2nd assignment - furnace(1)

7/28/2019 2nd Assignment - Furnace(1)

1/16

PROCESS

SECTIONDATE

NODE 100

NO PARAMETER Guide Words Deviation posssible causes possible consequences

1 PRESSURE MORE - MORE - PRESSUREcontinously high flame

to the furnace.

Piping/tube thermal shock and craking lead to lea

the heating oil to the furnace and get contact with

flame and resulting to high temperature in furnac

cracking and Explosion

fuel gas valve

malfuction - more fuel

gas into the furnace

More fuel gas in the furnace, lead to high temper

normal operation and may cause explosion durin

up.

Explosion at furnace stack or Fuel gas release to

atmosphere in normal operation

Flue gas control valve,

PIC 1 malfaction - close

position

High temperature of hot oil to reboiler, Distillatio

experience high pressure that possible to crack an

explosion.

Air supply to the

furnace high flow &

pressure

2 PRESSURE LESS - LESS - PRESSURE

Less combustion

(May caused by either

less air pressure or less

fuel gas)

The oil has not been heating up. The reboiler not

HC, the distillation flooding, liquid HC over flow toupper stream of distillation column.

Less air pressure to

furnace for combustion

More fuel gas in the furnace, lead to explosion es

during start-up or fuel gas release to atmosphere

stack due to low combustion

Less fuel gas to the

furnace

The oil has not been heating up. The reboiler not

HC, the distillation flooding, liquid HC over flow to

upper stream of distillation column.

3 TEMPERATURE MORE -MORE -

TEMPERATURE

High flame in the

furnace (high fuel and

air)

Piping/tube crack or burst due to overheating, m

oil burn and cause black smoke release

High coke in furnace and piping, less heat transfe

less hot oil flow to the

tubing (less heat

transfer )

Thermal craking to the furnace - fuel gas release ca jet fire

TEMPERATURE LESS -LESS -

TEMPERATURE

No ignition and No

flame in the furnace

High Fuel gas in the furnace - when it ignited it w

exploded during start-up

No heat transfer to Hot oil - No heating to reboile

distalltion column, if the Feed of the distillation i s

the distillation will flooding

No air Flow High Fuel gas in the furnace - when it ignited it wexploded

No heat transfer to Hot oil No heating to reboile

HAZOP STUDYFurnace/burner used to heat up using fuel oil + air Heating oil to 250 C to sup

FURNACE


2/16

PROCESS

Section

Date

NODE

200NO PARAMETER Guide Words DeviationFLOW

MORE - MORE - FLOW

LESS - LESS - FLOW

NO - NO - FLOW

OTHERS THAN

VALVE Valve malfuction

MAINTENANCE

SHUT DOWN &START UP

Not follow Procedure

HFurnace/burner used t


3/16

posssible causes possible consequences Safe Guard/Protection

the valve or control valve malfuctionair to fuel ratio not as per

stoikiometric,FT 2

high presure in the

furnacePT 1, PI 4 & PI 5

more gas rushing out to

atm, PIC 1

piping leaking

air to fuel ratio not as per

stoikiometric, more fuel

coming out from the stack

can cause

detonation/explosion

FT 2 & PI 2

piping leaking

pump/compressor failure

Piping blockage/valve malfuction

un-edequate maintenance

air supply to actuator block

controller malfuction

cost cutting

equipment malfuction and

error can occurred may

lead to explosion

Human Factor

Explosion can happen if

not following the SU and

SD procedure.

ZOP STUDY

Air line supply to the furnace

heat up using fuel oil + air Heating oil to 250 C to supply to Distillation re

more fuel gas in the

furnace can cause

explosion

more flow or no flow of

air to furnace

FT 2 & PI 2


4/16

action required/Recommendation

Air Flow Alarm Low and automatic

shut down the fuel supply or heater on

low air flow and/or low air/fuel ratio.

Periodic Piping inspection, Risk based

inspection (RBI)

boiler

Air Flow Alarm Low and automatic

shut down the fuel supply or heater on

low air flow and/or low air/fuel ratio.


5/16

PROCESS

section

date

study node 300

NO PARAMETER Guide Words Deviation

1 PRESSURE MORE - MORE - PRESSURE

LESS - LESS - PRESSURE

NO - NO -PRESSURE

3 TEMPERATURE MORE - MORE - TEMPERATURE

4 FLOW REVERSE - REVERSE - FLOW

MORE - MORE - FLOW

LESS - LESS - FLOW

NO - NO - FLOW

OTHERS THAN


MAINTENANCE

SHUT DOWN &

START UPNot follow Procedure

HAZO

Fuel ga

Furnace/burner used to he


6/16


7/16

posssible causes possible consequences

Safe

Guard/Protectio

n

Fuel gas control valve

malfunction

more fuel in the furnace, can cause

explosion during start-up

PI 3 & PI 6

piping leaking

valve malfuctionvalve malfuction

piping leaking

external heating cause the

gas expanded explosion when enter furnace.TI 11

Fuel gas control valvemalfunction - fully open more fuel in the furnace, can causeexplosion

FI 3

piping leaking

valve malfuction




cost cuttingequipment malfuction and error can

occurred may lead to explosion

Human FactorExplosion can happen if not following the

SU and SD procedure.

more flow or no flow to furnace

PI 3 & PI 6

FI 3

P STUDY

s line supply to Furnace

at up using fuel oil + air Heating oil to 250 C to supply to Distillation r

more air in the furnace, no enough heat

to heat up hot oil to desiredtemperature.

more air in the furnace, no enough heat

to heat up hot oil to desired

temperature.


8/16


9/16

Action required/Recommendation

Fuel Pressure Alarm High and automatic shut

down the fuel supply or heater on low air

low air/fuel ratio or high fuel supply

Automatic shut down fuel gas supply and

heater

Fuel control valve - Fail close

Fuel Flow Alarm High and automatic shut

down the fuel supply or heater on low air

low air/fuel ratio or high fuel supply

Fuel Perssure Alarm Low and automatic shut

down heater if Alarm Low Low triggered.

Fuel Flow Alarm Low

boiler


10/16


11/16

PROCESS

section

date

study node 400

NO PARAMETER Guide Words Deviation

1

PRESSURE MORE - MORE - PRESSURE

LESS - LESS - PRESSURE

NO - NO -PRESSURE

2

TEMPERATURE MORE - MORE - TEMPERATURE

3

LESS - LESS - TEMPERATURE

4

UN-EVEN TEMP

5

COMPOSITION OTHERS THEN - OTHERS THEN - COMPOSITION

Furnace/burner used to heat up using fu

HA

Heating oil piping/t


12/16

FLOW LESS - LESS - FLOW

NO - NO - FLOW

OTHERS THAN


MAINTENANCE

SHUT DOWN & START UP Not follow Procedure


13/16

posssible causes possible consequences Safe Guard/Protection

HC from reboiler leaking

into heating oil tube

Possible fie inside the tube and lead

to explosion of tube and burst

heating oil burn in furnace - black

smoke ,

less heating oil to reboiler - column

flooding with HC

high combustion in furnace -

more fuel and air

distillation column high pressure and

can cause explosion.TI 1 ~ TI 10 (exclude TI 8)

Low combustion in furnace column flooding with liquid HC TI 1 ~ TI 10 (exclude TI 8)

coking in the tubingpiping craking and less flow to

reboilerTI 1 ~ TI 10 (exclude TI 8)

HC leaking to the heating

oil, Reboiler crack, or tube

cracking

Possible fire inside the tube and lead

to explosion of tube and burst-

l oil + air Heating oil to 250 C to supply to Distillation re boiler

piping leaking - in the

furnace

OP STUDY

ubing going to furnace and out from furnace


14/16

High moisture content tube hammmering -

piping leaking to furnace heating oil burn in furnace - blacksmoke ,

coking in tubing column flooding with liquid HC -

piping leaking FT 1

pump failure

Piping blockage/valve

malfuction




cost cuttingequipment malfuction and error can

occurred may lead to explosion

Human FactorExplosion can happen if not following

the SU and SD procedure.

more flow or no flow of to furnace,

no heating reboiler

column flooding with liquid HC


15/16

Action

required/Recom

mendation

Indication of

pressure at tube

Indication of

pressure at tube

Indication of

pressure at tube

Temperature

High Alarm and

automatic shut

down the heater

if TemperatureAlarm High High

Temperature

Alarm Low and

automatic shut

down the heater

if Temperature

Alarm Low Low

Temperature

Alarm Low and

automatic shut

down the heater

if Temperature

Alarm Low Low

Indication of

composition at

tube


16/16

Vaporiser

instalation at

heating oil prior

to inlet to

furnace

Indication of

flow at exitstream of

furnace

Online decoking

peridically

Indication of

flow at exit

stream of

furnace

Standby pump,automatically cut

in if another fail

to function

Online decoking

peridically

2nd assignment - furnace(1)

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