University of Nottingham
Department of Chemical and Environmental Engineering
Project Title:
Group No.:
Design Intent/Process Outline:
Node No Parameter
Temperature (Process
3 More
Gas)
Temperature (Process
3 More
Gas)
Temperature (Process
3 More
Gas)
Temperature (Process
3 Less
Gas)
3 Pressure
3 Flow (Process Gas)
Flow (Process Gas)
3 Flow (Process Gas)
3 flow (Process Gas)
4 Flow (Boiler Feedwater)
Meeting Attendees
Guideword Cause
Boiler Feedwater supply failure.
Pipe 52 leakage/rupture.
Drain valve
MV082 is open
Higher temperature the process
stream caused by fouling of the
tubes in the Waste Heat Boiler
02-WHB-001.
All process stream passes through
the tubes of 02-WHB-001 and this
Internal bypass of 02-WHB-001
leads to a lower than required
fails closed
temperature entering 03-R-002.
Reduced productivity of 03-R-002
The tubes carrying the process
stream within 02-WHB-001
have a rupture causing water to
leak into the tubes of 02-WHB-
Less
001. This results in in a larger
pressure drop within the tubes.
Thus pressure within pipe
number 17 will be lower.
Increased process gas flow will
be caused by steam control
More valve (FCV02) failing open.
Excess steam will be fed into
the process stream.
Leaking of boiler feed water into
More heat exchanger tubes within 02-
WHB-001.
Pipe 17 rupture or leakegae
Less resulting in decreased flow of
procss stream to 03-R-002.
Closure of Spectacle blind on
outlet pipe from 02-WHB-001 or
None
possible rupture of pipe 17
exiting 02-WHB-001
Increased duty of the waste
More
heat boiler (02-WHB-001)
Consequence
Lower conversion within 03-R-
002, as a higher temperature
process stream from 02-WHB-001
enters 03-R-002. This results in
reduced productivity for the plant
an possibe thermal decompostion
of the catalyst.
Lower conversion within 03-R-
002, as a higher temperature
process stream from 02-WHB-001
enters 03-R-002. This results in
reduced productivity for the plant
an possibe thermal decompostion
of the catalyst.
Lower converison achineved in the
HT WGS (03-R-002). The process
stream not cooled enough thus
due to the exotheric nature of the
WGS reaction, it may cause
thermal degradation of the
catalyst.
Reduced productivity of the plant,
due to reduced conversion within
03-R-002. Efficiency of the
reactions taking place within 03-
R-002 is lowered
High molar flowrate of process
stream entering 02-WHB-001 will
mean insufficient cooling of
process stream within 02-WHB-
001. Pipe 17 could be damaged
due to handelling higher
temperature fluids than intended.
More process stream will leave
02-WHB-001 and there will a
higher molar flowrate in the
stream 17 because of partial
vaparisation of the boiler feed
water in the tubes.
Build up of toxic CO and
flammable H2 into the
atmosphere. Ths may lead to
respiratory issues, fires or an
explosion
Build up of pressure within tubes
of 02-WHB-001, leading to tube
rupture and pressurisation of
upstream units within the plant.
Potential for dangerous pressure
build up with the chance of an
explosion.
Increased steam production.
Higher flowrate will be casued by
grater convection which in turn is
caused by increased duty of the
02-WHB-001.
Rev:03
Date: September 2017
HAZOP RECORD SHEET
P&ID Title/Description P&ID No. Rev No.:
HAZOP Meet Date
Action Required Status
Current Safeguards Recommendations/Action Action Assigned To: Action Outcome
No. Completion Date Open/Closed
The pressure rating of pipes and
the whole boiler feed water
system was designed to
36.5bar, above the operating
pressure of 33 bar. Appropriate
external corosion allowance
was taken into consideration.
Strat up procedure in place, the
boiler feed water system will
turned on first, menaing that in
case of such malfunction, the
fault will be identifed before full
process opeation begins.
Heat excahgers were desinged
with a fouling coeffficent in
mind. The waste heat boiler
tubes we considred to have a
fouling coefficent of 5000 W/(m
K^2). Moreover, the internal
bypass allows to control the
temperature before the tubes
reach maximum fouling
allownce.
Identify wether the internal
A temperature control valve is bypass can be manually
installed on the 02-WHB-001 adjusted. If so, consider manual
that allows the process stream operation unit repair solutions
to pass via internal bypass thus are provided. Reveiew as a
reducing the likelyhood of team the possibility of the intral
condensation. bypass control vale failing in
place rather than fail closed.
A pressure indcator PI209 is
installed on pipe PG-017-250-
B2PD-H will transimt any
pressure deviations to the
control room.
Waste Heat Boiler (02-WHB-
001) is desinged to deal with a
20% higher duty than when
operating at 60 tonnes of Cosider a flow indicator on the
hydrogen output (Maximum process pipe (PG-014-250-
operating duty). The pressure E2PD-H) after process stream
rating of pipes and the whole and steam mixing.
system was designed to 26.4
bar, above the operating
pressure of 24 bar.
Heat excahgers were desinged
with a fouling coeffficent in
mind. The waste heat boiler
tubes we considred to have a
??
fouling coefficent of 5000 W/(m
K^2). The pressure indactor
PI209 will show a pressure
deviation the steam 17.
The pressure rating of pipes and
Regular inspection of the pipe
the whole system was designed
surfaces and thickness using
to 26.4 bar, above the operating
ultrasonic sensors.
pressure of 24 bar.
The pressure rating of pipes and
the whole system was designed
to 26.4 bar, above the operating
pressure of 24 bar. Pressure
relief valves PSV02A/B are
installed on the pipe that the
steam is fed to (PG-014-250-
E2PD-H), in case high pressure
surge.
The pressure rating of pipes and
the whole boiler feed water
system was designed to
36.5bar, above the operating
pressure of 33 bar.
Page 1 of 6

Project Title:
Group No.:
Design Intent/Process Outline:
Node No Parameter
4 Flow (Boiler Feedwater)
4 Flow (Boiler Feedwater)
4 Flow (Boiler Feedwater)
5 Flow (Steam)
5 Flow (Steam)
5 Flow (Steam)
5 Flow (Steam)
5 Flow (Steam)
Meeting Attendees
Guideword Cause
Level in 02-V-001 High, because
More
FCV03 fails open.
Less Low level in 02-V-001
Damage to pipe 52 carrying
boiler feedwater to 02-WHB-
less
001, may result in pipe rupture
or leakage.
High flow of boiler feedwater
into the shell of 02-WHB-001
due increased level in the steam
More
drum 02-V-001. This results in
increased steam flow in pipe 53
out of 02-WHB-001.
Increased temp of process
stream within 02-WHB-001 from
the reformer results in
increased phase change of
More
boiler feedwater to steam. This
results in increased flow of
boiler feedwater out of 02-WHB-
001 within pipe 53.
Drain valve
Less
MV082 open
Damage to pipe carrying steam
Less to 02-V-001, can result in pipe
rupture or leakage
Shell side outlet spectacle blinds stress corrosion cracking at the
for 02-WHB-001 are closed.
None
Ruptured pipe (pipe No. 53) out Cracks may develop ending in
of 02-WHB-001
Consequence
Temperature of process stream
will leave at a temperature below
the set point for the reaction
which takes place in 03-R-002.
Reduced productivity of the plant.
Reduced productivity of 02-WHB-
001 and 03-R-002 as the main
process stream will not be cooled
to the required temperature for
the reaction in 03-R-002. This is
due to no Boiler Feedwater
entering the shell for for 02-WHB-
001. Lower conversion for the
reaction within 03-R-002
Reduced productivity of 02-WHB-
001 and 03-R-002 as the main
process stream will not be cooled
to the required temperature for
the reaction in 03-R-002. This is
due to no Boiler Feedwater
entering the shell for for 02-WHB-
001. Lower conversion for the
reaction within 03-R-002
There is a pressure reilef valve
(PSV03A/B) on the steam drum,
to relieve dangerous pressure
Increased pressure within pipe 53
build ups within 02-V-001. The
and 02-V-001 due to higher
pressure rating of pipes and 02-
flowrate of boiler feed water.
V-001 was designed to
36.5bar, above the operating
pressure of 33 bar.
Increased pressure within pipe 53
and 02-V-001, due to increased
duty for 02-WHB-001
Less Steam within steam drum.
This results in reduced
productivity of exported steam.
Excessive draining, and continued
wear of MV082. This can lead to
valve failure or rupture.
Reduced productivity of steam
export. Leakage can result in hot
temperature steam coming into
contact with nearby personnel
Build up of Boiler feedwater and
steam withinn the shell of 02-
WHB-001, this can result in
increased corrosion, in particular
nozzles and welds of the shell.
fracture. This can lead to rupture
of the heat exchanger and slip
hazards. Pressure build up within
the shell of 02-WHB-001 with the
potential for an explosion
University of Nottingham Rev:03
Department of Chemical and Environmental Engineering Date: September 2017
HAZOP RECORD SHEET
P&ID Title/Description P&ID No. Rev No.:
HAZOP Meet Date
Action Required Status
Current Safeguards Recommendations/Action Action Assigned To: Action Outcome
No. Completion Date Open/Closed
A temperature control valve is
installed on the 02-WHB-001
that allows the process stream
to pass via internal bypass thus
reducing the likelyhood of
condensation.
A low-low level in the steam
drum will trigure ESD01 which
will close AV01 which will close
all of the natural gas supply
feed, and open steam bypass
via AV03 and AV04 to feed
steam from the header to cool
the process stream tubes down
and will flare all of it off.
The pressure rating of pipes and
the whole system was designed
to 33 bar, above the operating
pressure of 36.5 bar.
In order not to reduce steam
flowrate in the Steam
Superheating coil 01-CE-003,
implement a pressure relief
valve (PSV) after the coil. This
way the PSV after the coil will
be activated first, decreasing
the pressure within the pipe 57.
If pressure in the steam drum
contntinues to increase the
existing PSV03A/B will be
activated.
In order not to reduce steam
flowrate in the Steam
There is a pressure reilef valve Superheating coil 01-CE-003,
(PSV03A/B) on the steam drum, implement a pressure relief
to relieve dangerous pressure valve (PSV) after the coil. This
build ups within 02-V-001. The way the PSV after the coil will
pressure rating of pipes and 02- be activated first, decreasing
V-001 was designed to the pressure within the pipe 57.
36.5bar, above the operating If pressure in the steam drum
pressure of 33 bar. contntinues to increase the
existing PSV03A/B will be
activated.
The pressure rating of pipes and
Regular inspection of the pipe
the whole system was designed
surfaces and thickness using
to 36.5 bar, above the operating
ultrasonic sensors.
pressure of 33 bar.
The pressure rating of pipes and
Regular inspection of the pipe
the whole system was designed
surfaces and thickness using
to 36.5 bar, above the operating
ultrasonic sensors.
pressure of 33 bar.
Page 2 of 6
 University of Nottingham Rev:03
Department of Chemical and Environmental Engineering Date: September 2017
HAZOP RECORD SHEET
Project Title: P&ID Title/Description P&ID No. Rev No.:

Group No.: Meeting Attendees HAZOP Meet Date

Design Intent/Process Outline:

Action Required Status

Node No Parameter Guideword Cause Consequence Current Safeguards Recommendations/Action Action Assigned To: Action Outcome
No. Completion Date Open/Closed

Increased duty of the 02-WHB-
001 will result in a greater
5 Pressure More
fraction of boiler feed water
turning into steam in pipe 53.
Increased pressure within pipe 53 The pressure rating of pipes and
and 02-V-001, due to increased the whole system was designed
duty for 02-WHB-001 and higher to 36.5 bar, above the operating
steam fraction. pressure of 33 bar.

Reduced pressure drop across The pressure rating of pipes and

the waste heat boiler (02-WHB-
5 Pressure More
001) as a result of lower
operating capacity.
The preesure of the stream in
the whole system was designed
pipe 53 will have a higher
to 36.5 bar, above the operating
pressure as a result.
pressure of 33 bar.

If the pressure of the steam

Increased pressure drop due to
flouing between the tubes on
5 Pressure Less
the shell side of the waste heat
boiler (02-WHB-001)
Steam + Boiler Feedwater
pressure entering 02-V-001 will
be lower leading to a lower
operating pressure within 02-V-
001
produced drops below 30 barg
in pipe 56, a split range control
loop (PIC203) on the outlet pipe
from 02-DS-001, will flare of
steam which is off specification,
for the client's steam headerr

There are two level transimitters

The liquid water will flow into the LT 206 and LT211 to monitor Regulatly check the flow control
'steam superheat' tubes which is the high water level. The Level valve and level transmitter.
Flow Control valve FCV03 fails connected to the coil heat Gauge (LG204) can show the Make sure the level
10 level More 11.1
open exchanger. Water will boil in tubes curruent level of water in the measurement is accurate and
and pressure increases. Tubes steam drum. The LAHH with the energency shut dowm
may rupture. ESD and LSHH 212 can ensure system can work.
that the liquid level is limited.

There are two level transimitters

The boiler tubes will run dry when
the liquid water level is too low in
Flow Control valve FCV03 fails
Less the steam drum. It will cause
open
overheat and rupture for the
tubes.
LT 206 and LT210 to monitor
the low water level. The Level
Gauge (LG204) can show the
11.2
curruent level of water in the
steam drum. The LALL with ESD
and LSLL 210 can ensure that
the liquid level is limited.
Regulatly check the flow control
valve and level transmitter.
Make sure the level
measurement is accurate and
the energency shut dowm
system can work.

Too much water in steam drum

can lead the vapour pressure
increases. High steam pressure
Flow Control valve FCV03 fails has higher steam temperature
pressure more
open and it has negetative effect for
the system. The usable energy
latent heat is decrease.
Pressure relief valave is
Pressure gauge can be used to
installed which can reduce the
monitor the pressure in steam
pressure in steam drum. The
11.3 drum. Pressure also can be
LAHH will also work and the
controled by the level contol
pressure can be controled
system.
manually.

The water level is too low can lead

Pressure gauge can be used to
the vapour pressure decreases.
The LSLL will work and the monitor the pressure in steam
Flow Control valve FCV03 fails The steam temperature will also
Less pressure can be controlled 11.4 drum. Pressure also can be
open decrease and the steam outlet
manually. controled by the level contol
rate can be affected. The
system.
efficiency is lower.

Overpressure in pipe resulting in Flow on the line of steam out

pipe rupture; More steam into from the drum is measured and
Increased pressure in steam
reformer coil could cause transmit to bias controller to
9 Flow (steam) More drum (02-V-001) forces steam
temperature of superheated control the flow into steam
out from steam drum
steam from coil lower than drum and the level in steam
intended drum to maintain the pressure

Page 3 of 6
 University of Nottingham Rev:03
Department of Chemical and Environmental Engineering Date: September 2017
HAZOP RECORD SHEET
Project Title: P&ID Title/Description P&ID No. Rev No.:

Group No.: Meeting Attendees HAZOP Meet Date

Design Intent/Process Outline:

Action Required Status

Node No Parameter Guideword Cause Consequence Current Safeguards Recommendations/Action Action Assigned To: Action Outcome
No. Completion Date Open/Closed

Overpressure in pipe resulting in

pipe rupture; More steam into
Increased pressure in steam
reformer coil could cause
More drum (02-V-001) forces steam
temperature of superheated
out from steam drum
steam from coil lower than
intended
Pipe wall thickness has been
Regular maintenance performed
designed to handle high
on pipeline
pressure at 44 barg

Flow on the line of steam out

Low pressure in steam drum
(02-V-001) causing less steam
Less
can be forced out from steam
drum
Damage of pipeline causing
Less
leakage or rupture
Damage of pipeline causing
None
blockage
Increased pressure in steam
drum (02-V-001) forces high
pressure More
pressure steam out from steam
drum
Increased pressure in steam
More drum (02-V-001) forces steam
out from steam drum
Low pressure in steam drum
(02-V-001) causing less steam
Less
can be forced out from steam
drum
Flow control valve (FCV03) open More water into steam drum; high keep the level constants; high
10 Level More more than intended leading to level in steam drum could
flowrate above set point
Flow control valve (FCV03) fail
More
open
Less flow of steam resulting in from the drum is measured and
reduced productivity; steam used transmit to bias controller to
in process and steam export control the flow into steam
decrease drum and the level in steam
drum to maintain the pressure
Steam will leak from pipeline to
atmosphere resulting in the
Install a isolation valve on the
pressure in steam drum
pipeline to prevent pressure
decreases; Leakage of high
loss in steam drum; Regular
temperature and pressure steam
maintenance performed on
could resulting in danger to
pipeline
operators and reduced
productivity
Steam cannot flow out resulting in
the pressure in steam drum
increases and potential of rupture; Pressure relief valves has been Regular maintenance performed
No steam can be provided to installed on the steam drum on pipeline
process and export resulting in
reduced productivity
Pressure indicator has been
Overpressure in pipe resulting in installed on the steam out line;
pipe rupture pressure relief valves has been
installed on the steam drum
Pipe wall thickness has been
Overpressure in pipe resulting in Regular maintenance performed
designed to handle high
pipe rupture on pipeline
pressure at 44 barg
Pressure indicator has been
Less flow of steam resulting in
installed on the steam out line;
reduced productivity; steam used
Level control will keep the level
in process and steam export
in steam drum constants to
decrease
maintain the pressure
Level control on steam drum to
level alarms will sound if level is
resulting in flooding (or overflow?) high and the drain valve will be
manually opened
Level control on steam drum to
keep the level constants; high
More water into steam drum; high level alarms will sound if level is
level in steam drum could high and the drain valve will be
resulting in flooding (or overflow?) manually opened, the control
valve will be fixed to correct
position

Less or no water flow to waste

heat boiler and reformer so that
Damage of pipe causing
less steam can be produced and
More blockage on water outlet
liquid level in steam drum
streams
increases; high level in steam
drum could resulting in flooding
Level control on steam drum to
keep the level constants; high
Regular maintenance performed
level alarms will sound if level is
on pipeline
high and the drain valve will be
manually opened

Level control on steam drum to

Less heat can be transferred
keep the level constants; high Install a temperature indicator
Decreased temperature of water between water and steam
More level alarms will sound if level is on the water into steam drum
into steam drum resulting in steam condense and
high and the drain valve will be line to inform control room
could cause flooding
manually opened

Less water into steam drum and Level control on steam drum to
Flow control valve (FCV03) close the level steam drum will keep the level constants; low
Less more than intended leading to decreases, less steam can be level alarms will sound if level is
flowrate lower than set point produced resulting in reduced low and the control valve will be
productivity fixed to correct position

Level control on steam drum to

High temperature and pressure
keep the level constants; low
Drain valve (MV083) fails (? Not liquid flow out through drain valve
Less level alarms will sound if level is
sure) could resulting in danger to
low to inform operators to fix
operators
the valve

More heat can be transferred

between water and steam causes
Pressure relief valves has been Install a pressure indicator on
Increased temperature of water more water in steam drum can be
Pressure More installed on the steam drum to steam drum to inform control
into steam drum vaporised to steam, resulting in
reduce the pressure room if the pressure is high
pressure in steam drum increases
and potential of rupture

Page 4 of 6

Project Title:
Group No.: Meeting Attendees
Design Intent/Process Outline:
Node No Parameter Guideword Cause Consequence
Steam cannot flow out resulting in Pressure relief valves has been
Damage of steam outlet pipeline
More the pressure in steam drum
causing blockage
increases and potential of rupture reduce the pressure
Less heat can be transferred
Decreased temperature of water between water and steam
Less
into steam drum resulting in steam condense and
could cause flooding
Flow of BFW into steam drum
Control fault/failure: Flow
increases. Level in steam drum
6 Flow (BFW) more control valve FCV03 fail open
increases which will decrease
(remains open)
pressure in steam drum.
Low flowrate through pipe 51,
means level in 02-V-001 will
decrease, reulting in a pressure
increase within the vessel. This
6 Less Low level in 04-V-003 could lead to a potentially
dangerous build up of pressure
within 02-V-001, with the
possibility of an explosion
occuring.
Low flowrate through pipe 51,
means level in 02-V-001 will
decrease, reulting in a pressure
increase within the vessel. This
could lead to a potentially
6 Less Pipe 51 leakage/rupture
dangerous build up of pressure
within 02-V-001, with the
possibility of an explosion
occuring. Potential for burns and
slip hazards.
No flow through pipe 51, means
level in 02-V-001 will decrease,
reulting in a pressure increase
within the vessel. This could lead
6 None 04-P-002A/B failure
to a potentially dangerous build
up of pressure within 02-V-001,
with the possibility of an explosion
occuring.
Boiler Feedwater pressure
Pressure drop across 03-E-001 entering 02-V-001 will be higher
6 Pressure More
and 04-E-002 is reduced leading to a higher operating
pressure within 02-V-001.
Boiler Feedwater pressure
Pressure drop across 03-E-001 entering 02-V-001 will be lower
6 Less
and 04-E-002 is increased leading to a lower operating
pressure within 02-V-001.
Level in steam drum increases
which will decrease pressure in
steam drum. This will lead to an
High level in 02-V-001 resuting increased hydrostatic pressure of
7 Flow (BFW) More
a higher head of water BFW leaving the steam drum to
the heating coil 01-EC-004,
therefore a greater flow out of the
steam drum.
Increased steam production.
Higher flowrate will be casued by
7 Flow (BFW) More Increased duty in the 01-EC-004 grater convection which in turn is
caused by grate duty in the
convection bank of 01-H-001.
University of Nottingham Rev:03
Department of Chemical and Environmental Engineering Date: September 2017
HAZOP RECORD SHEET
P&ID Title/Description P&ID No. Rev No.:
HAZOP Meet Date
Action Required Status
Current Safeguards Recommendations/Action Action Assigned To: Action Outcome
No. Completion Date Open/Closed
Install a pressure indicator on
steam drum; regular
installed on the steam drum to
maintenance performed on
pipeline
Level control on steam drum to Install a pressure indicator on
decrease the level and then steam drum to inform control
maintain the pressure room if the pressure is low
LAH and LAHH are in place on
the steam drum. This will notify
the operator to take corrective
action to resolve the problem
A low-low level in the steam
drum will trigure ESD01 which
will close AV01 which will close
all of the natural gas supply
feed, and open steam bypass
via AV03 and AV04 to feed
steam from the header to cool
the process stream tubes down
and will flare all of it off.
The pressure rating of pipes and
the whole boiler feed water
system was designed to
36.5bar, above the operating
pressure of 33 bar. Appropriate
external corosion allowance
was taken into consideration.
A low-low level in the steam
drum will trigure ESD01 which
Consider the implementation of
will close AV01 which will close
a step by step operating
all of the natural gas supply
procedure for the ioperator to
feed, and open steam bypass
manuall shutdown the plant for
via AV03 and AV04 to feed
a hot restart, with the pilot light
steam from the header to cool
still active.
the process stream tubes down
and will flare all of it off.
The pressure rating of pipes and
Consider the installation of
the whole boiler feed water
Pressure indicators on pipe
system was designed to
BFW-050-100-B2SA-H, and
36.5bar, above the operating
pipe BFW-051-100-B2SA-H.
pressure of 33 bar.
If the pressure of the steam
produced drops below 30 barg
Consider the installation of
in pipe 56, a split range control
Pressure indicators on pipe
loop (PIC203) on the outlet pipe
BFW-050-100-B2SA-H, and
from 02-DS-001, will flare of
pipe BFW-051-100-B2SA-H.
steam which is off specification,
for the client's steam headerr
LAH and LAHH are in place on
the steam drum. This will notify
the operator to take corrective
action to resolve the problem
The pressure rating of pipes and
the whole boiler feed water
system was designed to
36.5bar, above the operating
pressure of 33 bar.
Page 5 of 6
 University of Nottingham Rev:03
Department of Chemical and Environmental Engineering Date: September 2017
HAZOP RECORD SHEET
Project Title: P&ID Title/Description P&ID No. Rev No.:

Group No.: Meeting Attendees HAZOP Meet Date

Design Intent/Process Outline:

Action Required Status

Node No Parameter Guideword Cause Consequence Current Safeguards Recommendations/Action Action Assigned To: Action Outcome
No. Completion Date Open/Closed

A low-low level in the steam

7 Flow (BFW)
Low level in 02-V-001 due to
decreased flowrate of boiler
Less
feed water to the steam drum
via pipe 51.
Low level in steam drum will lead
drum will trigure ESD01 which
to a decreased hydrostatic
will close AV01 which will close
pressure of BFW leaving the
all of the natural gas supply
steam drum to the heating coils
feed, and open steam bypass
(01-EC-004). More steam will be
via AV03 and AV04 to feed
genrated in the coil. As a result
steam from the header to cool
pressure in the steam drum will
the process stream tubes down
increase.
and will flare all of it off.

Reduced effciecy of steam

7 Flow (Boiler Feedwater)
Damage to pipe 54 carrying
boiler feedwater to 01-CE-004,
Less
may result in pipe rupture or
leakage
geration and energy recovery in
The pressure rating of pipes and
the convection bank resuling in
the whole system was designed
less steam being produced. The
to 36.5 bar, above the operating
temperature of air being
pressure of 33 bar.
preheated in the 01-EC-005 will
increase.

In order not to reduce steam

8 Flow (Steam)
flowrate in the Steam
There is a pressure reilef valve Superheating coil 01-CE-003,
High flow of boiler feedwater
(PSV03A/B) on the steam drum, implement a pressure relief
out of 02-V-001 due to FCV03
to relieve dangerous pressure valve (PSV) after the coil. This
failing open results in increased
build ups within 02-V-001. The way the PSV after the coil will
More flow into the steam gerating coil
pressure rating of pipes and 02- be activated first, decreasing
01-CE-004. This results in
V-001 was designed to the pressure within the pipe 57.
increased steam flow in pipe 55
36.5bar, above the operating If pressure in the steam drum
out of 01-CE-004.
pressure of 33 bar. contntinues to increase the
existing PSV03A/B will be
activated.

In order not to reduce steam

8 Flow (Steam)
Increased temperature of the
flue gases in the convection
bank of the reformer (01-H-
001) will result in a higher duty
in steam generating coil (01-CE-
More
004). In turn more boiler feed
water will turn into steam
leading a higher flowrate of the
boiler feed water in the stream
55.
There is a pressure reilef valve
(PSV03A/B) on the steam drum,
to relieve dangerous pressure
Increased pressure within pipe 55
build ups within 02-V-001. The
and 02-V-001, due to increased
pressure rating of pipes and 02-
duty for 01-CE-004.
V-001 was designed to
36.5bar, above the operating
pressure of 33 bar.
flowrate in the Steam
Superheating coil 01-CE-003,
implement a pressure relief
valve (PSV) after the coil. This
way the PSV after the coil will
be activated first, decreasing
the pressure within the pipe 57.
If pressure in the steam drum
contntinues to increase the
existing PSV03A/B will be
activated.

Reduced productivity of steam The pressure rating of pipes and

8 Flow (Steam)
Damage to pipe carrying steam Regular inspection of the pipe
export. Leakage can result in hot the whole system was designed
Less to 02-V-001, can result in pipe surfaces and thickness using
temperature steam coming into to 36.5 bar, above the operating
rupture or leakage ultrasonic sensors.
contact with nearby personnel pressure of 33 bar.

Increased duty of the 01-CE-
004 will result in a greater
8 Pressure More
fraction of boiler feed water
turning into steam in pipe 55.
Reduced pressure drop across
8 Pressure More 01-CE-004 as a result of lower
operating capacity.
Increased pressure within pipe 55
and 02-V-001, due to increased
duty for 01-CE-004 and higher
steam fraction.
The preesure of the stream in
pipe 55 will have a higher
pressure as a result.
The pressure rating of pipes and
the whole system was designed
to 36.5 bar, above the operating
pressure of 33 bar.
The pressure rating of pipes and
the whole system was designed
to 36.5 bar, above the operating
pressure of 33 bar.

If the pressure of the steam

Increased pressure drop due to
flouing between the tubes on
8 Pressure Less
the shell side of the waste heat
boiler (02-WHB-001)
Steam + Boiler Feedwater
pressure entering 02-V-001 will
be lower leading to a lower
operating pressure within 02-V-
001
produced drops below 30 barg
in pipe 56, a split range control
loop (PIC203) on the outlet pipe
from 02-DS-001, will flare of
steam which is off specification,
for the client's steam headerr

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