PC 1.2.1. SP-ARV-121J/JA is provided at the pump 34. Ensure that SP-ARV-121J/JA Rekayasa
Stripper (130-D) to PC Pump (121-J/JA) as discharge which will act as check valve to provided at Process Condensate
the Stripper is operated at 46 kg/cm2G. prevent the reverse flow. Pumps for 142-D1 (121-J/JA)
discharge is meeting the NRV
requirement.
1.3. Potential damage to Condensate 35. Provide check valve on the Rekayasa
Stripper Feed Effluent Exchanger (188- process condensate inlet to the
Process Condensate Stripper
40 of 151
C1/C2/C3) as it is designed for 300 degC. (130-D).

2. LIC-1003 malfunctions 2.1. Potential loss of PC to PC Stripper (130-
and closes LV-1003A/B on D). However, no major consequence.
PC line at pump discharge
2.2. PC pump for 142-D1 (121-J/JA) will 2.2.1. SP-ARV-121J/JA is provided at the pump
experience shut off condition. discharge.
3. FIC-1019 malfunctions 3.1. Potential loss of MP steam to PC 3.1.1. AIN-1017/ AV-1017 with high alarm is
and closes FV-1019 on MS Stripper (130-D) resulting in loss of stripping provided on the condensate line to divert PC to
line to Process and offspec condensate to condensate tank. waste water header on high conductivity.
Condensate Stripper (130-
D)
4. LIC-1025 malfunctions 4.1. Potential increase in level in PC Stripper 4.1.1. LSHH-1029 is provided on the Stripper
and closes LV-1025 on PC (130-D) leading to possible carryover of with interlock I-130D to close the Stripper feed
line at the outlet of water to process steam resulting in process LV-1003A.
Condensate Stripper Feed upset including possible catalyst damage.
4.1.2. TAL-1646 is provided on the MP steam
Effluent Exchanger (188- Inefficient stripping.
C3) header to process.
4.2. Potential loss of cooling for stripped 4.2.1. TAH-1652 is provided on the PC line to
condensate going to condensate tank. Also, condensate tank.
loss of heating for condensate to Stripper
4.2.2. LSHH-1029 is provided on the Stripper
(130-D).
with interlock I-130D to close the Stripper feed
LV-1003A.
5. AIN-1017/ AV-1017 5.1. Potential loss of on-spec condensate to
malfunctions and diverts waste water header. However, no major
the on-spec condensate to consequence.
waste water header
6. AIN-1017/ AV-1017 6.1. No major consequence is foreseen as 6.1.1. Sample point S-1902 is provided on the
malfunctions and diverts the condensate is treated in downstream. PC line upstream of AV-1017.
the off-spec condensate to
condensate tank
2. More/ High 1. LIC-1003 malfunctions 1.1. Potential increase in level in PC Stripper 1.1.1. TAL-1646 is provided on the MP steam
Flow and opens LV-1003A/B (130-D) leading to possible entrainment of header to process.
more than required on PC water to process steam resulting in decrease
line at pump discharge in temperature of process steam. However,
no immediate consequence as level control
valve LIC-1025 will maintain the level.
1.2. Potential more flow going to check pit. 1.2.1. LAH-4303 is provided on the checkpit.
However, no consequence as it is an open
pit.
2. FIC-1019 malfunctions 2.1. Potential high differential pressure in the 2.1.1. PDAH-1069/ PDAHH-1069 is provided on
41 of 151
and opens FV-1019 more Stripper resulting in entrainment of water the PC Stripper.
than required on MS line to with steam.
2.1.2. TAL-1646 is provided on the MP steam
Process Condensate
Stripper (130-D) header to process.
3. LIC-1025 malfunctions 3.1. Potential loss of level in PC Stripper 3.1.1. TAH-1652 is provided on the PC line to 36. Confirm that PRV-174C is Rekayasa
and opens LV-1025 more (130-D). In adverse case, steam/ gas blowby condensate tank. suitable for releasing the pressure
than required on PC line at to condensate tank and possible (steam blowby case) during LV-
3.1.2. LSLL-1029 is provided on the Stripper with
the outlet of Condensate overpressurization of downstream. (Normally 1025 full open scenario.
Stripper Feed Effluent condensate flows to tank and stripped interlock I-130D to close the Stripper feed LV-
Exchanger (188-C3) condensate is directed to waste water 1003A.
header when offspec.) 3.1.3. PRV-174C (set at 9 kg/cm2G) is provided
on the outlet of 188-C3.
3. Reverse/ 1. No new issue identified
Misdirected
Flow
4. More/ High 1. Blocked condition 1.1. Potential overpressure in process 1.1.1. PRV-174C (set at 9 kg/cm2G) is provided
Pressure downstream of process condensate line to tank. on the outlet of 188-C3.
condensate line
5. Low Pressure 1. Condensation of steam 1.1. Potential vacuum formation in the PC 1.1.1. PC Stripper is designed for full vacuum
in Process Condensate Stripper. condition.
Stripper (130-D)
6. More/ High 1. Cooling water failure to 1.1. Potential high temperature of PC to 1.1.1. TAH-1652 is provided on the PC line to
Temperature Stripped Condensate process condensate tank. condensate tank.
Cooler (174-C)
7. Low 1. Low temperature of MP 1.1. Potential inefficient stripping of process
Temperature steam to Process condensate in the Stripper. However, no
Condensate Stripper (130- significant consequence foreseen.
D)
10. Start-up/ 1. Requirement of autostart 1.1. Possible thermal shock and damage as 37. Review the requirement of Rekayasa
Shutdown/ of standby process the pump is operated at about 70 degC. warm-up line across SP-ARV-
Maintenance condensate pump 121J/JA for Process Condensate
Pumps for 142-D1 (121-J/JA).
2. Requirement of 2.1. Potential high temperature in LTSC 38. KBR recommends to add Rekayasa
temperature control of catalyst. BFW line from outlet of LTS
BFW from LTS Effluent/ Effluent/ BFW Preheater (131-C)
BFW Preheater (131-C) to Process Condensate Stripper
(130-D) as specified in KBR basic
42 of 151
during start-up engineering package.

11. Composition 1. High methanol/ 1.1. Potential off-spec condensate leading to 1.1.1. AIN-1017/ AV-1017 with high alarm is
change/ ammonia generation in high conductivity. provided on the condensate line to divert PC to
Contamination/ LTSC waste water header on high conductivity.
Additional
1.1.2. Sample point S-1901/02 is provided on the
Phase/ Loss
Phase PC line upstream of AV-1017.

Failure position.
13. Others 1. Tube leak in Condensate 1.1. Potential contamination of clean 1.1.1. AIN-1017/ AV-1017 with high alarm is
Stripper Feed Effluent condensate with untreated condensate as provided on the condensate line to divert PC to
Exchanger (188-C1/C2/C3) the tube and shell side are designed for waste water header on high conductivity.
same pressure.
2. Tube leak in Stripped 2.1. Potential leakage of process
Condensate Cooler (174- condensate to cooling water return header.
C1/C2) No significant consequence foreseen.

Node: 10. Process Air Compressor and air supply to Secondary Reformer including Hot and Cold Process air coil.
Drawing: P2B-10-02-EF-62D101-R/ Rev 2; P2B-10-02-EF-62D101A-R/ Rev 2; P2B-10-02-EF-62D101B-R/ Rev 2; P2B-10-02-EF-62D105-R/ Rev 2; P2B-10-02-EF-62D106-R/ Rev
2; P2B-10-02-EF-62D107-R/ Rev 2
1. No/ Low Flow 1. Plugging of Air Filter 1.1. Potential low suction pressure to 1st 1.1.1. PDAH-4100 is provided across the filter.
Package (101-L) stage of Process Air Compressor (101-J)
1.1.2. TAH-6142 is provided at the 1st stage
leading to high discharge temperature.
However, the chances of plugging is remote discharge of Process Air Compressor (101-J).
as Air Filter (101-L) is multistage automatic
self cleaning type.
2. Process Air Compressor 2.1. Loss of process air to Secondary
(101-J) trips Reformer and Cold Process Air Coil. For
discussion on this issue, refer to Node 3.
2.2. Potential loss of passivation air to CO2
Compressor. Refer to Urea HAZOP.
2.3. Potential loss of plant air to the OSBL.
Refer to OSBL HAZOP.
3. No flow of cooling water 3.1. Potential increase in air temperature 3.1.1. TAH-6141 is provided at 2nd stage suction 40. Review the design conditions Rekayasa/
to 101-J Stage-1 going to 2nd stage Process Air Compressor in consultation with Vendor for the Intercoolers
43 of 151
2; P2B-10-02-EF-62D107-R/ Rev 2
Intercooler (101-JC1) (101-J) suction and possible damage. of Process Air Compressor (101-J). Intercoolers (101-J Stage-1 Vendor/
Intercooler (101-JC1), 101-J Separator
Stage-2 Intercooler (101-JC2), Vendor
and 101-J Stage-3 Intercooler
(101-JC3)) and Separators
(Separator for 101-JC1 (101-
JD1), Separator for 101-JC2
(101-JD2) and Separator for 101-
JC3 (101-JD3)) with reference to
cooling water failure.
4. No flow of condensate 4.1. Potential high level in 1st Stage 4.1.1. LAH-1235A/B/C is provided on the 1st 42. Consider replacing the control Rekayasa
from Separator for 101-JC1 Separator (101-JD1). Potential liquid Stage Separator (101-JD1). valves LV-1006/1007/1008 at the
(101-JD1) due to carryover to 2nd stage of Process Air 1st, 2nd and 3rd stage Separator
4.1.2. LSHH-1235 (2oo3) is provided on the 1st
malfunction and closure of Compressor (101-J) and damage to (101-JD1/JD2/JD3) respectively
LIC-1006/ LV-1006 Compressor. Also, air coil damage due to Stage Separator (101-JD1) with interlock I-101J with required no of condensate
less flow. to trip Process Air Compressor (101-J). traps as per KBR basic
5. Plugging of 2nd stage 5.1. Potential low suction pressure to 2nd 5.1.1. TAH-6143 is provided at the 2nd stage 43. Provide differential pressure Rekayasa
suction strainer SP-STR- stage of Process Air Compressor (101-J) discharge of Process Air Compressor (101-J). measurements with high alarm
101J2 leading to high discharge temperature. Also, across the 2nd, 3rd and 4th stage
reduction in Compressor capacity and suction strainers for Process Air
increased power consumption. Compressor (101-J) as per KBR
basic engineering package.
6. No flow of cooling water 6.1. Potential increase in air temperature 6.1.1. TAH-6152 is provided at 2nd stage suction 40. Review the design conditions Rekayasa/
to 101-J Stage-2 going to 3rd stage suction and possible of Process Air Compressor (101-J). in consultation with Vendor for the Intercoolers
Intercooler (101-JC2) damage. Intercoolers (101-J Stage-1 Vendor/
7. No flow of condensate 7.1. Potential high level in 2nd Stage 7.1.1. LAH-1236A/B/C is provided on the 2nd 42. Consider replacing the control Rekayasa
from Separator for 101-JC2 Separator (101-JD2). Potential liquid Stage Separator (101-JD2). valves LV-1006/1007/1008 at the
(101-JD2) due to carryover to 3rd stage Process Air 1st, 2nd and 3rd stage Separator
malfunction and closure of Compressor (101-J) and damage to (101-JD1/JD2/JD3) respectively
LIC-1007/ LV-1007 Compressor. Also, air coil damage due to stage separator 101-JD2 with interlock I-101J to with required no of condensate
less flow. trip Process Air Compressor (101-J). traps as per KBR basic
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8. Plugging of 3rd stage 8.1. Potential low suction pressure to 3rd 8.1.1. TAH-6146 is provided at the 3rd stage 43. Provide differential pressure Rekayasa
suction strainer SP-STR- stage Compressor leading to high discharge discharge of Process Air Compressor (101-J). measurements with high alarm
101J3 temperature. Also, reduction in Compressor across the 2nd, 3rd and 4th stage
capacity and increased power consumption. suction strainers for Process Air
Compressor (101-J) as per KBR
9. No flow of cooling water 9.1. Potential increase in air temperature 9.1.1. TAH-6155 is provided at 4th stage suction 40. Review the design conditions Rekayasa/
to 101-J Stage-3 going to 4th stage suction and possible of Process Air Compressor (101-J). in consultation with Vendor for the Intercoolers
Intercooler (101-JC3) damage. Intercoolers (101-J Stage-1 Vendor/
44. Provide high alarm from TT- Rekayasa
6150 on 4th stage discharge of
Process Air Compressor (101-J).
41. Provide high high temperature Rekayasa/
trip from 4th stage discharge of Compressor
Process Air Compressor (101-J) Vendor
to trip 101-J in consultation with
Compressor Vendor.
10. No flow of condensate 10.1. Potential high level in 3rd stage 10.1.1. LAH-1237A/B/C is provided on the 3rd 42. Consider replacing the control Rekayasa
from Separator for 101-JC3 separator 101-JD3. Potential liquid carryover Stage Separator (101-JD3) valves LV-1006/1007/1008 at the
(101-JD3) due to to 4th stage Process Air Compressor (101-J) 1st, 2nd and 3rd stage Separator
10.1.2. LSHH-1237 (2oo3) is provided on the 3rd
malfunction and closure of and damage to Compressor. Also, air coil (101-JD1/JD2/JD3) respectively
LIC-1008/ LV-1008 damage due to less flow. stage separator 101-JD3 with interlock I-101J to with required no of condensate
trip Process Air Compressor (101-J). traps as per KBR basic
11. Plugging of 4th stage 11.1. Potential low suction pressure to 3rd 11.1.1. TAH-6155 is provided at 4th stage 43. Provide differential pressure Rekayasa
suction strainer SP-STR- stage Compressor leading to high discharge suction of Process Air Compressor (101-J). measurements with high alarm
101J4 temperature. Also, reduction in Compressor across the 2nd, 3rd and 4th stage
capacity and increased power consumption. suction strainers for Process Air
Compressor (101-J) as per KBR
44. Provide high alarm from TT- Rekayasa
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6150 on 4th stage discharge of
Process Air Compressor (101-J).
41. Provide high high temperature Rekayasa/
trip from 4th stage discharge of Compressor
Process Air Compressor (101-J) Vendor
to trip 101-J in consultation with
Compressor Vendor.
12. PIC-2200 malfunctions 12.1. No significant consequence is
and closes PV-2200 on expected on the Compressor as the flow is
passivation air line to CO2 very small.
Compressor
12.2. For impact on Urea plant, refer to Urea
HAZOP.
13. FIC-1004 malfunctions 13.1. Blocked condition at Compressor 45. Consider providing a PRV on Rekayasa
and does not open FV- discharge leading to overpressurization and the 4th stage discharge of
1004 when required damage to Compressor. Process Air Compressor (101-J)
as per KBR basic engineering
package.
14. XV-1212 malfunctions 14.1. Blocked condition at Compressor 14.1.1. FIC-1004/FV-1004 antisurge valve is
and closes discharge leading to overpressurization and provided to release the pressure to atmosphere.
damage to Compressor.
14.2. Potential overheating of the air preheat 14.2.1. FSLL-1203 is provided with interlock I-
coil 101-BCA1. 10J which will open FV-1044 to let in MP steam
to the coils.
14.2.2. TAH-1325 is provided on the air preheat
coil.
14.2.3. TAH-1044 is provided on 101-BCA1.
14.2.4. TIC-1312 with high alarm is provided on
the hot process air coil 101-BCA2.
15. FIC-1044 malfunctions 15.1. Potential overheating of the air preheat 15.1.1. TIC-1044 is provided on the air coil to
and does not open FV- coil 101-BCA1 and damage during start-up/ open TV-1044 to let in BFW.
1044 on MP steam line to shutdown or Compressor tripping case.
15.1.2. TAH-1325 is provided on the air coil and
Cold Process Air Coil (101-
BCA1) during process air operating instructions are provided to open the
cutoff to Secondary bypass valve on TAH-1325.
Reformer
16. TIC-1044 malfunctions 16.1. Potential overheating of the air preheat 16.1.1. TIC-1312 with high alarm is provided on
and does not open TV- coil 101-BCA1 and damage during start-up/ the hot process air coil 101-BCA2
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1044 on BFW line to Cold shutdown or Compressor tripping case. 16.1.2. Operating instructions are provided to
Process Air Coil (101- increase the steam flow to 101-BCA1 through
BCA1) during start-up/ FIC-1044/FV-1044.
shutdown
17. No supply of BFW to 17.1. Potential overheating of the air preheat 17.1.1. TAH-1044 is provided on 101-BCA1.
Cold Process Air Coil (101- coil 101-BCA1 and damage during start-up/
BCA1) shutdown or Compressor tripping case.
the hot process air coil 101-BCA2
17.1.3. Operating instructions are provided to
increase the steam flow to 101-BCA1 through
FIC-1044/FV-1044.
2. More/ High 1. More flow of condensate 1.1. Potential loss of suction pressure and in 1.1.1. FAL-1004 is available at the 4th stage 46. Provide low alarm from LT- Rekayasa
Flow from Separator for 101-JC1 turn may lead to less flow of air to discharge. 1235A/B/C on Separator for 101-
(101-JD1) due to downstream. In adverse case, damage to JC1 (101-JD1).
malfunction and opening of 2nd stage of Compressor and possible trip
42. Consider replacing the control Rekayasa
LIC-1006/ LV-1006 of Compressor.
valves LV-1006/1007/1008 at the
1st, 2nd and 3rd stage Separator
(101-JD1/JD2/JD3) respectively
with required no of condensate
traps as per KBR basic
2. More flow of condensate 2.1. Potential loss of suction pressure and in 2.1.1. FAL-1004 is available at the 4th stage 47. Provide low alarm from LT- Rekayasa
from Separator for 101-JC2 turn may lead to less flow of air to discharge. 1236A/B/C on Separator for 101-
malfunction and opening of 3rd stage of Compressor and possible trip of
LIC-1007/ LV-1007 Compressor.
3. More flow of condensate 3.1. Potential loss of suction pressure and in 3.1.1. FAL-1004 is available at the 4th stage 48. Provide low alarm from LT- Rekayasa
from Separator for 101-JC3 turn may lead to less flow of air to discharge. 1237A/B/C on Separator for 101-
malfunction and opening of 4th stage of Compressor and possible trip of
LIC-1008/ LV-1008 Compressor.
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4. PIC-2200 malfunctions 4.1. Potential loss of suction pressure to 4th 4.1.1. FAL-1004 is available at the 4th stage 49. Provide high alarm from FT- Rekayasa
and opens PV-2200 more stage and in turn may lead to less flow of air discharge. 1000 on passivation air line to
than required on to downstream. In adverse case, damage to CO2 Compressor.
passivation air line to CO2 4th stage of Compressor and possible trip of
Compressor Compressor.
4.2. Possible overpressurization of the 50. Review the requirement of Rekayasa
passivation line leaving the battery limit suitable safeguard to protect the
because the line may be subjected to 4th passivation line to CO2
stage suction pressure. Potential damage to Compressor in the case PIC-2200
the line as it is not design for 4th stage malfunctions and opens PV-2200.
suction pressure.
3. Reverse/ 1. FIC-1004 malfunctions 1.1. Potential loss of air flow to the 1.1.1. FSLL-1203 (process air) (2oo3) is
Misdirected and opens FV-1004 when Secondary Reformer resulting in eventual provided on the process air line with interlock I-
Flow not required plant trip. 101J will do the following actions:
a) Opens FV-1044 to allow MP steam into the
coil.
b) Ramps down the Primary Reformer to
minimum firing through PIC-1002 (Arch burners)
c) Feed gas forced into auto mode to ramps
down to minimum firing through FIC-1001
Burners
106-D.
1.2. Potential overheating of the air preheat 1.2.1. FSLL-1203 is provided with interlock I-10J
coil 101-BCA1. which will open FV-1044 to let in MP steam to
the coils.
coil.
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FIC-1044/ FV-1044.
2. FIC-1044 malfunctions 2.1. Possible condensation of the LTSC 2.1.1. TIC-1312 is provided with low alarm on
and opens FV-1044 on MP catalyst due to increased steam content in the Hot process air coil 101-BCX to close TV-
steam line to Cold Process the feed. Also, possible low temperature in 1312 on the bypass line.
Air Coil (101-BCA1) during the process air coil outlet of the Primary
normal operation Reformer (101-B).
bypass LTSC.
2.2. Potential reduction in the quantity of MP
steam exported to OSBL. However, no
significant consequence to the ammonia
plant.
3. TIC-1044 malfunctions 3.1. Possible low temperature in the process 3.1.1. TIC-1312 is provided with low alarm on
and opens TV-1044 on air coil outlet of the Primary Reformer (101- the Hot process air coil 101-BCX to close TV-
BFW line to Cold Process B). 1312 on the bypass line.
Air Coil (101-BCA1) during
normal operation
4. HIC-1020 malfunctions 4.1. Potential loss of air flow to the 4.1.1. FSLL-1203 (process air) (2oo3) is
and opens HV-1020 on the Secondary Reformer resulting in eventual provided on the process air line with interlock I-
2nd stage discharge when plant trip. 101J will do the following actions:
not required a) Opens FV-1044 to allow MP steam into the
coil.
b) Ramps down the Primary Reformer to
minimum firing through PIC-1002 (Arch burners)
c) Feed gas forced into auto mode to ramps
down to minimum firing through FIC-1001
Burners
106-D.
4.2. Potential overheating of the air preheat 4.2.1. FSLL-1203 is provided with interlock I-10J
coil 101-BCA1. which will open FV-1044 to let in MP steam to
the coils.
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coil.
FIC-1044/FV-1044.
5. Passing of TV-1044 5.1. Possible low temperature in the process 5.1.1. TIC-1312 is provided with low alarm on 52. Review the requirement of Rekayasa
bypass valve in due course air coil outlet of the Primary Reformer (101- the Hot process air coil 101-BCX to close TV- providing an additional gate valve
of time as upstream BFW B). 1312 on the bypass line. along with the available globe
is at about 130 kg/ cm2G valve on the bypass line of TV-
1044.
6. Tripping of Process Air 6.1. Potential reverse flow of plant air back 6.1.1. Standby air Compressor is available in the 53. Consider providing an NRV Rekayasa
Compressor (101-J) to the Compressor leading to low pressure utility. However, the same is connected to this on the line to PA header from the
of instrument air. line. 4th stage suction of Process Air
Compressor (101-J) to avoid
depressurization of the
Instrument air system.
6.2. Potential reverse flow of process gas 6.2.1. Check valve is provided on 4th stage
into Process Air Compressor and damage. Compressor discharge.
6.2.2. Continuous steam flow to the process air
coils through the bypass line of FV-1044.
6.2.3. FSLL-1203 is provided with interlock I-10J
which will open FV-1044 to let in MP steam to
the coils.
6.2.4. Interlock I-101J is provided to close XV-
1212 on the Compressor discharge line on
tripping of process air Compressor.
Pressure
6. More/ High 1. TIC-1312 malfunctions 1.1. Potential high temperature of process 1.1.1. TAH-1044 is provided on the outlet cold
Temperature and closes TV-1312 on the air to hot air coil and then to Secondary process air coil.
bypass line of process air Reformer. Possible overheating of the hot air
1.1.2. Desuperheater is provided to control the
coil coil which may lead to reaching of design
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temperature of the hot air coil. process air temperature.
7. Low 1. TIC-1312 malfunctions 1.1. Potential low temperature of process
Temperature and opens TV-1312 on the gas (downstream of Desuperheater) to
bypass line of process air Secondary Reformer. However, no major
coil consequence foreseen.
1.2. Potential overheating of the cold 1.2.1. TAH-1325 is provided on the air preheat
process air coil. coil.
10. Start-up/ 1. Introduction of huge 1.1. Potential damage of the catalyst/ 54. Provide MOV (with inching Rekayasa
Shutdown/ amount of air suddenly to refractory due to high/ sudden flow of air to facility) on the process air line
Maintenance Secondary Reformer (103- Secondary Reformer (103-D). from 4th stage discharge of
D) through XV-1212 (full Process Air Compressor (101-J)
open) during start-up to Secondary Reformer (103-D) to
control the process air flow during
start-up as per KBR basic
This valve should also close on
interlocks as per KBR basic

1.2. Potential damage to catalyst/ refractory 54. Provide MOV (with inching Rekayasa
in Secondary Reformer due to high facility) on the process air line
temperature (due to excess air) of process from 4th stage discharge of
air. Process Air Compressor (101-J)
to Secondary Reformer (103-D) to
control the process air flow during
start-up as per KBR basic
This valve should also close on
interlocks as per KBR basic

2. Blowing of feed pre-heat 2.1. Currently, the line for blowing of feed 55. Provide line for blowing of Rekayasa
coil, mixed feed preheat pre-heat coil, mixed feed preheat coil and feed pre-heat coil, mixed feed
coil and dedusting of dedusting of primary and Secondary preheat coil and dedusting of
primary and Secondary Reformer catalyst with process air is not catalyst with process air from
Reformer (103-D) catalyst provided. Process Air Compressor (101-J)
with process air during pre- discharge as per KBR basic
commissioning engineering package.
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change/
Contamination/
Additional
Phase/ Loss
Phase
Failure position.
13. Others 1. Spec break on the line 1.1. 4th stage suction is operating at 16 51. Review the requirement of Rekayasa
leading to PA header from kg/cm2G which may lead to suitable safeguard to protect the
4th stage suction of overpressurization of the line to PA header Plant air line from 4th stage
Process Air Compressor and damage. suction of Process Air
(101-J) Compressor (101-J) to PA header
as the upstream is operating at
16 kg/cm2G.
2. Tube leak in 101-J 2.1. Potential leakage of CW into air circuit 2.1.1. LAH-1235A/B/C is provided on the 1st
Stage-1 Intercooler (101- leading to high condensate level in the Stage Separator (101-JD1).
JC1) separator.
stage Separator (101-JD1) with interlock I-101J
to trip the Compressor.
3. Tube leak in 101-J 3.1. Potential leakage of air into cooling
Stage-2 Intercooler (101- water side. However, no significant
JC2) consequence as shell and tube are designed
for similar pressures.
4. Tube leak in 101-J 4.1. Potential leakage of air into cooling 4.1.1. RD-1003 is provided on the cooling water
Stage-3 Intercooler (101- water side leading to possible return line for 101-JC3.
JC3) overpressurization of the cooling water
return line.
5. Leakage in Cold 5.1. Refer to Node 3 for further discussion
Process Air Coil (101- on this issue.
BCA1)
52 of 151
Node: 11. Primary Reformer Forced Draft Fan and Induced Draft Fan
Drawing: P2B-10-02-EF-62D104-R/ Rev 2; P2B-10-02-EF-62D104A-R/ Rev 2; P2B-10-02-EF-62D105-R/ Rev 2; P2B-10-02-EF-62D106-R/ Rev 2
1. No/ Low Flow 1. Less flow of air from the 1.1. Potential low pressure of combustion air 1.1.1. PIC-1855 with low alarm is provided on 56. Provide trip action to trip the Rekayasa
air filter to the suction of to the burners. In adverse case it may lead the combustion air line to control the speed of Arch Burners (101-BBA),
the FD fan due to closure to loss of flame to the burners and turbine. Superheat Burners (101-BBS/
of suction damper (HZ- combustible build-up in the Primary 101-BBSA) and Tunnel Burners
1855/1855A) Reformer furnace. (101-BBT) with interlock I-101B
on low pressure of combustion air
from FD Fan (101-BJ1/ BJ1A) as
per KBR basic engineering
package.
1.1.2. AAH-1010B/1021B/1033B (combustible 58. FD fan Vendor shall be Rekayasa/ Fan
analyzer) is provided on the reformer furnace. consulted for the consequences Vendor
in case suction damper (HZ-
1.1.3. AAL-1021A/1033A (oxygen analyzer) is
1855/1855A) of FD fan closes.
provided on the reformer furnace.
2. Forced Draft Fan (101- 2.1. Potential low pressure of combustion air 2.1.1. PIC-1855 with low alarm is available on 56. Provide trip action to trip the Rekayasa
BJ1/ BJ1A) trips to the burners. In adverse case it may lead combustion air line. Arch Burners (101-BBA),
to loss of flame to the burners and Superheat Burners (101-BBS/
2.1.2. In the case of one FD fan trips, the other
combustible build-up in the Primary 101-BBSA) and Tunnel Burners
Reformer furnace. fan will be able to handle about 80% of the air (101-BBT) with interlock I-101B
requirement. Turbine speed indication is on low pressure of combustion air
available in DCS and operator to reduce the load from FD Fan (101-BJ1/ BJ1A) as
as per the operating instructions. per KBR basic engineering
2.1.3. Interlock I-101B on tripping of one FD fan package.
will close suction damper (HZ-1855/1855A) to
avoid air flowing to atmosphere through tripped
fan.
2.1.4. When both FD fan trips, both ID fans trips
as per Interlock I-101B.
3. Both Forced Draft Fan 3.1. Potential low pressure of combustion air 3.1.1. PIC-1855 with low alarm is available on 56. Provide trip action to trip the Rekayasa
(101-BJ1/ 101-BJ1A) trip to the burners. In adverse case it may lead combustion air line. Arch Burners (101-BBA),
to loss of flame to the burners and Superheat Burners (101-BBS/
combustible build-up in the Primary 101-BBSA) and Tunnel Burners
Reformer furnace. (101-BBT) with interlock I-101B
package.
3.1.2. Interlock I-101B on tripping of both FD fan 60. Include tripping of main Arch Rekayasa
will initiate the following actions: Burners on loss of combustion air
a) Trip Tunnel and Superheat burners through interlock I-101B.
b) Trip ID fan
c) Close XV-1222A/B on Sec gas to Arch
53 of 151
burners and open XV-1222C on vent.

4. Inadvertent closure of 4.1. Potential blocked out condition for FD 59. Consider replacing the MOV- Rekayasa
MOV-1143/1144 on the fan leading to damage. Also, PIC-1855 will 1143/1144 with a damper/ sliding
outlet of FD Fan (101-BJ1/ increase the speed of turbine which may leak proof door at the outlet of FD
BJ1A) further aggravate the consequence. Fan (101-BJ1/ BJ1A) for
maintenance purpose.
5. HIC-1501A/B 5.1. Potential less flow of combustion air to 5.1.1. HZ-1501A/B are of FLO type and may not
malfunctions and closes superheat burners may result in flame-out close completely.
HZ-1501A/B on the and increase in combustible build-up in the
5.1.2. PIC-1855 with low alarm is provided on
combustion air line to Primary Reformer furnace.
Superheat Burners (101- the combustion air line to control the speed of
BBS/BBSA) turbine.
5.1.3. Flame scanners are provided at each
burner to give alarm for flame-out condition.
5.1.4. Interlock BSLL-1200 A to I are provided
with following actions:
a) Close XV-1240A/B Superheat Main Burner
block valves
b) Open XV-1240C superheat Main Burner bleed
valve
c) Close XV-1245A/B Superheat pilot burner
block valves
d) Open XV-1245C superheat pilot burner bleed
valve
5.1.5. AAH-1010B/1021B/1033B (combustible
analyzer) is provided on the reformer furnace.
6. HIC-1502 malfunctions 6.1. Potential less flow of combustion air to 6.1.1. HZ-1502 are of FLO type and may not
and closes HZ-1502 on the tunnel burners may result in flame-out and close completely.
combustion air line to increase in combustible build-up in the
6.1.2. PIC-1855 with low alarm is provided on
Tunnel Burners (101-BBT) Primary Reformer furnace.
the combustion air line to control the speed of
turbine.
6.1.3. AAH-1010B/1021B/1033B (combustible
analyzer) is provided on the reformer furnace.
6.1.4. TAH-1812/1813 is provided for flue gas
temperature.
54 of 151

6.1.6. Possible post combustion as the
temperature is above auto-ignition temperature
of fuel gas in tunnel burner area.
7. PIC-1855 is provided on 7.1. Potential low pressure of combustion air 56. Provide trip action to trip the Rekayasa
combustion air line to the burners. In adverse case it may lead Arch Burners (101-BBA),
malfunctions and reduces to loss of flame to the burners and Superheat Burners (101-BBS/
the turbine speed combustible build-up in the Primary 101-BBSA) and Tunnel Burners
Reformer furnace. (101-BBT) with interlock I-101B
package.
60. Include tripping of main Arch Rekayasa
Burners on loss of combustion air
through interlock I-101B.
8. Inadvertent closure of 8.1. Potential accumulation of flue gas in 8.1.1. PAH-1058 with horn and light is provided 61. Consider tripping the FD Fan Rekayasa
MOV-1045/1145 on inlet to furnace resulting in increase in furnace in the Primary Reformer furnace. (101-BJ1/BJ1A) on closure of
ID fan pressure. Potential flame instability and MOV-1045/1145 at the inlet of ID
8.1.2. PSHH-1059A/B/C (2oo3) is provided in
escape of hot flue gases to atmosphere Fan (101-BJ/101-BJA).
through various joints. the Primary Reformer furnace with interlock I-
101B with following actions:
a) Close XV-1220A/B on F.G to Arch burners
and open XV-1220C on vent.
b) Close XV-1222A/B on Sec gas to Arch
9. Both ID Fan (101-BJ/ 9.1. Possible accumulation of flue gas in 9.1.1. PAH-1058 with horn and light is provided 61. Consider tripping the FD Fan Rekayasa
101-BJA) trip furnace resulting in increase in furnace in the Primary Reformer furnace. (101-BJ1/BJ1A) on closure of
pressure. MOV-1045/1145 at the inlet of ID
Fan (101-BJ/101-BJA).
9.1.2. In the case of one ID fan trips, the other 146. Review the requirement of Rekayasa/
fan will be able to handle about 80% of the draft tripping of Forced Draft Fan (101- Furnace
control. BJ1/ BJ1A) when both the Vendor
Induced Draft Fans (101-BJ and
Interlock I-101BJ closes XV-1222A/B on Sec 101-BJA) trip, in consultation of
gas to Arch burners and opens XV-1222C on Furnace Vendor. (From human
vent. Also, the primary fuel gas will cater to the safety point of view as hot gases
full load requirement. As the secondary gas will come out in case somebody
volume is higher it may be possible to run the opens the peep hole.)
furnace with one ID fan.
9.1.3. In adverse case, PSHH-1059A/B/C (2oo3)
55 of 151
is provided in the Primary Reformer furnace with
interlock I-101B with following actions:
10. HIC-1019/1119 10.1. Potential accumulation of flue gas in 10.1.1. PAH-1058 with horn and light is provided 61. Consider tripping the FD Fan Rekayasa
malfunctions and closes furnace resulting in increase in furnace in the Primary Reformer furnace. (101-BJ1/BJ1A) on closure of
the damper to ID fan (HZ- pressure. MOV-1045/1145 at the inlet of ID
1019/1119) Fan (101-BJ/101-BJA).
the Primary Reformer furnace with interlock I-
11. PIC-1019A/B is 11.1. Potential accumulation of flue gas in 11.1.1. PAH-1058 with horn and light is provided 61. Consider tripping the FD Fan Rekayasa
provided on combustion air furnace resulting in increase in furnace in the Primary Reformer furnace. (101-BJ1/BJ1A) on closure of
line malfunctions and pressure, leading to hazardous scenario. MOV-1045/1145 at the inlet of ID
reduces the turbine speed Fan (101-BJ/101-BJA).
2. More/ High 1. PIC-1855 provided on 1.1. Potential high pressure in the Primary 1.1.1. PIC-1019 with high alarm is provided in
Flow combustion air duct of FD Reformer furnace leading to damage and the furnace box will increase the turbine speed
Fan malfunctions and hazardous scenario. of the ID fan and controls the pressure in the
increases the turbine furnace.
speed
1.1.2. PAH-1058 with horn and light is provided
in the Primary Reformer furnace.
2. PIC-1019A/B provided in 2.1. Potential low pressure in the furnace 144. Furnace Vendor to take care Rekayasa/
reformer furnace for ID Fan box leading to damage. of the vacuum formation in the Furnace
malfunctions and increases heater and in turn damage when Vendor
56 of 151
the turbine speed PIC-1019A/B malfunctions and
the turbine rotates at maximum
speed.
145. Consider to provide low Rekayasa
pressure alarm on PI-1059
available on the Reformer
Furnace.
3. Reverse/ 1. Any ID Fan (101-BJ/ 1.1. Potential reverse flow of flue gas from 1.1.1. Interlock I-101B on tripping of one ID fan
Misdirected 101-BJA) trips discharge of running fan to tripped fan and will close suction damper HZ-1019/1119
Flow possible reverse rotation of tripped fan and to avoid air flowing to atmosphere through
damage. Also, reduced capacity of the tripped fan.
running fan and in adverse case the
pressure in reformer furnace will increase.
2. Any FD Fan (101-BJ1/ 2.1. Potential reverse flow of combustion air 2.1.1. Interlock I-101B on tripping of one FD fan
BJ1A) trips from discharge of running fan to tripped fan will close suction damper (HZ-1855/1855A)
and possible reverse rotation of tripped fan to avoid air flowing to atmosphere through
and damage. tripped fan.
Pressure
6. More/ High 1. High temperature in ID 1.1. Potential damage to ID fan due to high 1.1.1. ID fan is designed for 350 degC.
Temperature fan (101-BJ/ 101-BJA) temperature.
suction
1.2. Increase in flue gas volume leading to 1.2.1. PIC-1019 will increase the turbine speed
higher reformer furnace pressure. to maintain the furnace pressure.
Temperature
10. Start-up/ 1. Start-up procedure 1.1. Start-up procedure for Primary 62. Ensure that operating Rekayasa
Shutdown/ Reformer instructions are provided to keep
Maintenance the peep hole open and start the
ID fan (101-BJ/ BJA) first.
57 of 151

change/
Contamination/
Additional
Phase/ Loss
Phase
12. Utility 1. No issue identified
Failure
13. Others 1. I-101B interlock action 1.1. This action is not necessary as the on 57. At present interlock I-101B Rekayasa
trip of one FD fan, the other fan can take the closes HZ-1501A/B and HZ-1502
complete load. on low flow of combustion air
from FD fans 101-BJ1/ BJ1A. The
action of this interlock need not
close these valve as furnace is
not having any provision for hot/
cold air.
2. Leakage in Combustion 2.1. Potential leakage of combustion air into 2.1.1. PDAH-1214/ 8011 is provided across the
Air Preheater Coil (101-BC) flue gas resulting in increase in load in ID combustion air preheater.
fan.
2.1.2. AAH-1484A (oxygen analyzer) is provided
on the reformer furnace stack.
Node: 12. Methanator system

Drawing: P2B-10-02-EF-62D111-R/ Rev A; P2B-10-02-EF-62D111A-R/ Rev 2

1. No/ Low Flow 1. Less flow of process gas 1.1. No consequence foreseen on the
from CO2 Absorber Methanator.
Overhead KO Drum (142-
1.2. Potential low suction flow for Syngas 1.2.1. Antisurge valve is provided for Syngas
D2) to Methanator (106-D)
Compressor (103-J). Compressor.
2. PIC-1005 malfunctions 2.1. Potential overpressurization of the 2.1.1. PRV-142D1/121D (set at 42.8 and 41
and does not open PV- upstream system. kg/cm2G) are provided on the separator
1005 on syngas line to overhead line.
Methanator (106-D)
3. Inadvertent closure of 3.1. Potential blocked condition and 3.1.1. PIC-1005/ PV-1005 is provided to vent the
MOV-1011 on inlet to pressurization of upstream. gas to hot vent header.
Methanator Feed/Effluent
Exchanger (114-C)
58 of 151
Compressor. Compressor.
4. XV-1211 malfunctions 4.1. Potential blocked condition and 4.1.1. PIC-1005/ PV-1005 is provided to vent the
and closes on inlet to pressurization of upstream. gas to hot vent header.
Methanator Feed Effluent
Exchanger (114-C)
Compressor. Compressor.
5. No flow of HP steam to 5.1. No serious consequences expected is
Methanator Heater (172-C) used mainly during start-up and during
due to malfunction and normal operation the duty of Methanator
closure of TV-1012B heater is small (about 6 degC rise).
6. TIC-1012 malfunctions 6.1. Potential high temperature of process 6.1.1. Multiple TIs with high alarm are provided
and closes TV-1012A on gas resulting in high temperature in the on the Methanator bed.
the bypass line of Methanator (catalyst and vessel) which may
6.1.2. TSHH-1200/1201/1202/1203 (each 2oo3)
Methanator Feed Effluent lead to reaching of design temperature and
Exchanger (114-C) and damage. are provided on the Methanator bed with
Methanator Start-up Heater interlock I-106D to close feed valve XV-1211 and
(172-C) when required Possible vessel failure and damage to venting of syngas from upstream hot vent
catalyst. Release of flammable/ toxic gases. header (PV-1005).
7. No flow of steam 7.1. No serious consequences expected is

condensate from used mainly during start-up and during
condensate pot of normal operation the duty of Methanator
Methanator Start-up Heater heater is small (about 6 degC rise).
(172-C) due to LIC-1010
malfunctions and closes
LV-1010
8. No flow of cooling water 8.1. Potential high temperature of syngas to 8.1.1. PIC-1114 will open PV-1114 to
in Methanator Effluent Methanator Effluent Chiller (115-C1/C2) compensate the temperature increase, however
Cooler (115-C) resulting in increase of load in 115-C1/C2 within the maximum capacity of Ammonia
which in turn will increase load to Ammonia Refrigerant Compressor.
Refrigerant Compressor (105-J).
8.1.2. TAH-1363 is provided at the inlet to
Methanator Effluent Separator.
9. No flow of ammonia 9.1. Potential loss of cooling of syngas in 9.1.1. TAH-1363 is provided at the inlet to
refrigerant due to Methanator Effluent Chiller and Molecular Methanator Effluent Separator.
malfunction of LIC-1009 Sieve Dryer.
and closure of LV-1009 on
9.2. Potential increase in moisture content in 9.2.1. AAH-1014 (moisture analyzer) is provided
inlet to Methanator Effluent
Chiller (130-C1/C2) syngas to molecular sieve. Possible slippage at the outlet of Molecular Sieve Dryer.
of moisture from molecular sieve to Purifier.
10. PIC-1114 malfunctions 10.1. Potential loss of cooling of syngas in 10.1.1. TAH-1363 is provided at the inlet to
and closes PV-1114 on Methanator Effluent Chiller and Molecular Methanator Effluent Separator.
ammonia vapour outlet of Sieve Dryer.
59 of 151
Methanator Effluent Chiller 10.2. Potential increase in moisture content 10.2.1. AAH-1014 (moisture analyzer) is
(130-C1/C2) in syngas to molecular sieve. Possible provided at the outlet of Molecular Sieve Dryer.
slippage of moisture from molecular sieve to
Purifier.
11. LIC-1118 malfunctions 11.1. Potential loss of cooling of syngas in 11.1.1. TAH-1363 is provided at the inlet to
and does not open LV- Methanator Effluent Chiller and Molecular Methanator Effluent Separator.
1118 when required on the Sieve Dryer.
ammonia line from 130-C1
11.2. Potential increase in moisture content 11.2.1. AAH-1014 (moisture analyzer) is
outlet to 130-C2 inlet
in syngas to molecular sieve. Possible provided at the outlet of Molecular Sieve Dryer.
slippage of moisture from molecular sieve to
Purifier.
12. Process Condensate 12.1. Potential increase in level in the 12.1.1. LIC-1008 with high alarm is provided on
Pump for 144-D (122-J/JA) separator resulting in possible liquid the separator.
trips carryover with the syngas to Molecular Sieve
12.1.2. LSH-1208 is provided to autostart the
Dryer.
standby pump.
13. LIC-1008 malfunctions 13.1. Potential blocked condition for the 13.1.1. Minimum flow line is provided at the
and closes LV-1008 on the process condensate pump leading to pump discharge.
pump discharge. damage.
14. PIC-1084 malfunctions 14.1. Potential overpressurization of the 14.1.1. PRV-144D (set at 38.8 kg/cm2G) is
and does not open PV- system. provided on the separator overhead line.
1084 on overhead of
Methanator Effluent
Separator (144-D)
15. Inadvertent closure of 15.1. Potential overpressurization of the 15.1.1. PRV-144D (set at 38.8 kg/cm2G) is
MOV-1017/1018 on the system. provided on the separator overhead line.
vapour line to Molecular
Sieve Dryer (109-DA/DB)
2. More/ High 1. More flow of HP steam 1.1. No significant consequence as the
Flow to Methanator Heater (172- steam temperature is 328 degC and the feed
C) due to TIC-1012 temperature of Methanator is 316 degC.
malfunctions and opens
TV-1012B more than
required
2. TIC-1012 malfunctions 2.1. Potential low temperature of process 2.1.1. AAH-1003A/B (CO/CO2 analyzer) is
and opens TV-1012A on gas to Methanator resulting in possible provided on the Methanator Feed/Effluent
the bypass line of slippage of CO and CO2 to Molecular Sieve Exchanger outlet.
Methanator Feed/Effluent Dryer.
Exchanger (114-C) and
Methanator Start-up Heater
60 of 151
(172-C) when not required

3. More flow of steam 3.1. Potential steam breakthrough to 3.1.1. PRV-101U is provided on the Deaerator. 63. Verify that the PRV-101U on Rekayasa
condensate from Deaerator (101-U). the Deaerator (101-U) is suitable
condensate pot of to handle steam breakthrough
Methanator Start-up Heater case from Methanator Start-up
(172-C) due to LIC-1010 Heater (172-C).
malfunctions and opens
3.2. Potential loss of heat duty in 172-C.
LV-1010 more than
required However, no serious consequences
expected as Methanator Start-up Heater is
used mainly during start-up and during
normal operation the duty of Methanator
Heater is small (about 6 degC rise).
4. More flow of ammonia 4.1. Possible liquid ammonia carryover to
refrigerant due to unitized chiller. Refer to Node 16.
malfunction of LIC-1009
and higher opening of LV-
1009 on inlet to Methanator
Effluent Chiller (130-
C1/C2)
5. PIC-1114 malfunctions 5.1. Potential increase in cooling of the 5.1.1. TAL-1363 is provided on the outlet of
and opens PV-1114 on syngas to separator resulting in freezing of Methanator Effluent Chiller.
ammonia vapour outlet of water inside the tubes of 130-C2.
Methanator Effluent Chiller
(130-C1/C2)
6. LIC-1118 malfunctions 6.1. Possible liquid ammonia carryover to
and opens LV-1118 more unitized chiller. Refer to Node 16.
ammonia line from
130-C1 outlet to 130-C2
inlet
7. LIC-1008 malfunctions 7.1. Potential low level in the separator 7.1.1. LAL-1208 is provided on the Separator.
and opens LV-1008 more resulting in loss of suction to the process
than required on the pump condensate pump and damage.
discharge
Misdirected
Flow
4. More/ High 1. Ammonia Refrigerant 1.1. The ammonia vapours in the 1.1.1. Ammonia refrigeration circuit is designed
Pressure Compressor (105-J) trips Methanator Effluent Chiller (130-C1/C2) will for 15.8 kg/cm2(g), which is less than the
61 of 151
get heated up (instead of getting cooled) by possible increase in pressure due to Ammonia
the syngas flowing from the upstream Refrigerant Compressor tripping.
Methanator Effluent Cooler (115-C), and
thereby pressurization of the ammonia This 15.8 kg/cm2(g) corresponding the
refrigeration circuit. temperature of 42.2 degC, where as the inlet
temperature is about 38 degC.
2. Overpressurization of 2.1. Possible overpressurization of the 2.1.1. PRV-121D is available at the inlet of CO2 68. Review the requirement of HP Rekayasa
the Methanator system Methanator system as the upstream HP H2 Absorber (121-D) and set at 41 kg/cm2(g). H2 line from OEP. If required,
through the line of HP H2 in OEP is operating at about 75 kg/cm2G suitable safeguard (such as PRV)
from OEP where as the Methanator is designed for shall be provided to avoid
about 39 kg/cm2(g). overpressurization of the
Methanator system.
Temperature
7. Low 1. More cooling of syngas 1.1. Possible low temperature in the 1.1.1. TIL-1363 is available at the inlet of 69. Review the design Rekayasa
Temperature leading to Methanator Methanator Effluent Separator to less than 4 Methanator Effluent Separator. temperature of Methanator
Effluent Separator (144-D) degC. Effluent Separator (144-D) with
due to malfunctioning of reference to low temperature
PV-1114 in the refrigeration (more cooling due to refrigeration
circuit of Methanator 130-C1/C2).
C1/C2)
8. High Level 1. LIC-1118 malfunctions 1.1. Possible liquid ammonia carryover to
and opens LV-1118 more unitized chiller. Refer to Node 16.
ammonia line from
130-C1 outlet to 130-C2
inlet.
2. LIC-1008 malfunctions 2.1. Level in the Methanator Effluent 2.1.1. LAH-1208 is available on the Methanator
and closes LV-1008 on the Separator is likely to increase. In the worst Effluent Separator.
pump discharge. case, liquid may be carried over to the
Dryer, making damage to the molecular
sieve.
9. Low Level 1. LIC-1008 malfunctions 1.1. Level in the Methanator Effluent 1.1.1. LAL-1208 is available on the Methanator
and opens LV-1008 on the Separator is likely to decrease. Effluent Separator.
pump discharge.
Shutdown/
62 of 151
Maintenance
11. Composition 1. More CO content in feed 1.1. Possible very high temperature in 1.1.1. Multiple TIs with high alarm are provided
change/ gas to Methanator (106-D) Methanator (1% CO concentration increases on the Methanator bed.
Contamination/ the temperature to about 74 degC), leading
1.1.2. TSHH-1200/1201/1202/1203 (each 2oo3)
Additional to runaway reaction.
Phase/ Loss are provided on the Methanator bed with
Phase Possible vessel failure and damage to interlock I-106D to close feed valve XV-1211 and
catalyst. Release of flammable/ toxic gases. venting of syngas from upstream hot vent
header (PV-1005).
2. More CO2 content in 2.1. Possible very high temperature in 2.1.1. Multiple TIs with high alarm are provided
feed gas to Methanator Methanator (1% CO2 concentration on the Methanator bed.
(106-D) increases the temperature to about 60
2.1.2. TSHH-1200/1201/1202/1203 (each 2oo3)
degC), leading to runaway reaction.
Possible vessel failure and damage to interlock I-106D to close feed valve XV-1211 and
catalyst. Release of flammable/ toxic gases. venting of syngas from upstream hot vent
header (PV-1005).
Failure position.
13. Others 1. Design pressure of the 1.1. 64. Review the design pressure of Rekayasa
tube side of Methanator the tube side of Methanator Start-
Start-up Heater (172-C) up Heater (172-C) as it has been
designed for 136.4 kg/cm2(g),
whereas the upstream HP steam
design pressure is 139.9
kg/cm2(g).
2. Design temperature of 2.1. 65. Review the design Rekayasa
the shell side of temperature of the shell side of
Methanator Start-up Heater Methanator Start-up Heater (172-
(172-C) C) as it has been designed for
346 degC, whereas the
Methanator loop (including
Methanator Feed/Effluent
Exchanger (114-C)) is designed
for 457 degC.
3. Closure of manual valve 3.1. In case of closure of this valve 66. KBR strongly recommends to Rekayasa
on the effluent line leading inadvertently, Methanator feed will be flowing have the isolation valve as per
to Methanator to tube side, with no flow on the shell side. KBR basic engineering package,
Feed/Effluent Exchanger This may lead to damage to shell side as that is at outlet of Methanator
(114-C) Methanator Feed/Effluent Exchanger tubes Feed/Effluent Exchanger (114-C).
and tube sheet are designed for differential
pressure and not for the total absolute
63 of 151
pressure.
4. Design pressure of the 4.1. Blocked out condition leading to 4.1.1. PRV-121D is available at the inlet of CO2 67. In light of the PRV-121D set Rekayasa
Methanator system overpressurization. Absorber (121-D) and set at 41 kg/cm2(g). pressure, Methanator system
(Syngas side) with respect equipments design pressure shall
to overpressurization be minimum 41 kg/cm2(g)
instead of 39.22 kg/cm2(g)
or
Add another PRV for the
Methanator system set at suitable
pressure for overpressurization
protection.
5. Tube leak in Methanator 5.1. HP steam will flow with the syngas to 5.1.1. LAH-1208 and LAH-1008 are available at
Start-up Heater (172-C) the Methanator system. However, no the Separator.
consequences as the steam will be
condensed in Methanator Effluent Separator
(144-D).
6. Tube leak in Methanator 6.1. Methanator effluent will be slightly 6.1.1. AIH-1003A/B is available for high CO/CO2
Feed/Effluent Exchanger contaminated with the Methanator feed as content leading to downstream. However, this
(114-C) the operating pressures for the shell side will be taken care by molecular sieve Dryers.
and tube side are 35.8 and 36.4 kg/cm2(g).
7. Tube leak in Methanator 7.1. Possible carryover of syngas to cooling 7.1.1. RD-115C is available.
Effluent Cooler (115-C) water return header.
8. Tube leak in Methanator 8.1. Possible contamination of ammonia with 8.1.1. PRV is available in the ammonia
Effluent Chiller (130- syngas and overpressurization. refrigeration circuit.
C1/C2)
Node: 13. Molecular Sieve Dryer and Cryogenic Purification system

Drawing: P2B-10-02-EF-62D112-R/ Rev 2; P2B-10-02-EF-62D112A-R/ Rev 2; P2B-10-02-EF-62D112B-R/ Rev 2; P2B-10-02-EF-62D112C-R/ Rev 2

1. No/ Low Flow 1. No flow of syngas to 1.1. Possible pressurization in the upstream 1.1.1. PV-1084 and PRV-1440 is available at the
Molecular Sieve Dryer of Methanator Effluent Separator (144-D). outlet of 144-D.
(109-DA/DB) due to
1.2. Syngas Compressor (103-J) will 1.2.1. Syngas Compressor is provided with
inadvertent closure of
MOV-1017/1018 experience no flow leading to damage. antisurge protection.
2. No flow of syngas 2.1. For consequence on the Feed Gas

(recycle) to Feed Gas Compressor, refer to Node 1.
64 of 151
Compressor (102-J) due to 2.2. No consequence for the Purification
FIC-1703 malfunction and section
closure of FV-1703
3. Choking in the Molecular 3.1. No serious consequence envisaged. 3.1.1. PDG-1085/1086 is available.
Sieve Dryer Filter (154-
LA/LB)
4. Inadvertent closure of 4.1. Possible pressurization in the upstream 4.1.1. PV-1084 and PRV-1440 is available at the
MOV-1015/1016 leading to of Methanator Effluent Separator (144-D). outlet of 144-D.
no flow to Purifier
4.2. Syngas Compressor will experience no 4.2.1. Syngas Compressor is provided with spill
Feed/Effluent Exchanger
(132-C) flow leading to damage. back facility.
5. Inadvertent closure of 5.1. Possible pressurization in the upstream 5.1.1. PV-1084 and PRV-1440 is available at the 70. The effect of no flow of Rekayasa/
MOV-1051 leading to no of Methanator Effluent Separator (144-D). outlet of 144-D. syngas to Purifier Feed/ Effluent Package
flow to Purifier Exchanger (132-C) Vendor
Feed/Effluent Exchanger to be discussed with the package
(132-C) Vendor.
5.2. Syngas Compressor will experience no 5.2.1. Syngas Compressor is provided with spill
flow leading to damage. back facility.
6. No flow from Purifier 6.1. Low suction pressure to Syngas 6.1.1. All three stages of the Compressor are 71. The effect on Purifier Feed Rekayasa/
Feed Cold Box Package Compressor, leading to damage. provided with dedicated antisurge facility (FV- Cold Box Package (137-L) shall Package
(137-L) to Synthesis Gas 1007/1008/1059). be discussed with the package Vendor
Compressor (103-J) due to Vendor.
inadvertent closure of
MOV-1053
2. More/ High 1. More flow of syngas 1.1. No consequence at this system as this
Flow (recycle) to Feed Gas is a very small quantity.
Compressor (102-J) due to
FIC-1703 malfunction and
higher opening of FV-1703
3. Reverse/ 1. Inadvertent opening of 1.1. Less flow to Purifier Feed Cold Box
Misdirected MOV-1052 from the Dryer Package (137-L)
Flow on the line leading to
1.2. Syngas H2/N2 ratio will decrease,
Synthesis Gas Compressor
(103-J) leading to high synthesis loop pressure,
affecting ammonia production.
1.3. Increased inerts (argon and methane) in 1.3.1. Online analyzers AI-1029A/B/C/D
the synthesis gas loop leading to higher available for all the components of syngas.
pressure, and in turn leading to less
production of ammonia.
2. Inadvertent opening of 2.1. Syngas will flow into the Molecular 2.1.1. PV-1029 is available on the waste gas
65 of 151
XV-1164 or XV-1165 or Sieve Dryer which is under regeneration, header.
XV-1160 or XV-1161 or leading to upset in regeneration and possible
2.1.2. PRV-SG1119A/ PRV-SG1119B/ PSE-
PIC-1047/1048 malfunction overpressurization in the waste gas header.
and closure of PV-1047 or This in turn will lead to high pressure waste SG1119 are available on the waste gas header
PV-1048 gas to the burners. for protection of the waste gas header.
2.1.3. On PSHH-1226, interlock I-101B will
activate and close XV-1222A/B sec gas to Arch
burners and open XV-1222C sec gas bleed
valve.
Pressure
6. More/ High 1. No issue identified
Temperature
Temperature
10. Start-up/ 1. Deriming of Purifier 1.1. Difficulty in deriming of 137-L due to 154. Consider to provide a Rekayasa
Shutdown/ Feed Cold Box Package non-availability of vent valves on syngas line bypass line along with bleed valve
Maintenance (137-L) and waste gas line. (to measure the dew point) across
PRV-132C1 as well as PRV-
132C2.
11. Composition 1. More water content/ 1.1. Possible slippage of moisture from the 1.1.1. AAH-1014 provided for H2O
change/ CO2 in the feed gas to Dryer leading to Purifier.
1.1.2. AAH-1020 provided for CO2
Contamination/ Molecular Sieve Dryer
Additional (109-DA/DB)
Phase/ Loss
Phase
Failure position.
13. Others 1. Single valve provided on 1.1. Possible leakage of syngas to 72. For where a single valve is Rekayasa
syngas line for nitrogen atmosphere due to passing of valve in due given for nitrogen purging,
purging at many places course of time, resulting in hazardous consider to install an NRV at the
atmosphere. Also, possible syngas joining point.
contaminating nitrogen header during
nitrogen connection. This is a global recommendation
wherever a single valve is given
66 of 151
for nitrogen purging.

73. For where single valve is Rekayasa
given for nitrogen purging, it is
advisable to install double block
and bleed connection.
This is a global recommendation
wherever a single valve is given

for nitrogen purging.
Node: 14. Dryer Regeneration System

Drawing: P2B-10-02-EF-62D112-R/ Rev 2; P2B-10-02-EF-62D130-R/ Rev 2; P2B-10-02-EF-64D106-R/ Rev 2

1. No/ Low Flow 1. No flow of regeneration 1.1. Regeneration cycle will get extended.
(Heating Cycle) gas to Mol Sieve
Regeneration Heater (183-
C) due to FIC-1046
malfunction and closure of
FV-1046
2. No flow of MP steam to 2.1. Possible low temperature of 2.1.1. TI-1835/ TI-1043 is available on the Dryer 74. Provide low alarm on TI-1041 Rekayasa
Mol Sieve Regeneration regeneration gas leading to Molecular Sieve outlet line. available on the outlet of Mol
Heater (183-C) due to LIC Dryer and in turn regeneration cycle gets Sieve Regeneration Heater (183-
malfunction and closure of extended. C).
LV-1050
3. No flow of syngas to 3.1. Possible non-heating of the Dryer 3.1.1. TI-1835/ TI-1043 is available on the Dryer
Molecular Sieve Dryer leading to delay in regeneration. outlet line.
(109-DA/DB) for
3.1.2. FAL-1046 is available.
regeneration due to closure
of XV-1161 3.1.3. FSLL-1046 will stop the regeneration
cycle.
4. No flow of gas from the 4.1. Dryer under regeneration will experience 4.1.1. FAL-1046 is available.
Regeneration Dryer (109- blocked out condition with hot gas.
4.1.2. FSLL-1046 will stop the regeneration
DA/DB) to Purifier Waste
Gas Filter (144-L) due to cycle.
closure of XV-1165
5. No flow of gas from 5.1. Dryer under regeneration will experience
Regeneration Dryer (109- blocked out condition with hot gas. Also,
67 of 151
DA/DB) to Arch Burner due Arch Burner will lose the secondary fuel gas.
to closure of HV-1022 However, no major consequence foreseen.
5.2. Possible pressurization in the Purifier 5.2.1. PRV-132C2 is available on the waste gas
section. line from Purifier Feed/ Effluent Exchanger.
6. No flow of gas from 6.1. Dryer under regeneration will experience 6.1.1. PDG-1732 is available across 144-L and
Regeneration Dryer (109- blocked out condition with hot gas. Also, also bypass facility is available.
DA/DB) to Arch Burner due Arch Burner will lose the secondary fuel gas.
to choking of Purifier However, no major consequence foreseen.
Waste Gas Filter (144-L)
6.2. Possible pressurization in the Purifier 6.2.1. PRV-132C2 is available on the waste gas
section. line from Purifier Feed/ Effluent Exchanger.
7. No flow of heating gas to 7.1. Possible upset in the waste gas header 7.1.1. TAL-2042 is available on the waste gas
the waste gas header due temperature going to reformer, leading to header.
to malfunctioning of TIC- Primary Reformer outlet gas temperature
1042 and closure of TV- variation.
1042. This is applicable for
cooling cycle also.
2. No/ Low Flow 1. No flow of cooling gas to 1.1. Dryer under regeneration will experience 1.1.1. TI-1664 available on the outlet of Dryer
(Cooling Cycle) Mol Sieve Dryer (109- blocked out condition. connected to KIC and will give indication to the
DA/DB) due to malfunction operator.
and closure of XV-1165
2. No flow of cooling gas 2.1. Dryer under regeneration will experience 2.1.1. TI-1664 available on the outlet of Dryer
from Mol Sieve Dryer (109- blocked out condition. connected to KIC and will give indication to the
DA/DB) due to closure of operator.
XV-1161
2.1.2. XV-1161 is also connected to KIC and
deviation alarm is generated.
3. No flow of cooling gas 3.1. Dryer under regeneration will experience 3.1.1. TI-1664 available on the outlet of Dryer
from Mol Sieve Dryer (109- blocked out condition. connected to KIC and will give indication to the
DA/DB) due to closure of operator.
HV-1023
3.1.2. HV-1023 is also connected to KIC and
deviation alarm is generated.
4. No flow of gas from 4.1. Dryer under regeneration will experience 4.1.1. PDG-1732 is available across 144-L and
Regeneration Dryer (109- blocked out condition. also bypass facility is available.
DA/DB) to Arch Burner due
to choking of Purifier
Waste Gas Filter (144-L)
3. More/ High 1. More flow of 1.1. Possible disturbance in the Mol Sieve 75. To provide limit switches with Rekayasa
Flow regeneration gas due to Dryer bed alarm in FV-1046 available on the
FIC-1046 malfunction and regeneration gas to Mol Sieve
68 of 151
higher opening of FV-1046 Dryer (109-DA/DB).

2. More flow of 2.1. Possible increase in secondary fuel gas
regeneration gas due to temperature. However, no serious
TIC-1042 malfunction and consequence.
higher opening of TV-1042
3. More flow with 3.1. Sudden pressurization of the Dryer bed 77. KIC to include alarm in case Rekayasa
pressurization of Mol Sieve under regeneration. rate of opening of PV-1049A/B is
Dryer due to PIC-1049A/B higher than desired.
malfunction and full
opening of PV-1049A/B
4. More flow of MP steam 4.1. Possible steam blowby to downstream 4.1.1. PRV-101U is provided on the Deaerator. 76. Confirm that PRV-101U Rekayasa
condensate to Deaerator Deaerator, leading to overpressurization and available on the Deaerator (101-
(101-U) due to LIC-1050 damage as the Deaerator is designed for U) is suitable for steam blowby
malfunction and full about 3.5 kg/cm2G, where as the steam case from LV-1050.
opening of LV-1050 header is about 46 kg/cm2(g).
4. Reverse/ 1. Refer to Item No. 2
Misdirected under Reverse/ Misdirected
Flow Flow of Node 13.
Pressure
Temperature
8. Low 1. No new issue identified
Temperature
Shutdown/
Maintenance
12. Composition 1. No issue as analyzers
change/ are available at outlet of
Contamination/ Mol Sieve Dryer (109-
Additional DA/DB)
Phase/ Loss
Phase
69 of 151
Failure position.
14. Others 1. Tube leak in Mol Sieve 1.1. Possible leakage of MP steam to the 1.1.1. AAH-1014 (moisture analyzer) is provided 217. Consider providing interlock Rekayasa
Regeneration Heater (183- regeneration gas flowing to the Dryer, and in at the outlet of Molecular Sieve Dryer. to close FV-1046 on high
C) turn poorer regeneration. Possible slippage temperature from TI-1041 on 183-
1.1.2. Sample point S-1506 is provided on outlet
of moisture when this Dryer comes online. C.
of shell side of 183-C.
1.1.3. TI-1041 provided with high alarm.
1.2. Overpressurization of shell side of 183- 1.2.1. PRV-183C is provided on the syngas line 78. Confirm that PRV-183C Rekayasa
C from the shell side of 183-C. available on syngas line from the
shell side of Mol Sieve
Regeneration Heater (183-C) is
suitable for tube leakage case in
183-C.
Node: 15. Synthesis Gas Compressor system and Ammonia Synthesis Converter
Drawing: P2B-10-02-EF-62D113-R/ Rev 2; P2B-10-02-EF-62D114-R/ Rev 2; P2B-10-02-EF-62D115-R/ Rev 2; P2B-10-02-EF-64D113-R/ Rev 2; P2B-10-02-EF-62D102-R/ Rev 2

1. No/ Low Flow 1. No flow of syngas from 1.1. Loss of suction to Compressor leading 1.1.1. PI-6569A provided on 1st stage suction of 79. Consider to provide low flow Rekayasa/
Purifier Feed Cold Box to damage. 103-J alarm from existing FIC-1007 or Compressor
Package (137-L) to suction low suction pressure alarm. Vendor
of 1st stage of Syngas (Vendor scope)
Compressor (103-J)
1.1.2. Antisurge valve FV-1007 will open and the 80. Interlock I-103J shown Rekayasa
Compressor will run in closed loop. against PV-1004 in the P&ID is
not listed in the C&E chart.
81. Review the requirement of Rekayasa
interlock I-103J against PV-1004,
as the same is not given by the
Licensor in their basic design
package.
1.2. Loss of flow to Ammonia Synthesis 1.2.1. Import of MP steam facilities available 83. Ensure that import of MP Rekayasa
Converter (105-D) and in turn loss of from OSBL steam is sufficiently available to
generation of HP steam. Potential reduction cater the demand in case of loss
in MP steam extraction from Synthesis Gas of HP steam generation (123-
Compressor Turbine (103-JT). C1/C2) from the Ammonia
70 of 151
Synthesis Converter (105-D).

1.3. Loss of cooling of Ammonia Synthesis 1.3.1. Multiple TIs are provided on the skin of
Converter shell as the same Compressor Ammonia Synthesis Converter.
discharge gas is used for cooling. This in
turn lead to high temperature in the
Converter shell. manually depressurize Ammonia Synthesis
Converter. (HV-1019 available on the recycle
line from 120-C.)
2. Syngas Compressor 2.1. Possible blocked out condition in 2.1.1. Syngas Compressor trip alarm (XA- 82. Ensure that cold vent header Rekayasa
(103-J) trips (e.g. governor Purifier Feed Cold Box Package (137-L) 3211A/B) is available from turbine control is capable of handling the full flow
closes) system in DCS. from Purifier Feed Cold Box
Package (137-L) in case of
Syngas Compressor (103-J)
tripping through PV-1004.
2.1.2. PV-1004 available on the inlet line to the 84. Ensure that venting through Rekayasa
Compressor from 137-L and will open to release the cold vent header in case of
the pressure to cold vent header. Syngas Compressor (103-J)
tripping do not create any
hazardous/ environmental issues.
2.2. Possible loss of MP steam extraction 2.2.1. On Syngas Compressor (103-J) trips,
from Synthesis Gas Compressor Turbine interlock I-103J will open the letdown valve HIC/
(103-JT) HV-1028 to automatically open and pass MP
steam extraction flow equal to flow from turbine
FI-1124.
line from 120-C.)
2.5. Possible high pressure in the HP steam 2.5.1. On Syngas Compressor (103-J) trips,
header as the consumption for the 103-J has interlock I-103J will open the letdown valve HIC/
stopped. HV-1028 to automatically open and pass MP
71 of 151
FI-1124.
2.5.2. PRV-101B1/101B2 are available on the
HP steam header.
2.5.3. PAH-1018 is available on the HP steam
header.
2.5.4. PV-1018 is available to control the HP
steam header pressure.
3. No flow of cooling water 3.1. Possible high temperature at 2nd stage 3.1.1. TAH-6540 is available at the 2nd stage 86. Confirm with the Vendor that Rekayasa/
in Syngas Compressor suction (about 110 degC), and in turn the suction. the Syngas Compressor (103-J) Compressor
Interstage Cooler (116-C) discharge temperature of 2nd stage will do not experience any problem Vendor
3.1.2. The maximum allowable working
increase. such as vibration in case of
temperature of the 2nd stage Compressor is 200 cooling water failure in Syngas
degC. Compressor Interstage Cooler
(116-C) and in turn the 2nd stage
suction temperature raising to
110 degC.
4. No flow of syngas to 4.1. Possible pressurization of Purifier Feed 4.1.1. PV-1084 is available at the outlet of
cold vent header due to Cold Box Package (137-L) Methanator Effluent Separator (144-D) to cold
PIC-1004 malfunction and vent header.
non-opening of PV-1004
4.1.2. PRV-144D is available on the outlet of
when required
Methanator Effluent Separator (144-D) to cold
vent header.
5. No flow of syngas to 5.1. Possible surge to the Compressor 85. Compressor Vendor to Rekayasa/
suction of 1st stage of leading to damage. suggest suitable safeguard (such Compressor
Syngas Compressor (103- as vibration switch and trip) for Vendor
J) due to FIC-1007 the malfunction of the kickback
malfunction and non- valve (FV-1008) for Synthesis
opening of FV-1007 when Gas Compressor (103-J) when
required required.
6. No flow of syngas to 2nd 6.1. Less flow to 2nd stage suction as the 6.1.1. Antisurge valve FV-1008 will open and the
stage of Syngas recycle gas alone flowing from 120-C Compressor will run in closed loop.
Compressor (103-J) due to
closure of XV-1103
7. No flow of syngas to 7.1. Possible surge to the Compressor 85. Compressor Vendor to Rekayasa/
suction of 2nd stage of leading to damage. suggest suitable safeguard (such Compressor
Syngas Compressor (103- as vibration switch and trip) for Vendor
J) due to FIC-1008 the malfunction of the kickback
malfunction and non- valve (FV-1008) for Synthesis
opening of FV-1008 when Gas Compressor (103-J) when
72 of 151
required required.
8. No flow of syngas from 8.1. Possible surge to the Compressor 85. Compressor Vendor to Rekayasa/
the discharge of 3rd stage leading to damage (as this is a antisurge suggest suitable safeguard (such Compressor
of Syngas Compressor valve for 3rd stage). as vibration switch and trip) for Vendor
(103-J) to inlet of Ammonia the malfunction of the kickback
Converter Effluent Cooler valve (FV-1008) for Synthesis
(124-C1) due to FIC-1059 Gas Compressor (103-J) when
malfunction and closure of required.
FV-1059 when required
9. No flow of syngas from 9.1. Possible surge to the Compressor 9.1.1. Antisurge valve FV-1059 will open and the
the discharge of 3rd stage leading to damage. Compressor will run in closed loop.
of Syngas Compressor
9.2. Overpressurization of Compressor loop 9.2.1. PRV-103J is available at the discharge of
(103-J) to inlet of ammonia
Converter Feed/Effluent Compressor to release the makeup gas quantity.
Exchanger (121-C) due to 9.3. Possible pressure increase in Purifier 9.3.1. PV-1004 available on the inlet line to the
closure of HV-1101 Feed Cold Box Package (137-L) and Compressor from 137-L and will open to release
upstream the pressure to cold vent header.
line from 120-C.)
10. No flow of syngas to 10.1. Possible loss of syngas to Converter 10.1.1. Multiple TIs are provided on the skin of
Ammonia Synthesis will lead to high temperature in the Converter Ammonia Synthesis Converter.
Converter (105-D) due to shell.
10.1.2. HV-1044 is provided with disc cut to
closure of HV-1044
69000 kg/hr to ensure cooling of the Converter
shell.
10.2. Surging in the Compressor due to less 10.2.1. Antisurge valve is provided for Syngas
flow from the Compressor. (60% of flow Compressor.
takes place from upstream of HV-1044 to
Converter.)
10.3. Possible increase in Bed 2 10.3.1. TAH-1385/1386 are available on Bed 2
73 of 151
temperature due to loss of cooling in 122-C1 of Converter.
.
11. No flow of syngas to 11.1. Surging in the Compressor due to less 11.1.1. Antisurge valve is provided for Syngas
the annulus of Ammonia flow from the Compressor. (40% of flow Compressor.
Synthesis Converter (105- takes place from upstream of HV-1044 to
D) due to closure of HV- Converter.)
1046
11.2. Possible increase in Bed 3A/B 11.2.1. TAH-1387/1388/1389/1290 are available
temperature due to loss of cooling in 122- on Bed 3A/B of Converter.
C2.
11.3. Conversion of ammonia across the
Converter will decrease. Possible reduction
in ammonia production. No major
consequence.
12. No flow of syngas to 12.1. No serious consequence envisaged as 12.1.1. TAH-1383/1384 are available on Bed 1
Bed 1 of Ammonia this valve is normally closed and used only of Converter.
Synthesis Converter (105- during start-up. In the worst case, bed 1 inlet
D) due to closure of HV- temperature will increase.
1025
13. No flow to Start-up 13.1. Overheating of heater coil leading to 13.1.1. HCV-1047 is provided with disc cut.
Heater (102-B) e.g. due to failure. Possible damage to heater. Potential
13.1.2. TAH-1047 is available at heater coil
closure of HCV-1047 or for flame flashback to atmosphere due to
HV-1025 opened by pressurization of the combustion chamber. outlet
mistake or upstream 13.1.3. FSLL-1257 is available to actuate
control failure or Syngas interlock I-102B to stop fuel to the Main Burner
Compressor failure when in of 102-B.
line
13.1.4. TSHH-1396 is available to actuate
interlock I-102B to stop fuel to the Main Burner
of 102-B.
14. No flow of natural gas 14.1. Fuel gas header pressure to burners 14.1.1. PSLL-1155 will trip the pilot burner 87. P&ID is not showing the flame Rekayasa
from upstream due to will be too low to sustain the flame. Loss of through interlock I-102B to close XV-1255A/B scanners for Main Burner,
closure of PV-1051 main flame which might lead to hazardous and open XV-1255C. whereas the C&E chart is
scenario due to possible presence of indicating the same. Hence P&ID
14.1.2. PSLL-1150 will trip the Main Burner
unburnt gases. shall be corrected.
through interlock I-102B to close XV-1250A/B
and open XV-1250C.
14.1.3. Flame scanners (BSLL-0861) are
provided at each pilot burner to give alarm for
flame-out condition. Also, interlock I-102B will
close XV-1255A/B and open XV-1255C.
74 of 151
provided at each Main Burner to give alarm for
15. No flow of natural gas 15.1. Loss of pilot flame which might lead to 15.1.1. PSLL-1155 will trip the pilot burner
to the burner (102-B) due hazardous scenario due to possible through interlock I-102B to close XV-1255A/B
to closure of PCV-1154 presence of unburnt gases. and open XV-1255C.
provided at each pilot burner to give alarm for
16. No flow of natural gas 16.1. Same as 15.1 above.
to the burner (102-B) due
to closure of XV-1255A
17. No flow of purge gas to 17.1. No serious consequence envisaged.
atmosphere due to closure
of XV-1255C when
required
18. No flow of natural gas 18.1. Same as 15.1 above.
to the Burners (102-B) due
to closure of XV-1255B
19. No flow of natural gas 19.1. Loss of flame in the Main Burners 19.1.1. PSLL-1150 will trip the Main Burner
to the Burners (102-B) due leading to low coil outlet temperature through interlock I-102B to close XV-1250A/B
to closure of XV-1250A and open XV-1250C.
provided at each Main Burner to give alarm for
20. No flow of purge gas to 20.1. No serious consequence envisaged.
atmosphere due to closure
of XV-1250C when
required
21. No flow of natural gas 21.1. Same as 19.1 above
to the Burners (102-B) due
to closure of XV-1250B
22. No flow of nitrogen 22.1. No serious consequence envisaged as
from upstream to the fuel this is used for leakage testing before start-
gas line due to closure of up.
PCV-5143 when required
75 of 151
23. No flow of nitrogen to 23.1. Same as 22.1

the fuel gas line due to
closure of XV-1260A when
required
24. No flow of purge gas 24.1. Same as 22.1
(nitrogen) to atmosphere
due to closure of XV-
1260C when required
closure of XV-1260B when
required
closure of XV-1261A when
required
27. No flow of purge gas 27.1. Same as 22.1
(nitrogen) to atmosphere
due to closure of XV-
1261C when required
closure of XV-1261B when
required
29. Choking of Syngas 29.1. Loss of suction to Syngas Compressor 89. Consider to provide Rekayasa
Compressor (103-J) leading to damage. differential pressure indications
suction strainer at all across suction strainers as per
stages KBR basic engineering package.
2. More/ High 1. More flow of syngas 1.1. In adverse case, suction pressure of the 1.1.1. PV-1004 available on the inlet line to the
Flow from Purifier Feed Cold Syngas Compressor will increase and Compressor from 137-L and will open to release
Box Package (137-L) to pressurize the upstream section. the pressure to cold vent header.
suction of 1st stage of
Syngas Compressor (103-
J)
2. More flow of syngas to 2.1. Loss of suction to Syngas Compressor 88. Compressor Vendor shall be Rekayasa/
cold vent header due to leading to damage. consulted regarding the low low Compressor
PIC-1004 malfunction and suction pressure trip requirement. Vendor
higher opening of PV-1004
3. More flow of syngas to 3.1. Less flow to the downstream of 3.1.1. PV-1004 available on the inlet line to the
76 of 151
suction of 1st stage of Ammonia Synthesis Converter and in turn Compressor from 137-L and will open to release
Syngas Compressor (103- higher pressure build up in the upstream. the pressure to cold vent header.
J) due to FIC-1007
malfunction and higher
opening of FV-1007 Converter (105-D) and in turn loss of from OSBL steam is sufficiently available to
line from 120-C.)
4. More flow of syngas to 4.1. Same as 3.1 to 3.3 above
suction of 2nd stage of
Syngas Compressor (103-
J) due to FIC-1008
malfunction and
higher opening of FV-
1008
5. More flow of syngas 5.1. Same as 3.1 to 3.3 above
from the discharge of 3rd
stage of Syngas
Compressor (103-J) to inlet
of Ammonia Converter
Effluent Cooler (124-C1)
due to FIC-1059
opening of FV-1059
6. More flow to Start-up 6.1. No serious consequence envisaged.
Heater (102-B) due to
higher opening of HCV-
1047 when in line
7. More flow of natural gas 7.1. Fuel gas header pressure to burners will 90. Consider to provide suitable Rekayasa
from upstream due to PIC- be too high to sustain the flame and lead to safeguard (such as PSV) for the
1051 malfunction and flame liftoff. Loss of main flame might lead fuel gas line to take care of PV-
higher opening of PV-1051 to hazardous scenario due to possible 1051 full opening case
presence of unburnt gases. or
relocate the tapping for the fuel
gas for the 102-B burner from the
downstream of PV-1001A/B as
77 of 151
package.
7.2. Over firing in Start-up Heater (102-B) 7.2.1. TSHH-1396 is available to actuate
lead to higher coil outlet temperature and interlock I-102B to stop fuel to the Main Burner
damage. Overheating of heater coil leading of 102-B.
to failure. Possible damage to heater.
7.2.2. PSHH-1150 will trip the Main Burner
Potential for flame flashback to atmosphere
due to pressurization of the combustion through interlock I-102B to close XV-1250A/B
chamber. and open XV-1250C.
8. More flow of natural gas 8.1. Possible high pressure in the pilot 8.1.1. PSHH-1155 will trip the pilot burner
to the pilot burner (102-B) burner and may lead to loss of flame. This through interlock I-102B to close XV-1255A/B
due to higher opening of might lead to hazardous scenario due to and open XV-1255C.
PCV-1154 possible presence of unburnt gases.
9. More flow of nitrogen 9.1. No serious consequence envisaged as
from upstream to the fuel this is used for leakage testing before start-
gas line due to higher up.
opening of PCV-5143
10. Inadvertent opening of 10.1. Possible low temperature of syngas 91. Consider to provide low Rekayasa
HV-1034 available across leading to the Converter, which in turn lead temperature alarm on TI-
Ammonia Converter Feed/ to loss of reaction in the Converter. 1383/1384 available in Ammonia
Effluent Exchanger (121-C) Conv. Bed 1 Interchanger (122-
tube side C1).
10.2. Possible high temperature of syngas 10.2.1. TAH-1369 is available at the inlet of 124- 100. Review the design Rekayasa
leading to 124-C1/C2, and in turn to 120-C C1/C2. temperature of Ammonia
Converter Effluent Cooler (124-
C1/C2) shell side in light of HV-
1034 full opening, as it is reduced
from 150 degC to 118 degC as
package.
Misdirected
Flow
Pressure
6. More/ High 1. Ammonia Synthesis 1.1. High temperature of feed to Converter, 1.1.1. TI-1373 is available on feed line to the
Temperature Converter (105-D) is as the feed is heated in Ammonia Converter Converter.
operating at high Feed/ Effluent Exchanger (121-C). This will
1.1.2. TAH-1383/1384 are available on Bed 1 of
78 of 151
temperature result in low conversion of ammonia in the Converter.
Converter.
1.1.3. Operating instructions to be followed to
control the Bed 1 temperature by operating HV-
1025.
1.2. Possible damage to catalyst in the 1.2.1. Multiple TIs with high alarms are provided
Converter. on catalyst bed of Ammonia Synthesis
Converter.
control the Bed 1 temperature by operating HV-
1025.
Temperature
10. Start-up/ 1. Purging requirement of 1.1. Difficulty for routing the purge gas for 95. Provide a bypass across Rekayasa
Shutdown/ Syngas Compressor the Compressor PRV-103J available at the 3rd
Maintenance stage discharge of Syngas
Compressor.
2. Isolation requirement of 2.1. Loss of time and loss of gas with the 96. Provide blind on the upstream Rekayasa
Syngas Compressor present arrangement of FV-1059.
11. Composition 1. More moisture content in 1.1. Temporary poisoning of the catalyst. 1.1.1. Molecular Sieve Dryer and Purifier are
change/ syngas from upstream available at upstream, which will not allow any
Contamination/ moisture to come along with syngas.
Additional
1.1.2. AAH-1014 (moisture analyzer) is provided
Phase/ Loss
Phase at the outlet of Molecular Sieve Dryer.
1.1.3. Poisoning can be reversed with pure gas
operation.
2. Hydrogen/ Nitrogen ratio 2.1. Increased loop pressure. Low per pass 2.1.1. Online analyzers AT-1000 is available on
conversion leading to high circulation flow. the inlet and outlet lines of 105-D for all the
components of syngas.
3. High inerts (Argon/ 3.1. Increased loop pressure 3.1.1. Online analyzers AT-1000 is available on
Methane) content in the inlet and outlet lines of 105-D for all the
syngas components of syngas.
4. High CO/ CO2 content in 4.1. Not expected as CO2 will form ice in the
syngas upstream Purifier
79 of 151

Failure position.
13. Others 1. Tube leak in Ammonia 1.1. Converter feed will contaminate the
Converter Feed/Effluent effluent, leading to higher recycle flow.
Exchanger (121-C) However, no serious consequence.
2. SG-1438-4"-D1A2R line 2.1. 92. Review the design and Rekayasa
is taken from the requirement of SG-1438-4"-
Compressor inlet line, D1A2R line.
which is a B rating.
3. Design temperature of 3.1. 93. Review the design Rekayasa
Ammonia Converter temperature of Ammonia
Feed/Effluent Exchanger Converter Feed/Effluent
(121-C) tube side Exchanger (121-C) tube side as
the tube side is designed for 210
degC only. KBR recommends to
design the tube side for 275 degC
as per KBR basic engineering
package.
4. Specification of Start-up 4.1. 94. Deleted
Heater (102-B) as
mentioned in P&ID

Node: 16. Unitized Chiller system
Drawing: P2B-10-02-EF-62D113-R/ Rev 2; P2B-10-02-EF-62D114-R/ Rev 2; P2B-10-02-EF-62D115-R/ Rev 2; P2B-10-02-EF-62D116A-R/ Rev 2; P2B-10-02-EF-62D116-R/ Rev
2; P2B-10-02-EF-62D119-R/ Rev 2; P2B-10-02-EF-62D127-R/ Rev 2
1. No/ Low Flow 1. No flow of BFW to 1.1. Ammonia Converter effluent will flow at 1.1.1. TAH-1371 is available at the outlet of 123-
Ammonia Converter high temperature to Ammonia Converter C2 on the Converter effluent line.
Effluent/ BFW Preheater Feed/Effluent Exchanger (121-C) shell side
Exchanger (123-C1) and leading to damage. Also, high temperature
Ammonia Converter in 123-C2.
Effluent/ Steam Generator
1.2. Possible lower level in the Steam Drum 1.2.1. LSLL-1223 (HP Steam Drum low low
(123-C2) due to FIC-1020
malfunction and closure of (141-D) level) (2oo3) is provided on the HP Steam Drum
FV-1020 with interlock I-101 to trip the plant in adverse
case.
2. No flow of BFW through 2.1. Higher vaporization of BFW in Ammonia 2.1.1. High vaporization alarm UAH-1002
TV-1415 available across Converter Effluent/ BFW Preheater
80 of 151
Ammonia Converter Exchanger (123-C1) leading to Steam Drum. available
Effluent/ BFW Preheater
Exchanger (123-C2) when Possible damage to 123-C1 due to high
required vaporization.
3. No flow of Converter 3.1. No consequence as HV-1032 is
effluent through bypass line normally closed and used only during start-
across Ammonia Converter up.
Exchanger (123-C2) due to
closure of HV-1032
4. No flow of syngas from 4.1. For upstream consequences, refer to
3rd stage of Syngas Node 15.
Compressor (103-J) to
4.2. No consequence as this is a closed
Ammonia Converter
Feed/Effluent Exchanger loop.
(121-C) tube side due to
closure of HV-1101
5. No flow of effluent from 5.1. Possible loss of flow to Unitized Chiller, 5.1.1. Antisurge valve is provided for protection
Ammonia Converter Feed/ and in turn pressurize the upstream loop. of Syngas Compressor.
Effluent Exchanger (121-C)
5.2. Loss of ammonia production and 5.2.1. Antisurge valve is provided for protection
to Ammonia Converter
Effluent Coolers (124- reduction in ammonia refrigeration load, of Ammonia Refrigerant Compressor.
C1/C2) due to closure of leading to surge in Ammonia Refrigerant
HV-1033 Compressor (105-J).
6. No flow of recycle gas 6.1. Possible surge to the Compressor 85. Compressor Vendor to Rekayasa/
from 3rd stage of Syngas leading to damage. suggest suitable safeguard (such Compressor
Compressor (103-J) as vibration switch and trip) for Vendor
discharge to inlet of the malfunction of the kickback
Ammonia Converter valve (FV-1008) for Synthesis
Effluent Cooler (124-C1) Gas Compressor (103-J) when
due to FIC-1059 required.
malfunction and non-
opening of FV-1059 when
required
7. No flow of cooling water 7.1. High temperature effluent will lead to 97. Provide TAH from TI-1633 Rekayasa
in Ammonia Converter Ammonia Unitized Chiller (120-C) and in turn available on the outlet of
Effluent Coolers (124- ammonia refrigeration load will increase. Ammonia Converter Effluent
C2/C1) Cooler (124-C2).
8. No flow of purge gas 8.1. Possible accumulation of inerts in gas 8.1.1. PDAH-1052/1054 is provided across the 98. Consider to provide high Rekayasa
from Ammonia Separator leading to Ammonia Unitized Chiller (120-C), Ammonia Synthesis Converter due to increased alarm on PDI-6546 available
(146-D) due to FIC-1024 which in turn may increase the loop across 3rd stage of Synthesis
81 of 151
malfunction and closure of differential pressure across Ammonia circulation flow because of high inert level. Gas Compressor (103-J).
FV-1024 Synthesis Converter (105-D) and increase in
recycle gas flow.
8.2. Possible reduction in reformer outlet 8.2.1. Main fuel gas will takeover to compensate
temperature due to closure of purge gas flow for the reduction in temperature through TIC-
to fuel gas. 1314 at outlet of Primary Reformer (101-B).
9. No flow from the boot of 9.1. Possible high level of liquid ammonia in 9.1.1. LSHH-1218 with interlock I-103J will trip
Ammonia Separator (146- 146-D leading to liquid ammonia carryover to the Syngas Compressor (103-J) and close FV-
D) due to LIC-1013 3rd stage suction of Syngas Compressor 1024 on purge gas line. Also, HIC/ HV-1028 to
malfunction and closure of (103-J) or purge gas. Potential seal failure automatically open and pass MP steam
LV-1013 and release of ammonia/ hydrogen. extraction flow equal to flow from turbine.
Possible entrainment of liquid with syngas to
reactor, leading to inefficient conversion.

9.2. Possible lower level in 147-D and flow to
120-CF1/ 149-D will stop, leading to loss of
ammonia product to battery limit. However,
no serious consequence.
2. More/ High 1. More flow of BFW to 1.1. Less vaporization in 123-C2. However,
Flow Ammonia Converter no major consequence.
1.2. More vaporization in HTS Effluent/ 1.2.1. The control valve FV-1020 is provided with 99. High vaporization alarm shall Rekayasa
Exchanger (123-C1) and
Ammonia Converter Steam Generator & BFW Preheater (103- mechanical maximum stop. be provided from UI-1001
Effluent/ Steam Generator C1/C2) available for HTS Effluent/ Steam
(123-C2) due to FIC-1020 Generator & BFW Preheater
malfunction and higher (103-C1/C2).
opening of FV-1020
2. More flow of BFW 2.1. Possible low vaporization in 123-C1,
through TV-1415 available leading to less production of steam.
across Ammonia Converter However, no serious consequence.
2.2. Possible high temperature of converter 2.2.1. TAH-1371 is available at the outlet of 123-
Exchanger (123-C2)
effluent from 123-C2 to 121-C C2 on the Converter effluent line.
3. More flow of recycle gas 3.1. Loss of cooling of Ammonia Synthesis 3.1.1. Multiple TIs are provided on the skin of
from 3rd stage Syngas Converter (105-D) shell as the same Ammonia Synthesis Converter.
Compressor discharge to Compressor discharge gas is used for
inlet of Ammonia Converter cooling. This in turn lead to high temperature
Effluent Cooler (124-C1) in the Converter shell. manually depressurize Ammonia Synthesis
due to higher opening of Converter. (HV-1019 available on the recycle
FV-1059. (This is 3rd stage line from 120-C.)
82 of 151
Syngas Compressor 3.2. Less flow to the downstream of 3.2.1. PV-1004 available on the inlet line to the
antisurge.) Ammonia Synthesis Converter (105-D) and Compressor from Purifier Feed Cold Box
in turn higher pressure build up in the Package (137-L) and will open to release the
upstream. pressure to cold vent header.
4. More flow of purge gas 4.1. Possible overpressurization of HP 4.1.1. PAH-1033 is available on the vapor line
from Ammonia Separator Ammonia Scrubber (124-D) from the 124-D top.
(146-D) due to higher
4.1.2. PRV-124D is available on the inlet line
opening of FV-1024
leading to 124-D.
4.2. Possible high differential pressure in HP 4.2.1. PIC-1033 is available to release the
Ammonia Scrubber (124-D) pressure.
4.3. Possible higher ammonia slippage from 4.3.1. Sample point S-1807 is provided at outlet
HP Ammonia Scrubber (124-D) to of HP Ammonia Scrubber.
Methanator Effluent Chiller (130-C1/C2) or
4.3.2. Up to 20 ppm of ammonia slippage to
fuel system.
dryer will have no consequence.
No serious consequence envisaged in case
of fuel system.
Slippage of ammonia to 130-C1/C2 will lead
to more ammonia content in Mol Sieve Dryer

feed. In adverse case, ammonia may be
carried over to Purifier.
5. More flow from the boot 5.1. Possible gas blowby to Ammonia 5.1.1. PV-1108 is available to release pressure 101. PRVs in ammonia service Rekayasa
of Ammonia Separator Letdown Drum (147-D) and pressurization. to 123-D are provided with isolation valves
(146-D) due to malfunction with CSO facility. These PRVs
and higher opening of LV- cannot be removed when the
1013 plant is running, for purposes
such as maintenance.
In case isolation valves are
provided, the orientation of the

valve shall be in horizontal
83 of 151
condition or with the stem
pointing downwards to avoid
falling of the gate and the valve
gets closed.
5.1.2. PRV-147D1/D2 is available on 147-D 119. Verify that PRV-147D1/D2 Rekayasa
available on Ammonia Letdown
Drum (147-D) is suitable for gas
blowby from Ammonia Separator
(146-D) due to full opening of LV-
1013.

Misdirected
Flow
Pressure
6. More/ High 1. Refrigerant Compressor 1.1. High temperature of syngas to 1.1.1. TAH-1080 is available at the outlet of
Temperature (105-J) trips Ammonia Separator (146-D), and in turn Ammonia Unitized Chiller (120-C).
less condensation of ammonia in 146-D.
1.1.2. Refrigerant Compressor trip alarm (XA-
Also, more ammonia recycle back to
Ammonia Synthesis Converter (105-D). 3111B) is available at control room.
Reduced conversion in 105-D. Possible 1.1.3. AT-1000 is provided at the inlet of 105-D
increase in synthesis gas loop pressure. for monitoring NH3 content.
1.2. No MP steam from the turbine of 105-J 1.2.1. On Refrigerant Compressor (105-J) trips,
and thereby MP steam availability reduces. interlock I-105J will open the letdown valve HIC/
HV-1028 to automatically open and pass MP
(FI-1125).
Temperature
10. Start-up/ 1. Tripping of Ammonia 1.1. Chances of freezing of water in the 1.1.1. Pump running indication is provided in 103. Operating manual to indicate Rekayasa
Shutdown/ Injection Pump (120-J) Chiller. DCS. that in case of tripping of
Maintenance during catalyst reduction Ammonia Injection Pump (120-J)
1.1.2. This pump is used only during reduction
during catalyst reduction,
which cause for the new catalyst only. Ammonia Refrigerant
84 of 151
Compressor has to be unloaded
(open antisurge valve) to avoid
freezing of water in Ammonia
Unitized Chiller (120-C).
11. Composition 1. No new issue identified.
change/ Refer to Cause 8 of "No/
Contamination/ Low Flow" cases
Additional and Cause 3 and 4 of
Phase/ Loss "More/ High Flow" cases .
Phase Also refer to Cause 1 of
"More/ High Temperature"
Failure position.
13. Others 1. Tube leak in Ammonia 1.1. Possible leakage of syngas to steam
Converter Effluent/ Steam side and contaminating HP Steam Drum/
Generator & BFW system.
Preheater (123-C1/C2) Refer to Nodes 5 and 13 regarding leakage
of syngas and its consequences.

2. Tube leak in Ammonia 2.1. Possible contamination of cooling water
Converter Effluent Cooler with converter effluent (syngas). However,
(124-C1/C2) no consequence as the same will be
released from the Riser of the cooling tower.
2.2. Possible overpressurization of CW 2.2.1. RD-124C is available on the CW return 102. Confirm that RD-124C Rekayasa
return header. header. available on the CW return
header is suitable for tube leak in
Ammonia Converter Effluent
Cooler (124-C1/C2).

Node: 17. Ammonia Refrigeration system
Drawing: P2B-10-02-EF-62D114-R/ Rev 2; P2B-10-02-EF-62D116-R/ Rev 2; P2B-10-02-EF-62D116A-R/ Rev 2; P2B-10-02-EF-62D117-R/ Rev 2; P2B-10-02-EF-62D118-R/ Rev
2; P2B-10-02-EF-62D118A-R/ Rev 2; P2B-10-02-EF-62D118B-R/ Rev 2; P2B-10-02-EF-62D119-R/ Rev 2; P2B-10-02-EF-62D128-R/ Rev 2
1. No/ Low Flow 1. No/ Low flow of vapour 1.1. Possible loss of suction to 1st stage of 1.1.1. Antisurge protection is available through
from 1st Stage Refrigerant Ammonia Refrigerant Compressor (105-J), FV-1012.
Flash Drum (120-CF1) to leading to damage.
85 of 151
1st stage suction due to 1.2. Lower pressure in 120-CF1 1.2.1. 120-CF1 is designed for 0.25 vacuum.
problem in Ammonia
Unitized Chiller (120-C)
2. No flow of ammonia 2.1. Possible overpressurization in Ammonia
boiloff from storage due to Storage Tank. Storage tank system is
closure of XV-1801 when provided with suitable safeguards such as
required boiloff Compressor.
However, no consequence for the Ammonia

3. Choking of strainer SP- 3.1. Possible loss of suction to 1st stage of 89. Consider to provide Rekayasa
STR-105J1 at the 1st stage 105-J, leading to damage. differential pressure indications
suction of Ammonia across suction strainers as per
Refrigerant Compressor KBR basic engineering package.
(105-J)
104. Ammonia Refrigerant Rekayasa/
Compressor Vendor shall be Compressor
consulted in case of choking of Vendor
suction strainer leading to low
suction pressure.
3.2. Higher pressure in 120-CF1 3.2.1. 120-CF1 is designed for 15.8 kg/cm2G.
3.2.2. PAH-1009 is provided.
4. No flow of vapour from 4.1. Possible loss of suction to 2nd stage of 4.1.1. Antisurge protection is available through
2nd Stage Refrigerant 105-J, leading to damage. FV-1011.
Flash Drum (120-CF2) to
2nd stage suction due to
problem in Ammonia
5. Choking of strainer SP- 5.1. Possible loss of suction to 2nd stage of 89. Consider to provide Rekayasa
STR-105J2 at the 2nd 105-J, leading to damage. differential pressure indications
stage suction of Ammonia across suction strainers as per
(105-J)
suction pressure.
6. No flow of vapour from 6.1. Possible loss of suction to 3rd stage of 6.1.1. Antisurge protection is available through
86 of 151
3rd Stage Refrigerant 105-J, leading to damage. FV-1010.
Flash Drum (120-CF3) to
3rd stage suction due to
problem in Ammonia
7. Choking of strainer SP- 7.1. Possible loss of suction to 3rd stage of 89. Consider to provide Rekayasa
STR-105J3 at the 3rd 105-J, leading to damage. differential pressure indications
(105-J)
suction pressure.
8. No flow of vapour from 8.1. Possible loss of suction to 4th stage of 8.1.1. Antisurge protection is available through
4th Stage Refrigerant Flash 105-J, leading to damage. FV-1009.
Drum (120-CF4) to 4th
stage suction due to
problem in Ammonia
9. Choking of strainer SP- 9.1. Possible loss of suction to 4th stage of 89. Consider to provide Rekayasa
STR-105J4 at the 4th 105-J, leading to damage. differential pressure indications
(105-J)
suction pressure.
10. Ammonia Refrigerant 10.1. High temperature of syngas to 10.1.1. TAH-1080 is available at the outlet of
Compressor (105-J) trips Ammonia Separator (146-D), and in turn Ammonia Unitized Chiller (120-C).
less condensation of ammonia in 146-D.
10.1.2. Refrigerant Compressor trip alarm (XA-
Also, more ammonia recycle back to
Ammonia Converter (105-D). Reduced 3111B) is available at control room.
conversion in 105-D. 10.1.3. AT-1000 is provided at the inlet of 105-D
for monitoring NH3 content.
87 of 151
10.2. No MP steam from the turbine of 105-J 10.2.1. On Refrigerant Compressor (105-J) trips,
and thereby MP steam availability reduces. interlock I-105J will open the letdown valve HIC/
HV-1028 to automatically open and pass MP
(FI-1125).
10.3. Overpressurization of 120-CF.
However, no consequence for 120-CF as it
is taking care of the maximum possible
pressure.
10.4. Loss of ammonia production and
leading to upset in urea plant. Refer to Urea
Plant HAZOP.
10.5. Possible stoppage of boiloff gas from
Ammonia Storage and overpressurization in
Ammonia Storage Tank. Storage tank
system is provided with suitable safeguards
such as boiloff Compressor.
10.6. Possible reverse flow of ammonia 10.6.1. NRV is provided on the boiloff line joining 107. Consider to close XV-1801 Rekayasa
vapour to the storage tank (Compressor to Compressor suction. available on the boiloff gas line
system will see the settleout pressure, which joining to the Compressor
is much higher than the storage side suction, when the Ammonia
pressure), leading to overpressurization of Refrigerant Compressor (105-J)
storage tank. trips.
XV-1801 shall indicate the fail
position as well as tight shutoff

requirement.
Or
Consider to provide automatic
opening of block and bleed facility

in case of high pressure.
11. No flow of cooling 11.1. 4th stage suction of 105-J will likely to 11.1.1. TAH-6195 is available at suction of 4th 105. Ammonia Refrigerant Rekayasa/
water in Refrigerant experience higher temperature, leading to stage. Compressor Vendor shall be Compressor
Compressor 3rd Stage damage. consulted in case of high Vendor
11.1.2. TAH-6199 is available at the discharge of
Intercooler (128-C) temperature at the 4th stage
4th stage. discharge.
12. No flow of ammonia 12.1. Not expected.
vapour to dry gas seal from
88 of 151
4th stage discharge of
Ammonia Refrigerant
Compressor (105-J)
13. No flow of vapor from 13.1. No consequence for the Chiller
Ammonia Distillation section.
column 125-D to inlet of However, consequence for the Ammonia
Refrigerant Condenser
(127-C) due to closure of Distillation column is discussed in Node 18.
PV-1034
14. No flow of cooling 14.1. Possible overpressurization of 14.1.1. PRV-105J is available on 4th stage
water in Refrigerant Refrigerant Receiver (149-D). Compressor discharge, which will protect 149-D/
Condenser (127-C) 127-C.
14.1.2. Compressor is provided with antisurge
valves for all stages.
14.2. Loss of ammonia refrigerant level in 14.2.1. LAL-1015A is available.
149-D
14.2.2. LIC-1015A will reduce the discharge from
124-J/JA by closing LV-1015A. Pump 124-J/JA
is provided with SP-ARV-124J/ SP-ARV-124JA.
14.2.3. LIC-1015C will reduce the discharge
from 113-J/JA by closing LV-1015B. Pump 113-
J/JA is provided with SP-ARV-113J/ SP-ARV-
113JA.
14.2.4. LALL-1615 is available to trip 113-J/JA .
14.3. High temperature of ammonia from 106. Consider to provide high Rekayasa
127-C to 149-D. In adverse case, this will temperature alarm from TI-1428
lead to loss of refrigeration in Ammonia available on the warm ammonia
Unitized Chiller (120-C). outlet line from Refrigerant
Receiver (149-D).
15. No flow of vapor from 15.1. Possible overpressurization of 149-D 15.1.1. PRV-105J is available on 4th stage 108. Consider to provide high Rekayasa
Refrigerant Receiver (149- and in turn higher discharge pressure of Compressor discharge, which will protect 149-D/ pressure alarm from PT-6200
D) due to closure of PV- Ammonia Refrigerant Compressor (105-J) 127-C. available on the 4th stage
1109 due to accumulation of inerts in 149-D. discharge of Ammonia
16. No flow of ammonia 16.1. Possible carryover of ammonia with 16.1.1. Sample point S-1802 is provided on the
liquid from Ammonia inerts leading to LP Ammonia Scrubber vapor outlet line from 149-D.
Letdown Drum (147-D) to (123-D). In adverse case, possible carryover
Refrigerant Receiver (149- of ammonia to fuel system in case it is not
D) due to closure of HV- getting washed fully in 123-D.
89 of 151
1026 16.2. High temperature of vapour from 149- 109. Consider to provide high Rekayasa
D to 123-D. temperature alarm from TI-1404
available on the vapor outlet line
from Refrigerant Receiver (149-
D).
17. No flow of ammonia 17.1. Possible lower level in 149-D leading 17.1.1. LAL-1015A is available.
liquid from Ammonia to loss of ammonia to urea plant as LV-
17.1.2. Pump 113-J/JA is provided with SP-
Letdown Drum (147-D) to 1015B will close.
Refrigerant Receiver (149- ARV-113J/ SP-ARV-113JA.
D) due to closure of LV- 17.2. Possible level increase in 147-D. In 110. Consider to provide another Rekayasa
1012B adverse case, liquid ammonia will be carried LT on Ammonia Letdown Drum
over to LP Ammonia Scrubber (123-D). Also, (147-D) with high alarm as per
overpressurization of 147-D. KBR basic engineering package.
(It is possible to route the liquid to
1st Stage Refrigerant Flash Drum

(120-CF1) by opening LV-1012A
from control room.)
18. No flow of ammonia 18.1. Possible loss of ammonia to 120-CF4, 18.1.1. All the four compartments of 120-C are
from Refrigerant Receiver leading to loss of refrigeration in Ammonia provided with high as well as low level alarms.
(149-D) bottom due to Unitized Chiller (120-C). Refer to Node 16
closure of LV-1021 for further consequences and safeguards.
18.2. Possible mixing of cold and warm 18.2.1. LAH-1015A is available on 149-D.
ammonia. Possible high level in 149-D.
However, no serious consequence.
19. No flow of ammonia 19.1. Possible high temperature of ammonia
liquid from Ammonia leading to urea plant. Refer to Urea Plant
Letdown Drum (147-D) to HAZOP. No consequence on Ammonia plant
outlet of Refrigerant envisaged.
Receiver (149-D) due to
malfunctioning and closure
of TV-1607 available on the
bypass line of 149-D when
required
20. No flow of letdown 20.1. Higher level in 120-CF4 and lower level 20.1.1. LSHH-1214 is available to trip the 112. Consider to provide bypass Rekayasa
ammonia liquid from 120- in 120-CF3, leading to carryover of liquid Refrigerant Compressor through interlock I-105J. valve for LV-1022/1023/1024
CF4 to 120-CF3 due to ammonia to compressor, causing damage to available on Ammonia Unitized
malfunction and closure of compressor. Potential release of ammonia. Chiller (120-C) as per KBR basic
LV-1022 Refrigeration will be affected. Refer to Node engineering package.
16 for further consequences and
90 of 151
Drawing: P2B-10-02-EF-62D114-R/ Rev 2; P2B-10-02-EF-62D116-R/ Rev 2; P2B-10-02-EF-62D116A-R/ Rev 2; P2B-10-02-EF-62D117-R/ Rev 2; P2B-10-02-EF-62D118-R/ Rev 2; P2B-10-02-EF-
62D118A-R/ Rev 2; P2B-10-02-EF-62D118B-R/ Rev 2; P2B-10-02-EF-62D119-R/ Rev 2; P2B-10-02-EF-62D128-R/ Rev 2
safeguards.
ammonia liquid from 120- in 120-CF2. Refrigeration will be affected. Refrigerant Compressor through interlock I-105J. valve for LV-1022/1023/1024
CF3 to 120-CF2 due to Refer to Node 16 for further consequences available on Ammonia Unitized
malfunction and closure of and safeguards. Chiller (120-C) as per KBR basic
LV-1023 engineering package.
ammonia liquid from 120- in 120-CF1. Refrigeration will be affected. Refrigerant Compressor through interlock I-105J. valve for LV-1022/1023/1024
CF2 to 120-CF1 due to Refer to Node 16 for further consequences available on Ammonia Unitized
malfunction and closure of and safeguards. Chiller (120-C) as per KBR basic
LV-1024 engineering package.
23. No flow of letdown 23.1. Higher level in 120-CF1. Refrigeration 23.1.1. LSHH-1217 is available to trip the
ammonia liquid from 120- will be affected. Refer to Node 16 for further Refrigerant Compressor through interlock I-105J.
CF1 to suction of Cold consequences and safeguards.
Ammonia Product Pump
(124-J/JA)
24. No flow of liquid 24.1. Possible level increase in 147-D. In 118. Consider to provide another Rekayasa
ammonia to 120-CF1 from adverse case, liquid ammonia will be carried LT on Ammonia Letdown Drum
Ammonia Letdown Drum over to 123-D. Also, overpressurization of (147-D) with high alarm as per
(147-D) due to closure of 147-D. KBR basic engineering package.
LV-1012A when required LV-1012B can be taken in line to
transfer liquid ammonia to

Refrigerant Receiver (149-D)
using the recommended LT
above.
25. No flow of liquid 25.1. Possible level increase in 147-D. In 118. Consider to provide another Rekayasa
ammonia to 120-CF4 from adverse case, liquid ammonia will be carried LT on Ammonia Letdown Drum
147-D due to closure of LV- over to 123-D. Also, overpressurization of (147-D) with high alarm as per
1016 when required 147-D. KBR basic engineering package.
LV-1012B can be taken in line to

transfer liquid ammonia to
Refrigerant Receiver (149-D)
using the recommended LT
above.
26. No flow of vapour from 26.1. Possible overpressurization of 147-D 26.1.1. PRV-147D1/D2 is available on 147-D.
147-D to LP Ammonia
Scrubber (123-D) due to
closure of PV-1108
91 of 151
27. No flow of ammonia 27.1. Possible mixing of cold and warm 27.1.1. LIC-1015A will take over and send more 111. Review the requirement of Rekayasa
liquid from Refrigerant ammonia. Possible high level in 149-D. cold ammonia to storage through 120- autostart logic of Warm Ammonia
Receiver (149-D) due to However, no serious consequence. CF4/CF3/CF2/CF1. Product Pump (113-J/JA) on high
trip of Warm Ammonia level in Refrigerant Receiver (149-
Product Pump (113-J/JA) D).
27.2. Loss of liquid ammonia to Ammonia
Distillation Column (125-D). Possible higher
pressure in 125-D. Further consequence is
addressed in Node 18.
28. No flow of ammonia 28.1. Same as 24.1
liquid to urea plant/
28.2. Warm Ammonia Product Pump (113- 28.2.1. SP-ARV-113J/JA is provided at the
Refrigerant Receiver (149-
D) due to malfunction and J/JA) will experience shutoff condition, pump discharge.
closure of LV-1015B leading to damage.
29. No flow of ammonia 29.1. Refer to "Start-up/ Shutdown/

liquid to 124-C1/C2 due to Maintenance" in Node 16. No consequence
tripping of Ammonia for 149-D.
Injection Pump (120-J)
30. No flow of cold 30.1. Higher level in 120-CF1. Refrigeration 30.1.1. LSHH-1217 is available to trip the
ammonia to ammonia will be affected. Refer to Node 16 for further Refrigerant Compressor through interlock I-105J.
storage tank due to tripping consequences and safeguards.
30.1.2. Standby pump is available. (124-J/JA)
of Cold Ammonia Product
Pump (124-J/JA)
31. No flow of cold 31.1. Higher level in 120-CF1. Refrigeration 31.1.1. LSHH-1217 is available to trip the
ammonia to ammonia will be affected. Refer to Node 16 for further Refrigerant Compressor through interlock I-105J.
storage tank due to consequences and safeguards.
31.2. Cold Ammonia Product Pump (124- 31.2.1. SP-ARV-124J/JA is provided at the
LV-1015A
J/JA) is likely to experience shutoff pump discharge.
condition.
2. More/ High 1. Turbine speed increases 1.1. Possible more cooling in Ammonia 1.1.1. 120-CF1 is designed for minus 40 degC
Flow due to loss off speed Unitized Chiller (120-C), leading to lower and 0.25 vacuum.
control pressure in 120-CF1
1.2. Possible low pressure/ vacuum in the 113. Ammonia storage tank Rekayasa
worst case in the line connecting to HAZOP to take care of the
ammonia storage. situation of Ammonia Refrigerant
Compressor (105-J) overspeed
and in turn low pressure/ vacuum
formation in the line connecting to
first stage suction of Refrigeration
92 of 151
Compressor.
2. More flow of vapour from 2.1. In adverse case, high pressure in 120- 2.1.1. Compressor speed control is connected to
120-CF1 to 1st stage CF1 pressure in 120-CF1 and maintain the pressure.
suction due to more (PIC-1009)
vaporization in 120-CF1
2.1.2. PAH-1009 is available in 120-CF1.
3. More flow of vapour from 3.1. Same as 2.1 above.
120-CF2 to 2nd stage
suction due to more
120-CF3 to 3rd stage
suction due to more
120-CF4 to 4th stage
suction due to more
6. More flow of vapor from 6.1. No serious consequence envisaged as
Ammonia Distillation flow of vapor from distillation column is very
column 125-D to inlet of less and also cannot increase, as it is
Refrigerant Condenser handling only ammoniacal water.
(127-C) due to higher
opening of PV-1034
7. More flow of vapor from 7.1. Possible more vaporization of ammonia, 114. Consider to provide flow Rekayasa
Refrigerant Receiver (149- leading to loss of ammonia along with inerts element on waste gas line leaving
D) due to higher opening of to LP Ammonia Scrubber (123-D). Possible Refrigerant Receiver (149-D)
PV-1109 decrease in 149-D pressure compared to through PV-1109 as per KBR
normal operating pressure, as 123-D is basic engineering package. Also
operating at about 4 kg/cm2G less than 149- provide high flow alarm from that
D. FT in DCS.
This will lead to possible carryover of
ammonia from 123-D to fuel gas system

through PV-1038A.
7.2. In adverse case, loss of level in 149-D, 7.2.1. LAL-1015A is available on 149-D.
leading to loss of suction to Ammonia
8. More flow of ammonia 8.1. Possible low temperature waste gases 8.1.1. LAH-1015A is available on 149-D.
93 of 151
liquid from Ammonia flowing to downstream. 8.1.2. LAL-1011 is available on 147-D.
Letdown Drum (147-D) to
Refrigerant Receiver (149- Possible increase in level in 149-D and 8.1.3. LV-1012B will hold the level in 147-D.
D) due to higher opening of decrease in level in 147-D.
8.1.4. TAL-1404 is available on the waste gas
HV-1026
line leaving 149-D.
9. More flow of ammonia 9.1. Possible increase in level in 149-D and 9.1.1. LAH-1015A is available on 149-D. 111. Review the requirement of Rekayasa
liquid from Ammonia decrease in level in 147-D. autostart logic of Warm Ammonia
9.1.2. LAL-1011 is available on 147-D.
Letdown Drum (147-D) to Product Pump (113-J/JA) on high
Refrigerant Receiver (149- This may result in less flow from 147-D to 9.1.3. LAHH-1615 is available to start the level in Refrigerant Receiver (149-
D) due to higher opening of 120-CF1, as the level in 147-D is controlled standby pump 103-J/JA. However, LIC-1015A D).
LV-1012B by LV-1012A on the line leading to 120-CF1. will increase the cold ammonia product flow to
ammonia storage tank, and control the level in
149-D. Hence LAHH-1615 will not help.
9.2. Possible vapor blowby from 147-D to 115. Consider to design Rekayasa
149-D and pressurization of 149-D. Refrigerant Receiver (149-D) as
package. (Design pressure: 22.5
kg/cm2G and Design
temperature: 100 degC)
10. More flow of ammonia 10.1. Higher level in 120-CF4 leading to 10.1.1. LSHH-1214 is available to trip the
from Refrigerant Receiver carryover of liquid ammonia to compressor, Refrigerant Compressor through interlock I-105J.
(149-D) bottom due to causing damage to compressor. Potential
higher opening of LV-1021 release of ammonia.
11. More flow of ammonia 11.1. Possible low temperature ammonia 11.1.1. Warm Ammonia Product Pump (113- 116. Review the requirement of Rekayasa
liquid from Ammonia leading to Urea Plant. However, no serious J/JA) is designed for 20 degC. providing a TI with low alarm on
Letdown Drum (147-D) to consequence. Refer to Urea Plant HAZOP. the line leading to Warm
outlet of Refrigerant Ammonia Product Pump (113-
Receiver (149-D) due to J/JA) from Refrigerant Receiver
malfunctioning and higher (149-D), in light of TV-1607 full
opening of TV-1607 opening.
available on the bypass
117. Ensure that mixing of cold Rekayasa
line of 149-D when required
ammonia through TV-1607 with
the warm ammonia flow from
Refrigerant Receiver (149-D) do
not create any thermal shock in
the line and in turn damage
leading to toxic release of
ammonia.
12. More flow of letdown 12.1. Possible higher level in 120-CF3. 12.1.1. LSHH-1215 is available to trip the
ammonia liquid from 120- Potential carryover of liquid ammonia to
94 of 151
CF4 to 120-CF3 due to Refrigerant Compressor. Refrigerant Compressor through interlock I-105J.
12.2. Possible lower level in 120-CF4,
opening of LV-1022
leading to loss of refrigeration in 120-CF4.
Refer to Node 16 for further consequences
and safeguards.
ammonia liquid from 120- Potential carryover of liquid ammonia to Refrigerant Compressor through interlock I-105J.
CF3 to 120-CF2 due to Refrigerant Compressor.
opening of LV-1023
and safeguards.
ammonia liquid from 120- Potential carryover of liquid ammonia to Refrigerant Compressor through interlock I-105J.
CF2 to 120-CF1 due to Refrigerant Compressor.
opening of LV-1024
and safeguards.
15. More flow of letdown 15.1. Possible lower level in 120-CF1,
ammonia liquid from 120- leading to loss of refrigeration in 120-CF1.
CF1 to suction of 124-J/JA Refer to Node 16 for further consequences
due to malfunction of LV- and safeguards.
1015A available on the line
15.2. Possible loss of level in 120-CF1. Loss 15.2.1. LAL-1024A is available on 120-CF1
leading to cold ammonia
of suction to 124-J/JA leading to damage.
storage 15.2.2. PIC-1009 is connected to turbine speed.
No damage is expected for the pump.
15.3. Possible decrease in pressure in 120- 15.3.1. PAL-1009 is available on 120-CF1.
CF1.
15.3.2. PIC-1009 is connected to turbine speed.
No damage is expected for the pump.
16. More flow of ammonia 16.1. Possible decrease in level of 149-D, 16.1.1. LIC-1015C (low level override) will close
liquid to urea plant from and in adverse case, Warm Ammonia LV-1015B to limit product ammonia flow to Urea
Refrigerant Receiver (149- Product Pump (113-J/JA) may suffer due to Plant.
D) due to more drawoff by loss of suction.
16.1.2. In adverse case, LALL-1615 is available
urea plant
to trip 113-J/JA through DCS.
17. More flow of liquid 17.1. In adverse case, overpressurization of 17.1.1. PIC-1009 is available in 120-CF1 and will
ammonia to 120-CF1 from increase the speed of turbine/ refrigerant
95 of 151
147-D due to higher 120-CF1 due to gas blowby from 147-D. Compressor.
opening of LV-1012A
17.1.2. PAH-1009 is available in 120-CF1.
17.1.3. PRV-120CF1 is provided on 120-CF1
17.2. Possible overpressurization of 149-D 17.2.1. PAH-1109 is available on the vapour
and higher discharge pressure of 105-J due outlet line from 149-D.
to accumulation of inerts in 149-D.
17.2.2. PRV-105J is available on 4th stage
Compressor discharge.
18. More flow of liquid 18.1. In adverse case, overpressurization of 18.1.1. PRV-120CF4 is provided on 120-CF4
ammonia to 120-CF4 from 120-CF4 due to gas blowby from 147-D.
147-D due to high opening
18.2. Possible overpressurization of 149-D 18.2.1. PAH-1109 is available on the vapour
of LV-1016
and higher discharge pressure of 105-J due outlet line from 149-D.
to accumulation of inerts in 149-D.
18.2.2. PRV-105J is available on 4th stage
Compressor discharge.
19. More flow of vapour 19.1. Possible overpressurization of 123-D 19.1.1. PRV-123D is available on the inlet line
from 147-D to LP Ammonia from 147-D to LP Ammonia Scrubber,
19.2. Possible low pressure in 147-D, 19.2.1. LAH-1011 is available at 147-D. 120. Consider to provide low Rekayasa
high opening of PV-1108
leading to high level in 147-D (due to no flow pressure alarm from PIC-1108.
of liquid ammonia to 149-D).
3. Reverse/ 1. Tripping of Warm 1.1. Possible reverse flow from the minimum 121. Review the requirement of Rekayasa
Misdirected Ammonia Product Pump flow line to the pump which is not running. NRV on the minimum flow line
Flow (113J/JA) when it is leading to suction drum.
running on minimum flow This is a global recommendation.
2. Tripping of Cold 2.1. Possible reverse flow from the minimum 121. Review the requirement of Rekayasa
Ammonia Product Pump flow line to the pump which is not running. NRV on the minimum flow line
(124J/JA) leading to suction drum.

Pressure
Temperature
96 of 151
Temperature
Shutdown/
Maintenance
11. Composition 1. No new issue identified
change/
Contamination/
Additional
Phase/ Loss
Phase
Failure position.
13. Others 1. Tube leak in Refrigerant 1.1. Cooling water will be contaminated with 1.1.1. Regular sampling of cooling water as per
Compressor 3rd Stage ammonia vapor. Also, possible fouling of the operating instructions.
Intercooler (128-C) exchangers using cooling water.
1.1.2. RD-128C is available on the cooling water
return line
2. Tube leak in Refrigerant 2.1. Cooling water will be contaminated with 2.1.1. Regular sampling of cooling water as per
Condenser (127-C) ammonia vapor. Also, possible fouling of the operating instructions.
exchangers using cooling water.
2.1.2. RD-127C is available on the cooling water
return line
3. Bypass requirement for 3.1. Difficulty in depressurization after the 122. Consider to provide a Rekayasa
PRV-120J available on reduction of catalyst in the Converter. bypass across PRV-120J for
discharge of Ammonia depressurization purpose.
Node: 18. Loop Purge Ammonia Recovery system including Ammonia Distillation Column
Drawing: P2B-10-02-EF-62D127-R/ Rev 2; P2B-10-02-EF-62D128-R/ Rev 2; P2B-10-02-EF-64D106-R/ Rev 2; P2B-10-02-EF-64D106A-R/ Rev 2

1. No/ Low Flow 1. No flow of purge gas 1.1. No consequence on Ammonia Recovery
from Ammonia Letdown System.
Drum (147-D) to LP
97 of 151
Ammonia Scrubber (123-D)
due to malfunction and
closure of PV-1108
2. No flow of purge gas 2.1. No consequence on Ammonia Recovery
from Refrigerant Receiver System.
(149-D) to LP Ammonia
PV-1009
3. No flow of purge gas 3.1. Loss of recycle hydrogen from 124-D to 3.1.1. FAL-1022 is available on the recycle gas
from Ammonia Separator 102-J discharge leading to possible sulfur line.
(146-D) to HP Ammonia slippage from Desulfurizer.
3.1.2. Alternate source of recycle hydrogen is
malfunction and closure of available from 144-D through FV-1703.
FV-1024
4. No flow of condensate 4.1. Improper scrubbing in 123-D leading to 4.1.1. Sample point S-1806 is available on vapor
from Ammonia Distillation possible carryover of ammonia to fuel gas line from 123-D.
Column (125-D) (116-J/JA system. However, no immediate serious
discharge) to LP Ammonia consequence.
FV-1039
5. No flow of vapor from LP 5.1. Possible overpressurization of 123-D. 5.1.1. PRV-123D is available at the inlet of 123-
Ammonia Scrubber (123-D) D.
to fuel gas header due to
PV-1038A
6. No flow of vapor from LP 6.1. Possible overpressurization of 123-D. 6.1.1. PRV-123D is available at the inlet of 123-
Ammonia Scrubber (123-D) D.
to flare header due to
PV-1038B when required
7. No flow of ammoniacal 7.1. Possible level increase in 123-D, and in 7.1.1. LAH-1028 is available on 123-D.
water from bottom of LP turn the differential pressure in 123-D will
7.1.2. Pump running indication is provided in
Ammonia Scrubber (123-D) increase. In adverse case, ammoniacal
to Ammonia Distillation water may be carried over to the fuel gas DCS.
Column (125-D) due to system. 7.1.3. Standby pump is available.
tripping of LP Ammonia
Distillation Column Feed
Pump (160-J/JA)
8. No flow of vapor from 8.1. Possible overpressurization of 124-D. 8.1.1. PRV-124D is available on the inlet line 123. Review the requirement of Rekayasa
98 of 151
HP Ammonia Scrubber leading to 124-D. addition PT on HP Ammonia
(124-D) to Methanator Scrubber (124-D).
8.1.2. Alternatively purge gas can be routed to
C1/C2) due to malfunction fuel gas supply through FV-1029. However,
and closure of PV-1033A controlling the pressure in 124-D will be difficult
when PT-1033 is malfunctioned.
9. No flow of vapor from 9.1. Possible overpressurization of 124-D. 9.1.1. PRV-124D is available on the inlet line
HP Ammonia Scrubber leading to 124-D.
(124-D) to flare header due
to malfunction and closure
of PV-1033B when
required
10. No flow of vapor from 10.1. Possible overpressurization of 124-D. 10.1.1. PRV-124D is available on the inlet line
HP Ammonia Scrubber leading to 124-D.
(124-D) to fuel gas header
closure of FV-1029 when
required (e.g. in case 124-
D is not in line)
11. No flow of condensate 11.1. Improper scrubbing in 124-D leading to 11.1.1. Sample point S-1807 is available on
from HP Ammonia possible carryover of ammonia to fuel gas vapor line from 124-D.
Scrubber Feed Pump (161- system/ 130-C1/C2. However, no immediate
J/JA) discharge to HP serious consequence for fuel gas system.
Ammonia Scrubber (124-D) Refer to "More/ High Flow case 4.3" under
due to tripping of 161-J/JA
Node 16 for consequences in 130-C1/C2.
12. No flow of ammonia 12.1. Possible high level in 124-D. In 12.1.1. PDT-1055 is available in 124-D. 124. Consider to provide a high Rekayasa
liquid (Ammonia Distillation adverse case, condensate my be carried alarm from PDT-1055 available
12.1.2. Stand pipe is available on the 2nd fuel
Column feed) from bottom over to the fuel gas system. Also, high on HP Ammonia Scrubber (124-
of HP Ammonia Scrubber differential pressure in 124-D. gas line. D).
(124-D) to Ammonia
Distillation Column Feed/
Effluent Exchanger (161-
C1/C2) due to malfunction
and closure of LV-1026
13. No flow of Ammonia 13.1. Possible loss of suction to 161-J/JA, 13.1.1. FAL-1064 is available on the pump
Distillation Column (125-D) leading to damage discharge line.
bottom to the suction of HP
13.1.2. Standby pump is available.
Ammonia Scrubber Feed
Pump (161-J/JA) due to
choking of strainer
14. No flow of product 14.1. Possible pressurization of 125-D. 14.1.1. PRV-125D is available on 125-D.
99 of 151
ammonia vapors from
Ammonia Distillation Distillation will be affected and in turn
Column (125-D) to ammonia may be carried back to 124-D/
Refrigerant Condenser 123-D, leading to ammonia slippage in
(127-C)/ Refrigerant purge gas/ waste gas. However, no major
Receiver (149-D) due to consequence.
PV-1034
15. No flow of reflux to 15.1. Possible high temperature and 15.1.1. TAH-1667 is available in 125-D. 125. Consider to provide low flow Rekayasa
Ammonia Distillation pressure in 125-D, leading to poorer quality alarm on FT-1060 on the reflux
15.1.2. PRV-125D is available on 125-D.
Column (125-D) from (high moisture content) of ammonia vapor to line of Ammonia Distillation
Warm Ammonia Product 127-C. Column (125-D).
Pump (113-J/JA) due to
TV-1414
16. No flow of MP steam to 16.1. Distillation will be affected and in turn 16.1.1. TAL-1667 is available in Ammonia
Ammonia Distillation distillation column bottom will have more Distillation Column (125-D).
Column Reboiler (160-C) ammonia, and in turn carried over to 124-D/
due to malfunction and 123-D.
closure of FV-1027 This will lead to ammonia slippage in purge
gas leading to 130-C1/C2. Refer to "More/

High Flow case 4.3" under Node 16 for
consequences in 130-C1/C2.
However, no serious consequence for waste
gas.
17. No flow of MP 17.1. Distillation will be affected and in turn 17.1.1. TAL-1667 is available in 125-D.
condensate from Ammonia distillation column bottom will have more
17.1.2. FAL-1027 is available on MP steam line.
Distillation Column ammonia, and in turn carried over to 124-D/
Reboiler (160-C) due to 123-D.
malfunction and closure of This will lead to ammonia slippage in purge
LV-1049
gas leading to 130-C1/C2. Refer to "More/
High Flow case 4.3" under Node 16 for
consequences in 130-C1/C2.
However, no serious consequence for waste
gas.
18. No flow of MP steam 18.1. No serious consequence envisaged as 18.1.1. Alternate make-up is available from 104-
condensate to the process LV-1027 is designed for very small quantity. J/JA.
100 of 151
side of Ammonia
Distillation Column
Reboiler (160-C) inlet due
to malfunction and closure
of LV-1027 when required
2. More/ High 1. More flow of purge gas 1.1. Possible pressurization of 123-D and in 1.1.1. PDAH-1056 is available in 123-D.
Flow from Ammonia Letdown turn carryover of ammonia to fuel gas
1.1.2. PRV-123D is available at the inlet of 123-
Drum (147-D) to LP header. Possible high differential pressure
Ammonia Scrubber (123-D) across 123-D due to high flow. D.
2. More flow of purge gas 2.1. Possible pressurization of 123-D and in 2.1.1. PDAH-1056 is available in 123-D.
from Refrigerant Receiver turn carryover of ammonia to fuel gas
(149-D) to LP Ammonia header. Possible high differential pressure
Scrubber (123-D) due to across 123-D due to high flow. D.
opening of PV-1009
3. More flow of purge gas 3.1. Possible pressurization of 124-D and in 3.1.1. PAH-1033 is available on the vapor line 124. Consider to provide a high Rekayasa
from Ammonia Separator turn carryover of ammonia to fuel gas from the 124-D top. alarm from PDT-1055 available
(146-D) to HP Ammonia header/ 130-C1/C2. Refer to "More/ High on HP Ammonia Scrubber (124-
Scrubber (124-D)due to Flow case 4.3" under Node 16 for D).
malfunction and higher consequences in 130-C1/C2. D.
opening of FV-1024 Possible high differential pressure across
124-D due to high flow.

4. More flow of condensate 4.1. No serious consequence envisaged. 4.1.1. LAH-1028 is available on 123-D.
from Ammonia Distillation
4.1.2. LAH will increase the stroke of LP
Column (125-D) (161-J/JA
discharge) to LP Ammonia Ammonia Distillation Column Feed Pump (160-
Scrubber (123-D) due to J/JA).
opening of FV-1039
5. More flow of vapor from 5.1. Possibility of depressurization of 123-D 5.1.1. PDAH-1056 is available in 123-D.
LP Ammonia Scrubber and in turn carryover of ammonia to fuel gas
(123-D) to fuel gas header system.
5.2. Possible increase in level in 123-D as 5.2.1. LAH-1028 is available in 123-D.
higher opening of PV-
1038A pump 160-J/JA will not be able to pump due
to low suction pressure.
6. More flow of vapor from 6.1. Possibility of depressurization of 123-D 126. Consider to replace the Rekayasa
LP Ammonia Scrubber and in turn carryover of ammonia to flare existing PG-5013 on the inlet line
(123-D) to flare header due system. of LP Ammonia Scrubber (123-D)
101 of 151
to malfunction and higher to a PT with low alarm.
opening of PV-1038B
6.2. Possible increase in level in 123-D as 6.2.1. LAH-1028 is available in 123-D.
pump 160-J/JA will not be able to pump due
to low suction pressure.
7. More flow of vapor from 7.1. Possible depressurization of 124-D and 7.1.1. PRV-144D is available on the outlet of 128. Verify that PRV-144D is Rekayasa
HP Ammonia Scrubber in turn overpressurization of 130-C1/C2. Methanator Effluent Separator (144-D) to cold capable of releasing the pressure
(124-D) to Methanator vent header. in case of PIC-1033 malfunction
Effluent Chiller (130- and full opening of PV-1033A,
C1/C2) due to PIC-1033/ without pressurizing 130-C1/C2
FIC-1029 malfunction and and 144-D.
higher opening of PV-
7.2. Possible depressurization of 124-D and 7.2.1. PRV-SG1119A/ PRV-SG1119B/ PSE- 129. Verify that PRV-SG1119A/ Rekayasa
1033A/ PV-1033B/ FV-
1029/ in turn overpressurization of fuel gas line in SG1119 are available on the waste gas header PRV-SG1119B/ PSE-SG1119 is
case fuel gas line is connected. for protection of the waste gas header. capable of releasing the pressure
in case of PIC-1033 malfunction
and full opening of FV-1029,
without pressurizing the fuel gas
header.
7.3. Possible partial loss of feed (as the feed 7.3.1. LAL-1027 is available in 125-D.
from 123-D will continue) to Ammonia
7.3.2. FAL-1064 is available on the pump
Distillation Column (125-D). 161J/JA may
lose suction in adverse case. discharge line.
7.4. Possible carryover of ammonia to fuel

gas header, in case PV-1029 (fuel gas line)
is on line. However, no serious immediate
consequence.
7.5. In adverse case, Ammonia Distillation 130. Check the design Rekayasa
Column Feed/ Effluent Exchanger (161- temperature of Ammonia
C1/C2) may experience high temperature in Distillation Column Feed/ Effluent
the shell side. Exchanger (161-C1/C2) as it is
reduced from that of KBR basic
engineering package. (Shell side:
250 degC, Tube side: 260 degC)
7.6. Temperature in the Ammonia Distillation 7.6.1. 125-D is designed for high temperature.
Column (125-D) is likely to increase
7.6.2. TAH-1667 is available in 125-D.
momentarily.
7.7. No consequence expected to the flare in
case of PV-1033B opening
8. More flow of ammonia 8.1. Possible gas blowby to Ammonia 8.1.1. PV-1034 is available on the vapor outlet 131. Verify the design pressure of Rekayasa
liquid (Ammonia Distillation Distillation Column (125-D) and may line from 125-D. Refrigerant Condenser (127-C)
102 of 151
Column feed) from bottom overpressurize the 125-D as well as 127-C 8.1.2. PRV-125D is available on 125-D. shell side as well as Refrigerant
of HP Ammonia Scrubber shell side and 149-D. Receiver (149-D) as they are
(124-D) to Ammonia reduced from that of KBR basic
Distillation Column Feed/ PRV-125D set pressure is 22.5 kg/cm2G engineering package. (127-C
Effluent Exchanger (161- and the design pressure of 127-C shell side shell side: 22.5 kg/cm2G, 149-D:
C1/C2) due to malfunction and 149-D is 21.5 kg/cm2G. 22.5 kg/cm2G)
1026
9. More flow of product 9.1. No serious consequence envisaged as
ammonia vapors from flow of vapor from distillation column is very
Ammonia Distillation less and also cannot increase, as it is
Column (125-D) to handling only ammoniacal water.
Refrigerant Condenser
(127-C)/ Refrigerant
Receiver (149-D) due to
PIC-1034 malfunction and
10. More flow of reflux to 10.1. Possible less temperature in 125-D in 10.1.1. TAL-1667 is available in 125-D.
Ammonia Distillation adverse case and more level in the 125-D.
10.1.2. LAH-1027 available in 125-D bottom.
Column (125-D) from
Warm Ammonia Product 10.2. Possible carryover of ammonia with 10.2.1. TAL-1667 is available in 125-D.
Pump (113-J/JA) due to water, affecting the operation of LP and HP
TIC-1414 malfunction and Ammonia Scrubbers. 10.2.2. Sample point S-1415 is provided at 125-
higher opening of TV-1414 D bottom.
11. More flow of MP steam 11.1. Possible high temperature in 125-D, 11.1.1. TAH-1667 is available in 125-D.
to Ammonia Distillation and in turn carryover of water with ammonia
Column Reboiler (160-C) to 127-C/ 149-D.
due to FIC-1027
opening of FV-1027
12. More flow of MP 12.1. Possible less temperature in 125-D in 12.1.1. TAL-1667 is available in 125-D.
condensate from Ammonia adverse case and more level in the 125-D.
Distillation Column
12.2. Possible steam blowby to downstream 12.2.1. PRV-101U is provided on the Deaerator. 132. Confirm that PRV-101U Rekayasa
Reboiler (160-C) due to
LIC-1049 malfunction and condensate header and in turn to Deaerator available on the Deaerator (101-
higher opening of LV-1049 (101-U). This will lead to overpressurization U) is suitable for steam blowby
and damage as the 101-U is designed for case from LV-1049.
about 3.5 kg/cm2G), where as the steam
header is about 46 kg/cm2(g).
13. More flow of MP steam 13.1. No serious consequence as the flow is
condensate to the process very low.
side of Ammonia
Distillation Column
103 of 151
Reboiler (160-C) inlet due
to LIC-1027 malfunction
1027
14. More flow of 14.1. Possible lower level in Ammonia 14.1.1. LIC-1027 will open LV-1027 to make up
condensate from HP Distillation Column (125-D). In adverse case, the level from MP condensate line.
Ammonia Scrubber Feed 161J/JA may experience loss of suction and
14.1.2. LAL-1027 is available in 125-D.
Pump (161-J/JA) discharge damage.
to HP Ammonia Scrubber Refer to "More/ High Flow case 4.3" under
(124-D) due to FIC-1064
malfunction and in turn full Node 16 for consequences in 130-C1/C2.
stroke of 161-J/JA
3. Reverse/ 1. No issue identified.
Misdirected
Flow
Pressure
Temperature
Temperature
10. Start-up/ 1. Maintenance 1.1. Difficulty in removing the liquid 133. Consider suitable Rekayasa
Shutdown/ requirement for liquid distributor. arrangement (e.g. spool piece) for
Maintenance distributor in 123-D the removal of liquid distributor in
LP Ammonia Scrubber (123-D)
for maintenance.
This recommendation is also
applicable for all vessels with

liquid distributor in ammonia
recovery unit (ARU).
change/
Contamination/
Additional
Phase/ Loss
104 of 151
Phase
Failure position.
13. Others 1. Tube leak in Ammonia 1.1. Possible contamination of Ammonia 1.1.1. Sample point S-1812 is available on 161-
Distillation Column Feed/ Distillation Column (125-D) bottom with feed, C2 tube side outlet.
Effluent Exchanger (161- resulting in poor scrubbing in 123-D and
C1/C2) 124-D.
2. Tube leak in Ammonia 2.1. Possible carryover of steam into 125-D, 2.1.1. TAH-1667 is available in 125-D.
Distillation Column and in turn leading to high pressure and
Reboiler (160-C) temperature in 125-D.
2.1.3. PIC-1034 will release the pressure to 127-
C/ 149-D.
2.1.4. PAH-1034 is available in 125-D.
2.1.5. PRV-125D is available on 125-D.
Node: 19. LTS Reduction system

Drawing: P2B-10-02-EF-62D102A-R/ Rev 2

1. No/ Low Flow 1. No flow of nitrogen from 1.1. Delay in catalyst heating. No serious 1.1.1. FAL-1104 is available at the inlet of LTSC.
upstream to LTS Start-up consequence.
Blower (173-J) or 173-J
1.2. In case 173-J trips during reduction, 1.2.1. Multiple TIs are provided with high alarm
trips
hydrogen will continue to flow to the catalyst. in the LTSC catalyst bed.
This in turn results in high temperature in the
1.2.2. This is a supervised operation.
catalyst bed, leading to damage.
2. No flow of MP steam/ 2.1. Delay in catalyst heating. No serious 2.1.1. TAL-1306 is available on the nitrogen line
condensate in LTS Start-up consequence. exiting 175-C.
Heater (175-C)
3. No flow of cooling water 3.1. Higher temperature in LTS Reduction 3.1.1. TAH-2301 is available on the nitrogen line
to LTS Start-up Cooler System K. O. Drum (173-D), leading to exiting 173-C.
(173-C) damage.
4. No flow of hydrogen 4.1. Delay in catalyst reduction. No serious 4.1.1. FI-1602/1603 is available on the hydrogen
from OEP consequence. line.
5. No flow of cooling water 5.1. Possible overheating of 173-J, leading 134. Blower Vendor shall be Rekayasa/
from battery limit to LTS to damage. consulted regarding the safety Blower Vendor
105 of 151
Start-up Blower (173-J) precautions required on cooling
water failure.
6. No flow of cooling water 6.1. Possible overheating of 173-J, leading 134. Blower Vendor shall be Rekayasa/
return from LTS Start-up to damage. consulted regarding the safety Blower Vendor
Blower (173-J) precautions required on cooling
water failure.
2. More/ High 1. More flow of hydrogen to 1.1. Possible higher catalyst temperature 1.1.1. Multiple TIs are provided with high alarm
Flow the loop due to operator leading to catalyst damage. in the LTSC catalyst bed.
error
control the hydrogen flow.
2. More flow MP steam in 2.1. Possible higher catalyst temperature 2.1.1. Multiple TIs are provided with high alarm
LTS Start-up Heater (175- leading to catalyst damage. in the LTSC catalyst bed.
C)
2.1.2. TAH-1306 is provided on nitrogen line
from 175-C.
3. Malfunction and opening 3.1. No flow of nitrogen, but hydrogen will 3.1.1. Multiple TIs are provided with high alarm
of antisurge valve FV-1301 continue to flow to the catalyst. This in turn in the LTSC catalyst bed.
when not required results in high temperature in the catalyst
3.1.2. FAL-1104 is available at the inlet of LTSC.
bed, leading to damage.
3. Reverse/ 1. LTS Start-up Blower 1.1. Possible reverse rotation of 173-J 1.1.1. Check valve is provided on blower
Misdirected (173-J) trips discharge.
Flow
4. More/ High 1. Higher pressure of 1.1. Possible damage to hydrogen injection 135. Review the tie-in connection Rekayasa
Pressure hydrogen from hydrogen line. of hydrogen from OEP (Class D)
source to line from 142-D2 (Class B) with
reference to pressurization of the
line.
1.2. Possible overpressurization of nitrogen 1.2.1. PRV-175C is provided on nitrogen line 136. Ensure that PRV-175C is Rekayasa
loop. from LTS Start-up Heater (175-C). suitable for upstream high
pressure flow case.
5. Low Pressure 1. No issue identified
Temperature
106 of 151

Temperature
8. High Level 1. High level in LTS 1.1. Possible carryover of water to LTS 1.1.1. LAH-1301 is available to trip 173-J.
Reduction System K. O. Start-up Blower (173-J).
Drum (173-D)
9. Low Level 1. Low level in LTS 1.1. No consequence.
Reduction System K. O.
Drum (173-D)
Shutdown/
Maintenance
change/
Contamination/
Additional
Phase/ Loss
Phase
Failure position.
13. Others 1. Tube leak in LTS Start- 1.1. During operation of loop, nitrogen may
up Cooler (173-C) flow to the cooling water circuit. However, no
consequence.
2. Tube leak in LTS Start- 2.1. Possible overpressurization of nitrogen 2.1.1. PRV-175C is provided on nitrogen line 137. Ensure that PRV-175C is Rekayasa
up Heater (175-C) loop due to leakage of steam into the loop. from 175-C suitable for tube leak case in LTS
Start-up Heater (175-C).
Node: 20. OASE solution storage/ sump system


1. No/ Low Flow 1. Depletion of OASE 1.1. Non-availability of OASE solution to the 1.1.1. Operating instructions to be followed for
solution in OASE Solution process when required. estimating the required OASE solution in
Storage Tank (114-F) advance and make-up the content in 114-F.
2. No flow of OASE 2.1. No serious consequences except for
solution from OASE delayed in the transfer operation, as it is a
Solution Sump Tank (115- manually supervised operation.
107 of 151
F) to OASE Solution
Storage Tank (114-F) due
to tripping of OASE Sump
Pump (115-J) during
transfer
3. No flow of DM water 3.1. No serious consequences except for
from upstream for dilution delayed in the preparation of OASE solution,
as it is a manually supervised operation.
4. Choking in OASE Sump 4.1. Possible blocked out condition for 4.1.1. Local PDG-1115 is available across 115-L
Filter (115-L) OASE Sump Pump (115-J) in adverse
4.1.2. Level indication LI-1119 is available in
condition.
115-F with high alarm
4.1.3. Piping from 115-J is designed for blocked
out condition.
5. No flow of OASE 5.1. Make-up of OASE to the system is 5.1.1. Pump running indication is provided in
solution to the system delayed, and in turn LP Flash Column (122- DCS for OASE Solution Transfer Pump (111-J).
when required due to D1) operation may be affected slightly.
tripping of OASE Solution However, no major consequence.
Transfer Pump (111-J)
6. Choking of SP-STR- 6.1. No serious consequence as the pump
111J available at the can be stopped for some time and the
suction of OASE Solution strainer can be cleaned.
Transfer Pump (111-J)
7. No flow of nitrogen to 7.1. Possible vacuum formation in the tank 7.1.1. FAL-1120 is available on the nitrogen line.
OASE Solution Storage (114-F) in adverse case when the pumping
7.1.2. PRV-114F is available on 114-F to protect
Tank (114-F) due to operation is done.
closure of PCV-1676 against vacuum.
7.2. Possible ingress of oxygen from air into 7.2.1. FAL-1120 is available on the nitrogen line.
114-F, leading to degradation of OASE
solution in long run.
7.3. Possible ingress of oxygen from air into 7.3.1. FAL-1120 is available on the nitrogen line.
114-F may lead to explosive atmosphere in
the tank.
2. More/ High 1. More flow of nitrogen to 1.1. Possible overpressurization of the tank 1.1.1. FAH-1120 is available on the nitrogen line. 156. Ensure that PRV-114F is Rekayasa
Flow OASE Solution Storage (114-F) in adverse case. sized for the full opening case of
1.1.2. PRV-114F is available on 114-F.
Tank (114-F) due to full PCV-1676 available on the
opening of PCV-1676 nitrogen line leading to OASE
Solution Storage Tank (114-F).
2. More flow of DM water 2.1. OASE solution concentration may 2.1.1. Sample point S-1416 is available on 115-J
108 of 151
during preparation of deviate from the required level. discharge
OASE solution
2.1.2. Close circulation facility is available from
115-J discharge to 115-F.
2.2. Possible overfilling of OASE Solution 2.2.1. LAH-1119 is available on 115-F. Also, it is
Sump Tank (115-F), leading to spillage of a supervised operation.
OASE solution.
3. More flow of transfer 3.1. Possible dry running of OASE Sump 3.1.1. Possible to check the level by visual 157. Consider to provide a nozzle Rekayasa
from OASE Solution Sump Pump (115-J) leading to damage. inspection. for taking manual dip level of the
Tank (115-F) to OASE solution in OASE Solution Sump
Solution Storage Tank Tank (115-F).
(114-F) due to operator
negligence/ non-availability
of LI-1119
3. Reverse/ 1. Reverse flow from the 1.1. System getting depleted with OASE 1.1.1. NRV is available on the 111-J discharge.
Misdirected system to OASE Solution solution.
Flow Storage Tank (114-F) since
OASE Solution Transfer
Pump (111-J) is not
normally operating
2. Reverse flow of vapors 2.1. Possible contamination of nitrogen 2.1.1. NRV is available on the nitrogen line to
from OASE Solution header. 114-F.
Storage Tank (114-F) to
nitrogen header when
nitrogen header is not
having any flow
Pressure
6. More/ High 1. Not applicable
Temperature
7. Low 1. Not applicable
Temperature
8. High Level 1. More deinventory from 1.1. Possible high level in 114-F, leading to 1.1.1. Overflow line is available.
the system when the tank overflow from the tank.
1.1.2. LAH-1047 is available on 114-F.
is already having some
level
9. Low Level 1. LT-1047 malfunctions 1.1. Possible loss of suction to 111-J, 1.1.1. LG-1800 is available on 114-F, and this is
and in turn lower level in leading to damage. an supervised operation.
109 of 151
the tank during transfer

Shutdown/
Maintenance
11. Composition 1. Improper quantity of 1.1. OASE solution concentration may 1.1.1. Sample point S-1416 is available on 115-J
change/ OASE and DM water in deviate from the required level. discharge
Contamination/ OASE Solution Sump Tank
1.1.2. Close circulation facility is available from
Additional (115-F)
Phase/ Loss 115-J discharge to 115-F.
Phase
Failure
13. Others 1. More dirts from the 1.1. Possible contaminated OASE solution 1.1.1. 115-L is available to make the contents of
system when OASE is sent to the system leading to upset. 114-F filtered through close circulation line.
drained during shutdown
2. Safety issues regarding 2.1. 158. MSDS of OASE shall be Rekayasa/
OASE referred and accordingly followed Pusri
in operation.
3. Leakage from OASE 3.1. Possible spillage of OASE solution 159. Review the requirement of Rekayasa
Solution Storage Tank around 114-F. dike around the OASE tanks to
(114-F) hold the contents in case of tank
rupture as per regulations of
Indonesia.

Node: 21. Chemical Injection system (OASE Antifoam injection, Phosphate injection, Ammonia injection, Oxygen Scavenger injection)
Drawing: P2B-10-02-EF-63D101-R/ Rev 2; P2B-10-02-EF-62D120B-R/ Rev 2; P2B-10-02-EF-62D122-R/ Rev 2; P2B-10-02-EF-62D122A-R/ Rev 2; P2B-10-02-EF-64D106-R/ Rev 2
1. No/ Low Flow 1. No flow of anti-foam due 1.1. Refer to Nodes 6 and 8 for process
to tripping of OASE consequences.
Antifoam injection Pump
1.2. No consequence for the injection
(109-LJ/LJA)
system.
2. No flow of anti-foam due 2.1. Possible dry running of OASE Antifoam 2.1.1. LSL-1091 is available in Antifoam Injection 160. Review the requirement of Rekayasa
to non-making up of the Injection Pump leading to damage. Tank. tripping the OASE Antifoam
Antifoam Injection Tank Injection Pump (109-LJ) on low
(109-LF) low level of the Antifoam Injection
110 of 151
Tank (109-LF).
3. No flow of lean solution 3.1. No serious consequence but for delay in
from Lean Solution Water preparation of antifoam solution, as this is a
Cooler (108-C) supervised operation.
4. Choking of strainer SP- 4.1. Loss of anti-foam to the system. Refer 4.1.1. Spare pump with strainer is available for
STR-109LJ to Nodes 6 and 8 for process consequences. switching over.
system.
2. More/ High 1. More flow of anti-foam to 1.1. Possible upset in the system leading to 1.1.1. Measuring vessel is provided at the pump 161. Consider to provide level Rekayasa
Flow the system due to high CO2 slippage. suction for periodic checking of the stroke. indication in the Antifoam
malfunction of the stroke in Injection Tank (109-LF) (as the
the pump antifoam injection is not having
any flow measurement) which will
be useful for the quantity of
antifoam gets injected.
162. Review the requirement of Rekayasa/
providing an isolation valve at the Package
outlet of the Antifoam Injection Vendor
Tank (109-LF) before the tap-off
for the measuring vessel as this
may be required for checking the
stroke of the pump using this
measuring vessel.
3. Reverse/ 1. Reverse flow is not
Misdirected expected as all lines are
Flow provided with NRV
4. More/ High 1. Antifoam injection is 1.1. High pressure in the discharge line as 1.1.1. PRV is provided at the discharge of the
Pressure closed in the system side the pump is of positive displacement type, pump.
and in turn possible damage of the line.
Temperature
Temperature
8. High Level 1. Overfilling of Antifoam 1.1. Possible overflow through the vent line 1.1.1. Overflow line is provided to route it to
Injection Tank (109-LF) in adverse case, leading to loss of antifoam. OASE drain.
due to more lean amine
solution or antifoam
111 of 151

Shutdown/
Maintenance
11. Composition 1. Improper quantity of lean 1.1. Improper concentration of solution 1.1.1. Operating instructions shall be strictly
change/ solution and antifoam leading to system, resulting in upset. followed to make a proper mixture of lean
Contamination/ solution and antifoam as it is difficult to measure
Additional the concentration.
Phase/ Loss
Phase
Failure
13. Others 1. Safety issues regarding 1.1. 163. MSDS of antifoam shall be Rekayasa/
antifoam referred and accordingly followed Pusri
in operation.
2. Fluctuation of pressure 2.1. 164. Package vendor shall review Rekayasa/
in the discharge of OASE the requirement of pulsation Package
Antifoam Injection Pump dampener and provide Vendor
(109-LJ/LJA) accordingly.
14. No/ Low 1. No flow of gaseous 1.1. Refer to Node 12 for process
Flow ammonia from Methanator consequences.
Effluent Chiller (130-C2)
2. No flow of DM water 2.1. No serious consequence but for delay in 165. Review the requirement of Rekayasa
from upstream preparation of ammoniacal solution, as this tripping the pH Control Injection
is a supervised operation. Pump (107-LJ) on low low level of
the pH Control Injection Tank
(107-LF).
3. No flow of ammoniacal 3.1. Refer to Node 24 for consequences in
solution to Deaerator (101- the Deaerator.
U) due to tripping of pH
Control Injection Pump
(107-LJ/LJA) system.
4. Choking of strainer SP- 4.1. Loss of ammoniacal solution to the 4.1.1. Spare pump with strainer is available for
STR-107LJ system. Refer to Node 24 for process switching over.
consequences.
system.
15. More/ High 1. More flow of 1.1. Refer to Node 12 for process
112 of 151
Flow ammoniacal solution to the consequences.
system due to malfunction
1.2. Wastage of ammoniacal solution and in 167. Consider to provide level Rekayasa
of the stroke in the pump
turn the tank level gets emptied faster. indication in the pH Control
However, operating instructions shall be Injection Tank (107-LF) (as the
followed to have vigilance on the tank level. ammoniacal solution injection is
not having any flow
measurement) which will be
useful for the quantity of
ammoniacal solution gets
injected.
outlet of the pH Control Injection Vendor
measuring vessel.
Misdirected expected as the discharge
Flow line is provided with NRV
17. More/ High 1. ammoniacal solution 1.1. High pressure in the discharge line as 1.1.1. PRV is provided at the discharge of the
Pressure injection is closed in the the pump is of positive displacement type, pump.
system side and in turn possible damage of the line.
Pressure
Temperature
Temperature
21. High Level 1. Overfilling of pH Control 1.1. Possible overflow through the vent line 1.1.1. Overflow line is provided to route it to
Injection Tank (107-LF) in adverse case, leading to loss of drain.
due to more DM water ammoniacal solution.
23. Start-up/ 1. Requirement of 1.1. 169. Consider to provide either Rekayasa
Shutdown/ ammonia during start-up start-up ammonia source or pH
Maintenance control chemical in the pH Control
Injection Tank (107-LF).
113 of 151

change/
Contamination/
Additional
Phase/ Loss
Phase
Failure
26. Others 1. Safety issues regarding 1.1. 166. MSDS of ammoniacal Rekayasa/
ammoniacal solution solution shall be referred and Pusri
accordingly followed in operation.
in the discharge of pH the requirement of pulsation Package
Control Injection Pump dampener and provide Vendor
27. No/ Low 1. No flow of DM water 1.1. No serious consequence but for delay in 170. Review the requirement of Rekayasa
Flow from upstream preparation of phosphate solution, as this is tripping the Phosphate Injection
a supervised operation. Pump (108-LJ) on low low level of
the Phosphate Injection Tank
(108-LF).
2. No flow of phosphate 2.1. Refer to Node 24 for consequence in
solution to Steam Drum the Steam Drum.
(141-D) due to tripping of
Phosphate Injection Pump
(108-LJ/LJA) system.
3. Choking of strainer SP- 3.1. Loss of phosphate solution to the 3.1.1. Spare pump with strainer is available for
STR-108LJ system. Refer to Node 24 for process switching over.
consequences.
system.
28. More/ High 1. More flow of phosphate 1.1. Refer to Node 24 for process
Flow solution to the system due consequences.
to malfunction of the stroke
1.2. Wastage of phosphate solution and in 171. Consider to provide level Rekayasa
in the pump
turn the tank level gets emptied faster. indication in the Phosphate
However, operating instructions shall be Injection Tank (108-LF) (as the
followed to have vigilance on the tank level. phosphate solution injection is not
having any flow measurement)
which will be useful for the
quantity of phosphate solution
114 of 151
gets injected.
outlet of the Phosphate Injection Vendor
measuring vessel.
30. More/ High 1. Phosphate solution 1.1. High pressure in the discharge line as 1.1.1. PRV is provided at the discharge of the
Pressure injection is closed in the the pump is of positive displacement type, pump.
system side and in turn possible damage of the line.
Pressure
Temperature
Temperature
34. High Level 1. Overfilling of Phosphate 1.1. Possible overflow through the vent line 1.1.1. Overflow line is provided to route it to
Injection Tank (108-LF) in adverse case, leading to loss of drain.
due to more DM water phosphate solution.
Shutdown/
Maintenance
37. Composition 1. Improper quantity of DM 1.1. Improper concentration of solution 1.1.1. Operating instructions shall be strictly
change/ water and phosphate leading to system, resulting in upset. followed to make a proper mixture of DM water
Contamination/ and phosphate. Specific gravity meter and lab
Additional analysis shall be used to establish the required
Phase/ Loss concentration.
Phase
Failure
39. Others 1. Safety issues regarding 1.1. 173. MSDS of phosphate solution Rekayasa/
shall be referred and accordingly
115 of 151
phosphate solution followed in operation. Pusri

in the discharge of the requirement of pulsation Package
Phosphate Injection Pump dampener and provide Vendor
40. No/ Low 1. No flow of DM water 1.1. No serious consequence but for delay in 174. Review the requirement of Rekayasa
Flow from upstream preparation of oxygen scavenger solution, as tripping the Oxygen Scavenger
this is a supervised operation. Injection Pump (106-LJ) on low
low level of the Oxygen
Scavenger Tank (106-LF).
2. No flow of oxygen 2.1. Refer to Node 24 for consequence in
scavenger solution to the Deaerator.
Deaerator (101-U) due to
tripping of Oxygen
Scavenger Injection Pump system.
(106-LJ/LJA)
3. Choking of strainer SP- 3.1. Loss of oxygen scavenger solution to 3.1.1. Spare pump with strainer is available for
STR-106LJ the system. Refer to Node 24 for process switching over.
consequences.
system.
41. More/ High 1. More flow of oxygen 1.1. Refer to Node 24 for process
Flow scavenger solution to the consequences.
system due to malfunction
1.2. Wastage of oxygen scavenger solution 175. Consider to provide level Rekayasa
of the stroke in the pump
and in turn the tank level gets emptied indication in the Oxygen
faster. However, operating instructions shall Scavenger Tank (106-LF) (as the
be followed to have vigilance on the tank oxygen scavenger solution
level. injection is not having any flow
measurement) which will be
useful for the quantity of oxygen
scavenger solution gets injected.
outlet of the Oxygen Scavenger Vendor
measuring vessel.
116 of 151

43. More/ High 1. Oxygen scavenger 1.1. High pressure in the discharge line as 1.1.1. PRV is provided at the discharge of the
Pressure solution injection is closed the pump is of positive displacement type, pump.
in the system side and in turn possible damage of the line.
Pressure
Temperature
Temperature
47. High Level 1. Overfilling of Oxygen 1.1. Possible overflow through the vent line 1.1.1. Overflow line is provided to route it to
Scavenger Tank (106-LF) in adverse case, leading to loss of oxygen drain.
due to more DM water scavenger solution.
Shutdown/
Maintenance
50. Composition 1. Improper quantity of DM 1.1. Improper concentration of solution 1.1.1. Operating instructions shall be strictly
change/ water and oxygen leading to system, resulting in upset. followed to make a proper mixture of DM water
Contamination/ scavenger and oxygen scavenger.
Additional
Phase/ Loss
Phase
Failure
52. Others 1. Safety issues regarding 1.1. 177. MSDS of oxygen scavenger Rekayasa/
oxygen scavenger solution solution shall be referred and Pusri
accordingly followed in operation.
in the discharge of Oxygen the requirement of pulsation Package
Scavenger Injection Pump dampener and provide Vendor
3. Difficulty in mixing of 3.1. 178. Review the requirement of Rekayasa
oxygen scavenger with DM agitator in the Oxygen Scavenger
water in Oxygen Scavenger Tank (106-LF) for the preparation
117 of 151
Tank (106-LF) of homogenous oxygen
scavenger solution.

Node: 22. Water Jackets for Primary Reformer (107-D) effluent transfer line and Secondary Reformer (103-D)
Drawing: P2B-10-02-EF-64D105A-R/ Rev 2; P2B-10-02-EF-64D105C-R/ Rev 2; P2B-10-02-EF-64D105D-R/ Rev 2; P2B-10-02-EF-64D105E-R/ Rev 2; P2B-10-02-EF-64D105F-R/ Rev
2; P2B-10-02-EF-64D109-R/ Rev 2
1. No/ Low Flow 1. No flow of condensate 1.1. No serious consequence as there are
from 102-JTC due to two more turbine condensates available.
tripping of Condensate
Pump for 102-JTC (119-
J/JA)
2. No flow of condensate 2.1. No serious consequence as there are
from 102-JTC due to LIC- two more turbine condensates available.
6018 malfunction and
closure of LV-6018
AV-6019
J/JA)
closure of LV-1018
AV-1019
118 of 151
2; P2B-10-02-EF-64D109-R/ Rev 2
J/JA)
closure of LV-4018
AV-4019
10. No flow of condensate 10.1. Loss of condensate to the jackets, 10.1.1. DM water backup is available through 179. Review the control logic for Rekayasa
to water jackets due to leading to potential damage to 107-D and LV-1030 which is acting on the Deaerator level. DM water backup for jacket
choking in Condensate 103-D. cooling system as the DM water
Filter (112-L) flow is controlled under the level
of Deaerator LV-1030.
10.1.2. Bypass for Condensate Filter is 188. Consider to provide isolation Rekayasa
available. valve as well as bypass valve for
LV-1030 available on the DM
water inlet line from battery limit.
11. No flow of condensate 11.1. Loss of condensate to the jackets, 11.1.1. FAL-1152 is available. 179. Review the control logic for Rekayasa
to 107-Water Jacket due to leading to potential damage to 107-D. DM water backup for jacket
LIC-1143 malfunction and cooling system as the DM water
closure of LV-1143 flow is controlled under the level
of Deaerator LV-1030.
12. No flow of condensate 12.1. Loss of condensate to the jackets, 12.1.1. FAL-1151 is available. 179. Review the control logic for Rekayasa
to 103-Water Jacket due leading to potential damage to 103-D. DM water backup for jacket
12.1.2. Multiple skin/ wall TIs with high alarm are
LIC-1142 malfunction and cooling system as the DM water
closure of LV-1142 provided on the Secondary Reformer (103-D) flow is controlled under the level
shell. of Deaerator LV-1030.
13. No flow of condensate 13.1. Loss of condensate to the jackets, 180. Review the hydraulics of the Rekayasa
to water jackets due to leading to potential damage to 107-D and line leading to jackets under level
elevation difference 103-D. control. This is to ensure that
between topmost jacket jackets are getting water as the
and the Deaerator other part of the line is leading to
Deaerator which is operating at a
lower pressure, and also may be
located at a lower elevation than
the jackets.
In case of the failure in the
hydraulic calculation in getting

119 of 151
2; P2B-10-02-EF-64D109-R/ Rev 2
water in the jackets, KBR basic
engineering package can be
followed.
2. More/ High 1. More flow of condensate 1.1. No consequence except for more flow of
Flow to 107-Water Jacket due to condensate. (However, it will be recovered in
LIC-1143 malfunction and downstream.)
full opening of LV-1143
2. More flow of condensate 2.1. No consequence except for more flow of
to 103-Water Jacket due condensate. (However, it will be recovered in
LIC-1142 malfunction and downstream.)
full opening of LV-1142
3. Inadvertent opening of 3.1. Depletion of water in the jacket, leading 3.1.1. FAH-1152 is available.
the drain valve from 107- to high temperature and damage.
3.1.2. LIC-1143 with low alarm is available.
Water Jacket
4. Inadvertent opening of 4.1. Depletion of water in the jacket, leading 4.1.1. FAH-1151 is available.
the drain valve from 103- to high temperature and damage.
4.1.2. LIC-1142 with low alarm is available.
Water Jacket
3. Reverse/ 1. Not expected
Misdirected
Flow
4. More/ High 1. Not expected
Pressure
Temperature
Temperature
8. High Level 1. Not expected
Shutdown/
Maintenance
11. Composition 1. Not applicable
change/
Contamination/
Additional
120 of 151
2; P2B-10-02-EF-64D109-R/ Rev 2
Phase/ Loss
Phase
Failure position.
13. Others 1. No new issue identified

Node: 23. Fuel gas system to Primary Reformer Arch Burners (101-BBA), Primary Reformer Tunnel Burners (101-BBT) and Primary Reformer Superheat Burners (101-BBS/BBSA)
Drawing: P2B-10-02-EF-64D111-R/ Rev 2; P2B-10-02-EF-64D112-R/ Rev 2; P2B-10-02-EF-64D114-R/ Rev 2; P2B-10-02-EF-64D115-R/ Rev 2
1. No/ Low Flow 1. Low flow (no flow is not 1.1. Possible flame instability in the Burners. 1.1.1. TIC-1314 with low alarm is provided at the
expected as there are three Low temperature in the Reformer outlet due outlet of Primary Reformer. Fuel gas supply from
different sources) of waste to reduced firing. feed gas continues to flow to the Burners. This
gases from upstream to the will try to increase fuel gas flow to burners by
Arch Burners (101-BBA) opening PV-1002B.
2. No flow of waste gases 2.1. Low temperature in the Reformer outlet 2.1.1. TIC-1314 with low alarm is provided at the
from upstream due to due to loss of waste gas firing. outlet of Primary Reformer. Fuel gas supply from
closure of XV-1222A/B feed gas continues to flow to the Burners. This
will try to increase fuel gas flow to burners by
opening PV-1002B.
2.2. Possible overpressurization of waste 2.2.1. PV-1029 is available to release pressure 181. Review the suitability of Rekayasa
gas piping at upstream of the XV-1222A/B to NH3 flare header. waste gases being released to
ammonia flare header in case of
opening of PV-1029.
2.2.2. PRV-SG1119A is available and is routed 182. Ensure that PRV-SG1119A Rekayasa
to safe location in the atmosphere. discharge do not create any
hazardous/ toxic atmosphere in
the ground level.
3. No flow of fuel gas to the 3.1. Low temperature in the Reformer outlet 3.1.1. PAL-1221A/B/C are available on the fuel 183. Deleted
Arch Burners (101-BBA) due to reduced firing. gas header leading to the Burners.
due to PIC-1001B/ PIC-
In adverse case, possible condensation of 3.1.2. TIC-1314 with low alarm is provided at the
closure of PV- steam in the Reformer leading to catalyst outlet of Primary Reformer.
1001B/1002B when damage. 3.1.3. Interlock I-101B (2oo3) is available to trip
required the burners on PSLL-1221. This will also do the
following actions:
a) Close XV-1220A/B
121 of 151
b) Open XV-1220C
4. No flow of fuel gas to 4.1. Fuel gas header pressure to burners will 4.1.1. PSLL-4241 available with interlock 101-
Tunnel Burners (101-BBT) be too low to sustain the flame. Loss of main BBT, this will do the following actions:
due to PIC-4143 flame which might lead to hazardous a) Close XV-4240A/B
malfunction and closure of scenario due to possible presence of b) Open XV-4240C
PV-4143 or closure of XV- unburnt gases. Refer to Node 3 regarding
4240A/B when required low temperature in the coil.
However, no consequence in the Tunnel
Burners.
4.2. Possible overpressurization in the 4.2.1. PV-1001B is available to control the
upstream of PV-4143 pressure
4.2.2. PRV-FG1002 is available to release the
pressure to hot vent header.
5. No flow of main fuel gas 5.1. Fuel gas header pressure to burners will 5.1.1. PSLL-1241 available with interlock 101-
to Superheat Burners (101- be too low to sustain the flame. Loss of main BBS, this will do the following actions:
BBS/BBSA) due to TIC- flame which might lead to hazardous a) Close XV-1240A/B
1005 malfunction and scenario due to possible presence of b) Open XV-1240C
closure of TV-1005 or unburnt gases. Refer to Node 3 regarding
5.1.2. UV scanners are available for pilot burners
closure of XV-1240A/B low temperature in the coil.
with interlock 101-BBS. On BSLL-1200, this will
However, no consequence in the Tunnel do the following actions:
Burners. a) Close XV-1240A/B
b) Open XV-1240C
c) Close XV-1245A/B
d) Open XV-1245C
6. No flow of pilot fuel gas 6.1. Loss of pilot flame which might lead to 6.1.1. PSLL-1246 available with interlock 101-
to Superheat Burners (101- hazardous scenario due to possible BBS, this will do the following actions:
BBS/BBSA) due to closure presence of unburnt gases. a) Close XV-1245A/B
of PCV-1144 or XV- b) Open XV-1245C
1245A/B
6.1.2. UV scanners are available for pilot burners
with interlock 101-BBS. On BSLL-1201, this will
do the following actions:
a) Close XV-1240A/B
b) Open XV-1240C
c) Close XV-1245A/B
d) Open XV-1245C
7. Malfunction and closure 7.1. Possible non-uniform heating in the 184. Review the requirement of Rekayasa
of any of the HVs (e.g. HV- Reformer tubes and in turn leading to HVs on fuel gas line to Arch
1207) on fuel gas line to possible mechanical damage of the tubes in Burners (101-BBA) as the same
adverse case due to differential expansion of is not required as per KBR basic
122 of 151
Arch Burners (101-BBA) the tubes. engineering package.
185. The failure position of HVs Rekayasa
shall also be indicated in case
these valves are retained.
2. More/ High 1. More flow of waste 1.1. Possible overpressurization of the waste 1.1.1. PV-1029 is available to release pressure 181. Review the suitability of Rekayasa
Flow gases from upstream gas header. to NH3 flare header. waste gases being released to
ammonia flare header in case of
1.1.2. PRV-SG1119A/ PRV-SG1119B/ PSE-
opening of PV-1029.
SG1119 are available on the waste gas header
for protection of the waste gas header.
1.1.3. Interlock I-101B is available to trip waste
gas burners on PAHH-1226. This will also do the
following actions:
a) Close XV-1222A/B
b) Open XV-1222C
1.2. Possible high temperature in the 1.2.1. TIC-1314 with high alarm is available at
Reformer outlet. In adverse case, possible the Reformer outlet which in turn reduces the
pressurization of the Reformer box with main fuel gas flow to the Arch Burners.
unburnt waste gases, leading to hazardous
1.2.2. Combustible analyzer with high alarm AI-
atmosphere.
1021-B and AI-1010-B is available in the flue gas
duct.
1.2.3. AAL-1021A (oxygen analyzer) is available
in the flue gas duct.
1.2.4. Interlock I-101B is available to trip waste
gas burners on PSHH-1221. This will also do the
following actions:
a) Close XV-1220A/B
b) Open XV-1220C
2. More flow of fuel gas to 2.1. Possible high temperature of flue gas
Tunnel Burners (101-BBT) and in turn more heat input to the mix feed
due to PIC-4143 coil and process air coil in the convection
malfunction and higher section of the reformer. Refer to Node 3
opening of PV-4143 regarding high temperature in the coil.
However, no consequence in the Tunnel
Burners.
2.2. Possible high temperature flue gas will
flow to ID fan suction. However, no serious
consequence as there are two ID fans and
the maximum flue gas temperature will not
123 of 151
exceed the design temperature of the ID
fans. Refer to Node 11 regarding high
pressure in the Reformer box.
3. More flow of main fuel 3.1. Fuel gas header pressure to burners will 3.1.1. TAH-1552 is available at the outlet of cold
gas to Superheat Burners be too high to sustain the flame and lead to superheat coil.
(101-BBS/BBSA) due to flame liftoff. Loss of main flame might lead
3.1.2. Interlock I-101BBS is available on TSHH-
TIC-1005 malfunction and to hazardous scenario due to possible
higher opening of TV-1005 presence of unburnt gases. Excessive 1009, this will do the following actions:
combustion may increase the furnace a) Close XV-1240A/B
pressure and process temperature. The high b) Open XV-1240C
temperature may exceed the design 3.1.3. TIC-1553 will open TV-1553 on the BFW
temperature of the coils as well as the line leading to Desuperheater.
turbines. Possible damage to the coil as well
as the turbines. 3.1.4. Interlock I-101BBS is available on TSHH-
1007, this will do the following actions:
a) Close XV-1240A/B
b) Open XV-1240C
4. More flow of pilot fuel 4.1. Loss of pilot flame which might lead to 4.1.1. Interlock I-101BBS is available to trip
gas to Superheat Burners hazardous scenario due to possible Superheat Burners on PSHH-1246. This will also
(101-BBS/BBSA) due to presence of unburnt gases. do the following actions:
higher opening of PCV- a) Close XV-1245A/B
1144 b) Open XV-1245C
3. Reverse/ 1. Inadvertent opening of 1.1. Possible loss of waste gas (secondary
Misdirected vent valve XV-1222C fuel) to the Burners in adverse case.
Flow available across the waste However, main fuel gas will compensate the
gas line XV-1222A/1222B requirement. Hence no serious
consequence.
2. Inadvertent opening of 2.1. In adverse case (as the vent valve is of
vent valve XV-1220C only 3/4" compared to the main line size of
available across the waste 10"), possible less flow of fuel gas (primary
gas line XV-1220A/1220B fuel) to the Burners. However, no serious
consequence.
3. Inadvertent opening of 3.1. Possible loss of fuel gas (primary fuel)
vent valve XV-4240C to the Burners in adverse case. This is
available across the fuel similar to No Flow case. Refer Cause 4
gas line XV-4240A/4240B under "No/ Low Flow" case.
vent valve XV-1240C to the Burners in adverse case. This is
available across the main similar to No Flow case. Refer Cause 5
fuel gas line XV- under "No/ Low Flow" case.
1240A/1240B
124 of 151

vent valve XV-1245C to the Pilot Burners in adverse case. This is
available across the pilot similar to No Flow case. Refer Cause 6
fuel gas line XV- under "No/ Low Flow" case.
1245A/1245B
4. More/ High 1. High pressure of fuel 1.1. Fuel gas header pressure to burners will 1.1.1. Interlock I-101B is available to trip waste
Pressure gas to the Burners due to be too high to sustain the flame and lead to gas burners on PSHH-1221. This will also do the
full opening of PV-1001B or flame liftoff. Loss of main flame might lead following actions:
PV-1002B on the line to hazardous scenario due to possible a) Close XV-1220A/B
leading to Primary presence of unburnt gases. Excessive b) Open XV-1220C
Reformer Arch Burners combustion may increase the furnace
1.1.2. Interlock I-101BBT is available to trip
(101-BBA) pressure and process temperature.
or Tunnel Burners on PSHH-4241. This will also do
PV-4143 on the line the following actions:
leading to Primary a) Close XV-4240A/B
Reformer Tunnel Burners b) Open XV-4240C
(101-BBT) 1.1.3. Interlock I-101BBS is available to trip
or Tunnel Burners on PSHH-1241. This will also do
TV-1005 on the line leading the following actions:
to Primary Reformer a) Close XV-1240A/B
Superheat Burners (101- b) Open XV-1240C
BBS/BBSA)
1.2. Possible increase in reformer outlet
temperature as well as reformer tube skin
temperature. Refer to Node 3 (No/ Low Flow
items 1 and 3).
6. More/ High 1. High temperature of 1.1. No serious consequence.
Temperature waste gases from
upstream
2. High temperature of
main fuel gas from
upstream is not expected
7. Low 1. Low temperature of 1.1. Possible formation of ammonium 1.1.1. TIC-1042 with low low alarm is available to
Temperature waste gases from carbamate as the waste gases contains control the temperature from the downstream of
upstream CO2 as well as NH3. 183-C.
1.1.2. TAL-2042 is available.
2. Low temperature of main
fuel gas from upstream is
not expected
125 of 151

Shutdown/
Maintenance
11. Composition 1. Liquid carryover with 1.1. Liquid will be carried over to the 1.1.1. LAH-1299 and LG-1200 is provide on the
change/ waste gases burners, leading to hazardous scenario waste gas header. Operating instructions shall
Contamination/ inside Reformer. be followed to regularly drain the header.
Additional
Phase/ Loss
Phase
Failure position.

Node: 24. Steam system
Drawing: P2B-10-02-EF-62D123-R/ Rev 2; P2B-10-02-EF-62D109-R/ Rev 2; P2B-10-02-EF-64D106-R/ Rev 2; P2B-10-02-EF-64D106A-R/ Rev 2; P2B-10-02-EF-62D114-R/ Rev 2; P2B-10-02-EF-
62D108-R/ Rev 2; P2B-10-02-EF-64D101-R/ Rev 2; P2B-10-02-EF-62D107-R/ Rev 2; P2B-10-02-EF-64D102-R/ Rev 2; P2B-10-02-EF-62D111-R/ Rev A; P2B-10-02-EF-64D108-R/ Rev 2; P2B-10-02-EF-
64D107-R/ Rev 2; P2B-10-02-EF-64D105-R/ Rev 2; P2B-10-02-EF-64D103-R/ Rev 2; P2B-10-02-EF-64D104-R/ Rev 2; P2B-10-02-EF-64D105B-R/ Rev 2; P2B-10-02-EF-64D105F-R/ Rev 2; P2B-10-02-
EF-64D108B-R/ Rev 2; P2B -10-02-EF-64D108A-R/ Rev 2; P2B-10-02-EF-64D108C-R/ Rev 2; P2B-10-02-EF-64D108D-R/ Rev 2; P2B-10-02-EF-64D108E-R/ Rev 2; P2B-10-02-EF-64D108F-R/ Rev 2;
P2B-10-02-EF-64D108G-R/ Rev 2; P2B-10-02-EF-64D108I-R/ Rev 2; P2B-10-02-EF-64D108H-R/ Rev 2
1. No/ Low Flow 1. Low flow (No flow is not 1.1. For process side, refer to Node 8 (No
possible) of condensate/ Flow case item 8).
DM water to Lean Solution/
1.2. Possible level decrease in Deaerator. In 1.2.1. LIC-1030 will open LV-1030 available on
Demin Water Preheater
(109-C), LTS Effluent/ adverse case, BFW pump may lose suction the DM water line from the battery limit.
Demin Water Exchanger and damage. 1.2.2. LSL-1030 will start offsite standby DM
(106-C) and Deaerator Water Pump.
(101-U) from upstream
1.2.3. Deaerator has a hold up of 15 minutes.
1.2.4. LIC-1031 will close LV-1031 available on
the drain line leading to sewer.
1.2.5. LSLL-1123 will actuate interlock I-104J to
stop HP BFW Standby Pump (104-JA) and trip
HP BFW Pump Turbine (104-JT)
126 of 151
1.3. Possible high temperature of DM water 1.3.1. TI-1644 is available on the DM water 186. Consider to provide high Rekayasa
leading to Deaerator. This will lead to two- outlet from 106-C. temperature alarm from existing
phase flow and also poor stripping operation TI-1644 available on the DM
in the Deaerator as the LP steam will get water outlet from LTS Effluent/
stopped due to higher pressure. (PV-1031 Demin Water Exchanger (106-C).
will close.) However, no immediate
consequence.
2. No flow of LP steam 2.1. Low pressure as well as low 2.1.1. Local pressure indication
from upstream to temperature in Deaerator. Possible poor
2.1.2. TI-1556 is available on Deaerator outlet
Deaerator (101-U) due to stripping in the Deaerator.
PIC-1031 malfunction and line.
closure of PV-1031
3. No flow of oxygen 3.1. Possible slippage of oxygen in BFW 3.1.1. Sample point S-1905 is provided on BFW
scavenger from upstream leading to corrosion in long run. However, no line from Deaerator.
to Deaerator (101-U) immediate consequence.
3.1.2. Operating instruction shall be followed for
keeping a watch of oxygen scavenger injection
package.
4. No flow of BFW from 4.1. In adverse case, possible carryover of 4.1.1. LIC-1030 will close LV-1030 available on
Deaerator to Sewer when BFW into the LP steam header. the DM water line from the battery limit.
required due to LIC-1031
LV-1031
5. No flow of ammoniacal 5.1. Possible lower pH than required (pH 9.5 5.1.1. AAL-1007 is available on the outlet line.
water from upstream to is required for operation.)
outlet line of Deaerator
(101-U)
6. No flow of deaerated 6.1. Possible level increase in Deaerator and 6.1.1. Autostart facility from FSL-1106 (available
water to LTS Effluent/ BFW in turn carryover of DM water to LP steam at the discharge of the pump) for electric motor
Preheater (131-C) due to header. is available when the turbine trips.
tripping of HP BFW Pump
6.2. Possible level decrease in Steam Drum. 6.2.1. Autostart facility from FSL-1106 (available
(104-J/JA)
at the discharge of the pump) for electric motor
is available when the turbine trips.
6.2.2. LSLL-1223A/B/C (2oo3) with interlock I-
101 is available to do the following actions:
a) Close XV-1212 to stop process air
b) Close XV-1201 to stop feed gas to 101-B
127 of 151
c) Close FV-1001 to stop feed gas to 101-B
d) Close XV-1220A/B to stop fuel gas to Arch
Burners
e) Close XV-1222A/B to stop secondary fuel gas
to Arch Burners
f) Trip Syngas Compressor
7. Choking in the suction 7.1. Possible loss of NPSH to the pump 203. Consider to provide a PDI Rekayasa
strainer of HP BFW Pump (multistage) leading to cavitation and across the strainers SP-STR-
(104-J/JA) damage. 104J/JA.
8. No flow of BFW from 8.1. Possible level decrease in Steam Drum 8.1.1. LAL-1223A/B/C is available on 141-D
LTS Effluent/ BFW in adverse case. Possible reduction of
8.1.2. LSLL-1223A/B/C (2oo3) with interlock I-
Preheater (131-C) to steam generation.
Ammonia Converter 101 is available to do the following actions:
Effluent/ Steam Generator a) Close XV-1212 to stop process air
(123-C2) and Ammonia b) Close XV-1201 to stop feed gas to 101-B
Converter Effluent/ BFW c) Close FV-1001 to stop feed gas to 101-B
Preheater Exchanger (123- d) Close XV-1220A/B to stop fuel gas to Arch
C1) and due to FIC-1020 Burners
malfunction and closure of e) Close XV-1222A/B to stop secondary fuel gas
FV-1020 to Arch Burners
9. No flow of BFW in the 9.1. Refer to Node 16 (No/ Low Flow item 2).
bypass line of Ammonia
Converter Effluent/ Steam
Generator (123-C2) due to
TIC-1415 malfunction and
closure of TV-1415
10. No flow of BFW from 10.1. Refer to Node 4 (No/ Low Flow item 2)
LTS Effluent/ BFW for process consequences.
Preheater (131-C) to HTS
10.2. Possible level decrease in Steam 10.2.1. LAL-1223A/B/C is available on 141-D
Effluent BFW Preheater
(103-C2) and Ammonia Drum in adverse case. Possible increase in 10.2.2. LSLL-1223A/B/C (2oo3) with interlock I-
Converter Effluent/ BFW BFW header pressure.
101 is available to do the following actions:
Preheater Exchanger (123- a) Close XV-1212 to stop process air
C1) due to FIC-1072 b) Close XV-1201 to stop feed gas to 101-B
malfunction and closure of c) Close FV-1001 to stop feed gas to 101-B
FV-1072 d) Close XV-1220A/B to stop fuel gas to Arch
Burners
e) Close XV-1222A/B to stop secondary fuel gas
128 of 151
to Arch Burners
10.2.3. FV-1072 is provided with minimum
mechanical stop.
11. No flow of BFW in the 11.1. Refer to Node 4 (Low Temperature
bypass line of HTS Effluent item 2), as this bypass is provided to control
BFW Preheater (103-C2) the process side temperature at the LTS
due to TIC-1011 inlet.
TV-1011
12. No flow of phosphate 12.1. Possible solid accumulation in Steam 12.1.1. Operating instruction shall be followed to
injection from upstream to Drum, leading to corrosion in the long run. keep phosphate injection package healthy.
Steam Drum (141-D) inlet
12.1.2. Sample point S-1903 is available on the
line
blowdown line.
13. No flow of blowdown 13.1. Poor quality of BFW in Steam Drum 13.1.1. Operating instruction shall be followed to
from Steam Drum (141-D) leading to contamination of steam, which in make the blowdown regularly.
to Blowdown Drum (186-D) turn may damage the turbine blades.
13.1.2. One continuous blowdown is already
due to non-opening of
blowdown valves when available.
required 13.1.3. Sample point S-1903 is available on the
blowdown line.
14. No flow of blowdown 14.1. Possible carryover of blowdown water 14.1.1. TAL-1555 is available on the LP steam 187. Review the requirement of Rekayasa
water from Blowdown to LP steam header leading to hammering header. isolation valves as well as bypass
Drum (186-D) due to LIC- and low temperature of LP steam. valve for LV-1129 available on the
1129 malfunction and blowdown line leading to the
closure of LV-1129 Blowdown Cooler (191-C).
15. No flow of cooling 15.1. Possible high temperature of water 189. Consider to provide a TI with Rekayasa
water to Blowdown Cooler leading to CW basin/ check pit. high alarm on the outlet line (shell
(191-C) side) of Blowdown Cooler (191-
C).
16. No flow of steam from 16.1. Not expected as there is no isolation
Steam Drum to HP Steam valve in between.
Superheater (102-C) with
Secondary Reformer (103-
D) Effluent
129 of 151
17. No flow of steam from 17.1. Not expected.

Steam Drum (141-D) to
Cold Steam Superheat Coil
(101-BCS1)
18. No flow of BFW to 18.1. Possible high HP steam temperature 18.1.1. TIC-1005 is available to give high alarm.
Desuperheater due to TIC- to Hot Steam Superheat Coil (101-BCS2)
18.1.2. TIC-1005 also controls the firing (TV-
1553 malfunction and and to HP steam header/ turbines. Potential
closure of TV-1553 failure of Steam Superheat Coil. 1005 on the fuel gas line) in the Superheat
Burners.
18.1.3. Interlock I-101BBS is available on TSHH-
1007, this will do the following actions:
a) Close XV-1240A/B
b) Open XV-1240C
19. No flow of BFW to 19.1. Same as 17.1 above.
Desuperheater (BH-1020)
due to tripping of HP BFW
Pump (104-J/JA)
20. No flow of steam from 20.1. Not expected.
upstream to Hot Steam
Superheat Coil (101-BCS2)
21. No flow of superheated 21.1. Low pressure in MP header, leading to 21.1.1. HV-1028 is available to letdown HP to 191. Consider to provide low Rekayasa
steam to MP steam header possible trip of Primary Reformer. MP steam. alarm from existing PT-1014 on
due to PIC-1018 the MP steam header.
PV-1018 when required
22. No flow of BFW to 22.1. High temperature of MP steam flowing 22.1.1. TAH-1554 is available on MP steam 192. Consider to provide two Rekayasa
Desuperheater (BH-1020) to MP steam header, leading to damage as header. dedicated desuperheating system
due to TIC-1016 the design temperature of the MP steam for HP steam to MP steam as per
malfunction and closure of header may be exceeded. KBR basic engineering package.
TV-1016 when required
23. No flow of steam to 23.1. Refrigerant Compressor may trip.
Steam Turbine for 105-J Refer to Node 17 (No/ Low Flow item 10).
(105-JT)
23.2. Possible high pressure in the HP 23.2.1. Interlock I-105J is available to open HV-
steam header and possible low pressure in 1028 to the extent of the extraction flowing out of
MP steam header, leading to loss of steam 105-JT. (XS-1128)
to MP steam consumers.
130 of 151
HP steam header.
24. No flow of HP steam to 24.1. Refer to Node 12 (No/ Low Flow item
Methanator Start-up Heater 5).
(172-C) due to malfunction
24.2. No consequence for the HP steam
and closure of TV-1012B
header as the quantity is very low.
25. No flow of condensate 25.1. Refer to Node 12 (No/ Low Flow item
from Methanator Start-up 7).
Heater (172-C) to
LIC-1010 malfunction and
closure of LV-1010
26. No flow of MP steam to 26.1. Syngas Compressor may trip. Refer to
Steam Turbine for 103-J Node 15 (No/ Low Flow item 2).
(103-JT) due to closure of
26.2. Possible high pressure in the HP 26.2.1. Interlock I-103J is available to open HV-
HV-1103 or XV-405A/B
steam header and possible low pressure in 1028 to the extent of the extraction flowing out of
MP steam header, leading to loss of steam 103-JT. (XS-103J)
to MP steam consumers.
HP steam header.
27. No flow of MP steam 27.1. Possible increase in the extraction 27.1.1. PV-1015 available on the MP steam 193. Turbine Vendor shall be Rekayasa/
from Steam Turbine for pressure from 103-JT. This will lead to low header will close and import of MP steam from consulted regarding the working Turbine Vendor
103-J (103-JT) to MP pressure in the MP steam header, leading to Urea Plant/ battery limit will take place through of the turbine in case of closure of
steam header due to loss of steam to MP steam consumers. the bypass NRV of PV-1015. XV-6410 or HV-1013 .
closure of XV-6410 or HV-
27.1.2. PV-1018 will open and letdown HP 191. Consider to provide low Rekayasa
1013
steam to Desuperheater and maintain the MP alarm from existing PT-1014 on
steam header pressure. the MP steam header.
27.1.3. PRV-103JT is available on the extraction
MP steam line.
28. No flow of cooling 28.1. Possible high exhaust pressure and 28.1.1. PAH-3284 is available. 194. Consider to provide tripping Rekayasa
water in Surface high temperature in 103-JT. This may lead of turbine on high exhaust
28.1.2. TAH-1756 is available.
Condenser (103-JTC) to damage of the turbine. pressure with 2oo3 logic.
This is applicable for all
condensing turbines.
29. No flow of condensate 29.1. Possible level increase in Surface 29.1.1. Autostart facility of the Condensate 194. Consider to provide tripping Rekayasa
131 of 151
from the boot of Surface Condenser, which will lead to high exhaust Pump on high high level LAHH-1127 is available. of turbine on high exhaust
Condenser (103-JTC) due pressure in the turbine and damage. pressure with 2oo3 logic.
to tripping of Condensate
Pump (123-J/JA) This is applicable for all
30. No flow of condensate 30.1. Possible blocked out condition for 30.1.1. ARVs are provided for the pump.
from the boot of Surface Condensate Pump leading to damage.
Condenser (103-JTC) due
30.2. Possible level increase in Surface 30.2.1. LAH-1127 is available in the boot of the 194. Consider to provide tripping Rekayasa
to LIC-1018 malfunction
and closure of LV-1018 Condenser, which will lead to high exhaust Surface Condenser. of turbine on high exhaust
pressure in the turbine and damage. pressure with 2oo3 logic.
This is applicable for all
30.3. Possible increase in outlet pressure of 30.3.1. PAHH-3284 is available. 215. C&E diagram shows an Rekayasa
the turbine. interlock I-103J with PSHH-3284.
This has to be incorporated in the
P&ID.
31. No flow of LP steam to 31.1. Possible loss of vacuum in the Surface 31.1.1. PAH-3284 is available. 194. Consider to provide tripping Rekayasa
Ejectors of Condenser Condenser due to inert build up, and in turn of turbine on high exhaust
(103-JTC) high exhaust pressure in the turbine and pressure with 2oo3 logic.
damage. This is applicable for all
32. No flow of MP steam to 32.1. Refer to Node 11 (No/ Low Flow item
Steam Turbine for 101-BJ1 2).
FD Fan (101-BJ1T) and in
32.2. Possible increase in the MP steam 32.2.1. PV-1014 is available on the MP steam
turn tripping of turbine
header pressure. header to release the pressure.
32.2.2. PRV-1314 is available on the MP steam
header.
32.3. Possible reduction in LP steam supply 32.3.1. PIC-1017A/B with low alarm is available.
to consumers.
32.3.2. PIC-1017A/B will close LP steam to 101-
JT and maintain the LP steam header pressure.
32.3.3. PIC-1016 will letdown MP steam to LP
steam header.
132 of 151
33. No flow of MP steam to 33.1. Possible pressurization of MP steam 33.1.1. PV-1014 is available on the MP steam
export line due to PIC-1015 header leading to damage. header to release the pressure.
PV-1015 or blockage in the
Urea Plant header.
34. No flow of MP steam to 34.1. Possible pressurization of MP steam 34.1.1. PV-1014 is available on the MP steam
LP steam header due to header leading to damage. header to release the pressure.
PV-1016 when required
header.
35. No flow of MP steam to 35.1. Process Air Compressor may trip.
Steam Turbine for 101-J Refer to Node 10 (No/ Low Flow item 2).
(101-JT)
35.2. Possible high pressure in the MP 35.2.1. PV-1014 is available on the MP steam
steam header. header to release the pressure.
header.
36. No flow of condensate 36.1. Refer to Node 12 (No/ Low Flow item
from Methanator Start-up 7).
Heater (172-C) to
Deaerator (101-U)due to
LIC-1010 malfunction and
closure of LV-1010
37. No flow of LP steam 37.1. Possible increase in LP steam header 37.1.1. PIC-1017B is available to give high
from LP steam header to pressure. However, no major consequence alarm.
Steam Turbine for 101-J for the turbine.
37.1.2. PV-1017B will release the pressure.
(101-JT) due to closure of
XV-8194 37.1.3. PRV-2239 is available on LP steam
header.
2. More/ High 1. More flow of 1.1. Possible lower temperature of DM water 1.1.1. LIC-1031 will open LV-1031 available on
Flow condensate/ DM water to leading to Deaerator. This in turn will lead to the drain line leading to sewer to control the
Lean Solution/ Demin high level in Deaerator. level.
Water Preheater (109-C),
LTS Effluent/ Demin Water
Exchanger (106-C) and
Deaerator (101-U) from
upstream
133 of 151
2. More flow of LP steam 2.1. Possible high pressure in Deaerator. 2.1.1. PRV-101U is provided on the Deaerator.
from upstream to
PIC-1031 malfunction and
3. More flow of BFW from 3.1. No consequence as the line connecting
Deaerator Deaerator (101- the LV is only an overflow line. However, LP
U) to Sewer when required steam may be vented from the Deaerator to
due to LIC-1031 the atmosphere through the 14" drum.
opening of LV-1031
4. More flow of BFW from 4.1. Refer to Node 16 (More Flow item 1).
LTS Effluent/ BFW
Preheater (131-C) to
Ammonia Converter
Effluent/ Steam Generator
(123-C2) and Ammonia
Converter Effluent/ BFW
Preheater Exchanger (123-
C1)due to FIC-1020
opening of FV-1020
5. More flow of BFW in the 5.1. Refer to Node 16 (More Flow item 2).
bypass line of Ammonia
5.2. No consequence on the BFW side.
Converter Effluent/ Steam
Generator (123-C2) due to
TIC-1415 malfunction and
higher opening of TV-1415
6. More flow of BFW from 6.1. Refer to Node 4 (More Flow item 1).
LTS Effluent/ BFW
6.2. Possible high level in the Steam Drum 6.2.1. LAH-1001A is available on the Steam
Preheater (131-C) to HTS
Effluent BFW Preheater and in turn carryover of water to the HP Drum.
(103-C2) and HTS Effluent/ steam header. 6.2.2. LAH-1223A/B/C are available on the
Steam Generator (103-C1) Steam Drum.
due to FIC-1072
opening of FV-1072
7. More flow of BFW in the 7.1. Refer to Node 4 (More Temperature
134 of 151
bypass line of HTS Effluent item 2).
BFW Preheater (103-C2)
7.2. No consequence on the BFW side.
due to TIC-1011
opening of TV-1011
8. More flow of blowdown 8.1. Possible LP steam breakthrough from
water from Blowdown 186-D to cooling tower basin through 191-C.
Drum (186-D) due to LIC-
higher opening of LV-1129
9. More flow of blowdown 9.1. Possible more generation of LP steam 9.1.1. LAH-1129 is available on the Blowdown 195. Check the hydraulic system Rekayasa
from Steam Drum (141-D) as well as condensate and in turn likely to Drum. of the Blowdown Drum (186-D)
to Blowdown Drum (186-D) pressurize the Blowdown Drum as well as including the LP steam line from
due to full opening of the LP steam header. the Blowdown Drum for not
blowdown valves getting overpressurized in case of
blowdown valves SP-BDV-
141/142 get opened fully.
10. More flow of BFW to 10.1. Possible low temperature in 10.1.1. TIC-1005 is available to give low alarm.
Desuperheater (BH-1020) superheated steam (may be some carryover
10.1.2. TAL-1754 is available at the inlet of the
due to TIC-1553 of BFW also) leading to Hot Steam
malfunction and higher Superheat Coil (101-BCS2). turbine.
opening of TV-1553
11. More flow of 11.1. Possible low pressure of HP steam
superheated steam to MP leading to turbine.
steam header due to PIC-
11.2. Possible pressurization of the MP 11.2.1. PV-1014 is available on the MP steam
higher opening of PV-1018 steam header. header to release the pressure.
when required 11.2.2. PV-1015 available on the MP steam
header will open and export MP steam to Urea
Plant/ battery limit.
11.2.3. PAL-1755 is available at the turbine inlet
header.
12. More flow of BFW to 12.1. Possible low temperature in MP steam 12.1.1. TAL-1554 is available on the MP steam 197. Consider to provide low Rekayasa
Desuperheater (BH-1020) header. header. temperature alarms from the TIs
due to TIC-1016 available on the inlet line of MP
135 of 151
opening of TV-1016 when steam driven turbines.
required
13. More flow of HP steam 13.1. No serious consequence as this is
to Methanator Start-up used only during start-up, which is a
Heater (172-C) due to supervised operation.
opening of TV-1012B
14. More flow of 14.1. Refer to Node 16 (More Flow item 3)
condensate from
Methanator Start-up Heater
(172-C) to Deaerator (101-
U) due to LIC-1010
malfunction and
higher opening of LV-
1010
15. More flow of 15.1. Possible low level in the Surface 15.1.1. LSLL-1127 is available to trip the pump
condensate from the boot Condenser boot, and in turn loss of suction on low low level.
of Surface Condenser to Condensate Pump.
(103-JTC) due to LIC-1018
opening of LV-1018
16. More flow of MP steam 16.1. Possible low pressure of MP steam 16.1.1. FI-1350B is available on the export line 191. Consider to provide low Rekayasa
to export line due to PIC- header. to give high alarm. alarm from existing PT-1014 on
1015 malfunction and the MP steam header.
or more drawoff in the Urea
Plant
17. More flow of MP steam 17.1. Possible overpressurization of LP 17.1.1. PRV-2239 is available on LP steam 201. Ensure that PRV-2239 is Rekayasa
to LP steam header due to steam header. header. sized to take care of full opening
malfunction and opening of of PV-1016 case.
PV-1016
3. Reverse/ 1. Inadvertent opening of 1.1. Possible loss of MP steam to 1.1.1. FFSLL-1201 (steam to carbon ratio)
Misdirected PV-1014 available on the consumers/ Reformer. In adverse scenario, (2oo3) is provided with interlock I-101 to ramp
Flow MP steam header the plant will trip on low S/C ratio. the Primary Reformer to minimum firing through
PIC-1002 and closes XV-1201 and FV-1001 on
the feed gas line to Primary Reformer.
1.2. Possible reduction in HP steam 1.2.1. PAL-1018 is available on the HP steam
pressure as it will letdown (PV-1018) to MP header.
136 of 151
steam header.
2. Condensate Pump for 2.1. Possible reverse flow of steam to the 202. Consider to provide a check Rekayasa
102-JTC (119-J/JA) trips pump through the sealing line, from the LP valve on the line (TC-5013-1 1/2"-
steam line leading to Desuperheater. This in ASA2R) leading to Desuperheater
turn will cause damage to the pump as the (BH-1020) at the upstream of TV-
steam is at high temperature. 1023.
3. Steam flow back from 3.1. During normal operating, it is not 205. Consider to provide an NRV Rekayasa
Deaerator (101-U) to expected as the Deaerator is operating at a on the line SC-1180-2"-ASA2R
upstream exchangers lower pressure. However, during start-up, leading to Deaerator (101-U).
steam from the Deaerator may flow to the
upstream exchangers.
4. More/ High 1. High pressure in HP 1.1. 186-D will experience the pressure of 190. Consider to provide a PSV Rekayasa
Pressure Steam Blowdown Drum Steam Drum and possible damage. on the HP Steam Blowdown
(186-D) in case the outlet Drum (186-D).
line valve is closed for any
reason
Temperature
7. Low 1. Low temperature in the 1.1. Possible damage when the standby 200. Review the requirement of Rekayasa
Temperature standby HP BFW Pump pump is started automatically. providing a warm up connection
(104-J/JA) for the pumps across SP-ARV-
104J/JA.
10. Start-up/ 1. Requirement of 1.1. Non-availability of MP steam. 192. Consider to provide two Rekayasa
Shutdown/ maintenance for dedicated desuperheating system
Maintenance Desuperheater of HP for HP steam to MP steam as per
steam (PV-1018/ BH-1020/ KBR basic engineering package.
TV-1016)
196. Review the requirement of Rekayasa
additional isolation valve for
letdown valve (PV-1018/ HV-
1028) as it is operating at about
123 kg/cm2G.
137 of 151
11. Composition 1. Carryover of silica from 1.1. Silica deposition on the turbine blades 198. DM plant operation is to be Rekayasa
change/ DM plant to steam leading to vibration and damage. monitored for not allowing silica to
Contamination/ flow to downstream.
Additional
199. In case of collidal silica Rekayasa
Phase/ Loss
Phase present in the source water,
pretreatment section to be
monitored for removing the same.
2. Carryover of phosphate 2.1. Phosphate deposition on the turbine 2.1.1. Operating instruction shall be followed to
due to overdosing blades leading to vibration and damage. keep phosphate injection package healthy.
2.1.2. Sample point S-1903 is available on the
blowdown line.
Failure position.
Node: 25. Water Jacket Overflow Recovery system


1. No/ Low Flow 1. Low flow of condensate 1.1. No consequence in this system.
from water jackets
1.2. For process side, refer to Node 22 (No/
Low flow item 10)
2. No flow of condensate 2.1. Possible cavitation in the pump leading 2.1.1. Standby pump with strainer is available. 206. Consider to provide a PDI Rekayasa
from Recovery Pit (1001- to damage. across the strainers SP-STR-
AD) to Condensate Jacket 1001J/JA.
Overflow Pump (1001- cleaning the strainer regularly.
J/JA) suction due to
choking of suction strainer
(SP-STR-1001J/JA)
3. No flow of condensate to 3.1. Possible high level in the Recovery Pit 3.1.1. Pump running indication is provided in
Ammonia Cooling Tower leading to overflow of the condensate. DCS.
138 of 151
Basin due to tripping of 3.1.2. LAH-1033 is available
Condensate Jacket
Overflow Pump (1001- 3.1.3. Overflow line is provided and is routed to
J/JA) safe location.
2. More/ High 1. More flow of condensate 1.1. Possible high level in the Recovery Pit 1.1.1. LAH-1033 is available
Flow from water jackets leading to overflow of the condensate.
1.1.2. Autostart facility available for the pump on
high level.
1.1.3. Overflow line is provided and is routed to
safe location.
Misdirected
Flow
4. More/ High 1. Pressurization of 1.1. Possible damage to the Recovery Pit. 207. Review the requirement of a Rekayasa
Pressure Recovery Pit (1001-AD) vent in the Recovery Pit (1001-
during the condensate flow AD) to take care of the pump in/
from the water jacket and pump out conditions.
the pump is not running
5. Low Pressure 1. Vacuum formation in 1.1. Possible damage to the Recovery Pit. 207. Review the requirement of a Rekayasa
Recovery Pit (1001-AD) vent in the Recovery Pit (1001-
when the condensate is AD) to take care of the pump in/
pumped out pump out conditions.
Temperature
Temperature
Shutdown/
Maintenance
11. Composition 1. High conductivity of the 1.1. Possible upset in Ammonia Cooling 1.1.1. Sample point S-1204 is available for
change/ condensate in Recovery Pit Tower Basin. conductivity.
Contamination/ (1001-AD)
Additional
Phase/ Loss
Phase
139 of 151
Failure
13. Others 1. Pump is situated above 1.1. 208. Ensure that Condensate Rekayasa
the ground and Recovery Jacket Overflow Pump (1001-
Pit (1001-AD) is below the J/JA) is capable of pumping the
ground condensate (possible maximum
temperature: 100 degC) from the
Recovery Pit (1001-AD) to the
Ammonia Cooling Tower Basin.
Node: 26. Oily Drain system

Drawing: P2B-10-02-EF-64D122-R/ Rev 2

1. No/ Low Flow 1. Low flow of oily water 1.1. No consequence in this system.
from the unit
2. No flow of oily water 2.1. Possible cavitation in the pump leading 2.1.1. Operating instruction shall be followed for 209. Consider to provide a PDI Rekayasa
from Oily Drain Pit (1002- to damage. cleaning the strainer regularly. across the strainers SP-STR-
AD) to Oily Water Pump 1002J/JA.
(1002-J) suction due to
choking of suction strainer
(SP-STR-1002J)
3. No flow of oily water to 3.1. Possible high level in the Oily Water Pit 3.1.1. Pump running indication is provided in
waste water header due to leading to overflow of the oily water. DCS.
tripping of Oily Water
3.1.2. LAH-1991 is available.
Pump (1002-J)
3.1.3. Overflow line is connected to storm water
sewer.
2. More/ High 1. More flow of oily water 1.1. Possible high level in the Oily Water Pit 1.1.1. LAH-1991 is available.
Flow from the unit leading to overflow of the oily water.
high level.
1.1.3. Overflow line is connected to storm water
sewer.
3. Reverse/ 1. Reverse flow from the 1.1. Possible damage to the pump in 1.1.1. NRV is provided at discharge of the pump.
Misdirected waste water header to the adverse case.
Flow Oily Water Pump (1002-J)
discharge
140 of 151
Node: 26. Oily Drain system
4. More/ High 1. Pressurization of Oily 1.1. Possible damage to the Oily Drain Pit. 210. Review the requirement of a Rekayasa
Pressure Drain Pit (1002-AD) during vent in the Oily Drain Pit (1002-
the oily water flow from the AD) to take care of the pump in/
unit and the pump is not pump out conditions as the
running specification of the Pit in the
P&ID is indicating as flat cover
(where as the cover is not shown
in the P&ID).
5. Low Pressure 1. Vacuum formation in 1.1. Possible damage to the Oily Drain Pit. 210. Review the requirement of a Rekayasa
Oily Drain Pit (1002-AD) vent in the Oily Drain Pit (1002-
when the oily water is AD) to take care of the pump in/
pumped out pump out conditions as the
specification of the Pit in the
P&ID is indicating as flat cover
(where as the cover is not shown
in the P&ID).
Temperature
Temperature
Shutdown/
Maintenance
change/
Contamination/
Additional
Phase/ Loss
Phase
Failure
13. Others 1. Pump is situated above 1.1. 211. Ensure that Oily Water Rekayasa
the ground and Oily Drain Pump (1002-J) is capable of
Pit (1002-AD) is below the pumping the oily water from the
ground Oily Drain Pit (1002-AD) to the
waste water header.
141 of 151
Node: 27. Chemical Waste/ OASE Spill system
1. No/ Low Flow 1. Low flow of chemical 1.1. No consequence in this system.
waste from the unit
2. No flow of chemical 2.1. Possible cavitation in the pump leading 2.1.1. Standby pump with strainer is available. 212. Consider to provide a PDI Rekayasa
waste from OASE to damage. across the strainers SP-STR-
Chemical Waste Pit (1003- 1003J/JA.
AD) to OASE Chemical cleaning the strainer regularly.
Waste Pump (1003-J/JA)
suction due to choking of
suction strainer (SP-STR-
1003J/JA)
3. No flow of chemical 3.1. Possible high level in the OASE 3.1.1. Pump running indication is provided in
waste to waste water Chemical Waste Pit leading to overflow of DCS.
header due to tripping of the chemical waste.
3.1.2. LAH-1990 is available.
OASE Chemical Waste
Pump (1003-J/JA)
2. More/ High 1. More flow of chemical 1.1. Possible high level in the OASE 1.1.1. LAH-1990 is available.
Flow waste from the unit Chemical Waste Pit leading to overflow of
the chemical waste.
high level.
3. Reverse/ 1. Reverse flow from the 1.1. Possible damage to the pump in 1.1.1. NRV is provided at discharge of the pump.
Misdirected waste water header to the adverse case.
Flow OASE Chemical Waste
Pump (1003-J/JA)
discharge
4. More/ High 1. Not expected
Pressure
5. Low Pressure 1. Not expected
Temperature
Temperature
8. High Level 1. LT-1990 malfunctions 1.1. Unable to check the level in the tank. 214. Consider to provide a Rekayasa
manway for maintenance/ taking
manual dip level of the solution in
OASE Chemical Waste Pit (1003-
AD).
142 of 151
Node: 27. Chemical Waste/ OASE Spill system
Shutdown/
Maintenance
change/
Contamination/
Additional
Phase/ Loss
Phase
Failure
13. Others 1. Pump is situated above 1.1. 213. Ensure that OASE Chemical Rekayasa
the ground and OASE Waste Pump (1003-J/JA) is
Chemical Waste Pit (1003- capable of pumping the chemical
AD) is partially below the waste to the waste water header.
ground
143 of 151
JOB NO. : 12-1812/ BA1066 REV
DOC. NO. : 2
APPENDIX 4 – RECOMMENDATION LIST

Appendix 4 – Recommendation List
Actions required Action by Place(s) Used
1. Review the requirement of providing a low pressure alarm with low low pressure interlock Rekayasa/ Consequences:
at suction of Feed Gas Compressor (102-J) to trip the Feed Gas Compressor. Compressor 1.1.1.1, 1.1.2.1,
Vendor 1.1.2.2, 1.1.3.1,
1.1.6.1, 1.2.3.1
2. Compressor Vendor to suggest suitable safeguard (such as vibration switch and trip) for Rekayasa/ Consequences:
the malfunction of the kickback valve for Feed Gas Compressor (102-J) when required. Compressor 1.1.4.1
Vendor
3. Check that the increase in suction pressure of the Feed Gas Compressor (102-J) in the Rekayasa Consequences:
event of Compressor trip does not exceed the design pressure (27.5 kg/cm2G) of the 1.3.1.1
Compressor suction system (including Feed Gas K. O. Drum).
In the case the suction system pressure exceeds 27.5 kg/cm2G, suitable safeguards to be
provided.
4. Review the requirement of overpressure protection for the Feed Gas Knockout Drum Rekayasa Consequences:
(174-D) considering the FV-1130 full open scenario. 1.2.5.1
5. Review the requirement of high temperature alarm and high high temperature interlock to Rekayasa/ Consequences:
trip Feed Gas Compressor (102-J) in consultation with the Vendor. Compressor 1.6.1.1
Vendor
6. Catalyst Vendor of Hydrotreater (101-D) and Desulfurizer (108-DA/DB) to confirm that the Rekayasa/ Consequences:
catalyst will work to give the required output of sulfur (0.1 ppmv) under reduced lifecycle Catalyst Vendor 2.11.1.1
conditions due to increase in sulfur content of more that 15 ppmv in the feed.
7. Catalyst Vendor to suggest appropriate procedure to unload and dispose the used Rekayasa/ Consequences:
catalyst of Desulfurizer (108-DA/DB). Catalyst Vendor 2.13.1.1
This is applicable for all the catalysts in this plant.
8. KBR recommends to have 2 x 100% capacity control valves (currently FV-1002) for MP Rekayasa Consequences:
steam supply to Primary Reformer (101-B) as per KBR basic engineering package. This is to 3.1.3.2
avoid damage to reformer tubes as the reformer is operated at high temperature.
9. Ensure that gases from Hot Vent Header which are currently routed to atmosphere do not Rekayasa Consequences:
result in flammable mixture (LFL/UFL) at ground level. 3.1.4.1, 3.1.4.2,
This is a global recommendation. 5.1.4.1
10. Provide S/C ratio high alarm on FFI-1001 on the process feed gas line. Rekayasa/ KBR Consequences:
3.2.3.1
11. Ensure that operating instructions are provided for bypassing the Low Temperature Shift Rekayasa/ KBR Consequences:
Converter (LTSC) (104-D2A/B) on S/C ratio high alarm. 3.2.3.1
12. Provide high alarm from TI-1352 on syngas outlet from LTS Effluent/ Demin Water Rekayasa Consequences:
Exchanger (106-C). 5.1.3.1, 5.3.1.1
13. Provide LI with high alarm and high high level interlock on the CO2 Absorber Overhead Rekayasa Consequences:
Knockout Drum (142-D2) to trip the Methanator (106-D). 5.1.6.1,
5.1.10.1,
5.1.11.1,
5.2.4.1, 5.2.5.1,
5.2.6.1, 5.2.6.2,
6.2.4.1
14. Check the suitability of waste water header and check pit for the gas breakthrough case Rekayasa Consequences:
from Raw Gas Separator (142-D1) in case of LIC-1003/ LV-1003B malfunctions and opens. 5.2.2.1
KBR recommends to have a shutdown valve at the upstream of LV-1003B to take care of
gas breakthrough scenario as per KBR basic engineering package.

15. Provide high alarm from LT-1204 on CO2 Absorber (121-D). Rekayasa Consequences:
5.1.10.1
16. Review the requirement of additional dissimilar check valve on the condensate line to Rekayasa Consequences:
CO2 Absorber (121-D) as per KBR basic design package as the CO2 Stripper Reflux Drum 5.3.3.1
(153-D) is designed for 3.5 kg/cm2G.
17. Review the requirement of additional dissimilar check valve on the lean amine solution Rekayasa Consequences:
line to CO2 Absorber (121-D) as per KBR basic design package as the CO2 Stripper (122- 5.3.5.1
D2) is designed for 4 kg/cm2G.
18. Review the requirement of additional dissimilar check valve on the semi-lean solution Rekayasa Consequences:
line to CO2 Absorber (121-D) as per KBR basic design package as the LP Flash Column 5.3.6.1, 6.3.1.1
(122-D1) is designed for 4 kg/cm2G.
1 of 10
19. Provide high alarm from AI-1103 (Hydrogen analyzer) on the CO2 line from CO2 Stripper Rekayasa Consequences:
Reflux Drum (153-D) to Urea Plant. 5.13.2.2,
6.2.3.2, 7.11.1.1
20. Confirm that PRV-153D provided on the CO2 Stripper Reflux Drum (153-D) is sized to Rekayasa Consequences:
take care of the syngas leakage scenario to the CO2 Stripper (122-D2). 5.13.2.1
21. Confirm that PRV-101U provided on the Deaerator (101-U) is sized to take care of the Rekayasa Consequences:
syngas leakage scenario to the DM water line from LTS Effluent/ DM Water Exchanger (106- 5.13.3.1
C).
22. Ensure that operating instructions are provided to stop the Semi-lean Solution Rekayasa Consequences:
Circulating Pump (117-J/JA) on LALL-1045 manually from the control room. 6.1.1.1, 6.1.7.2
23. KBR recommends only a manual isolation valve instead of MOV-1038 at the Hydraulic Rekayasa Consequences:
Turbine (107-JAHT) discharge in order to avoid hydraulic turbine being subjected to high 6.1.6.1
pressure.
24. KBR recommends to provide an interlock on LAHH-1048 with a shutdown valve on the Rekayasa Consequences:
outlet line from HP Flash Column (163-D) overhead leading to Primary Reformer (101-B) at 6.1.7.1
upstream of FT-1163 as per KBR basic engineering package.
25. Review the requirement of providing interlock to trip Semi-lean Solution Pumps (107- Rekayasa Consequences:
JA/JB/JC) in case of closure of MOV-1135/1137/1139. Also, consider providing start 6.13.1.1
26. Review the requirement of providing interlock to trip Semi-lean Solution Pumps (107- Rekayasa Consequences:
JA/JB/JC) in case of closure of MOV-1136/1138/1140. Also, consider providing start 6.13.2.1
27. Review the requirement of providing interlock to trip Semi-lean Solution Circulating Rekayasa Consequences:
Pumps (117-J/JA) in case of closure of HV-1014/1016 on the suction of the pump. Also, 8.1.1.1
consider providing start permissive facility.
28. Review the requirement of providing interlock to trip Semi-lean Solution Circulating Rekayasa Consequences:
Pumps (117-J/JA) in case of closure of HV-1015/1017 available on the discharge of the 8.1.3.1
pump. Also, consider providing start permissive facility.
29. Review the requirement of providing interlock to trip Lean OASE Solution Pumps (108- Rekayasa Consequences:
J/JA) in case of closure of MOV-1264/1266 on the suction of the pump. Also, consider 8.1.10.1
providing start permissive facility.
30. Review the requirement of providing interlock to trip the Lean OASE Solution Pumps Rekayasa Consequences:
(108-J/JA) in case of closure of MOV-1265/1267 on the discharge of the pump. Also, 8.1.12.1
consider providing start permissive facility.
31. Provide high alarm from LI-1043A/B/C on the CO2 Stripper (122-D2). Rekayasa Consequences:
8.2.1.1
32. Consider replacing the butterfly valve with gate valve for HV-1014/1015/1016/1017 at Rekayasa Consequences:
suction and discharge of Semi-lean Solution Circulating Pump (117-J/JA). 8.10.1.1
33. Consider providing MOV instead of HV for HV-1014/1015/1016/1017 at suction and Rekayasa Consequences:
discharge of Semi-lean Solution Circulating Pump (117-J/JA). 8.10.1.1
34. Ensure that SP-ARV-121J/JA provided at Process Condensate Pumps for 142-D1 (121- Rekayasa Consequences:
J/JA) discharge is meeting the NRV requirement. 9.1.1.2
35. Provide check valve on the process condensate inlet to the Process Condensate Rekayasa Consequences:
Stripper (130-D). 9.1.1.3
36. Confirm that PRV-174C is suitable for releasing the pressure (steam blowby case) Rekayasa Consequences:
during LV-1025 full open scenario. 9.2.3.1
37. Review the requirement of warm-up line across SP-ARV-121J/JA for Process Rekayasa Consequences:
Condensate Pumps for 142-D1 (121-J/JA). 9.10.1.1
38. KBR recommends to add BFW line from outlet of LTS Effluent/ BFW Preheater (131-C) Rekayasa Consequences:
to Process Condensate Stripper (130-D) as specified in KBR basic engineering package. 9.10.2.1
39. Consider replacing LV-1004C with HV-XXX as per KBR basic engineering package. Rekayasa Consequences:
6.1.3.1
40. Review the design conditions in consultation with Vendor for the Intercoolers (101-J Rekayasa/ Consequences:
Stage-1 Intercooler (101-JC1), 101-J Stage-2 Intercooler (101-JC2), and 101-J Stage-3 Intercoolers 10.1.3.1,
Intercooler (101-JC3)) and Separators (Separator for 101-JC1 (101-JD1), Separator for 101- Vendor/ 10.1.6.1,
JC2 (101-JD2) and Separator for 101-JC3 (101-JD3)) with reference to cooling water failure. Separator 10.1.9.1
Vendor
41. Provide high high temperature trip from 4th stage discharge of Process Air Compressor Rekayasa/ Consequences:
(101-J) to trip 101-J in consultation with Compressor Vendor. Compressor 10.1.9.1,
Vendor 10.1.11.1
2 of 10
42. Consider replacing the control valves LV-1006/1007/1008 at the 1st, 2nd and 3rd stage Rekayasa Consequences:
Separator (101-JD1/JD2/JD3) respectively with required no of condensate traps as per KBR 10.1.4.1,
basic engineering package. 10.1.7.1,
10.1.10.1,
10.2.1.1,
10.2.2.1,
10.2.3.1
43. Provide differential pressure measurements with high alarm across the 2nd, 3rd and 4th Rekayasa Consequences:
stage suction strainers for Process Air Compressor (101-J) as per KBR basic engineering 10.1.5.1,
package. 10.1.8.1,
10.1.11.1
44. Provide high alarm from TT-6150 on 4th stage discharge of Process Air Compressor Rekayasa Consequences:
(101-J). 10.1.9.1,
10.1.11.1
45. Consider providing a PRV on the 4th stage discharge of Process Air Compressor (101-J) Rekayasa Consequences:
as per KBR basic engineering package. 10.1.13.1
46. Provide low alarm from LT-1235A/B/C on Separator for 101-JC1 (101-JD1). Rekayasa Consequences:
10.2.1.1
10.2.2.1
10.2.3.1
49. Provide high alarm from FT-1000 on passivation air line to CO2 Compressor. Rekayasa Consequences:
10.2.4.1
50. Review the requirement of suitable safeguard to protect the passivation line to CO2 Rekayasa Consequences:
Compressor in the case PIC-2200 malfunctions and opens PV-2200. 10.2.4.2
51. Review the requirement of suitable safeguard to protect the Plant air line from 4th stage Rekayasa Consequences:
suction of Process Air Compressor (101-J) to PA header as the upstream is operating at 16 10.13.1.1
kg/cm2G.
52. Review the requirement of providing an additional gate valve along with the available Rekayasa Consequences:
globe valve on the bypass line of TV-1044. 10.3.5.1
53. Consider providing an NRV on the line to PA header from the 4th stage suction of Rekayasa Consequences:
Process Air Compressor (101-J) to avoid depressurization of the Instrument air system. 10.3.6.1
54. Provide MOV (with inching facility) on the process air line from 4th stage discharge of Rekayasa Consequences:
Process Air Compressor (101-J) to Secondary Reformer (103-D) to control the process air 10.10.1.1,
flow during start-up as per KBR basic engineering package. 10.10.1.2
This valve should also close on interlocks as per KBR basic engineering package.
55. Provide line for blowing of feed pre-heat coil, mixed feed preheat coil and dedusting of Rekayasa Consequences:
catalyst with process air from Process Air Compressor (101-J) discharge as per KBR basic 10.10.2.1
56. Provide trip action to trip the Arch Burners (101-BBA), Superheat Burners (101-BBS/ Rekayasa Consequences:
101-BBSA) and Tunnel Burners (101-BBT) with interlock I-101B on low pressure of 11.1.1.1,
combustion air from FD Fan (101-BJ1/ BJ1A) as per KBR basic engineering package. 11.1.2.1,
11.1.3.1,
11.1.7.1
57. At present interlock I-101B closes HZ-1501A/B and HZ-1502 on low flow of combustion Rekayasa Consequences:
air from FD fans 101-BJ1/ BJ1A. The action of this interlock need not close these valve as 11.13.1.1
furnace is not having any provision for hot/ cold air.
58. FD fan Vendor shall be consulted for the consequences in case suction damper (HZ- Rekayasa/ Fan Consequences:
1855/1855A) of FD fan closes. Vendor 11.1.1.1
59. Consider replacing the MOV-1143/1144 with a damper/ sliding leak proof door at the Rekayasa Consequences:
outlet of FD Fan (101-BJ1/ BJ1A) for maintenance purpose. 11.1.4.1
60. Include tripping of main Arch Burners on loss of combustion air through interlock I-101B. Rekayasa Consequences:
11.1.3.1,
11.1.7.1
61. Consider tripping the FD Fan (101-BJ1/BJ1A) on closure of MOV-1045/1145 at the inlet Rekayasa Consequences:
of ID Fan (101-BJ/101-BJA). 11.1.8.1,
11.1.9.1,
11.1.10.1,
11.1.11.1
62. Ensure that operating instructions are provided to keep the peep hole open and start the Rekayasa Consequences:
3 of 10
ID fan (101-BJ/ BJA) first. 11.10.1.1

63. Verify that the PRV-101U on the Deaerator (101-U) is suitable to handle steam Rekayasa Consequences:
breakthrough case from Methanator Start-up Heater (172-C). 12.2.3.1
64. Review the design pressure of the tube side of Methanator Start-up Heater (172-C) as it Rekayasa Consequences:
has been designed for 136.4 kg/cm2(g), whereas the upstream HP steam design pressure is 12.13.1.1
139.9 kg/cm2(g).
65. Review the design temperature of the shell side of Methanator Start-up Heater (172-C) Rekayasa Consequences:
as it has been designed for 346 degC, whereas the Methanator loop (including Methanator 12.13.2.1
Feed/Effluent Exchanger (114-C)) is designed for 457 degC.
66. KBR strongly recommends to have the isolation valve as per KBR basic engineering Rekayasa Consequences:
package, that is at outlet of Methanator Feed/Effluent Exchanger (114-C). 12.13.3.1
67. In light of the PRV-121D set pressure, Methanator system equipments design pressure Rekayasa Consequences:
shall be minimum 41 kg/cm2(g) instead of 39.22 kg/cm2(g) 12.13.4.1
or
Add another PRV for the Methanator system set at suitable pressure for overpressurization
protection.
68. Review the requirement of HP H2 line from OEP. If required, suitable safeguard (such as Rekayasa Consequences:
PRV) shall be provided to avoid overpressurization of the Methanator system. 12.4.2.1
69. Review the design temperature of Methanator Effluent Separator (144-D) with reference Rekayasa Consequences:
to low temperature (more cooling due to refrigeration 130-C1/C2). 12.7.1.1
70. The effect of no flow of syngas to Purifier Feed/ Effluent Exchanger (132-C) Rekayasa/ Consequences:
to be discussed with the package Vendor. Package Vendor 13.1.5.1
71. The effect on Purifier Feed Cold Box Package (137-L) shall be discussed with the Rekayasa/ Consequences:
package Vendor. Package Vendor 13.1.6.1
72. For where a single valve is given for nitrogen purging, consider to install an NRV at the Rekayasa Consequences:
joining point. 13.13.1.1
This is a global recommendation wherever a single valve is given for nitrogen purging.
73. For where single valve is given for nitrogen purging, it is advisable to install double block Rekayasa Consequences:
and bleed connection. 13.13.1.1
This is a global recommendation wherever a single valve is given for nitrogen purging.
74. Provide low alarm on TI-1041 available on the outlet of Mol Sieve Regeneration Heater Rekayasa Consequences:
(183-C). 14.1.2.1
75. To provide limit switches with alarm in FV-1046 available on the regeneration gas to Mol Rekayasa Consequences:
Sieve Dryer (109-DA/DB). 14.3.1.1
76. Confirm that PRV-101U available on the Deaerator (101-U) is suitable for steam blowby Rekayasa Consequences:
case from LV-1050. 14.3.4.1
77. KIC to include alarm in case rate of opening of PV-1049A/B is higher than desired. Rekayasa Consequences:
14.3.3.1
78. Confirm that PRV-183C available on syngas line from the shell side of Mol Sieve Rekayasa Consequences:
Regeneration Heater (183-C) is suitable for tube leakage case in 183-C. 14.14.1.2
79. Consider to provide low flow alarm from existing FIC-1007 or low suction pressure alarm. Rekayasa/ Consequences:
(Vendor scope) Compressor 15.1.1.1
Vendor
80. Interlock I-103J shown against PV-1004 in the P&ID is not listed in the C&E chart. Rekayasa Consequences:
15.1.1.1
81. Review the requirement of interlock I-103J against PV-1004, as the same is not given by Rekayasa Consequences:
the Licensor in their basic design package. 15.1.1.1
82. Ensure that cold vent header is capable of handling the full flow from Purifier Feed Cold Rekayasa Consequences:
Box Package (137-L) in case of Syngas Compressor (103-J) tripping through PV-1004. 15.1.2.1
83. Ensure that import of MP steam is sufficiently available to cater the demand in case of Rekayasa Consequences:
loss of HP steam generation (123-C1/C2) from the Ammonia Synthesis Converter (105-D). 15.1.1.2,
15.1.2.3,
15.1.9.4,
15.2.3.2,
16.2.3.3
84. Ensure that venting through the cold vent header in case of Syngas Compressor (103-J) Rekayasa Consequences:
tripping do not create any hazardous/ environmental issues. 15.1.2.1
85. Compressor Vendor to suggest suitable safeguard (such as vibration switch and trip) for Rekayasa/ Consequences:
the malfunction of the kickback valve (FV-1008) for Synthesis Gas Compressor (103-J) Compressor 15.1.5.1,
4 of 10
when required. Vendor 15.1.7.1,
15.1.8.1,
16.1.6.1
86. Confirm with the Vendor that the Syngas Compressor (103-J) do not experience any Rekayasa/ Consequences:
problem such as vibration in case of cooling water failure in Syngas Compressor Interstage Compressor 15.1.3.1
Cooler (116-C) and in turn the 2nd stage suction temperature raising to 110 degC. Vendor
87. P&ID is not showing the flame scanners for Main Burner, whereas the C&E chart is Rekayasa Consequences:
indicating the same. Hence P&ID shall be corrected. 15.1.14.1
88. Compressor Vendor shall be consulted regarding the low low suction pressure trip Rekayasa/ Consequences:
requirement. Compressor 15.2.2.1
Vendor
89. Consider to provide differential pressure indications across suction strainers as per KBR Rekayasa Consequences:
basic engineering package. 15.1.29.1,
17.1.3.1,
17.1.5.1,
17.1.7.1,
17.1.9.1
90. Consider to provide suitable safeguard (such as PSV) for the fuel gas line to take care of Rekayasa Consequences:
PV-1051 full opening case 15.2.7.1
or
relocate the tapping for the fuel gas for the 102-B burner from the downstream of PV-
1001A/B as per KBR basic engineering package.
91. Consider to provide low temperature alarm on TI-1383/1384 available in Ammonia Conv. Rekayasa Consequences:
Bed 1 Interchanger (122-C1). 15.2.10.1
92. Review the design and requirement of SG-1438-4"-D1A2R line. Rekayasa Consequences:
15.13.2.1
93. Review the design temperature of Ammonia Converter Feed/Effluent Exchanger (121-C) Rekayasa Consequences:
tube side as the tube side is designed for 210 degC only. KBR recommends to design the 15.13.3.1
tube side for 275 degC as per KBR basic engineering package.
94. Deleted Consequences:
15.13.4.1
95. Provide a bypass across PRV-103J available at the 3rd stage discharge of Syngas Rekayasa Consequences:
Compressor. 15.10.1.1
96. Provide blind on the upstream of FV-1059. Rekayasa Consequences:
15.10.2.1
97. Provide TAH from TI-1633 available on the outlet of Ammonia Converter Effluent Cooler Rekayasa Consequences:
(124-C2). 16.1.7.1
98. Consider to provide high alarm on PDI-6546 available across 3rd stage of Synthesis Gas Rekayasa Consequences:
Compressor (103-J). 16.1.8.1
99. High vaporization alarm shall be provided from UI-1001 available for HTS Effluent/ Rekayasa Consequences:
Steam Generator & BFW Preheater (103-C1/C2). 4.1.2.2, 16.2.1.2
100. Review the design temperature of Ammonia Converter Effluent Cooler (124-C1/C2) Rekayasa Consequences:
shell side in light of HV-1034 full opening, as it is reduced from 150 degC to 118 degC as 15.2.10.2
per KBR basic engineering package.
101. PRVs in ammonia service are provided with isolation valves with CSO facility. These Rekayasa Consequences:
PRVs cannot be removed when the plant is running, for purposes such as maintenance. 16.2.5.1
In case isolation valves are provided, the orientation of the valve shall be in horizontal
condition or with the stem pointing downwards to avoid falling of the gate and the valve gets
closed.
102. Confirm that RD-124C available on the CW return header is suitable for tube leak in Rekayasa Consequences:
Ammonia Converter Effluent Cooler (124-C1/C2). 16.13.2.2
103. Operating manual to indicate that in case of tripping of Ammonia Injection Pump (120- Rekayasa Consequences:
J) during catalyst reduction, Ammonia Refrigerant Compressor has to be unloaded (open 16.10.1.1
antisurge valve) to avoid freezing of water in Ammonia Unitized Chiller (120-C).
104. Ammonia Refrigerant Compressor Vendor shall be consulted in case of choking of Rekayasa/ Consequences:
suction strainer leading to low suction pressure. Compressor 17.1.3.1,
Vendor 17.1.5.1,
17.1.7.1,
17.1.9.1
5 of 10
105. Ammonia Refrigerant Compressor Vendor shall be consulted in case of high Rekayasa/ Consequences:
temperature at the 4th stage discharge. Compressor 17.1.11.1
Vendor
106. Consider to provide high temperature alarm from TI-1428 available on the warm Rekayasa Consequences:
ammonia outlet line from Refrigerant Receiver (149-D). 17.1.14.3
107. Consider to close XV-1801 available on the boiloff gas line joining to the Compressor Rekayasa Consequences:
suction, when the Ammonia Refrigerant Compressor (105-J) trips. 17.1.10.6
XV-1801 shall indicate the fail position as well as tight shutoff requirement.
Or
Consider to provide automatic opening of block and bleed facility in case of high pressure.
108. Consider to provide high pressure alarm from PT-6200 available on the 4th stage Rekayasa Consequences:
discharge of Ammonia Refrigerant Compressor (105-J). 17.1.15.1
109. Consider to provide high temperature alarm from TI-1404 available on the vapor outlet Rekayasa Consequences:
line from Refrigerant Receiver (149-D). 17.1.16.2
110. Consider to provide another LT on Ammonia Letdown Drum (147-D) with high alarm as Rekayasa Consequences:
per KBR basic engineering package. 17.1.17.2
(It is possible to route the liquid to 1st Stage Refrigerant Flash Drum (120-CF1) by opening
LV-1012A from control room.)

111. Review the requirement of autostart logic of Warm Ammonia Product Pump (113-J/JA) Rekayasa Consequences:
on high level in Refrigerant Receiver (149-D). 17.1.27.1,
17.2.9.1
112. Consider to provide bypass valve for LV-1022/1023/1024 available on Ammonia Rekayasa Consequences:
Unitized Chiller (120-C) as per KBR basic engineering package. 17.1.20.1,
17.1.21.1,
17.1.22.1
113. Ammonia storage tank HAZOP to take care of the situation of Ammonia Refrigerant Rekayasa Consequences:
Compressor (105-J) overspeed and in turn low pressure/ vacuum formation in the line 17.2.1.2
connecting to first stage suction of Refrigeration Compressor.
114. Consider to provide flow element on waste gas line leaving Refrigerant Receiver (149- Rekayasa Consequences:
D) through PV-1109 as per KBR basic engineering package. Also provide high flow alarm 17.2.7.1
from that FT in DCS.
115. Consider to design Refrigerant Receiver (149-D) as per KBR basic engineering Rekayasa Consequences:
package. (Design pressure: 22.5 kg/cm2G and Design temperature: 100 degC) 17.2.9.2
116. Review the requirement of providing a TI with low alarm on the line leading to Warm Rekayasa Consequences:
Ammonia Product Pump (113-J/JA) from Refrigerant Receiver (149-D), in light of TV-1607 17.2.11.1
full opening.
117. Ensure that mixing of cold ammonia through TV-1607 with the warm ammonia flow Rekayasa Consequences:
from Refrigerant Receiver (149-D) do not create any thermal shock in the line and in turn 17.2.11.1
damage leading to toxic release of ammonia.
118. Consider to provide another LT on Ammonia Letdown Drum (147-D) with high alarm as Rekayasa Consequences:
per KBR basic engineering package. 17.1.24.1,
LV-1012B can be taken in line to transfer liquid ammonia to Refrigerant Receiver (149-D) 17.1.25.1
using the recommended LT above.

119. Verify that PRV-147D1/D2 available on Ammonia Letdown Drum (147-D) is suitable for Rekayasa Consequences:
gas blowby from Ammonia Separator (146-D) due to full opening of LV-1013. 16.2.5.1
120. Consider to provide low pressure alarm from PIC-1108. Rekayasa Consequences:
17.2.19.2
121. Review the requirement of NRV on the minimum flow line leading to suction drum. Rekayasa Consequences:
17.3.1.1,
This is a global recommendation. 17.3.2.1
122. Consider to provide a bypass across PRV-120J for depressurization purpose. Rekayasa Consequences:
17.13.3.1
123. Review the requirement of addition PT on HP Ammonia Scrubber (124-D). Rekayasa Consequences:
18.1.8.1
124. Consider to provide a high alarm from PDT-1055 available on HP Ammonia Scrubber Rekayasa Consequences:
(124-D). 18.1.12.1,
18.2.3.1
6 of 10
125. Consider to provide low flow alarm on FT-1060 on the reflux line of Ammonia Rekayasa Consequences:
Distillation Column (125-D). 18.1.15.1
126. Consider to replace the existing PG-5013 on the inlet line of LP Ammonia Scrubber Rekayasa Consequences:
(123-D) to a PT with low alarm. 18.2.6.1
127. Consider to provide two drain valves at the upstream and downstream for control Rekayasa Consequences:
valves of FC type and one drain valve for control valve of FO type as advised by KBR. 1.10.2.1
128. Verify that PRV-144D is capable of releasing the pressure in case of PIC-1033 Rekayasa Consequences:
malfunction and full opening of PV-1033A, without pressurizing 130-C1/C2 and 144-D. 18.2.7.1
129. Verify that PRV-SG1119A/ PRV-SG1119B/ PSE-SG1119 is capable of releasing the Rekayasa Consequences:
pressure in case of PIC-1033 malfunction and full opening of FV-1029, without pressurizing 18.2.7.2
the fuel gas header.
130. Check the design temperature of Ammonia Distillation Column Feed/ Effluent Rekayasa Consequences:
Exchanger (161-C1/C2) as it is reduced from that of KBR basic engineering package. (Shell 18.2.7.5
side: 250 degC, Tube side: 260 degC)
131. Verify the design pressure of Refrigerant Condenser (127-C) shell side as well as Rekayasa Consequences:
Refrigerant Receiver (149-D) as they are reduced from that of KBR basic engineering 18.2.8.1
package. (127-C shell side: 22.5 kg/cm2G, 149-D: 22.5 kg/cm2G)
132. Confirm that PRV-101U available on the Deaerator (101-U) is suitable for steam blowby Rekayasa Consequences:
case from LV-1049. 18.2.12.2
133. Consider suitable arrangement (e.g. spool piece) for the removal of liquid distributor in Rekayasa Consequences:
LP Ammonia Scrubber (123-D) for maintenance. 18.10.1.1
This recommendation is also applicable for all vessels with liquid distributor in ammonia
recovery unit (ARU).

134. Blower Vendor shall be consulted regarding the safety precautions required on cooling Rekayasa/ Consequences:
water failure. Blower Vendor 19.1.5.1,
19.1.6.1
135. Review the tie-in connection of hydrogen from OEP (Class D) to line from 142-D2 Rekayasa Consequences:
(Class B) with reference to pressurization of the line. 19.4.1.1
136. Ensure that PRV-175C is suitable for upstream high pressure flow case. Rekayasa Consequences:
19.4.1.2
137. Ensure that PRV-175C is suitable for tube leak case in LTS Start-up Heater (175-C). Rekayasa Consequences:
19.13.2.1
138. Review the requirement of the recycle hydrogen line joining at the inlet of Primary Rekayasa Consequences:
Reformer (101-B). 3.1.2.1, 3.2.2.1
139. Review the design temperature of CO2 Stripper Reboiler (105-C) as it is designed from Rekayasa Consequences:
200 degC, in light of no BFW flow from upstream. (Design temperature as per KBR basic 5.1.2.2
engineering package is 245 degC.)
140. Interlock number shown as I-130D against LV-1003B shall be corrected as I-142D1. Rekayasa Consequences:
5.2.2.1
141. As LV-1003B is closing on interlock, this valve shall not be provided with a bypass. Rekayasa Consequences:
5.2.2.1
142. LV-1003B is indicated as FO type, whereas it is of FC type. Rekayasa Consequences:
5.2.2.1
143. I-142D1 on LSLL-1205 will be able to close LV-1003B even though LIC-1003 Rekayasa/ Pusri Consequences:
malfunctions as claimed by Rekayasa. However, interlock acting on the same malfunctioned 5.2.2.1
element needs to be reviewed and confirmed by Owner, to ensure availability when on
demand.
144. Furnace Vendor to take care of the vacuum formation in the heater and in turn damage Rekayasa/ Consequences:
when PIC-1019A/B malfunctions and the turbine rotates at maximum speed. Furnace Vendor 11.2.2.1
145. Consider to provide low pressure alarm on PI-1059 available on the Reformer Furnace. Rekayasa Consequences:
11.2.2.1
146. Review the requirement of tripping of Forced Draft Fan (101-BJ1/ BJ1A) when both the Rekayasa/ Consequences:
Induced Draft Fans (101-BJ and 101-BJA) trip, in consultation of Furnace Vendor. (From Furnace Vendor 11.1.9.1
human safety point of view as hot gases will come out in case somebody opens the peep
hole.)
147. Review the tie-in connection of hydrogen from OEP (Class D) to the outlet of Feed Gas Rekayasa Consequences:
K.O Drum (174-D) (Class B) with reference to pressurization of the line. 1.13.2.1
7 of 10
148. Consider to provide a bypass valve for FV-1001 available on the line leading to 101- Rekayasa Consequences:
BCK, as per KBR basic engineering package. 3.10.1.1
149. Consider to relocate the hydrogen line from OEP joining upstream of FV-1001 to the Rekayasa Consequences:
downstream of XV-1201. 3.10.2.1
150. Consider to provide a bypass valve for FV-1072 available on the BFW line leading to Rekayasa Consequences:
HTS Effluent/ Steam Generator & BFW Preheater (103-C1/C2), as per KBR basic 4.10.1.1
151. Consider to provide forcing valve at the inlet of HTS Effluent BFW Preheater (103-C2) Rekayasa Consequences:
on the BFW line as per KBR basic engineering package to control the LTS inlet 4.10.2.1,
temperature. 4.13.2.1
152. Review the design temperature of tube side (80 degC) of LTS Effluent/Demin Water Rekayasa Consequences:
Exchanger (106-C) as per KBR basic engineering package (200 degC), since it will 5.3.1.2
experience high temperature in case of full opening of HV-1421.
153. Review the requirement of additional dissimilar check valve on the condensate line to Rekayasa Consequences:
CO2 Absorber Overhead Knockout Drum (142-D2) as per KBR basic design package as the 5.3.4.1
CO2 Stripper Reflux Drum (153-D) is designed for 3.5 kg/cm2G.
154. Consider to provide a bypass line along with bleed valve (to measure the dew point) Rekayasa Consequences:
across PRV-132C1 as well as PRV-132C2. 13.10.1.1
155. Consider to reroute line MEA-1099-3" from the bottom of HP Flash Column (163-D) to Rekayasa Consequences:
the sump instead of OASE Solution Storage Tank (114-F). 6.13.3.1
Also provide spectacle blind on the downstream of 3" valve available on this line.
156. Ensure that PRV-114F is sized for the full opening case of PCV-1676 available on the Rekayasa Consequences:
nitrogen line leading to OASE Solution Storage Tank (114-F). 20.2.1.1
157. Consider to provide a nozzle for taking manual dip level of the solution in OASE Rekayasa Consequences:
Solution Sump Tank (115-F). 20.2.3.1
158. MSDS of OASE shall be referred and accordingly followed in operation. Rekayasa/ Pusri Consequences:
20.13.2.1
159. Review the requirement of dike around the OASE tanks to hold the contents in case of Rekayasa Consequences:
tank rupture as per regulations of Indonesia. 20.13.3.1
160. Review the requirement of tripping the OASE Antifoam Injection Pump (109-LJ) on low Rekayasa Consequences:
low level of the Antifoam Injection Tank (109-LF). 21.1.2.1
161. Consider to provide level indication in the Antifoam Injection Tank (109-LF) (as the Rekayasa Consequences:
antifoam injection is not having any flow measurement) which will be useful for the quantity 21.2.1.1
of antifoam gets injected.
162. Review the requirement of providing an isolation valve at the outlet of the Antifoam Rekayasa/ Consequences:
Injection Tank (109-LF) before the tap-off for the measuring vessel as this may be required Package Vendor 21.2.1.1
for checking the stroke of the pump using this measuring vessel.
163. MSDS of antifoam shall be referred and accordingly followed in operation. Rekayasa/ Pusri Consequences:
21.13.1.1
164. Package vendor shall review the requirement of pulsation dampener and provide Rekayasa/ Consequences:
accordingly. Package Vendor 21.13.2.1,
21.26.2.1,
21.39.2.1,
21.52.2.1
165. Review the requirement of tripping the pH Control Injection Pump (107-LJ) on low low Rekayasa Consequences:
level of the pH Control Injection Tank (107-LF). 21.14.2.1
166. MSDS of ammoniacal solution shall be referred and accordingly followed in operation. Rekayasa/ Pusri Consequences:
21.26.1.1
167. Consider to provide level indication in the pH Control Injection Tank (107-LF) (as the Rekayasa Consequences:
ammoniacal solution injection is not having any flow measurement) which will be useful for 21.15.1.2
the quantity of ammoniacal solution gets injected.
168. Review the requirement of providing an isolation valve at the outlet of the pH Control Rekayasa/ Consequences:
169. Consider to provide either start-up ammonia source or pH control chemical in the pH Rekayasa Consequences:
Control Injection Tank (107-LF). 21.23.1.1
170. Review the requirement of tripping the Phosphate Injection Pump (108-LJ) on low low Rekayasa Consequences:
level of the Phosphate Injection Tank (108-LF). 21.27.1.1
171. Consider to provide level indication in the Phosphate Injection Tank (108-LF) (as the Rekayasa Consequences:
8 of 10
phosphate solution injection is not having any flow measurement) which will be useful for the 21.28.1.2
quantity of phosphate solution gets injected.
172. Review the requirement of providing an isolation valve at the outlet of the Phosphate Rekayasa/ Consequences:
173. MSDS of phosphate solution shall be referred and accordingly followed in operation. Rekayasa/ Pusri Consequences:
21.39.1.1
174. Review the requirement of tripping the Oxygen Scavenger Injection Pump (106-LJ) on Rekayasa Consequences:
low low level of the Oxygen Scavenger Tank (106-LF). 21.40.1.1
175. Consider to provide level indication in the Oxygen Scavenger Tank (106-LF) (as the Rekayasa Consequences:
oxygen scavenger solution injection is not having any flow measurement) which will be 21.41.1.2
useful for the quantity of oxygen scavenger solution gets injected.
176. Review the requirement of providing an isolation valve at the outlet of the Oxygen Rekayasa/ Consequences:
Scavenger Tank (106-LF) before the tap-off for the measuring vessel as this may be Package Vendor 21.41.1.2
required for checking the stroke of the pump using this measuring vessel.
177. MSDS of oxygen scavenger solution shall be referred and accordingly followed in Rekayasa/ Pusri Consequences:
operation. 21.52.1.1
178. Review the requirement of agitator in the Oxygen Scavenger Tank (106-LF) for the Rekayasa Consequences:
preparation of homogenous oxygen scavenger solution. 21.52.3.1
179. Review the control logic for DM water backup for jacket cooling system as the DM Rekayasa Consequences:
water flow is controlled under the level of Deaerator LV-1030. 22.1.10.1,
22.1.11.1,
22.1.12.1
180. Review the hydraulics of the line leading to jackets under level control. This is to ensure Rekayasa Consequences:
that jackets are getting water as the other part of the line is leading to Deaerator which is 22.1.13.1
operating at a lower pressure, and also may be located at a lower elevation than the jackets.
In case of the failure in the hydraulic calculation in getting water in the jackets, KBR basic
engineering package can be followed.

181. Review the suitability of waste gases being released to ammonia flare header in case Rekayasa Consequences:
of opening of PV-1029. 23.1.2.2,
23.2.1.1
182. Ensure that PRV-SG1119A discharge do not create any hazardous/ toxic atmosphere Rekayasa Consequences:
in the ground level. 23.1.2.2
183. Deleted Consequences:
23.1.3.1
184. Review the requirement of HVs on fuel gas line to Arch Burners (101-BBA) as the Rekayasa Consequences:
same is not required as per KBR basic engineering package. 23.1.7.1
185. The failure position of HVs shall also be indicated in case these valves are retained. Rekayasa Consequences:
23.1.7.1
186. Consider to provide high temperature alarm from existing TI-1644 available on the DM Rekayasa Consequences:
water outlet from LTS Effluent/ Demin Water Exchanger (106-C). 24.1.1.3
187. Review the requirement of isolation valves as well as bypass valve for LV-1129 Rekayasa Consequences:
available on the blowdown line leading to the Blowdown Cooler (191-C). 24.1.14.1
188. Consider to provide isolation valve as well as bypass valve for LV-1030 available on the Rekayasa Consequences:
DM water inlet line from battery limit. 22.1.10.1
189. Consider to provide a TI with high alarm on the outlet line (shell side) of Blowdown Rekayasa Consequences:
Cooler (191-C). 24.1.15.1
190. Consider to provide a PSV on the HP Steam Blowdown Drum (186-D). Rekayasa Consequences:
24.4.1.1
191. Consider to provide low alarm from existing PT-1014 on the MP steam header. Rekayasa Consequences:
24.1.21.1,
24.1.27.1,
24.2.16.1
192. Consider to provide two dedicated desuperheating system for HP steam to MP steam Rekayasa Consequences:
as per KBR basic engineering package. 24.1.22.1,
24.10.1.1
193. Turbine Vendor shall be consulted regarding the working of the turbine in case of Rekayasa/ Consequences:
closure of XV-6410 or HV-1013 . Turbine Vendor 24.1.27.1
194. Consider to provide tripping of turbine on high exhaust pressure with 2oo3 logic. Rekayasa Consequences:
24.1.28.1,
9 of 10
This is applicable for all condensing turbines. 24.1.29.1,
24.1.30.2,
24.1.31.1
195. Check the hydraulic system of the Blowdown Drum (186-D) including the LP steam line Rekayasa Consequences:
from the Blowdown Drum for not getting overpressurized in case of blowdown valves SP- 24.2.9.1
BDV-141/142 get opened fully.
196. Review the requirement of additional isolation valve for letdown valve (PV-1018/ HV- Rekayasa Consequences:
1028) as it is operating at about 123 kg/cm2G. 24.10.1.1
197. Consider to provide low temperature alarms from the TIs available on the inlet line of Rekayasa Consequences:
MP steam driven turbines. 24.2.12.1
198. DM plant operation is to be monitored for not allowing silica to flow to downstream. Rekayasa Consequences:
24.11.1.1
199. In case of collidal silica present in the source water, pretreatment section to be Rekayasa Consequences:
monitored for removing the same. 24.11.1.1
200. Review the requirement of providing a warm up connection for the pumps across SP- Rekayasa Consequences:
ARV-104J/JA. 24.7.1.1
201. Ensure that PRV-2239 is sized to take care of full opening of PV-1016 case. Rekayasa Consequences:
24.2.17.1
202. Consider to provide a check valve on the line (TC-5013-1 1/2"-ASA2R) leading to Rekayasa Consequences:
Desuperheater (BH-1020) at the upstream of TV-1023. 24.3.2.1
203. Consider to provide a PDI across the strainers SP-STR-104J/JA. Rekayasa Consequences:
24.1.7.1
204. Review the design temperature of LTSC (104-D2A and B) as it has been made as 265 Rekayasa Consequences:
degC and 270 degC, where as KBR basic engineering package is specifying as 275 degC 4.6.2.1
for both the reactors.
205. Consider to provide an NRV on the line SC-1180-2"-ASA2R leading to Deaerator (101- Rekayasa Consequences:
U). 24.3.3.1
25.1.2.1
207. Review the requirement of a vent in the Recovery Pit (1001-AD) to take care of the Rekayasa Consequences:
pump in/ pump out conditions. 25.4.1.1,
25.5.1.1
208. Ensure that Condensate Jacket Overflow Pump (1001-J/JA) is capable of pumping the Rekayasa Consequences:
condensate (possible maximum temperature: 100 degC) from the Recovery Pit (1001-AD) to 25.13.1.1
the Ammonia Cooling Tower Basin.
26.1.2.1
210. Review the requirement of a vent in the Oily Drain Pit (1002-AD) to take care of the Rekayasa Consequences:
pump in/ pump out conditions as the specification of the Pit in the P&ID is indicating as flat 26.4.1.1,
cover (where as the cover is not shown in the P&ID). 26.5.1.1
211. Ensure that Oily Water Pump (1002-J) is capable of pumping the oily water from the Rekayasa Consequences:
Oily Drain Pit (1002-AD) to the waste water header. 26.13.1.1
27.1.2.1
213. Ensure that OASE Chemical Waste Pump (1003-J/JA) is capable of pumping the Rekayasa Consequences:
chemical waste to the waste water header. 27.13.1.1
214. Consider to provide a manway for maintenance/ taking manual dip level of the solution Rekayasa Consequences:
in OASE Chemical Waste Pit (1003-AD). 27.8.1.1
215. C&E diagram shows an interlock I-103J with PSHH-3284. This has to be incorporated Rekayasa Consequences:
in the P&ID. 24.1.30.3
216. Consider the closure of FV-1703 and FV-1022 in the event of FSLL-1201 initiation from Rekayasa/ Consequences:
the interlock. Compressor 1.1.1.2
Vendor
217. Consider providing interlock to close FV-1046 on high temperature from TI-1041 on Rekayasa Consequences:
183-C. 14.14.1.1
218. Change 4”manual globe valve on line V-1090-4’’-D1A2R-H100 to HV so that operator Rekayasa Consequences: 2
in DCS can maintain flow in 101-BCF to remove heat. 3.1.1.2
10 of 10

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Sheet 3 of 11

JOB NO. : 12-1812/ BA1066 REV

17 Jul 14 ALI MRI/ ER HH

JOB NO. : 12-1812/ BA1066 REV

17 Jul 14 ALI MRI/ ER HH

HAZOP STUDY REPORT – SUMMARY

Study Hazard and Operability (HAZOP) Study

Session Days 14 (between 09 and 20 December 2013 and between 06

JOB NO. : 12-1812/ BA1066 REV

17 Jul 14 ALI MRI/ ER HH

A few key objectives are listed as below:

3. SCOPE & BASIS

JOB NO. : 12-1812/ BA1066 REV

17 Jul 14 ALI MRI/ ER HH

3.2 BASIS OF STUDY

Apart from the P&IDs, following documents were used as reference:

session from 6th to 9th January 2014.

JOB NO. : 12-1812/ BA1066 REV

17 Jul 14 ALI MRI/ ER HH

HAZOP is an identification technique and is not necessarily intended as a means of solving

JOB NO. : 12-1812/ BA1066 REV

17 Jul 14 ALI MRI/ ER HH

Figure 5.1: HAZOP Methodology

Select a System/ Unit

Select a Node From the chosen

Brief the design intention

Examine Possible Causes

Decide on any Required Actions

Repeat for Other

Yes Property Words

Repeat for all

JOB NO. : 12-1812/ BA1066 REV

17 Jul 14 ALI MRI/ ER HH

Table 7.1 HAZOP Guidewords/ Parameters

Shutdown/ covers issues such as isolation,

JOB NO. : 12-1812/ BA1066 REV

17 Jul 14 ALI MRI/ ER HH

Deviation. Guidewords Parameter Description

 Identify the purpose and operation of the equipment/ process;

9. ASSUMPTIONS FOR THE STUDY

JOB NO. : 12-1812/ BA1066 REV

17 Jul 14 ALI MRI/ ER HH

JOB NO. : 12-1812/ BA1066 REV

17 Jul 14 ALI MRI/ ER HH

10. WORKSHEETS RECORDING

12. FOLLOW UP ACTIONS

JOB NO. : 12-1812/ BA1066 REV

17 Jul 14 ALI MRI/ ER HH

APPENDIX 1 – DRAWING LIST

JOB NO. : 12-1812/ BA1066 REV

17 Jul 14 ALI MRI/ ER HH

APPENDIX 2 – NODE LIST

Des./ Oper. Temp.: 160/ 101 degC

112-C/CA P2B -10-02-EF-62D109-R/

Des./ Oper. Temp. (shell & tube): 120/

Air Compressor Vent Silencer, SP-151

Cold Process Air Coil, 101-BCA1

Des./ Oper. Temp. (shell & tube): 65/ -

Des./ Oper. Temp.: 538/ 508 degC

Refrigerant Condenser, 127-C

Des./ Oper. Temp. (shell & tube): 151/ -

manually supervised operation. Des./ Oper. Press.: ATM/ ATM

Des./ Oper. Temp. (shell & tube): 150/

Des./ Oper. Temp. (shell & tube): 150/