Hazop Procedures Kenny Sample

1TechnipItaly/21184/023rep

OK LNG FEED HAZOP

Utility Units (Units 003, 017, 031 041/42, 043, 051, 052, 053, 054, 055, 056, 057 & 059)

Final Report to Technip Italy

27 September 2006

Arthur D. Little LimitedScience Park, Milton RoadCambridge CB4 0XLUnited KingdomTelephone +44 (0)870 336 6700Fax +44 (0)870 336 6701www.adlittle.uk.comReference 21184


Notice

This report was commissioned by Technip Italy on terms specifically limiting the liability of Arthur D. Little Limited. Our conclusions are the results of the exercise of our best professional judgement, based in part upon materials and information provided to us by Technip Italy and others. Use of this report by any third party for whatever purpose should not, and does not, absolve such third party from using due diligence in verifying the report’s contents.

Any use which a third party makes of this document, or any reliance on it, or decisions to be made based on it, are the responsibility of such third party. Arthur D. Little Limited accepts no duty of care or liability of any kind whatsoever to any such third party, and no responsibility for damages, if any, suffered by any third party as a result of decisions made, or not made, or actions taken, or not taken, based on this document.


Contents

Executive Summary1.

FEED HAZOP procedure

HAZOP Approach2.

Appendices3.

I.

AttendanceII.

Node ListIII.

HAZOP RecommendationsIV.

HAZOP WorksheetsV.

HAZOP Master P&IDsVI.


Executive Summary – Introduction 1

Arthur D. Little has completed the FEED HAZOP review for Technip’s OK LNG Project Utility units

The HAZOP was based on 65 Process & Instrumentation Diagrams:– Unit 003 Well Water Pumping– Unit 017 Hot Oil System– Unit 031 Jetty– Unit 041/42 Instrument Plant Air– Unit 043 Nitrogen System– Unit 051 Raw Water Treatment System– Unit 052 Service Water System– Unit 053 Potable Water System– Unit 054 Demin. Water System– Unit 055 Fire Water System– Unit 056 Oily Water System– Unit 057 Effluent Treatment– Unit 059 Sewage/Waste Water Treatment

Cause & Effects Diagrams and other relevant reference documents were also considered

The HAZOP team members, detailed discussions and any identified recommendations are recorded on the daily record sheets and summarised in Appendices I – V


The Utilities (Part 2) HAZOP identified a total of 149 recommendations

Significant recommendations fall into six main categories: – Review of Vendor Packages. The Contractor is to review the various vendor

packages during the detailed design phase of the project– Review of equipment and pipework design. The Contractor is to review

aspects of equipment and pipework design including design temperatures, materials selection, requirement for individual furnace fuel gas KO drums, and additional check valves to prevent utility header de-pressurisation

– Review of PSV sizing and design basis. The Contractor is to review requirements for additional PSV protection, and aspects of the design of various existing PSVs

– Utilities area equipment specification. The Contractor will need to undertake a review of utilities area equipment specifications and provision of flammable gas detection in light of the results of the QRA and location hazard area classification.

– Review of flare area oily water system design. The Contractor is to review the requirement for connection of lifting pumps to emergency power supply and pump capacity/basin volume upon receipt of site specific rainfall data

– Provision of additional local instrumentation and DCS process control instrumentation and alarms. The Contractor is to review provision of additional instrumentation to facilitate operation and local maintenance/sampling activities

Detailed recommendations are included in Appendix IV

Executive Summary – Overview of recommendations 1


Contents

Executive Summary1.


HAZOP Approach2.

Appendices3.

I.

AttendanceII.

Node ListIII.


HAZOP WorksheetsV.



Study Approach 2

Arthur D. Little conducted a HAZOP review as part of Technip’s FEED phase for the OK LNG Project

The HAZOP followed the relevant Technip Italy procedure Document code PP202, Rev. B (see Appendix I)

The study was completed during the period 11 to 18 September 2006, and was based on the current revision of the Process & Instrumentation Diagrams (P&IDs)

The study focussed on process design and operational control arrangements

Review of the associated ESD trip function reliability/redundancy was to be completed separately during the related SIL review


Team Composition 2

The HAZOP team comprised representatives from the independent consultant, project owner and design contractor

The independent HAZOP Leader and Scribe were from Arthur D. Little Limited

Team members represented the following project stakeholders:– Company/Operator: OK LNG Project Team– Subcontractor: Snamprogetti SpA

HAZOP attendees are listed in Appendix II


List of P&IDs 2

The Gas Treatment Units review studied 65 Process & Instrumentation Diagrams

Unit Drawing Number(PID) Revision Date Sheet Description

Unit 3 2252-003-PID-00-31-01 A 23-May-06 Well Water Pumping


Unit 17 2252-017-PID-00-31-01 A 25-Aug-06 Hot Oil Furnace (017-H-101 A)

Unit 17 2252-017-PID-00-31-02 A 25-Aug-06 Hot Oil Furnace (017-H-101 B)

Unit 17 2252-017-PID-00-31-03 A 25-Aug-06 Hot Oil Furnace (017-H-101 C)

Unit 17 2252-017-PID-00-31-04 A 25-Aug-06 Hot Oil Dis tribution

Unit 17 2252-017-PID-00-31-05 A 25-Aug-06 Expans ion Drum & Circula tion Pumps

Unit 17 2252-017-PID-00-31-06 A 25-Aug-06 Hot Oil Dra inage Sys tem


Unit 31 2252-031-PID-00-31-01 A 23-Jun-06 Je tty Air Sys tem and Nitrogen Receiver

Unit 31 2252-031-PID-00-31-02 A 14-Jul-06 Je tty Fire Fighting Sys tem


Unit 41 2252-041-PID-00-31-01 A 23-May-06 Air Compressors Package

Unit 41 2252-041-PID-00-31-02 A 23-May-06 Air Drying Package

Unit 41 2252-041-PID-00-31-04 A 23-May-06 Air Compressors Package

Unit 41 2252-041-PID-00-31-04 A 24-May-06 Emergency Compressor and P lant Air Receiver

Unit 41 2252-041-PID-00-31-05 A 24-May-06 Ins trument Air Receivers




List of P&IDs 2

The Gas Treatment Units review studied 65 Process & Instrumentation Diagrams (continued)


Unit 43 2252-043-PID-00-31-01 A 23-May-06 Nitrogen Genera tion Package

Unit 43 2252-043-PID-00-31-02 A 23-May-06 Nitrogen S torage and Vaporisa tion


Unit 46 2252-046-PID-00-31-01 A 23-May-06 Diese l Oil Sys tem


Unit 51 2252-051-PID-00-31-01 A 23-May-06 Raw Water Filtra tion Sys tem

Unit 51 2252-051-PID-00-31-02 A 24-May-06 Filte red and Fire Water S torage

Unit 51 2252-051-PID-00-31-03 A 24-May-06 Filte red and Fire Water S torage

Unit 51 2252-051-PID-00-31-04 A 23-May-06 Reverse Osmosis Sys tem

Unit 51 2252-051-PID-00-31-05 A 24-May-06 Desalina ted Water S torage and Pumping


Unit 52 2252-052-PID-00-31-01 A 23-May-06 Service Water Pumping


Unit 53 2252-053-PID-00-31-01 A 24-May-06 Desalina ted Water Potabilisa tion

Unit 53 2252-053-PID-00-31-02 A 24-May-06 Potable Water S torage and Pumping

Unit 53 2252-053-PID-00-31-03 A 24-May-06 Potable Water A.C. Filte rs Section


Unit 54 2252-054-PID-00-31-03 A 24-May-06 Demin. Water Package

Unit 54 2252-054-PID-00-31-05 A 24-May-06 Demin. Water S torage and Pumping


List of P&IDs 2



Unit 55 2252-055-PID-00-31-01 A 14-Jul-06 Fire Water Sys tem

Unit 55 2252-055-PID-00-31-02 A 14-Jul-06 Fire Water Sys tem


Unit 56 2252-056-PID-00-31-01 A 12-Sep-06 Collection Bas in

Unit 56 2252-056-PID-00-31-02 A 12-Sep-06 Oily Water Equalisa tion and Pumping

Unit 56 2252-056-PID-00-31-03 A 12-Sep-06 Oily Watter Trea tment

Unit 56 2252-056-PID-00-31-04 A 12-Sep-06 Treated Oily Water Discharge











Unit 56 2252-056-PID-00-31-15 A 12-Sep-06 Inle t Facilities Collection Bas in

Unit 56 2252-056-PID-00-31-16 A 12-Sep-06 Inle t Facilities Collection Bas in






Unit 56 2252-056-PID-00-31-22 A 12-Sep-06 Flare Collection Bas in



List of P&IDs 2



Unit 57 2252-057-PID-00-31-03 A 12-Sep-06 LNG Tra in 1 & 2 Boilers Blow Down Collection Bas ins

Unit 57 2252-057-PID-00-31-05 A 12-Sep-06 Labora tory and Chemical Sewer Receiving P it

Unit 57 2252-057-PID-00-31-06 A 12-Sep-06 Chemical Water Neutra lisa tion

Unit 57 2252-057-PID-00-31-07 A 12-Sep-06 Nuetra lisa tion Dos ing Sys tem

Unit 57 2252-057-PID-00-31-08 A 12-Sep-06 LNG Tra in 3 & 4 Boilers Blow Down Collection Bas ins


Unit 59 2252-059-PID-00-31-01 A 12-Sep-06 Sanitary Water Collection P its


Unit 59 2252-059-PID-00-31-03 A 12-Sep-06 Sanitary Water Trea tment

Unit 59 2252-059-PID-00-31-04 A 12-Sep-06 Sanitary Water Discharge and Drying Beds



Reference Documents 2

In addition to the P&IDs, a number of reference documents were used

Company Statement of Requirements, No. OKLNG-GG-PM-DB-0001

FEED Process Basis of Design, No. OKLNG-GG-PR-DB-0002

Cause and Effects Diagrams

Equipment FEED Stage Specifications

PSV Sizing Basis Specifications


HAZOP Record 2

The HAZOP record fully details the daily discussions

For each HAZOP node, the record presents the relevant deviations considered, existing mitigation factors and any recommendations arising

The record sheet also lists and prioritises the 149 recommendations identified

HAZOP record sheets for the Utility Units are included in Appendix V


Contents

Executive Summary1.


HAZOP Approach2.

Appendices3.

I.

AttendanceII.

Node ListIII.


HAZOP WorksheetsV.


Project N° Unit Document Code Serial N° Rev. Page

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OK LNG DEVELOPMENT PROJECT

FRONT END ENGINEERING DESIGN – WP1

B 16/06/06 ISSUED FOR FEED A.SCALESSE C. SCALA – F.GIOPPO PAESANI / HONORE

A 19/05/06 ISSUED FOR REVIEW A.SCALESSE C. SCALA – F.GIOPPO PAESANI-DENORA / HONORE

REV. DATE

STATUS WRITTEN BY (name & visa)

CHECKED BY (name & visa)

APPROV./AUTHOR. BY (name & visa)

DOCUMENT REVISIONS

TECHNIP ITALY S.p.A. - 00148 ROMA - Viale Castello della Magliana, 68

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HAZOP REVIEW PROCEDURE


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FRONT END ENGINEERING DESIGN – WP1 HAZOP REVIEW PROCEDURE


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TABLE OF CONTENTS

1. PURPOSE ................................................................................................................................. 3 2. REFERENCE DOCUMENTS .................................................................................................... 3 3. ORGANIZATION....................................................................................................................... 3

3.1. Responsabilities .............................................................................................................. 3 3.2. Timing ...............................................................................................................................4

4. METHODOLOGY ...................................................................................................................... 5 4.1. Risk Ranking .................................................................................................................... 7 4.2. Recommendations ........................................................................................................ 10

5. REPORTING ........................................................................................................................... 10 5.1. HAZOP Worksheets....................................................................................................... 10 5.2. HAZOP Report................................................................................................................ 10

6. SCHEDULE............................................................................................................................. 11 7. FOLLOW-UP........................................................................................................................... 11

ATTACHMENT A


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1. PURPOSE

This procedure defines the requirements and methodology of Hazard and Operability (HAZOP) Study within the Front End Engineering Design (FEED) phase of OK LNG DEVELOPMENT Project.

2. REFERENCE DOCUMENTS HAZOP Study will be based primarily on P&ID issued for FEED. In addition the following documentation will be made available as reference:

• Process Flow Diagrams (PFDs)

• H&M Balances

• Project Design Basis

• Process Philosophies and Narratives

• Major Equipment Data Sheets

• Relief Valve applicable Emergency Scenarios

• Fluid List

• Material Selection Diagrams

• Cause&Effect Diagrams

• Plot Plans

3. ORGANIZATION

3.1. Responsabilities

The HAZOP team will typically comprise the following members:

• Chairman

• Scribe

• JV Process Engineer

• Other JV discipline engineers on call as required


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• Client’s representatives (possible including operations)

Particular responsibilities of team members will be as follows:

Chairman: an experienced, independent technical person, who is responsible for leading the reviews with appropriate guidewords, establishing the detailed work schedule, ensuring that procedures are followed and that notes and results of the reviews are properly recorded and distributed, resolving any conflict that may arise during the sessions, ensuring that the team works toward a common goal by utilizing expertise of all team members, and checking on progress of sessions. Scribe: is responsible for preparing HAZOP Worksheets, and recording and filing all documents used and generated during the sessions in accordance with instructions of the Chairman; is responsible for distributing HAZOP Worksheets to attendees and specialists concerned. Other Team Members: are responsible for providing comments based on their knowledge and experience to assist the team in resolving issues emerging during the sessions.

3.2. Timing A detailed agenda and logistic organization of HAZOP Study will be transmitted to Company before starting of the sessions.

As general approach, due to the intensive nature of the HAZOP technique, the duration of daily sessions should be not excessive. The Chairman will monitor the meeting time, adjusting study progress to meet time targets, without causing reduction in effectiveness.

HAZOP meetings will be held in Rome in JV offices.

Session will start at 9:00 up to 13:00 and from 14:00 to 18:00 with 15 minutes break in the morning and in the afternoon.


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4. METHODOLOGY Present HAZOP methodology is derived from “A Guide to Hazard and Operability Studies”, Chemical Industries Association, London 1992. The HAZOP technique is a systematic analysis that uses a guide word approach to identify deviations from intended process design. The technique uses a team of reviewers with expertise in several key areas to identify deviations and their causes using a “brainstorming” approach. Although the primary goal of a HAZOP study is the identification of process hazards, it is also a valuable tool for uncovering operability problems as well. The scope of the HAZOP technique is therefore identifying potential process hazards or operability concerns, not finding solutions to reduce or eliminate them. Attempting to solve problems uncovered by the HAZOP can result in an unduly long and inefficient study process. At the same time, a HAZOP study can not be intended as a review of project design basis and operating philosophies, since these must be considered as resolved when the HAZOP study is carried out. The methodology to be applied to the HAZOP of the project is summarized here below. The Chairman divides the P&IDs into a number of discrete systems for review (nodes). In this way the team can focus close attention on a single circuit and then produce recommendations for each node. At the start of the review sessions scheduled for a complete plant unit, the Process Engineer describes briefly the process to the HAZOP team. Working through the P&IDs, the Chairman reviews a selected node by examining which deviations from normal operation can lead to undesired outcomes. All applicable deviations are examined combining appropriate guidewords to process or others parameters. Deviations will be considered with reference to normal operation and maintenance; where considered critical, the start-up and the shut-down operations will be analyzed in specific nodes. Suitable guidewords and parameters for a continuous process are listed in Table 1. Other parameters may be developed by the HAZOP team as required. Typically the team considers deviations as: • High flow, low flow, no flow, reverse flow • High temperature, low temperature • High pressure, low pressure • Contaminants in process materials, etc. Events, which can cause these deviations to occur, include: • Malfunction of process control systems • Blockages


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• Operational error (e.g. opening wrong valve) • Faulty maintenance activities (e.g. leaving in a slip-plate) • Failure of power supply or utilities (instrument air, cooling water etc.) For each deviation, the team asks, "Can it happen?”. If the answer is positive then the team asks "Would it cause a hazard?" (where a 'hazard' could be a fire, explosion, release of flammable or toxic material, production of off-specification material, production stoppage, equipment damage). Where a deviation can occur and can cause a hazard, the team considers what mitigating features may exist, e.g. relief valves, shutdown systems, alarms, etc. When a potential hazard is identified, remedial action may be required depending on the likelihood of the event and its consequence. If a deviation with potential to create hazard is identified, then, after the guidance of the Chairman, the Scribe records on the appropriate columns of HAZOP Worksheet possible Causes, possible Consequences, and definition of the problem in the Recommendation. The recommendation is identified univocally by means of a number shown on worksheet and on P&ID. Discussion of problems during the meeting should be kept to a minimum, and at the discretion of the Chairman. A dedicated software will be used to record the outcome of the review for each node and each deviation. The marked-up P&IDs will be the HAZOP Master P&IDs and will form part of the HAZOP report. The study is basically qualitative and recording of HAZOP findings on Worksheet is done “by exception”, i.e. the experience of the team was used to judge if a particular risk is:

• So unlikely (“not credible”) or of such low consequence (“no hazard”) that no further action is needed. For such a case, the point is marked on P&ID (by colored pencil) but the details of discussion are not included in the Worksheet.

• One which could have consequences if failure occurred, and where the probability and severity may engender a significant risk (safety recommendation); in this case relevant item is marked on P&ID (identification number) and on worksheet (identification number, causes, consequences……….and recommendation texts).

• One which would have consequences in term of facility operability (operability recommendation); in this case relevant item is marked on P&ID (identification number) and on worksheet (identification number, causes, consequences……….and recommendation texts).

The study continues with the selection by the Chairman of a new node and deviations are then analysed as before to evaluate the new node under review. The approach is repeated until all systems of the project have been examined. Each line and vessel studied is marked with highlighted coloured pencil to ensure no items are missed.


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If P&ID minor drafting errors are observed during the review, the Chairman may mark the corrections in a different colour to that used for HAZOP comments without recording it on the Worksheet. Each recommendation will be marked on P&ID with a red colour, while minor drafting errors will be corrected with green colour.

TABLE 1

TYPICAL HAZOP GUIDEWORDS/PARAMETERS AND RELATED DEVIATIONS FOR CONTINUOS PROCESS

PARAMETERS GUIDEWORDS DEVIATIONS

FLOW

More Less None Reverse

high flow low flow no flow reverse flow

PRESSURE More Less None

high pressure low pressure vacuum

TEMPERATURE More Less As well as

high temperature low temperature cryogenic

LEVEL More Less None

high level low level no level

STATE/ COMPOSITION

More Less Reverse Part of As well as Other than

additional phase loss of phase change of state off-spec composition contaminants corrosive concentration

REACTION More As well as Other than

runway reaction side reaction explosion

UTILITY: power, air, steam, nitrogen, cooling water

Other than loss of …

UNSTEADY OPERATION: startup, shutdown, maintenance, sampling, drainage

As well as Other than

difficult … hazardous …

CONTAINMENT Other than loss of containment

DOCUMENTATION Part of As well as Other than

incomplete documentation unclear documentation incorrect documentation

4.1. Risk Ranking


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In order to prioritise the recommendations for implementation, a risk-ranking scheme will be used to rank failure scenarios according to their estimated severity and likelihood. The following hazard severity and likelihood levels, and corresponding risk grid shall be used:

HAZARD SEVERITY LEVELS

Level Severity 1. Very High • Multiple employee fatalities

• Public fatalities and injuries • Extensive property damage • Major environmental impact • Major adverse public reaction

2. High • Employee fatalities • Public injuries • Significant property damage • Significant environmental impact • Adverse public reaction • Employee injuries 3. Medium • Minor public injuries • Moderate property damage • Moderate environmental impact • Moderately adverse public reaction

4. Low • Minor employee injuries • No public injuries • Minor property damage • Minor environmental impact • No adverse public reaction

5. Insignificant • Operational Upset • No employee injuries • No public injuries • No property damage • No environmental impact • No adverse public reaction


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HAZARD LIKELIHOOD LEVELS

Level Likelihood (events / year)

1. Very High Greater than 1E-2

2. High From 1E-2 to 1E-3

3. Medium From 1E-3 to 1E-4

4. Low From 1E-4 to 1E-6

5. Very Low Less than 1E-6

RISK GRID

Likelihood 1 2 3 4 5

1 1 2 3 4 5

2 2 4 6 7 8

3 3 6 7 8 9

4 4 7 8 9 10

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4.2. Recommendations

A number of recommendations for changes to equipment and procedures or for additional analysis/verifications will be identified during the HAZOP study, which in the team's opinion will improve the safety and operability of the facility; recommendations and party responsible for addressing the action will be recorded by the HAZOP Scribe on relevant fields of HAZOP worksheets.

5. REPORTING

5.1. HAZOP Worksheets HAZOP Worksheets will be prepared daily to record study findings in accordance with Chairman’s instructions. HAZOP Worksheets will be generated using dedicated HAZOP software. The first issue of HAZOP Worksheets will be checked and approved by the Chairman and subsequently distributed to other attendees for their concurrence.

5.2. HAZOP Report

After completion of scheduled HAZOP sessions, a HAZOP Study Report will be prepared. The outline of the HAZOP Study Report is: 1) Main body of report

Introduction and Scope of Work Executive Summary Study Approach Study Results Conclusions

2) Attachments

HAZOP Attendees HAZOP Node List HAZOP Worksheets HAZOP Master P&IDs


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6. SCHEDULE

Contractor will provide a written notice about the recommended start and duration of the HAZOP Study. The notice will include the proposed team leader for Company approval.

HAZOP meetings will be held daily. Detailed daily schedule and logistic of HAZOP sessions will be provided in advance. At the beginning of each daily session, the HAZOP secretary will distribute to the HAZOP team attendance the HAZOP Worksheet relevant to the previous working day. At the end of each session the HAZOP leader will collect on his own master copy the comments, if any, relevant to the HAZOP worksheet issued at the beginning of the session.

7. FOLLOW-UP

At the end of HAZOP sessions, beside to the HAZOP Report, Action Sheets containing the recommendations listed in the worksheets and assigned to a party for closure, will be produced. Action Sheets will be followed-up by the party responsible for the action. Changes proposed as the result of HAZOP review will be discussed and agreed with Company. On satisfactory resolution of actions, a formal HAZOP Follow-up Report showing resolutions and actions implemented will be issued for information.


Contents

Executive Summary1.


HAZOP Approach2.

Appendices3.

I.

AttendanceII.

Node ListIII.


HAZOP WorksheetsV.



Appendix II – Attendance

The following personnel participated in the Utility Unit (Part 2) FEED HAZOP

11/09/2006 12/09/2006 13/09/2006 14/09/2006 15/09/2006 18/09/2006Monday Tuesday Wednesday Thursday Friday Monday

Name DepartmentMr James Perry Arthur D Little - HAZOP Leader Y Y Y Y Y YMr Philip Webster Arthur D Little - HAZOP Scribe Y Y Y Y Y YMr Francesco Mussetto Snamprogetti SpA Y Y Y Y YMr Luciano Vanneschi Snamprogetti SpA Y Y Y Y YMrs Lorena Rosa Snamprogetti SpA Y Y Y Y YMr Christian Scala Technip Y (am)Mr Alfonso Ricciardi Snamprogetti SpA Y YMr Fred Preston OK LNG Y YMr Eric Holland OK LNG Y (am)


Contents

Executive Summary1.


HAZOP Approach2.

Appendices3.

I.

AttendanceII.

Node ListIII.


HAZOP WorksheetsV.



Appendix III – Node List – Air Compressors Package & Nitrogen

Unit Drawing Number(PID) Revision Date Sheet Description Node

(FEED) Node Description Equipment Day

Unit 41 2252-041-P ID-00-31-01 A 23-May-06 Air Compressors Package

Unit 41 2252-041-P ID-00-31-02 A 23-May-06 Air Drying Package

Unit 41 2252-041-P ID-00-31-04 A 24-May-06 Emergency Compressor and P lant Air Rece iver

Unit 41 2252-041-P ID-00-31-02 A 23-May-06 Air Drying Package

Unit 41 2252-041-P ID-00-31-05 A 24-May-06 Ins trument Air Rece ivers



1

2 Compressed air drier package and downstream instrument air receivers

041-U-102 041-U-103 041-V-103 041-V-104 041-V-102A 041-V-102B 041-V-102C

1

1 Air Compression Package 041-U-101041-V-101



Unit 43 2252-043-PID-00-31-01 A 23-May-06 Nitrogen Genera tion Package

Unit 43 2252-043-PID-00-31-02 A 23-May-06 Nitrogen S torage and Vaporisa tion

1 Nitrogen System 043-U-101043-U-102

1


Appendix III – Node List – Raw and Service Water



Unit 3 2252-003-PID-00-31-01 A 23-May-06 Well Water Pumping


Unit 51 2252-051-PID-00-31-02 A 24-May-06 Filtered and Fire Water S torage






Unit 51 2252-051-PID-00-31-04 A 23-May-06 Reverse Osmos is Sys tem

Unit 51 2252-051-PID-00-31-05 A 24-May-06 Desalinated Water S torage and Pumping

Unit 53 2252-053-PID-00-31-02 A 24-May-06 Potable Water S torage and Pumping



Unit 52 2252-052-PID-00-31-01 A 23-May-06 Service Water Pumping

3

3 Reverse osmos is package and desa lina ted water

s torage tank

051-T-101A/B051-U-103051-T-102053-T-120

3

2 Raw water sterilisation package

051-U-102 2

21 Well Water Pumps and Raw Water Filtration

003-P-101A-C051-U-101051-T-101A/B

4 Service wate r sys tem 051-T-101A/B052-P-130A/B052-P-131A/B


Appendix III – Node List – Potable & Demin. Water

UnitD ra wing N um be r

(P ID )R e v is io n D a te S he e t D e s c ript io n

N o de(F EED )

N o de D e s c ript io n Equipm e nt D a y

Unit 53 2252-053-P ID-00-31-01 A 24-May-06 Des a lina ted Water P o tabilis a tio n

Unit 53 2252-053-P ID-00-31-02 A 24-May-06P o table Water S to rage and P umping

Unit 53 2252-053-P ID-00-31-03 A 24-May-06 P o table Water A.C . F ilte rs Sec tio n

Unit 53 2252-053-P ID-00-31-02 A 24-May-06P o table Water S to rage and P umping

Unit 53 2252-053-P ID-00-31-03 A 24-May-06 P o table Water A.C . F ilte rs Sec tio n

2 P o table water chilling unit, s to rage tank and

dis tributio n

053-T-120053-P -120A/B053-U-123

3

1 P ro ductio n and s to rage o f P o table Water

053-U-120053-U-122053-T-120

3



Unit 51 2252-051-PID-00-31-05 A 24-May-06 Desa lina ted Wate r S torage and Pumping





Unit 54 2252-054-PID-00-31-05 A 24-May-06 Demin. Water S torage and Pumping 3 Deminera lised water pumps and header

054-T-110054-P -110A/B

3

3

2 Water demineralisa tion unit package regenera tion

054-U-110054-T-111054-P -111A/B054 T 110

3

1 Production of demineralised water

051-T-102051-P -101A/B054-U-110054-T-110


Appendix III – Node List – Hot Oil System and Diesel Oil



Unit 17 2252-017-P ID-00-31-01 A 25-Aug-06 Hot Oil Furnace (017-H-101 A)

Unit 17 2252-017-P ID-00-31-02 A 25-Aug-06 Hot Oil Furnace (017-H-101 B)

Unit 17 2252-017-P ID-00-31-03 A 25-Aug-06 Hot Oil Furnace (017-H-101 C)

Unit 17 2252-017-P ID-00-31-04 A 25-Aug-06 Hot Oil Dis tribution

Unit 17 2252-017-P ID-00-31-05 A 25-Aug-06 Expans ion Drum & Circula tion Pumps

Unit 17 2252-017-P ID-00-31-01 A 25-Aug-06 Hot Oil Furnace (017-H-101 A)

Unit 17 2252-017-P ID-00-31-02 A 25-Aug-06 Hot Oil Furnace (017-H-101 B)

Unit 17 2252-017-P ID-00-31-03 A 25-Aug-06 Hot Oil Furnace (017-H-101 C)

Unit 17 2252-017-P ID-00-31-04 A 25-Aug-06 Hot Oil Dis tribution

Unit 17 2252-017-P ID-00-31-06 A 25-Aug-06 Hot Oil Dra inage Sys tem 3 Hot oil sump 017-V-102/3 017-P-103/4

4

1 Hot oil circuit 017-V-101017-P-101017-FL-101017-H-101A/B/C017-A-101

4

2 Furnace firing and firebox 017-H-101A/B/C 4



Unit 46 2252-046-P ID-00-31-01 A 23-May-06 Diesel Oil Sys tem

1 Diesel oil sys tem 046-F-101A/B046-T-101046-F-102 A/B046-U-101

4


Appendix III – Node List – Jetty Facilities and Firewater



Unit 31 2252-031-P ID-00-31-01 A 23-Jun-06 Jetty Air Sys tem and Nitrogen Rece iver

1 Nitrogen supply 031-V-101 4

Unit 31 2252-031-P ID-00-31-01 A 23-Jun-06 Jetty Air Sys tem and Nitrogen Rece iver

2 Jetty compressed air system 031-U-104031-V-103

4



Unit 51 2252-051-P ID-00-31-02 A 24-May-06 Filtered and Fire Wate r S torage

Unit 51 2252-051-P ID-00-31-03 A 24-May-06 Filtered and Fire Wate r S torage

Unit 55 2252-055-P ID-00-31-01 A 14-Jul-06 Fire Water Sys tem

Unit 55 2252-055-P ID-00-31-02 A 14-Jul-06 Fire Water Sys tem

Unit 31 2252-031-P ID-00-31-02 A 14-Jul-06 Je tty Fire Fighting Sys tem

Unit 52 2252-052-P ID-00-31-01 A 23-May-06 Service Wate r Pumping

2 Jetty area firewate r sys tem 052-P-131A/B031-P-103A/B 031-U-101

5

1 Process a rea firewate r sys tem

051-T-101A/B055-P-101A/B/C055-P-102A/B

5


Appendix III – Node List – Oily Water System



Unit 56 2252-056-P ID-00-31-01 A 12-Sep-06 Collection Bas in

Unit 56 2252-056-P ID-00-31-02 A 12-Sep-06 Oily Water Equa lisa tion and Pumping


















Unit 56 2252-056-P ID-00-31-15 A 12-Sep-06 Inle t Facilities Collection Bas in

Unit 56 2252-056-P ID-00-31-16 A 12-Sep-06 Inle t Facilities Collection Bas in

Unit 56 2252-056-P ID-00-31-22 A 12-Sep-06 Flare Collection Bas in



Unit 56 2252-056-P ID-00-31-03 A 12-Sep-06 Oily Water Trea tment

Unit 56 2252-056-P ID-00-31-04 A 12-Sep-06 Trea ted Oily Water Discharge

6

6

3 Type 3 (fla re area) collection bas in

056-BA-512056-P -512A/B056-BA-513056-P -513A/B

6

2 Type 2 (inle t facility) collection bas in

056-BA-504056-BA-506056-P -504A/B056-P -506A/B

4 Oily water trea tment 056-TK-120056-Z-101056-BA-121056-P -121A/B056-P -150A/B056-U-101056-BA-122056-BA-123056-P -122A/B056-P -123A/B

1 Type 1 (process area) collection bas in

Process a rea collection bas ins and lifting pumps

6


Appendix III – Node List – Effluent Facilities



Unit 57 2252-057-P ID-00-31-03 A 12-Sep-06 LNG Tra in 1 & 2 Boile rs Blow Down Collection Bas ins

Unit 57 2252-057-P ID-00-31-05 A 12-Sep-06 Labora tory and Chemical Sewer Rece iving P it

Unit 57 2252-057-P ID-00-31-06 A 12-Sep-06 Chemica l Water Neutra lisa tion

Unit 57 2252-057-P ID-00-31-07 A 12-Sep-06 Neutra lisa tion Dosing Sys tem

Unit 57 2252-057-P ID-00-31-08 A 12-Sep-06LNG Tra in 3 & 4 Boile rs Blow Down Collection Bas ins

1 Effluent trea tment sys tem 057-BA-110057-BA-111057-BA-112057-BA-113057-P -110A/B057-P-111A/B057-P-112A/B057-P-113A/B075-BA-120057-BA-126057-BA-121A/B057-P-121A/B057-U-102057-U-103

5



Unit 59 2252-059-P ID-00-31-01 A 12-Sep-06 Sanitary Wate r Collection P its



Unit 59 2252-059-P ID-00-31-03 A 12-Sep-06 Sanitary Wate r Treatment

Unit 59 2252-059-P ID-00-31-04 A 12-Sep-06Sanitary Wate r Discharge and Drying Beds

2 Sanitary water trea tment Sanitary wate r collection bas in 059-BA-107Sanitary wate r feeding pumps 059-P-107Sanitary wate r trea tment package 059-U-101Sanitary wate r discharge bas in 059-BA-108Sanitary wate r discharge pumps 059-P-108A/BDrying beds 059-BA-111A-ERecovery water pit 059-BA-112Recovery water pump 059-P-112

6

1 Sanita ry wate r collection pits 059-BA-101059-P-101-A/B059-BA-102059-P-102A/B059-BA-103059-P-103A/B059-BA-104059-P-104A/B059-BA-105059-P-105A/B059-BA-106059-P-106A/B059-BA-107

6


Contents

Executive Summary1.


HAZOP Approach2.

Appendices3.

I.

AttendanceII.

Node ListIII.


HAZOP WorksheetsV.



Appendix IV – HAZOP Recommendations – Air Compressors Package

HAZOP Item No.

Node Recommendations Action by: Action resolution S L R

759 Node 1 R759.1 Consider requirement for vendor package HAZOP during detailed design

TS 3 3 7

761 Node 1 R761.1 Consider requirements for redundancy in electrical feeders to the air compressor packages, to enable distribution of air compressors over multiple electrical feeders.

TS 2 4 7

761 Node 1 R761.2 Consider requirements for dP indication and PDAH alarm on interstage and discharge filters on the air compressor packages

TS 3 3 7

761 Node 1 R761.3 Review control system for air compressor packages to determine whether possible to continue operation of air compressor packages at full flow rate in manual mode in the event of malfunction 041-PIC-0005 and operator intervention

TS 3 2 6

763 Node 1 R763.1 Confirm requirements for check valves and configuration of air compressor package and start-up compressor and drier with vendor

TS 3 3 7

764 Node 1 R764.1 Update P&ID to show internal baffle plate on wet air vessel TS 2 2 4765 Node 1 R765.1 Consider vapourisation of water collected in wet air vessel in sizing

basis for 041-PSV-0001TS 3 4 8

769 Node 1 R769.1 Discuss with vendor requirements for air compressor package temperature indication and alarms (e.g. discharge of interstage cooler)

TS 3 3 7

769 Node 1 R769.2 Provide AAH on 041-AI-0001A/B to warn operator of water breakthrough to instrument air system

TS 3 3 7

778 Node 1 R778.1 Consider requirements for flammable gas detection in vicinity of the air compressor package as located downwind of the LNG process area

TS 2 4 7

784 Node 2 R784.1 Provide DCS pressure indication and low pressure alarm on each individual instrument receiver

TS 4 4 9

787 Node 2 R787.1 See R784.1 for provision of DCS PI and PAL indication on individual instrument air receivers

TS 4 4 9

788 Node 2 R788.1 Consider and confirm requirements for PSV on each air drying package vessel

TS 3 3 7

791 Node 2 R791.1 Ensure operating manual highlights moisture breakthrough alarm has no trip and/or sequence action

TS 3 3 7

798 Node 2 R798.1 Consider requirements for dP indication on air drier filter elements in discussion with vendor

TS 3 3 7

798 Node 2 R798.2 Ensure operating manual requires operator check and draining of free water from the compressor casing before start-up

TS 3 3 7

801 Node 2 R801.1 Consider requirement for flammable gas detection on start-up compressor inlet

TS 2 4 7

804 Node 2 R804.1 P&ID will be updated to remove instrument air header to jetty given dedicated jetty air compressor

TS 2 2 4


Appendix IV – HAZOP Recommendations – Nitrogen

HAZOP Item No.


805 Node 1 R805.1 Consider requirement for vendor package HAZOP during detailed design

TS 3 3 7

806 Node 1 R806.1 Operating manual should clearly state requirement to start vapouriser package before using significant volumes of nitrogen for purging and maintainance activities to protect nitrogen header pressure and minimise potential for reverse flow of flammable mixtures into the nitrogen header

TS 3 3 7

806 Node 1 R806.2 Operating manual should clearly state requirement for operator to initiate LIN & GAN operating mode

TS 3 3 7

806 Node 1 R806.3 Consider configuration of trip of LIN production in the event of high level in both downstream liquid nitrogen storage tanks in consultation with vendor

TS 3 3 7

806 Node 1 R806.4 Consider updates of nitrogen generation plant P&ID to show HS selector for either GAN or GAN & LIN production modes in consultation with vendor

TS 3 3 7

807 Node 1 R807.1 Ensure atmospheric vent for nitrogen is at safe location TS 3 3 7814 Node 1 R814.1 Investigate whether additional requirement for oxygen analyser on

liquid nitrogen production to prevent contamination of liquid nitrogen storageTS 3 3 7

816 Node 1 R816.1 Discuss during vendor package HAZOP protections against exceedance of vapouriser gaseous discharge pipework specification

TS 3 3 7

818 Node 1 R818.1 Discuss during vendor package HAZOP protections against overfilling and overpressurising storage

TS 3 3 7

818 Node 1 R818.2 See Recommendation R806.3 for configuration of trip of LIN production in the event of high level in both downstream liquid nitrogen storage tanks

TS 3 3 7

819 Node 1 R819.1 Consider configuration of LAL at higher level in the tank (e.g. 60-80% full) if no requirement to have LAL at low level in the tank, e.g. for protection of pump and/or gas breakthrough from storage

TS 3 3 7


Appendix IV – HAZOP Recommendations – Raw and Service Water

HAZOP Item No.


828 Node 1 R828.1 Consider HAZOP of vendor package during detailed design TS 3 3 7828 Node 1 R828.2 Review all utility water storage tanks and provide maintenance blinds

and/or spacers to enable isolation of tanks for maintenanceTS 2 2 4

829 Node 1 R829.1 Update P&ID to show correct relative location of 051-LALL-0005A/B vs non firewater nozzles

TS 2 2 4

829 Node 1 R829.2 Consider whether DCS panel alarms 051-LAH-0006A/B and 051-LAH-0004A/B are required as these will be nuisance alarms during normal operating conditions and tank levels

TS 3 3 7

829 Node 1 R829.3 During detailed design, following selection of well water pump type and filter capacity, consider requirement for minimum flow protection on well pumps

TS 3 3 7

830 Node 1 R830.1 Consider during detailed design whether permissive of well water pump operating is required to commence the backwash cleaning sequence

TS 4 2 7

830 Node 1 R830.2 Provision of pressure indication on suction of raw water filtration package, requested by client as permissive for on/off control of raw water sterilisation package

TS 2 2 4

831 Node 1 R831.1 Consider LO and/or CSO of the firewater supply line and minimum flow return on the filtered and firewater storage tank to prevent closure in error by operator

TS 1 4 4

832 Node 1 R832.1 Consider during detailed design, provision of syphon breaker on top entry to filtered and firewater storage tanks to prevent reverse flow and/or additional check valve on tank inlet in the event of bottom filling

TS 5 2 8

833 Node 1 R833.1 Detailed design to consider requirement for external protection of water tanks floors via CP or coating

TS 4 3 8

833 Node 1 R833.2 Review of raw water, filtered water and service water pipework will be completed during detailed design following conformation of well water composition (salt and solids content)

TS 4 3 8

834 Node 1 R834.1 Review requirement for pressure relief provision on filters in revised design (not yet issued) to prevent overpressure of filters and tank inlet pipework as well water pump discharge presure rating increased to class 600, but filters and downstream pipework remain class 150

TS 3 3 7

834 Node 1 R834.2 Review requirement for thermal relief on raw water pipework from well during detailed design

TS 3 3 7

835 Node 1 R835.1 Review sizing basis for the vent on filtered and firewater storage tanks to ensure sufficient for combined maximum flow rate out of tank

TS 2 4 7

842 Node 1 R842.1 In new revision of P&ID (not issued) assumption that three independent wells will be used for provision of well water for site with individual low low level trip of single well water pump

TS 2 2 4

844 Node 1 R844.1 Consider during detailed design and reciept of raw water composition implications on proposed filtration package configuration and design

TS 3 3 7


Appendix IV – HAZOP Recommendations – Raw and Service Water

HAZOP Item No.


844 Node 1 R844.2 Consider during detailed design and reciept of raw water composition implications on anticipated solids production from the backwash filters and discharge to off-site receiving waters

TS 3 3 7

847 Node 1 R847.1 See Recommendation R833.2 for review of materials following reciept of well water composition during detailed design

TS 3 3 7

847 Node 1 R847.2 Review reverse osmosis package design for removal of dissolved solids during detailed design following reciept of well water composition

TS 3 3 7

847 Node 1 R847.3 Consider during detailed design and reciept of raw water composition implications on salt concentration of concentrate discharged to off-site receiving waters (more significant issue if creek is freshwater rather than brackish or saline)

TS 3 3 7

851 Node 2 R851.1 Consider HAZOP of vendor package during detailed design TS 3 3 7853 Node 2 R853.1 Consider provision raw water sterilisation package sodium

hypochlorite storage DCS level indicationTS 2 2 4

855 Node 2 R855.1 Next revision of P&IDs will show manual isolation valve at chemical injection tie-in. Consider requirement for check valve given increase in well water pump discharge pressure

TS 2 2 4

856 Node 2 R856.1 Undertake HAZOP of injection package during detailed design. At present, preference is to use iso tank as means of storage of sodium hypochlorite chemical, removing requirements for additional vessel and/or handling requirements

TS 3 3 7

861 Node 2 R861.1 Recommend provision of shelter for raw water sterilisation package (shade, not enclosed building)

TS 4 2 7

874 Node 3 R874.1 Consider HAZOP of vendor package during detailed design TS 3 3 7875 Node 3 R875.1 Review proposed on/off level set points in desalinated water and

potable water storage tanks to ensure it is possible to refill tanks, taking into account with single and combined filling rates

TS 3 3 7

878 Node 3 R878.1 Consider requirement for tank inlet check valve in the event bottom filling

TS 2 2 4

890 Node 3 R890.1 Consider requirements for DCS dP indication and PDAH on the reverse osmosis package inlet filters

TS 3 3 7

900 Node 4 R900.1 Consider provision of LO manual isolation valve at tie-in to jetty firewater ring main to enable maintainance of check valve and interconnecting header (from booster pump to jetty) as approximately 9 km long without compromising firewater provision at jetty

TS 2 2 4

902 Node 4 R902.1 See R833.2 for review of filtered water specification during detailed design upon confirmation of well water composition

TS 3 3 7


Appendix IV – HAZOP Recommendations – Potable Water

HAZOP Item No.


920 Node 1 R920.1 Undertake HAZOP of potable water vendor packages during detailed design

TS 3 3 7

922 Node 1 R922.1 Review water potablisation and biocide packages to consider what DCS alarms, etc. are required to notify operator of malfunction

TS 2 2 4

923 Node 1 R923.1 Ensure water potabilisation package control logic inhibits continued injection of sodium hydroxide (normally controlled by 053-AIC-0001) to prevent overinjection of sodium hydroxide during no-flow conditions (via 053-FIC-0001)

TS 2 2 4

924 Node 1 R924.1 Consider provision of check valve on inlet to potable water storage tank and desalinated water storage tank

TS 2 2 4

934 Node 1 R934.1 Consider provision of DCS level indication using 053-LALL-0003 instrument

TS 2 2 4

934 Node 1 R934.2 See R922.1 for provision of appropriate DCS indication and alarms TS 2 2 4

939 Node 1 R939.1 Ensure during detailed design that potable water sample point enables collection of representative potable water sample

TS 3 3 7

944 Node 2 R944.1 Consider relocation of potable water tie-in for CWT make-up, upstream of the activated carbon filter package, given flow rate limitation on activated carbon filter package

TS 2 2 4

946 Node 2 R946.1 Review during detailed design the design of chilling unit package and protections against ice formation in the event of loss of potable water flow through the chilling unit package

TS 3 3 7

946 Node 2 R946.2 Consider inclusion of chilling unit package trip in Cause and Effect in the event of 053-LALL-0003 on the potable water tank in consulation with vendor

TS 3 3 7

949 Node 2 R949.1 Review design pressure of chilling unit package and activated carbon filters

TS 2 2 4

949 Node 2 R949.2 Review proposed potable water system distribution and design pressure, as it appears high compared with allowable user pressures

TS 2 2 4

954 Node 2 R954.1 See R946.1 for review of chilling unit package design during detailed design

TS 3 3 7

957 Node 2 R957.1 See R934.1 for configuration of level indication on 053-LALL-0003 instrument

TS 2 2 4


Appendix IV – HAZOP Recommendations – Potable Water

HAZOP Item No.


966 Node 1 R966.1 Undertake HAZOP of water demineralisation package during detailed design

TS 3 3 7

969 Node 1 R969.1 Consider provision of level indication on 054-LALL-0003 instrument on DCS

TS 2 2 4

969 Node 1 R969.2 Consider in consultation with downstream users (Steam and Acid Gas Removal Units) whether trip of demineralised water pumps needs to initate action on downstream unit e.g. 102-P-107A/B Demin water make up metering pump. Update Cause and Effect Diagram as necessary

TS 2 2 4

972 Node 1 R972.1 Nitrogen purge connection will be removed in subsequent version of P&ID. Boiler feed water is dosed with oxygen scavenger and tank is stainless steel

TS 2 2 4

992 Node 2 R992.1 Vendor package logic sequences will be finalised during detailed design, including action in the event of common trouble alarm, e.g. continuation of sequence, stop of sequence or restart of sequence (general recommendation for all utility vendor packages)

TS 3 3 7

992 Node 2 R992.2 Consider provision of conductivity meter in regeneration wash of the neutralisation basin

TS 3 3 7

1002 Node 2 R1002.1 Review proposed design and consider configuration of alarm (e.g. LAH on the neutralisation basin and/or regeneration complete alarm) to notify operator to empty neutralisation basin

TS 2 2 4

1003 Node 2 R1003.1 If level indication and alarm provided (see R1002.1), consider provision of low level stop of neutralisation pumps

TS 3 3 7

1008 Node 2 R1008.1 Review requirement for sequence valve on plant air mixing sparger as neutralisation in the basin is normally part of the automatic regeneration sequence

TS 3 3 7

1008 Node 2 R1008.2 Review during detailed design of vendor package HAZOP specific protections for contamination of duty mineralisation discharge during regeneration, e.g. double valving, limit switches on sequence panels, conductivity analyser on discharge of each resin bed

TS 3 3 7

1011 Node 2 R1011.1 Water demineralisation package sizing basis will be reviewed during detailed design following reciept of raw water composition

TS 3 3 7

1014 Node 3 R1014.1 Configure PAL on 054-PI-0002 on demineralised water header TS 2 2 41015 Node 3 R1015.1 Consider requirement for check valve on common demineralised

water header to prevent depressurisation to tankTS 2 2 4


Appendix IV – HAZOP Recommendations – Hot Oil

HAZOP Item No.


1035 Node 1 R1035.1 HAZOP of fired furnace vendor package to be undertaken during detailed design

TS 3 3 7

1036 Node 1 R1036.1 Undertake complete review of furnace vendor package control, trip functions, cause & effect and flow control configuration to individual passes during detailed design

TS 3 3 7

1036 Node 1 R1036.2 Consider configuration of FI and FQI to enable operator monitoring of flow to individual condensate stabilisers and gas heaters

TS 5 5 10

1036 Node 1 R1036.3 Consider provision of manual globe valve to enable operator regulation of flow through filter, especially when clean

TS 4 4 9

1037 Node 1 R1037.1 Review during vendor package HAZOP furnace protections for low and/or no flow on individual passes

TS 3 3 7

1037 Node 1 R1037.2 See Reccomendation R1036.3 for provision of flow control element in slipstream

TS 4 4 9

1037 Node 1 R1037.3 Review with furnace vendor whether 017-FV-0001 is required given master flow controller of individual inlet flow controllers.

TS 3 3 7

1040 Node 1 R1040.1 Configure LAL on 017-LI-0004 to act as pre-alarm before circulating pump trip

TS 3 3 7

1040 Node 1 R1040.2 See R1040.1 for configuration of LAL TS 3 3 71040 Node 1 R1040.3 Ensure piping layout enables draining of hot oil to drum for

maintenance activitiesTS 4 4 9

1041 Node 1 R1041.1 Confirm against code requirements whether dedicated PSV required for filter vessel sized for fire, or CSO manual isolation valve to ensure protection via expansion drum pressure relief

TS 3 3 7

1042 Node 1 R1042.1 Consider handwheel, if not already provided, on 017-PV-0015 to enable continued operation with manual control

TS 3 3 7

1045 Node 1 R1045.1 Review design temperature of hot oil exchangers to match hot oil unit design temperature

TS 2 2 4

1045 Node 1 R1045.2 Review design temperature of hot oil expansion drum TS 2 2 41063 Node 2 R1063.1 Confirm during vendor package HAZOP provision of firebox venting

and purge requirements prior to ignitionTS 3 3 7

1063 Node 2 R1063.2 Confirm with vendor proposed simultaneous isolation of both fuel gas to the furnace and flow of hot oil through the furnace tubes. Ensure tube design temperature sufficient for residual heat in the firebox and no flow condition

TS 3 3 7


Appendix IV – HAZOP Recommendations – Hot Oil

HAZOP Item No.


1064 Node 2 R1064.1 Review during detailed vendor package HAZOP flame protection and flame-out protection, including trip actions

TS 3 3 7

1065 Node 2 R1065.1 See R1064.1 TS 3 3 71068 Node 2 R1068.1 Detailed furnace design to confirm potential for flame impingment

and protection against over-firing in furnaceTS 3 3 7

1074 Node 2 R1074.1 Evaluate the need for KO drum provision on common fuel gas to Unit 17 furnaces to minimise potential for furnace upset (general recommendation)

TS 3 3 7

1087 Node 3 R1087.1 Consider relocation of manual globe valve to inlet of hot oil sump to control purging flow

TS 4 4 9

1087 Node 3 R1087.2 Add note to P&ID to state that pressure gauge should be visible from nitrogen purge manual globe valve

TS 4 4 9

1088 Node 3 R1088.1 Ensure nitrogen purge sizing basis and local indication is sufficient to prevent formation of vacuum in sump during pump out conditions

TS 4 4 9


Appendix IV – HAZOP Recommendations – Diesel Oil & Jetty Air Compressor

HAZOP Item No.


1104 Node 1 R1104.1 Undertake vendor package HAZOP during detailed design TS 3 3 71105 Node 1 R1105.1 Consider provision of pump to enable filling of diesel truck for onsite

distributionTS 2 2 4

1108 Node 1 R1108.1 Consider provision of check valve at harbour to prevent reverse flow TS 2 2 4

1109 Node 1 R1109.1 Evaluate requirement for overflow on diesel oil storage tank, given potential environmental aspects associated with the overflow of diesel oil to bunded area

TS 2 2 4

HAZOP Item No.


1150 Node 2 R1150.1 Undertake vendor air compressor package HAZOP during detailed design

TS 3 3 7


Appendix IV – HAZOP Recommendations – Plant and Jetty Firewater

HAZOP Item No.


1180 Node 1 R1180.1 Review configuration of firewater system. Consider provision of check valve to prevent depressurisation of ring main through main firefighting pump minimum flow to tank

TS 2 2 4

1180 Node 1 R1181.2 Next revision of P&IDs will remove 051-LALL-007A/B stop of main firewater pumps

TS 2 2 4

1200 Node 2 R1200.1 Next revision of P&ID will show double check valve arrangement on service water tie-in to jetty firewater ring main

TS 2 2 4

1201 Node 2 R1201.1 OK LNG to review proposed design of jetty firewater pump discharge headers and minimum flow lines. Consider requirements for upgrade of proposed materials as draining of seawater from system not really appropriate due to weekly fire pump test and jetty availability issues.

OK LNG 2 2 4

1202 Node 2 R1202.1 Next revision of P&ID will show discharge of 031-PSV-0003B downstream of minimum flow control valve

TS 2 2 4

1212 Node 2 R1212.1 Next revision of P&ID will show biocide dosing connection to pump firewater basin screen

TS 2 2 4

1215 Node 2 R1215.1 Detailed HAZOP of vendor package during detailed design will consider alarms to notify operator of malfunction and low level biocide dosing to jetty firewater ring main

TS 3 3 7


Appendix IV – HAZOP Recommendations – Effluent Treatment

HAZOP Item No.


1220 Node 1 R1220.1 Consider whether switch in chemical sewer neutralisation basin logic should wait until high alarm in duty basin before opening inlet valve on standby basin to ensure the two basins operate in sequence

TS 5 1 5

1220 Node 1 R1220.2 Consider benefits for automatic start of boiler blowdown lifting pumps based on high level in collection basin, given blowdown flow rate is continous at approximately 12 m3/hr

TS 5 1 5

1221 Node 1 R1221.1 In the event that R1220.2 is implemented, autostart of standby pump will occur if level does not start to decrease in the basin once start signal initiated. In the event of pump trip during pumpout, high level in basin will initiate additional pump start signal

TS 5 1 5

1221 Node 1 R1221.2 HAZOP of chemical dosing packages will be undertaken during detailed design

TS 3 3 7

1222 Node 1 R1222.1 Review with instrumentation group whether provision of sequence failure alarm is possible and/or necessary for the chemical sewer neutralisation basin

TS 4 3 8

1235 Node 1 R1235.1 Consider provision of hard pipework connection for removal of solids from bottom of blowdown collection basins using vacuum truck

TS 5 2 8

1238 Node 1 R1238.1 Provide sample connection on discharge of chemical sewer neutralisation pumps for sampling purposes

TS 4 1 4


Appendix IV – HAZOP Recommendations – Oily Water

HAZOP Item No.


1243 Node 1 R1243.1 Operating procedures to recommend notification and communication with utilities area personel before starting pumpout of oily water collection basins to prevent overwhelming oily water tank and oily water treatment packages following heavy rainfall

TS 5 3 9

1251 Node 1 R1251.1 Ensure appropriate flammable gas detection is provided in process area, including in vicinity of collection basins, in the event that non-ExD pumps provided. Emergency scenarios should also consider what action to take in the event of large release simultaneous with pump operation

TS 2 4 7

1258 Node 1 R1258.1 Consider provision of hard piping to each collection basin to facilitate cleaning and removal of solids by vacuum truck

TS 5 2 8

1261 Node 1 R1261.1 Ensure operating procedures clearly state requirements for treatment of washing waters from amine process areas following large amine spillage offsite. Neutralisation and release to oily water system is inappropriate due to high COD of effluent and no downstream biological treatment process

TS 4 3 8

1262 Node 1 R1262.1 Detailed design phase will consider requirements for corrosion protection on base of tank, e.g. CP, etc.

TS 3 3 7

1278 Node 2 R1278.1 Review proposed design of oily water system to consider and develop operating procedure for management of oil collected on surface of each collection basin over time

TS 4 3 8

1290 Node 3 R1290.1 Review whether flare lifting pumps need to be connected to emergency power supply and/or provision of one electric and one diesel pump, given location and function

TS 2 3 6

1290 Node 3 R1290.2 During detailed design, review proposed design following reciept of further rainfall information specific to site location. It may be necessary to consider increasing flare lifting basin size and/or revise pump configuration (three 50% pumps)

TS 2 3 6

1301 Node 3 R1301.1 Consider requirements for independent level indication, high level alarm and high high level alarm, given potential impact on other flare area related equipment, i.e. flare KO drum condensate pump, incinerators, etc.

TS 2 3 6

1302 Node 3 R1302.1 See Recommendation R1301.1, and consider provision of independent low low level pump trip to prevent pump damage

TS 2 3 6


Appendix IV – HAZOP Recommendations – Oily Water

HAZOP Item No.


1313 Node 4 R1313.1 Consider deletion of pump discharge flow control, if not removed, ensure 056-FV-0001 is FO

TS 5 3 9

1313 Node 4 R1313.2 Update P&ID to show on-off control signal from 056-LI-0004 to control panel on oily water treatment package to control injection of oily water treatment package chemicals

TS 4 3 8

1316 Node 4 R1316.1 Consider provision of skimming nozzles in tank at normal operating level for use in event of failure of floating skimmer device (see acid gas removal process HAZOP)

TS 5 4 10

1317 Node 4 R1317.1 Consider requirement for PSV protection on sludge pump discharge since this is a positive displacement type pump

TS 4 3 8

1318 Node 4 R1318.1 Consider configuration of low alarm on air pressure on oily water treatment package

TS 3 3 7

1318 Node 4 R1318.2 Undertake HAZOP of vendor package during detailed design TS 3 3 71325 Node 4 R1325.1 Ensure suitable level device is provided since dirty service TS 5 2 8


Appendix IV – HAZOP Recommendations – Sanitary Waste Water Treatment

HAZOP Item No.


1353 Node 1 R1353.1 During detailed design, review sizing basis for sanitary water pits (especially inlet facilities pit), taking into account anticipated manning levels for each area

TS 3 3 7

1376 Node 2 R1376.1 Confirm with process department potential and maximum concentration of benzene, toluene and xylene in LNG process effluent. Determine in consultation with vendor potential impact on sanitary water treatment package

TS 2 4 7

1376 Node 2 R1376.2 Undertake HAZOP of vendor sanitary water treatment package during detailed design

TS 3 3 7


Contents

Executive Summary1.


HAZOP Approach2.

Appendices3.

I.

AttendanceII.

Node ListIII.


HAZOP WorksheetsV.


HAZOP Record Sheet: Air Compression Package Version: FinalSheet 1/125

Team members: see attached listTeam Leader/Assistant Perry/Webster

HAZOP Item No.

Plant Section

Deviation Causes Consequences Safeguards Recommendations Remarks Action by: Action resolution S L R

759 Node 1 Air compression package

Overview 1. HAZOP of air compressor and drier packages

R759.1 Consider requirement for vendor package HAZOP during detailed design

TS 3 3 7

760 Flow - High 1. Large demand in downstream

nitrogen, plant or instrument air systems

1. Gradual decrease in pressure in downstream discharge of air compressor2. Increased flow of instrument air and demand on air drying package3. Potential for higher dP over the air drying package

1. 041-FI/FAH-0002 on flow to plant air, 041-FI-0001on flow to nitrogen generation and 041-FI-0003 on flow to instrument air 2. 041-PIC/PAL-0005 controls the air compression, increasing output from air compression packages3. 041-PIC-0008 controls pressure to downstream instrument air receivers and upstream wet air supply to nitrogen package by closing 041-PV-0008 air supply to utility plant air system4. 041-PAL-0006 closes 041-SDV-0001 to plant air. 041-PALL-0006 closes 043-SDV-0001 on nitrogen air generation package inlet. 041-PALL-0007 activates unit 41 alarm only, manual operator hand switch trip of air compressor package 041-U-101 and start of 041-U-103 startup compressor and drier.5. Dedicated plant area instrument air receivers each sized for 15 mins hold up volume of instrument air6. 2 x 100% air drying packages with one normally in standby. Online air drying package has two towers, one in regeneration, one in operation with timed regeneration switchover sequence.

1. Discussion is taking place with process to confirm 15 mins hold up of instrument air is sufficient for safe shutdown of downstream process units. 2. SDV, ESDV have dedicated air supply buffers sized for 20 mins and 3 valve strokes.

Design intent Compression of wet air in 3 normally operating air compression package units to feed downstream nitrogen generation, plant and instrument air systems. Water from the compression is removed in the compressor discharge KO drums and wet air vessel 041-V-101.

Node Equipment Air compression package 041-U-101Wet air vessel 041-V-101

General Section Description:

Wet air is compressed in the air compression package 041-U-101. In normal operation, 3 x 33% compressors in operation with 4th compressor on standby. Normal discharge pressure is 9 bar with total rated capacity of 18990 Standard m3/hr. Compressed air is used to feed the nitrogen generation system (5000 Normal m3/hr), plant air 600 Normal m3/hr and instrument air 12000 Normal m3/hr. Wet air for the plant and instrument air is dried in the air drying package 041-U-102 (Desiccant heated type drier using dried air for regeneration with heating). Each of the downstream instrument air receivers (one for each plant area) is sized for 15 mins hold up.

Drawing Number/Sheet Number /Rev.Number/Date

2252-041-PID-00-31-01/Rev A/23-05-062252-041-PID-00-31-02/Rev A/23-05-062252-041-PID-00-31-04/Rev A/24-05-06

HAZOP Date 11-Sep-06

Section ID Air compression and feed to plant air, nitrogen generation and instrument air systems

Company TECHNIPFacility OK LNG Facility FEED Study

Prepared by Arthur D. Little for OK LNG



HAZOP Item No.

Plant Section







2. Maintenance in plant requiring high flow of plant air

1. Increase in demand of dried air for plant utility service2. Potential for gradual decrease in pressure in instrument air system

1. 041-FI/FAH-0002 on flow to plant air, 041-FI-0001on flow to nitrogen generation and 041-FI-0003 on flow to instrument air 2. 041-PIC/PAL-0005 controls the air compression, increasing output from air compression packages3. 041-PIC-0008 controls pressure to downstream instrument air receivers and upstream wet air supply to nitrogen package by closing 041-PV-0008 air supply to utility plant air system4. 041-PAL-0006 closes 041-SDV-0001 to plant air. 041-PALL-0006 closes 043-SDV-0001 on nitrogen air generation package inlet. 041-PALL-0007 activates unit 41 alarm only, manual operator hand switch trip of air compressor package 041-U-101 and start of 041-U-103 startup compressor and drier.5. Dedicated plant area instrument air receivers each sized for 15 mins hold up volume of instrument air6. 2 x 100% air drying packages with one normally in standby. Online air drying package has two towers, one in regeneration, one in operation with timed regeneration switchover sequence.

1. Plant air is a maintenance utility service and air supply to instrument air and nitrogen generation service takes precedence




HAZOP Item No.

Plant Section







3. Malfunction/incorrect set point of 041-PIC-0005

1. Increase in compressor flow rate 2. Gradual increase in dried air pressure3. Potential for equipment overpressure

1. Independent 041-PIC-0008 on dried air system downstream 2. 041-XL-0001A/B/C/D running indication on individual air compression packages3. Individual air compressor package recycle and anti-surge protection, in the event of low actual demand for instrument/plant air4. 041-PI/PAH-0001A/B/C/D on discharge of individual air compressors 5. Possible for operator to override 041-PIC-0005 and operate air compressors manually6. Dedicated PSVs on discharge of individual air compressors and 041-PSV-0001 on wet air vessel

761 Flow - Low 1. Low demand in downstream

instrument air, nitrogen generation and/or plant air

1. Gradual increase in pressure in the discharge of the air compressor packages2. Potential for overpressure of upstream equipment

1. Design pressure of air compressors and downstream equipment is 10 barg2. 041-PSV-0001 on wet air vessel discharge to safe location 3. 041-PIC-0005 controls the number of air compressors online (control logic will always maintain single air compressor online)4. In normal operating mode, constant demand for instrument air and nitrogen generation. Flow rate dependent mainly on number of LNG trains in operation5. 041-PI/PAH-0001A/B/C/D on discharge of each individual air compressor package6. 041-XL-0001A/B/C/D running status indication for each air compressor package




HAZOP Item No.

Plant Section







2. Trip of single air compressor package

1. Decrease in production of compressed air 2. Potential for decrease in downstream plant air, nitrogen generation and instrument air pressure3. Potential for downstream process equipment trips due to loss of instrument air and/or nitrogen

1. 041-PIC-0005 controls the number of duty air compressors (start of stand-by compressor)2. 041-PAL-0006 closes 041-SDV-0001 to plant air. 041-PALL-0006 closes 043-SDV-0001 on nitrogen air generation package inlet. 041-PALL-0007 activates unit 41 alarm only, manual operator hand switch trip of air compressor package 041-U-101 and start of 041-U-103 startup compressor and drier.

R761.1 Consider requirements for redundancy in electrical feeders to the air compressor packages, to enable distribution of air compressors over multiple electrical feeders.

TS 2 4 7

3. Blockage of air compressor package inlet filters (one per compressor package)

1. Reduction in flow of air to individual air compressor packages 2. Decrease in discharge flow rate from individual air compressor3. Potential for decrease in pressure in downstream instrument air/nitrogen generation systems

1. 041-PIC-0005 controls the number of duty air compressors (start stand-by compressor)2. 041-PAL-0006 closes 041-SDV-0001 to plant air. 041-PALL-0006 closes 043-SDV-0001 on nitrogen air generation package inlet. 041-PALL-0007 activates unit 41 alarm only, manual operator hand switch trip of air compressor package 041-U-101 and start of 041-U-103 startup compressor and drier.

R761.2 Consider requirements for dP indication and PDAH alarm on interstage and discharge filters on the air compressor packages

TS 3 3 7




HAZOP Item No.

Plant Section







4. Malfunction or incorrect set pointof 041-PIC-0005

1. 041-PIC-0005 staged shutdown of online air compressors 2. Gradual decrease in dried air pressure3. Potential for loss of instrument air supply to process

1. Independent 041-PIC-0008 controls feed to plant air system 2. 041-XL-0001A/B/C/D running indication on individual air compression packages3. 041-PAL-0006 on feed to instrument air system 4. Possible for operator to override 041-PIC-0005 and start air compressors manually5. Dedicated plant area instrument air storage receivers with inlet check valves sized for 15 mins normal operation

R761.3 Review control system for air compressor packages to determine whether possible to continue operation of air compressor packages at full flow rate in manual mode in the event of malfunction 041-PIC-0005 and operator intervention

1. Requirements for 2 oo 3 voting on 041-PIC-0005 not considered necessary by HAZOP team (reference course HAZOP recommendation 2.1.1.1)

TS 3 2 6

762 Flow - No No new issues

763 Flow - Reverse 1. Standby air compressor 1. Potential for reverse flow

through stand-by air compressor and/or start-up compressor equipment2. Potential for compressor damage

R763.1 Confirm requirements for check valves and configuration of air compressor package and start-up compressor and drier with vendor

TS 3 3 7

2. Trip of air compressor 1. Potential for reverse flow from instrument air recievers with damage to air drying package2. Potential for loss of buffer air pressure in instrument air receivers

1. Common check valve on inlet to plant air receiver 041-V-1032. Check valve on inlet to each individual instrument air receiver




HAZOP Item No.

Plant Section







764 Loss of Containment

1. Compressor seal failure 1. Release of instrument air to atmosphere2. Reduced performance in individual compressor

1. 041-PI/PAL-001A/B/C/D on individual air compressor discharge2. Periodic operator inspection of equipment 3. 041-PIC-0005 start of stand-by compressor

2. Corrosion of wet air system 1. Potential for release of compressed air to atmosphere2. Potential for increased duty on air compressors

1. Wet air system is carbon steel with 3mm corrosion allowance (pipework and wet air vessel) 2. Demister pad in wet air vessel is stainless steel, minimising potential for corrosion and blockage3. Inlet baffle on wet air vessel, minimises potential for entrainment of solids and blockage of the wet air vessel demister pad

R764.1 Update P&ID to show internal baffle plate on wet air vessel

1. HAZOP team does not consider requirement for dP indication over demister necessary given provision of inlet baffle

TS 2 2 4

765 Pressure - High 1. Fire in vicinity of wet air vessel 1. Potential overpressure of

compressed air system 1. 041-PSV-0001 sized for fire on wet air vessel

R765.1 Consider vapourisation of water collected in wet air vessel in sizing basis for 041-PSV-0001

TS 3 4 8

2. Sequence failure in the air drying package

1. Blocked discharge of air compressor package resulting in increase in discharge pressure2. Loss of flow of dried air to instrument air and plant air distribution network 3. Gradual decrease in pressure downstream of plant air receiver4. 041-PIC-0005 would tend to modulate inlet vane position on air compressors to increase flow rate further

1. 041-UUA-003A/B common trouble alarm on air drying package2. Individual surge control on each air compressor3. Individual compressor discharge PSV sized for full design capacity of compressor

766 Pressure - Low No new issues

767 Vacuum No new issues




HAZOP Item No.

Plant Section







768 Partial Pressure 1. Changes in air humidity 1. Increased generation of water in discharge from air compressor package2. Potential for increased load on air drying package3. Potential for damage to desiccant due to ingress of free water

1. Air compressor package will be provided with interstage and final stage cooler and K/O drums2. Wet air vessel with 041-LAH-001 and operator manual draining prevents free water ingress into air drying package (no normal level)

769 Temperature -

High1. Malfunction in air compressor package (e.g. loss of interstage or afterstage cooling)

1. Increase in discharge temperature from air compressor package2. Increased duty on downstream air drying package

1. 041-TI/TAH-003/A/B/C/D on discharge of each air compressor package2. 041-AI-0001A/B moisture indication on downstream air drying package3. Dedicated drier package on inlet to nitrogen generation package unit

R769.1 Discuss with vendor requirements for air compressor package temperature indication and alarms (e.g. discharge of interstage cooler)R769.2 Provide AAH on 041-AI-0001A/B to warn operator of water breakthrough to instrument air system

TS 3 3 7

770 Temperature -

Low1. Low ambient temperature 1. Potential for ice formation 1. Minimum design temperature

for location is 4 degrees C

771 Cryogenic (Sub -

Zero)No new issues

772 Level - High 1. Malfunction in upstream

compressor discharge K/O drum level control

1. Potential for carryover of water into wet air vessel 2. Potential for free water ingress into nitrogen generation and air drying packages

1. Wet air vessel with 041-LAH-0001 requires manual operator draining2. Dehydration package within nitrogen generation package

773 Level - Low 1. Normal condition in wet air

vessel

774 Level - No No new issues

775 Phase - More No new issues

776 Phase - Less No new issues

777 Change of State No new issues




HAZOP Item No.

Plant Section







778 Wrong Concentration (Part of)

1. Ingress of flammable gas into air compressor package

1. Potential for explosion in air compressor package

R778.1 Consider requirements for flammable gas detection in vicinity of the air compressor package as located downwind of the LNG process area

TS 2 4 7

779 Corrosive (As

well as)No new issues

780 Explosive No new issues

781 Wrong Material

(Other than)No new issues




HAZOP Item No.

Plant Section







782 Node 2 Compressed air drier package and downstream instrument air receivers

Overview

783 Flow - High See Node 1

Node Equipment 041-U-102 Air drying package041-U-103 Startup compressor and drier041-V-103 Plant air reciever041-V-104 Instrument air receiver (utilities area)041-V-102A Instrument air receiver (LNG train 1)041-V-102B Instrument air receiver (LNG train 2)041-V-102C Instrument air receiver (LNG train 3)041-V-102D Instrument air receiver (LNG train 4)041-V-105 Instrument air receiver (storage area)041-V-106 Instrument air receiver (receiver area)


2252-041-PID-00-31-02/Rev A/23-05-062252-041-PID-00-31-04/Rev A/24-05-062252-041-PID-00-31-05/Rev A/24-05-062252-041-PID-00-31-06/Rev A/24-05-062252-041-PID-00-31-07/Rev A/24-05-06

Design intent The air drying package is provided to reduce the humidity of the instrument air and prevent condensation in downstream pipework and possible instrument damage. Design dew point for the drier is -20 degrees C at normal operating pressure. The air drying package is a desiccant type with non-heated regeneration sequence. Two 100% air drying packages are provided, each with two drying columns which alternate regeneration and absorbtion operating modes (timed sequence). Each of the dedicated downstream instrument air receivers have a capacity of 10 mins hold up.




HAZOP Item No.

Plant Section







784 Flow - Low 1. Operator error in lineup of instrument air receivers

1. Loss of instrument air supply to individual plant area

1. Operating procedures R784.1 Provide DCS pressure indication and low pressure alarm on each individual instrument receiver

TS 4 4 9

2. Sequence failure in air drying package

1. Potential for loss of flow to downstream instrument and plant air systems 2. Potential to overpressure air drier package and wet air vessel

1. Individual air drier package common trouble alarm 041-UUA-0003A/B, drier status 041-XL-0002A/B indication, and step indication 041-XL-0003A/B (local panel)2. Each individual instrument air receiver has 15 mins holdup capacity 3. Individual compressor anti-surge control and discharge PSV prevent overpressure of upstream systems 4. 100% spare air drier package provided, requiring operator action to bring online




HAZOP Item No.

Plant Section







3. Blockage of the plant air drier desiccant packings with corrosion scale

1. Reduced throughput in air dryingpackage2. Potential for decrease in pressure in downstream plant and instrument air systems due to reduced drying capacity

1. Individual air drier package common trouble alarm 041-UUA-0003A/B would be initiated in the event of high differential pressure over the packing2. Each individual instrument air receiver has 15 mins holdup capacity 3. 041-PAL-0006 isolates plant air, 041-PALL-006 isolates wet air feedto nitrogen generation package to protect feed of dried, compressed air to the instrument air headers4. Individual compressor anti-surge control and discharge PSV prevent overpressure of upstream systems 5. 100% spare air drier package provided, requiring operator action to bring online6. Requirement for complete charge of desiccant for individual air drying package to be stored in warehouse

4. Startup of LNG liquifaction plant 1. Reduced requirement for instrument air and nitrogen generation

1. Provision of dedicated startup compressor and drier (2320 Standard m3/hour) 2. Startup compressor is connected to single electrical feeder and emergency power generator to enable commissioning of plant and power generation unit3. Main air compressor package will be commissioned to supply feed required for single train LNG operation

785 Flow - No 1. Local electrical failure 1. Loss of electricity to main air

drying package1. All control sequence valves are pneumatic2. Electrical supply for control panel is connected to emergency power supply




HAZOP Item No.

Plant Section







786 Flow - Reverse 1. Reverse flow of dry air during air drying package regeneration

1. Normal operating condition during regeneration2. Check valves provided in the regeneration pipework to prevent flow of high moisture content air into the downstream instrument air system

787 Loss of

Containment1. Regeneration of air drying package desiccant

1. Use of dried air to regenerate the package desiccant2. Potential for impact on downstream instrument air network pressure

1. Sizing basis for air compressor packages takes into account the regeneration flow rate

2. Corrosion and/or leakage in instrument air network

1. Potential for leakage of instrument air to atmosphere

1. Dry instrument air network (downstream of air drying package 041-U-102) is galvanized steel, minimising potential for scale formation 2. Instrument air receivers are carbon steel and epoxy lined3. Corrosion and leakage flow rate would be small in comparison with capacity of the network4. Each instrument air receiver is provided with manual isolation valve and check valve on the inlet to enable manual isolation and prevent depressurisation in the event of failure of pipework in upstream system

R787.1 See R784.1 for provision of DCS PI and PAL indication on individual instrument air receivers

TS 4 4 9

788 Pressure - High 1. Fire in vicinity of instrument air

receiver1. Potential for overpressure 1. PSV fire protection on each

individual instrument air receiver and upstream plant air receiver

R788.1 Consider and confirm requirements for PSV on each air drying package vessel

TS 3 3 7






HAZOP Item No.

Plant Section







791 Partial Pressure 1. Incorrect sequence timing on air drying package

1. Potential for insufficient regeneration time and/or exceedance of drying capacity within the desiccant, resulting in moisture breakthrough

1. 041-AI-0001A/B on each drying air package2. Manual sample collection points in the discharge of the air drying package 041-U-102 and startup compressor and drier 041-U-103

R791.1 Ensure operating manual highlights moisture breakthrough alarm has no trip and/or sequence action

TS 3 3 7

792 Temperature -

High1. Malfunction in startup air compressor package (e.g. loss of afterstage cooling)

1. Increase in discharge temperature from air compressor package2. Increased duty on downstream startup air drying package

1. 041-TI/TAH-0006 on discharge of the startup air compressor package2. 041-AI/AAH-0002 moisture indication on downstream startup air drying package

793 Temperature -

LowNo new issues


Zero)No new issues

795 Level - High 1. Malfunction of main air drying

package and/or startup drier1. Increase in moisture content of instrument air2. Potential for formation of condensate, corrosion and instrumentation damage downstream

1. 041-AI-0001A/B on discharge of main air drier package2. 0041-AI/AAH-0002 on discharge of startup drier3. Drain valve on plant air receiver and each individual instrument air receiver which could be used to check for liquid formation 4. Dry air pipework is galvanized and air receivers are epoxy lined

796 Level - Low No new issues





HAZOP Item No.

Plant Section







798 Phase - More 1. Entrainment of solids (desiccant) from the main air drying package and/or start up drier

1. Blockage in downstream instrument air fittings

1. Integral filter element will be provided in the air drier packages

R798.1 Consider requirements for dP indication on air drier filter elements in discussion with vendor

TS 3 3 7

2. Free water ingress into startup compressor

1. Potential for damage of positive displacement type compressor (piston type and/or screw type compressor)

1. Location of compressor and drier package under shelter2. Local start of startup air compressor

R798.2 Ensure operating manual requires operator check and draining of free water from the compressor casing before start-up

TS 3 3 7



801 Wrong

Concentration (Part of)

1. Contamination of instrument air with hydrocarbon from the air compressor packages

1. Requirement for vendor supply of oil free instrument air

2. Ingress of flammable gas into startup compressor

1. Potential for explosion 1. Compressor only used during start-up

R801.1 Consider requirement for flammable gas detection on start-up compressor inlet

TS 2 4 7

802 Corrosive (As


803 Explosive

804 Wrong Material

(Other than)1. Provision of jetty instrument air from main plant air system

R804.1 P&ID will be updated to remove instrument air header to jetty given dedicated jetty air compressor

TS 2 2 4


HAZOP Record Sheet: Nitrogen Version: FinalSheet 15/125


HAZOP Item No.

Plant Section


805 Node 1 Nitrogen System

Overview 1. HAZOP of nitrogen generation, nitrogen liquid storage and vapouriser package unit

R805.1 Consider requirement for vendor package HAZOP during detailed design

TS 3 3 7

806 Flow - High 1. Malfunction in downstream

nitrogen user control element 1. Increase in requirement for GAN2. Potential for decrease in nitrogen header pressure

1. 043-PI/PAL-0002 on common gaseous nitrogen header2. 043-FI-0005 on common gaseous nitrogen header3. Independent 043-FI-0006A/B from nitrogen generation unit4. In the event of 043-PAL-002, gaseous nitrogen is produced from the vapourisation of liquid nitrogen to maintain header pressure5. 043-FI-0004A/B gaseous nitrogen flow rate from each vapouriser

2. Maintenance/purging of single LNG train with continued operation on remaining three LNG trains

1. Significant increase in gaseous nitrogen requirement 2. Decrease in nitrogen header pressure

1. Nitrogen storage and vapourising package is designed to enable both vapourisers to operate simultaneously and combine with normal nitrogen generation package GAN to maintain nitrogen header pressure2. 043-PI/PAL-0002 on common gaseous nitrogen header initiates vapourisation of liquid nitrogen to maintain header pressure

R806.1 Operating manual should clearly state requirement to start vapouriser package before using significant volumes of nitrogen for purging and maintainance activitiesto protect nitrogen header pressure and minimise potential for reverse flow of flammable mixtures into the nitrogen header

TS 3 3 7

Design intent See section description

Node Equipment 043-V-101 Nitrogen generation package043-V-102 Nitrogen storage and vapourising package


Nitrogen is generated by cryogenic separation of nitrogen from atmospheric air. The nitrogen generation package has two operating modes (gaseous nitrogen - GAN and gaseous and liquid nitrogen production - GAN & LIN). Liquid nitrogen (sufficient for four days normal consumption or purge in one LNG train) is stored in two 50% vessels, which take approximately four weeks to fill in GAN & LIN operating mode. In the event of a decrease in gaseous nitrogen header pressure, liquid nitrogen is vapourised to supplement gaseous nitrogen production. The liquid nitrogen vapourisers are sized for purge flow rate requirements which is significantly larger than the normal continuous nitrogen consumption.


2252-043-PID-00-31-01/Rev A/23-05-062252-043-PID-00-31-02/Rev A/23-05-06


Section ID Nitrogen system





HAZOP Item No.

Plant Section







3. Requirement for LIN production (storage not full)

1. Potential decrease in GAN production

1. Nitrogen generation package designed to enable continued production of normal consumption GAN and design flowrate LIN concurrently2. LIN production design flow rate enables filling of nitrogen storage within a period of 4 weeks 3. 043-LI/LAH-0001A/B nitrogen storage liquid level feedback to nitrogen generation control panel

R806.2 Operating manual should clearly state requirement for operator to initiate LIN & GAN operating mode R806.3 Consider configuration of trip of LIN production in the event of high level in both downstream liquid nitrogen storage tanks in consultation with vendorR806.4 Consider updates of nitrogen generation plant P&ID to show HS selector for either GAN or GAN & LIN production modes in consultation with vendor

TS 3 3 7

807 Flow - Low 1. Reduction in gaseous nitrogen

requirement, e.g. 1 or 2 LNG trains offline

1. Gradual increase in gaseous nitrogen header pressure2. Potential to overpressure the nitrogen generation package

1. Internal nitrogen generation package control. For single train operation, requirement to vent nitrogen. However, for 2 and 3 train operation, possible to regulatenitrogen generation package at turndown conditions2. 043-PI-002 on gaseous nitrogen header 3. 043-FI-0005 on gaseous nitrogen header

R807.1 Ensure atmospheric vent for nitrogen is at safe location

TS 3 3 7

808 Flow - No 1. Plant shutdown 1. Loss of gaseous nitrogen usage

2. Potential to overpressure the nitrogen generation package

1. Internal nitrogen generation package control will control pressure by release of nitrogen to atmosphere under pressure control2. On total plant shutdown, wet air feed to nitrogen package will be isolated and liquid nitrogen storage isolated for use during startup




HAZOP Item No.

Plant Section







2. High level in liquid nitrogen storage tanks

1. No requirement for LIN production

1. Possible to operate nitrogen generation package in gaseous nitrogen mode only with reduced total nitrogen production

809 Flow - Reverse 1. Malfunction of pressure control

on nitrogen vapourisation package1. Potential for production of nitrogen at higher pressure than feed nitrogen generation package

1. Internal vapouriser package pressure control to ensure production of GAN at same pressure as nitrogen generation package

810 Loss of

Containment1. Valve and/or equipment failure 1. Potential for release of nitrogen

to atmosphere with the production of nitrogen rich atmosphere

1. Equipment design

811 Pressure - High 1. Thermal expansion and

vapourisation of liquid nitrogen in isolated pipework

1. Overpressure of pipework and equipment

1. Equipment design and/or pressure relief

2. Fire in vicinity of liquid nitrogen package units

1. Potential for overpressure of pipework and equipment

1. Equipment design and/or pressure relief

812 Pressure - Low 1. Upstream air compressor trip

and/or isolation of nitrogen generation package due to Low Low instrument air pressure

1. Loss of wet air feed to nitrogen generation package and production of GAN

1. 043-PI/PAL-002 on GAN header initiates vapourisation of stored liquid nitrogen to maintain header pressure 2. 041-PALL-006 from upstream instrument air system initiates trip of nitrogen generation package but enables continued operation and vapourisation of liquid nitrogen3. Liquid nitrogen storage for 4 days normal consumption or purge in one LNG train





HAZOP Item No.

Plant Section







814 Partial Pressure 1. Upset in nitrogen generation package

1. Increase in oxygen concentration in nitrogen produced2. Potential for ingress of oxygen into downstream systems containing flammable fluids

1. 043-AI-0005 oxygen analyser on GAN distribution header2. 043-AI-0001A/B oxygen analyser on nitrogen generation control panel

R814.1 Investigate whether additional requirement for oxygen analyser on liquid nitrogen production to prevent contamination of liquid nitrogen storage

TS 3 3 7

1. Upset in nitrogen generation package dehydration

1. Potential for ice formation in nitrogen generation package and liquid nitrogen systems

1. 043-AI-0004A/B moisture analyser on nitrogen generation package

815 Temperature -

HighNo issues identified

816 Temperature - Low

1. Production of cryogenic liquid nitrogen

1. Potential for exceedence of material design specifications and brittle fracture

1. All liquid nitrogen pipework is stainless steel and designed for low temperature service

1. Malfunction in liquid nitrogen vapouriser

1. Liquid ingress into nitrogen header2. Potential to exceed material specification of gaseous nitrogen pipework leaving nitrogen vapourisers3. Potential for pipework brittle fracture

R816.1 Discuss during vendor package HAZOP protections against exceedance of vapouriser gaseous discharge pipework specification

TS 3 3 7


Zero)1. Normal condition for nitrogen generation, liquid storage and vapourisers

818 Level - High 1. Flow of liquid nitrogen to liquid

nitrogen storage tanks1. Potential to liquid fill storage tanks2. Potential to overpressure liquid nitrogen storage tanks

1. 043-LI/LAH0001A/B on liquid nitrogen storage tanks

R818.1 Discuss during vendor package HAZOP protections against overfilling and overpressurising storage R818.2 See Recommendation R806.3 for configuration of trip of LIN production in the event of high level in both downstream liquid nitrogen storage tanks

TS 3 3 7




HAZOP Item No.

Plant Section







819 Level - Low 1. Periodic requirement for vapourisation of liquid nitrogen to maintain GAN header pressure

1. Gradual decrease in level of liquid nitrogen in the storage tanks2. Potential for insufficient liquid nitrogen availability for one LNG train purge (largest requirement)

1. During normal GAN production mode, the nitrogen generation package produces greater than 100% normal nitrogen consumption requirement2. Requirement for operator to manually switch nitrogen generation package from GAN to GAN & LIN operation mode. This isnormally manual to prevent continual upset to air separation column reflux and operation3. 043-LI/LAL-001A/B on liquid nitrogen storage

R819.1 Consider configuration of LAL at higher level in the tank (e.g. 60-80% full) if no requirement to have LAL at low level in the tank, e.g. for protection of pump and/or gas breakthrough from storage

TS 3 3 7





824 Wrong


1. Upset in the nitrogen generation package

1. Increase in carbon dioxide concentration in nitrogen product2. Potential for formation of solid carbon dioxide in liquid nitrogen system

1. 043-AI/AAH-0002A/B carbon dioxide analyser

825 Corrosive (As



827 Wrong Material



HAZOP Record Sheet: Raw and Service Water Version: FinalSheet: 20/125


HAZOP Item No.

Plant Section


828 Node 1 Well Water Pumps and Raw Water Filtration

Overview HAZOP of Backwash Filter Control System and Configuration

R828.1 Consider HAZOP of vendor package during detailed design

LALL actions in these units are configured as DCS stop/inhibit actions, not hardwired ESD trip actions as no immediate safety impact. No SIL rating of 051-LALL-005A/B or 051-LALL-0013 required by project

TS 3 3 7

Maintenance on Water Tanks R828.2 Review all utility water storage tanks and provide maintenance blinds and/or spacers to enable isolation of tanks for maintenance

TS 2 2 4

Design intent Raw water is extracted from a brackish well (1600ppm salts) via the well water unit 003, pumped through inlet filtration equipment and stored in two filter and firewater storage tanks (15300 m3 individual storage tank; 4500 m3 required in each tank for firewater based upon two hours largest fire scenario, 10800 m3 in each tank for 2.5 days normal consumption of filtered water). During normal operation, two well pumps are used to maintain level in the filtered and firewater storage tanks and five filters operate in parallel, with the sixth filter in backwash operating mode, or in standby.

Node Equipment Well water pumps 003-P-101A-CRaw water filtration package 051-U-101Filtered and firewater storage tank 051-T-101A/B


Raw water is extracted from a brackish well (1600ppm salts) via the well water unit 003, pumped through inlet filtration equipment and stored in two filter and firewater storage tanks (15300 m3 individual storage tank; 4500 m3 required in each tank for firewater based upon two hours largest fire scenario, 10800 m3 in each tank for 2.5 days normal consumption of filtered water). The filtered water is also sterilised using chlorine to prevent growth of algae and other microbes within the storage tankage. The brackish filtered water is then treated in a reverse osmosis unit to produce desalinated water which is then stored in additional separate tankage (2400 m3 sized for 1 day demin water production) for use in production of demin water, and is sent directly for production and storage of potable water


2252-003-PID-00-31-01/Rev A/23-05-062252-051-PID-00-31-01/Rev A/23-05-062252-051-PID-00-31-02/Rev A/24-05-062252-051-PID-00-31-03/Rev A/24-05-06

HAZOP Date 12/09/2006 - 13/09/2006

Section ID Raw water production and treatment





HAZOP Item No.

Plant Section




HAZOP Date 12/09/2006 - 13/09/2006



829 Flow - High 1. High demand for filter water, e.g. requirement for fire water in LNG plant

1. Gradual decrease in level in filtered fire water storage tank

1. 051-LAH-0004A starts two well pumps2. 051-LI/LAL-0004A on filtered storage water tank3. 051-LALL-0005A/B inhibits both the backwash of the raw water filtration package and the use of filtered water for service and demineralised water production (only firewater usage is permitted)4. 051-LALL-0005A/B on filtered and firewater storage tank stops non firewater user pumps (service water, reverse osmosis & backwash pumps) to prevent pump cavitation5. Firewater inventory in the filtered and firewater storage tank is protected by elevated non-firewater water nozzles on tank6. 051-LI/LAL-0006A/B starts third standby well pump to increase filling rate to maximum flow rate7. 051-LALL-0007A/B trips firewater pumps to prevent cavitation (in next revision, LALL-0007A/B will only be alarm with no trip action)

R829.1 Update P&ID to show correct relative location of 051-LALL-0005A/B vs non firewater nozzles

TS 2 2 4

2. Malfunction/incorrect set point 051-LI-0006A/B

1. Loss of stop signal for well water pumps2. Continued operation of three well water pumps 3. High dP over raw water filtration package and high filling rate for filtered and fire water storage tanks4. Potential to overfill and damage filtered and firewater storage tanks

1. 051-LI/LAHH-0004A/B stops all operating well water pumps to prevent overfilling2. Filtered and fire water storage tanks have 12" overflow 3. 051-PDAH-0001 on filter package may anunciate in the event of operation of three well water pumps with five filters online

R829.2 Consider whether DCS panel alarms 051-LAH-0006A/B and 051-LAH-0004A/B are required as these will be nuisance alarms during normal operating conditions and tank levelsR829.3 During detailed design, following selection of well water pump type and filter capacity, consider requirement for minimum flow protection on well pumps

TS 3 3 7




HAZOP Item No.

Plant Section




HAZOP Date 12/09/2006 - 13/09/2006



830 Flow - Low 1. Reduction in requirement for service water and/or demin water, e.g. two train operation only

1. Reduced flow rate from filtered/fire water storage tank2. Reduced duty for well water pumps and/or reduced filling time for filtered and firewater storage tanks3. Increased frequency and duration of no well pumps operating

1. 051-LI/LAH0004A/B starts two well pumps to maintain operating level in filtered and firewater storage tanks 2. 051-LI/LAHH-0004A/B stops all operating well water pumps to prevent overfilling3. Filtered and fire water storage tanks have 12" overflow

R830.1 Consider during detailed design whether permissive of well water pump operating is required to commence the backwash cleaning sequence

TS 4 2 7

2. Malfunction/incorrect setpoint in 051-LI-0004A/B

1. Loss of start signal for two well pumps2. Continued decrease in level in filtered and firewater storage tanks with loss of firewater hold up volume3. 051-LALL-0005A/B inhibits filter backwash and stops service and reverse osmosis water pumps4. Loss of both filling and emptying of the filtered and firewater storage pumps5. Potential for over-chlorination of raw water from raw water sterilisation package 051-U-102

1. 051-LALL-0005A/B on filter and firewater storage tanks inhibits filter backwash and stops service and reverse osmosis water pumps2. 051-LIC/LAL-0011 on downstream desalinated water storage tank3. 053-LI/LAL-0001 on downstream potable water storage tank

R830.2 Provision of pressure indication on suction of raw water filtration package, requested by client as permissive for on/off control of raw water sterilisation package

TS 2 2 4

3. Malfunction/incorrect setpoint in 051-LI-0006A/B

1. Loss of start signal to well water pumps during initial commissioning activities2. Increased duration to fill filtered and firewater storage tanks

1. Malfunction of 051-LI-0006A/B has no major impact on the operation of filtered and firewater storage tanks during normal operation




HAZOP Item No.

Plant Section




HAZOP Date 12/09/2006 - 13/09/2006



4. Trip of a well water pump, e.g. local power loss and/or mechanical failure

1. Reduction in flow rate of filtered water to the filtered and firewater storage tanks2. Gradual reduction in level in filtered and firewater storage tanks3. Potential for reduction in level and usage of firewater for normal operating systems

1. Auto-start of standby well pump on low discharge pressure2. 051-LI/LAL-0004A/B on filtered and firewater storage tanks3. 051-LALL-0005A/B on filtered and firewater storage tank stops non firewater user pumps (service water, reverse osmosis & backwash pumps) to prevent pump cavitation4. Firewater inventory in the filtered and firewater storage tank is protected by elevated non-firewater water nozzles on tank5. Filtered and firewater storage tanks combined capacity provides five days normal operation holdup volume

831 Flow - No 1. Failure in filter backwash

sequence and/or backwash sequence valve

1. Loss of backwash cleaning of single filter2. Potential for blockage of single filtration package filter3. Potential impact on normal operating flow rate to filtered and firewater storage tanks

1. 051-PDAH-0001 common alarm on raw water filter package2. 051-UUA-0001 common trouble alarm on raw water filtration package3. Six filters in parallel with one filter in backwash during normal operation4. 051-LI/LAL-0004A/B on filtered and firewater storage tanks

2. Operator error - closing manual isolation valve on filtered water and firewater storage tank

1. Potential for loss of flow of filtered water to tank and/or supply to other service requirements2. Potential for loss of backwash feed to filter package

1. Normal operating procedures R831.1 Consider LO and/or CSO of the firewater supply line and minimum flow return on the filtered and firewater storage tank to prevent closure in error by operator

TS 1 4 4




HAZOP Item No.

Plant Section




HAZOP Date 12/09/2006 - 13/09/2006



3. Maintenance on filter and firewater storage tank

1. Potential for impact on normal process operations

1. Each filter and firewater tank capacity is sized to provide 100% of firewater storage inventory 2. Each tank capacity is sized to provide 50% of filtered water holdup inventory for downstream users (2.5 days) 3. All tank inlet and discharge pipework is designed to enable normal 100% flow rate of filtered water and would therefore enable continued operation of process during maintenance on single storage tank

832 Flow - Reverse 1. Total loss of well water pump

power supply 1. Potential for reverse flow through raw water filtration package to wells via syphon and/orhydrostatic head

1. Check valve on discharge of each individual well water pump

R832.1 Consider during detailed design, provision of syphon breaker on top entry to filtered and firewater storage tanks to prevent reverse flow and/or additional check valve on tank inlet in the event of bottom filling

TS 5 2 8

833 Loss of

Containment1. Corrosion of carbon steel pipework and filtered and firewater storage tanks with brackish well water

1. Potential for leakage of raw water to atmosphere

1. Filtered and firewater tankage is completely internally epoxy lined2. Carbon steel pipework with 3mm corrosion allowance3. Carbon steel filters with 5mm corrosion allowance 4. Firewater underground main is GRP

R833.1 Detailed design to considerrequirement for external protection of water tanks floors via CP or coatingR833.2 Review of raw water, filtered water and service water pipework will be completed during detailed design following conformation of well water composition (salt and solids content)

TS 4 3 8




HAZOP Item No.

Plant Section




HAZOP Date 12/09/2006 - 13/09/2006



834 Pressure - High 1. Blockage of filtered water inlet pipework to the storage tank

1. Deadhead well water pumps2. Potential for damage to well water pumps 3. Potential for overpressure of filtered water pipework and filters

1. Complete blockage of six filter packages not considered credible, as normal inlet and outlet sequence valves are FO2. Well water pumps, discharge pipework and filters have the same design pressure 3. Operating procedures

R834.1 Review requirement for pressure relief provision on filters in revised design (not yet issued) to prevent overpressure of filters and tank inlet pipework as well water pump discharge presure rating increased to class 600, but filters and downstream pipework remain class 150

TS 3 3 7

2. Thermal expansion of blocked water pipework section and/or fire in vicinity of filtration package

1. Potential for overpressure of pipework and/or filters

1. Filters located in area with no fire potential, therefore no fire protection PSV provided

R834.2 Review requirement for thermal relief on raw water pipework from well during detailed design

TS 3 3 7

3. Filling of filtered and firewater storage tank with three well water pumps operating, e.g. during initial filling of tanks

1. Potential for overpressure of atmospheric tank

1. 4 inch vent on each filtered and firewater atmospheric storage tanks sufficient2. 12 inch overflow protection on tank

835 Pressure - Low 1. Operation of two firewater

pumps and normal flow of service water from single tank, i.e. one tank out for maintenance activities

1. Potential for decrease in filtered and firewater storage tank vapour space pressure2. Potential for filtered and firewater storage tank collapse

1. 4 inch vent on each filtered and firewater atmospheric storage tanks 2. 12 inch overflow protection on tank

R835.1 Review sizing basis for the vent on filtered and firewater storage tanks to ensure sufficient for combined maximum flow rate out of tank

TS 2 4 7


837 Partial Pressure No new issues

838 Temperature -

HighNo new issues

839 Temperature -

Low1. Low ambient temperatures 1. Minimum design temperature

for location is 4 degrees C


Zero)No new issues

841 Level - High No new issues




HAZOP Item No.

Plant Section




HAZOP Date 12/09/2006 - 13/09/2006



842 Level - Low 1. Reduction in water level in site aquifer

1. Potential for loss of well water for LNG liquifaction terminal and/or damage of water water pumps

1. 0003-LT-0001 stops well water pumps to prevent pump cavitation2. Five days holdup volume in filtered and firewater storage tanks

R842.1 In new revision of P&ID (not issued) assumption that three independent wells will be used for provision of well water for site with individual low low level trip of single well water pump

TS 2 2 4


844 Phase - More 1. High solids concentration in well

water1. High solids loading in the raw water filtration package2. Potential for blockage of filters3. Potential for loss of feed to filtered and firewater storage tanks and/or filter overpressure

1. Five days storage of filtered water in filtered and firewater storage tanks 2. 051-PDAH-0001 common alarm on filter package3. High dP over single filter initiates backwash sequence 4. Six filters provided, in normal operation five online with sixth filter in backwash

R844.1 Consider during detailed design and reciept of raw water composition implications on proposed filtration package configuration and design

TS 3 3 7

2. High solids concentration in the filter backwash water

1. Potential contamination of non contaminated water sewer system and off-site receiving waters with high solids content water

R844.2 Consider during detailed design and reciept of raw water composition implications on anticipated solids production from the backwash filters and discharge to off-site receiving waters

TS 3 3 7

3. Contamination of well water with hydrocarbon

1. Contamination of downstream potable water, demin water etc.

1. Raw water will be obtained from deep water wells with no potential for hydrocarbon contamination2. Biocide dosing of the raw water on the inlet to the filtration package prevents algal/bacteria growth in the filtered and firewater storage tank.






HAZOP Item No.

Plant Section




HAZOP Date 12/09/2006 - 13/09/2006




1. Increase in dissolved salts concentration in well water, i.e. highly brackish water

1. Potential for accelerated corrosion of carbon steel materials 2. Increased load on reverse osmosis desalination package

R847.1 See Recommendation R833.2 for review of materials following reciept of well water composition during detailed designR847.2 Review reverse osmosis package design for removal of dissolved solids during detailed design following reciept of well water composition R847.3 Consider during detailed design and reciept of raw water composition implications on salt concentration of concentrate discharged to off-site receiving waters (more significant issue if creek is freshwater rather than brackish or saline)

TS 3 3 7

848 Corrosive (As



850 Wrong Material





HAZOP Item No.

Plant Section




HAZOP Date 12/09/2006 - 13/09/2006



851 Node 2 Raw water sterilisation package

Overview HAZOP of raw water sterilisation package


TS 3 3 7

852 Flow - High 1. Malfunction/incorrect setpoint of

051-AIC-001 chlorine analyser on inlet to storage filter tank

1. Increased usage of sodium hypochlorite solution2. Decrease in level in sodium hypochlorite storage vessel3. Potential upset in downstream reverse osmosis package unit

1. Independent 051-LAL-0001 on sterilisation package2. Independent calibration pot provided on raw water sterilisation package for calibration of metering pumps3. SCXX on filtered and firewater storage tanks to enable manual sample of filtered water chlorine concentration 4. Bisulphide injection on downstream reverse osmosis package for removal of residual chlorine

853 Flow - Low 1. Malfunction/incorrect setpoint of

051-AIC-001 chlorine analyser on inlet to storage filter tank

1. Decreased usage of sodium hypochlorite solution2. Potential for algal and bacterial growth in filtered and firewater storage tanks3. Potential for impact on downstream water systems

1. Independent calibration pot provided on raw water sterilisation package for calibration of metering pumps2. SCXX on filtered and firewater storage tanks to enable manual sample of filtered water chlorine concentration 3. Periodic operator inspection of raw water sterilisation package sodium hypochlorite level

R853.1 Consider provision raw water sterilisation package sodium hypochlorite storage DCS level indication

TS 2 2 4

Node Equipment Raw water sterilisation package 051-U-102


2252-051-PID-00-31-01/Rev A/23-05-062252-051-PID-00-31-02/Rev A/24-05-06

Design intent Raw water from well borehole is sterilised by the injection of sodium hypochlorite (14% free chlorine) into the inlet to the raw water filtration package




HAZOP Item No.

Plant Section




HAZOP Date 12/09/2006 - 13/09/2006



854 Flow - No 1. Metering pump trip 1. Loss of sodium hypochlorite injection2. Potential for algal and bacterial growth in filtered and firewater storage tanks3. Potential for impact on downstream water systems

1. Pump status indication from raw water sterilisation package 2. Provision of spare metering pump (no autostart provision)3. SCXX on filtered and firewater storage tanks to enable manual sample of filtered water chlorine concentration 4. Periodic operator inspection of raw water sterilisation package sodium hypochlorite level

855 Flow - Reverse 1. Pump trip 1. Potential for reverse flow of raw

water into sodium hypochlorite storage

1. Integral check valve in metering pump

R855.1 Next revision of P&IDs will show manual isolation valve at chemical injection tie-in. Consider requirement for check valve given increase in well water pump discharge pressure

TS 2 2 4

856 Loss of

Containment1. Small bore pipework failure and/or metering pump piston seal failure

1. Potential for spray release of sodium hypochlorite to atmosphere2. Potential for operator hazard and chemical burns

1. Operator PPE for use when handling chemicals2. Raw water sterilisation package equipment will be contained within a small kerbed area

2. Filling and handling of sodium hypochlorite injection chemical

1. Potential for operator hazard and chemical burns

1. Operator PPE for use when handling chemicals

R856.1 Undertake HAZOP of injection package during detailed design. At present, preference is to use iso tank as means of storage of sodium hypochlorite chemical, removing requirements for additional vessel and/or handling requirements

TS 3 3 7

857 Pressure - High 1. Operator error isolating

discharge on metering pump1. Potential to overpressure pipework

1. Integral PSV protection within metering pump






HAZOP Item No.

Plant Section




HAZOP Date 12/09/2006 - 13/09/2006




861 Temperature -

High1. Thermal radiation on sodium hypochlorite storage

1. Potential for increased decomposition of sodium hypochlorite producing free chlorine

R861.1 Recommend provision of shelter for raw water sterilisation package (shade, not enclosed building)

TS 4 2 7

862 Temperature -

LowNo new issues


Zero)No new issues


865 Level - Low 1. Injection of sodium hypochlorite

solution1. Gradual decrease in level in sodium hypochlorite tank

1. 051-LAL-0001 sodium hypochlorite storage vessel level alarm





870 Wrong


No new issues

871 Corrosive (As



873 Wrong Material





HAZOP Item No.

Plant Section




HAZOP Date 12/09/2006 - 13/09/2006



874 Node 3 Reverse osmosis package and desalinated water storage tank

Overview HAZOP of reverse osmosis package


TS 3 3 7

875 Flow - High 1. High usage of desalinated water

for production of demineralised water in downstream demineralised water package

1. Gradual decrease in level in the desalinated water storage tank

1. 051-LIC/LAL-0011 starts reverseosmosis package pumps 2. Reverse osmosis package desalinated water production flow rate is 100m3/hr whilst normal flow rate of desalinated water to demineralised water unit is 80m3/hr3. 051-FIC-0002 flow rate of desalinated water to demineralisation water unit4. 051-LAH-0011 closes inlet on/offvalve to desalinated water storage tank

Design intent Filtered water from the filtered and fire water storage tank is desalinated using a reverse osmosis package to produce desalinated water for feed to the demineralisation unit 054 and potable water unit 053. The reverse osmosis package has a design flow rate of 100m3/hr production of permeate and operates in on/off mode based on the level in the downstream desalinated water storage tank and potable water storage tank. The concentrated effluent from the reverse osmosis package (high in dissolved salts) is disposed in the non-contaminated water sewer.

Node Equipment Filtered and firewater storage tank 051-T-101A/BReverse osmosis package 051-U-103Desalinated water storage tank 051-T-102Potable water storage tank 053-T-120


2252-051-PID-00-31-02/24-05-062252-051-PID-00-31-03/24-05-062252-051-PID-00-31-04/23-05-062252-051-PID-00-31-05/24-05-062252-053-PID-00-31-02/24-05-06




HAZOP Item No.

Plant Section




HAZOP Date 12/09/2006 - 13/09/2006



2. Increased usage of potable water on site, e.g. maintenance or shutdown duration

1. Gradual decrease in level in the potable water storage tank

1. 053-LIC/LAL-0001 starts reverseosmosis package pumps2. Reverse osmosis package desalinated water production flow rate is 100m3/hr whilst average flow rate of desalinated water to potable water unit is 15m3/hr3. 053-FAH-0003 flow rate of potable water to distribution4. 053-LAH-0001 closes inlet on/offvalve to potable water storage tank

3. Combined filling of desalinated water storage tank and potable water storage tank (both on/off level control)

1. Reduced filling rate to both potable water and desalinated water storage tanks. Net available capacity in reverse osmosis package is 5 m3/hr given average potable water consumption of 15 m3/hr and desalinated water consumption of 80 m3/hr

R875.1 Review proposed on/off level set points in desalinated water and potable water storage tanks to ensure it is possible to refill tanks, taking into account with single and combined filling rates

TS 3 3 7

876 Flow - Low 1. Low water usage in either

demineralisation package and/or potable water network

1. Reduced usage of water 2. Potential for duration when no filling of either desalinated water storage tank or potable water storage tank, as both have on/off control3. Deadhead of reverse osmosis package pumps4. Potential for damage to reverse

1. 051-PIC/PAH-0002 on discharge of reverse osmosis package stops reverse osmosis package pumps

877 Flow - No 1. Reverse osmosis package

pump trip1. Loss of flow of filtered water through the reverse osmosis package

1. 051-XL-0003 reverse osmsis package pump run status indication2. 051-UUA-0005 common trouble alarm3. Standby reverse osmosis pump (no autostart)4. Desalinated water storage tank has capacity of 1 day normal operation 5. Potable water storage tank has 4 days normal average consumption capacity




HAZOP Item No.

Plant Section




HAZOP Date 12/09/2006 - 13/09/2006



2. Low level in upstream filtered and firewater storage tank

1. Potential for loss of firewater storage inventory in upstream filtered and firewater storage tank2. Potential for loss of production of desalinated water to refill desalinated water tank and/or potable water storage tank

1. 051-LALL-0005A/B on filtered and firewater storage tank stops non firewater user pumps (service water, reverse osmosis & backwash pumps) to prevent pump cavitation2. Firewater inventory in the filtered and firewater storage tank is protected by elevated non-firewater water nozzles on tank3. Sufficient capacity in desalinatedwater storage tank and downstream demineralised water storage tank to enable continued normal process production condition4. Potable water storage tank has sufficient capacity for four days operation

878 Flow - Reverse 1. Combined filling of desalinated

water and potable water storage tanks

1. Potential for level equalisation between desalinated water potable water storage tanks during filling and/or in the event of pump trip

1. Anticipated that both tanks will be top filling with syphon breaker to prevent reverse flow between desalinated water and potable water storage tanks

R878.1 Consider requirement for tank inlet check valve in the event bottom filling

TS 2 2 4

879 Loss of

Containment1. Pump seal failure on reverse osmosis package pump

1. Spray release of water to atmosphere

1. Periodic operator inspection of the area2. In the event of major pump seal failure, 051-FI-0001 on permeate flow rate3. Desalinated water storage tank has capacity of 1 day normal operation 4. Potable water storage tank has 4 days normal average consumption capacity

2. Failure of reverse osmosis membrane

1. Release of desalinated water into waste concentrate stream 2. Reduced production of desalinated water

1. 051-FI-0001 on permeate flow rate2. 051-AI/AAH-0002 output conductivity analyser on reverse osmosis package

3. Corrosion and leakage from desalinated water storage tank

1. Release of desalinated water to atmosphere

1. Desalinated water tank is stainless steel




HAZOP Item No.

Plant Section




HAZOP Date 12/09/2006 - 13/09/2006



4. Corrosion and leakage from potable water storage tank

1. Release of desalinated water to atmosphere

1. Potable water tank is carbon steel with epoxy lining on all internal surfaces

880 Pressure - High 1. Filling of desalinated water

and/or potable water storage tanks1. Potential for increase in vapour space pressure

1. Two inch vent on vapour space for tank 2. Tanks have overflow protection

881 Pressure - Low 1. Emptying of desalinated water

and/or potable water storage tanks with no inlet flow (on/off filling)

1. Potential for decrease in vapour space pressure

1. Two inch vent on vapour space for tank



884 Temperature -

HighNo new issues

885 Temperature -

LowNo new issues


Zero)No new issues

887 Level - High 1. Malfunction of 051-LIC-0011 on

desalinated water tank 1. Loss of stop signal closing inlet isolation on/off valve2. Potential to liquid fill and over-pressure storage tank

1. 8 inch overflow on desalinated water storage tank

1. Malfunction of 053-LIC-0001 on potable water tank

1. Loss of stop signal closing inlet isolation on/off valve2. Potential to liquid fill and over-pressure storage tank

1. 8 inch overflow on potable water storage tank

888 Level - Low 1. Malfunction of 051-LIC-0011 on

desalinated water tank 1. Loss of start signal for opening inlet isolation on/off valve and starting reverse osmosis package pumps2. Gradual decrease in level in tank3. Potential to loose liquid level and cavitate desalinated water pumps

1. Independent LALL-0013 stops desalinated water pumps2. 054-LI/LAL-0004 on downstream demineralised water storage tank

1. Possible to operate both reverse osmosis package pumps in emergency to refill desalinated water storage tank




HAZOP Item No.

Plant Section




HAZOP Date 12/09/2006 - 13/09/2006



2. Malfunction of 053-LIC-0001 on potable water tank

1. Loss of start signal for opening inlet isolation on/off valve and starting reverse osmosis package pumps2. Gradual decrease in level in tank3. Potential to loose liquid level and cavitate potable water pumps

1. Independent LALL-0003 stops potable water pumps2. 053-PI/PAL-0004 on potable water distribution header


890 Phase - More 1. Carryover of solids from

upstream raw water filtration package

1. Potential for blockage of reverse osmosis membrane

1. Filter on inlet of reverse osmosis package

R890.1 Consider requirements for DCS dP indication and PDAH on the reverse osmosis package inlet filters

TS 3 3 7



893 Wrong


1. Incorrect addition of reverse osmosis package chemicals (anti-scale, sulphuric acid, bisulphite)

1. Reduced performance of reverse osmosis package2. Potential contamination of desalinated water

1. 051-AI/AAH-0002 outlet conductivity2. 051-LAL-008/9/10 chemical buffer storage in the event of high addition flowrates

894 Corrosive (As

well as)1. Corrosion of CS pipework by desalinated water

Potential leakage and release of treated water

1. Discharge pipework from reverse osmosis package and desalinated water network pipework is stainless steel 2. Downstream of the Potable water sanitisation package the potable water system is galvanised CS

No new issues


896 Wrong Material





HAZOP Item No.

Plant Section




HAZOP Date 12/09/2006 - 13/09/2006



897 Node 4 Service water system

Overview

898 Flow - High 1. Maintainance in process area

(e.g. shutdown of one LNG train)1. Increased requirement for service water for cleaning activities2. Gradual decrease in service water header pressure3. Gradual decrease in jetty firewater main pressure4. Gradual decrease in level in filtered and firewater storage tank

1. 052-FIC/FAH-0001 will close minimum flow protection of service water pump 2. 052-PIC/PAL will start standby service water pump to maintain service water header pressure and suction pressure to service water booster pump for jetty3. 051-LI/LAL-0004A/B on filtered and firewater storage tank4. 051-LALL-0005A/B on filtered and firewater storage tank stops non firewater user pumps (service water, reverse osmosis & backwash pumps) to prevent pump cavitation5. Firewater inventory in the filtered and firewater storage tank is protected by elevated non-firewater water nozzles on tank

Node Equipment Filtered and firewater storage tank 051-T-101A/BService water pumps 052-P-130A/BService water booster pumps 052-P-131A/B


2252-051-PID-00-31-02/24-05-062252-051-PID-00-31-03/24-05-062252-052-PID-00-31-01/23-05-06

Design intent Filtered water from filtered and firewater storage tank is used as service utility water. In the process area, this will be used for cleaning and other maintainance activities and design basis is average flow of 80 m3/hr with potential to increase to 160 m3/hr with both pumps operating depending upon demandService water is also used to maintain the jetty firewater ring main pressurised and other cleaning activities at jetty (design basis 20m3/hr).




HAZOP Item No.

Plant Section




HAZOP Date 12/09/2006 - 13/09/2006



2. Maintainance in jetty area 1. Increased use of service water at jetty 2. Potential for decrease in pressure in jetty supply pipeline3. Potential for decrease in firewater main pressure at jetty

1. Design basis for service water supply to jetty is to maintain jetty firewater ring main pressurised and supply water for up to two hoses for maintenance activties2. 031-PIC-0006 initiates jetty firewater pump start in the event of low jetty firewater ring main pressure

3. Malfunction/incorrect setpoint 052-FIC-0001 minimum flow protection

1. Minimum flow protection on service water pumps will open 2. Reduced flow rate of service water to service water header, with potential for decrease in service water pressure depending on demand

1. 052-PIC/PAL-0001 starts standby service water pump in the event of high demand and low header pressure 2. Service water pump running light indication in DCS3. 031-PIC-0006 initiates jetty firewater pump start in the event of low jetty firewater ring main pressure

899 Flow - Low 1. Low demand for service water in

process area and/or jetty1. Gradual pressurisation of service water header2. Potential to dead-head the service water pumps3. Potential for damage to service water pumps if operated below minimum flow for prolonged period

1. 052-FIC/FAL-0001 minimum flow protection for service water pumps2. 052-RO-0002 minimum flow protection for service water booster pumps (for jetty service)3. 052-FI/FAL-0003 flow to jetty area

900 Flow - No 1. Service water pump trip 1. Gradual decrease in pressure in

service water header2. Potential cavitation of service water booster pump3. Potential for reduction in jetty firewater ring main

1. 052-PIC/PAL-0001 autostart of standby service water pump to maintain service water header pressure2. Check valve at tie in of service water header to the jetty firewatre ring main




HAZOP Item No.

Plant Section




HAZOP Date 12/09/2006 - 13/09/2006



2. Service water booster pump trip 1. Potential for gradual reduction in jetty firewater ring main pressure, depending on service water usage at jetty2. Autostart of standby jetty firewater pumps 3. Ingress of seawater into firewater ring main

1. Autostart of stand-by service water booster pump 2. Check valve at tie-in of service water to jetty firewater ring main 3. 031-PIC-0006 autostart of jetty firewater pumps

R900.1 Consider provision of LO manual isolation valve at tie-in to jetty firewater ring main to enable maintainance of check valve and interconnecting header (from booster pump to jetty) as approximately 9 km long without compromising firewater provision at jetty

TS 2 2 4

3. Low low level in upstream filtered and firewater storage tank

1. Stop of service water pumps 052-P-130A/B and service water booster pumps 052-P-131A/B upon 051-LALL-0005A/B in upstream tank to prevent cavitation of pumps2. Loss of jockey pump for jetty firewater ring main and potential depressurisation

1. Check valve at tie-in of service water to jetty firewater ring main 2. 031-PIC-0006 autostart of jetty firewater pumps3. Filtered and firewater storage tanks have significant inventory of filtered water as use as service water, demineralised water production and potable water usage (5 days holdup capacity total filtered water for services)4. Firewater inventory is protected as elevated service water suction nozzle in filtered and firewater tank

1. Acceptance by client and project team for potential loss of service water supply to maintain jetty firewater ring main pressure. Jetty firewater ring main supply is not compromised as low pressure in jetty firewater header will automatically start jetty firewater pumps

901 Flow - Reverse No new issues

902 Loss of

Containment1. Service water pump seal failure 1. Spray release of filtered water to

atmosphere2. Potential for reduction in pressure in service water header

1. Operator inspection of area2. Spare service water pump with autostart on low discharge service water header pressure

2. Service water booster pump seal failure

1. Spray release of filtered water to atmosphere2. Potential for reduction in pressure in service water header to jetty

1. Operator inspection of area2. Spare service water booster pump with autostart on low discharge service water header pressure3. Autostart of jetty firewater pumps if jetty firewater ring main pressure drops




HAZOP Item No.

Plant Section




HAZOP Date 12/09/2006 - 13/09/2006



3. Corrosion of carbon steel pipework due to filtered water salt concentration

1. Potential for spray release of service water to atmosphere

R902.1 See R833.2 for review of filtered water specification during detailed design upon confirmation of well water composition

TS 3 3 7

4. Corrosion of service water header on trestle to jetty

1. Potential for spray release of service water to atmosphere2. Potential for decrease in firewater ring main pressure in event of significant release

1. Service water pipework on trestle will be painted and/or provided with alternative anti-corrosion protection

5. Corrosion of jetty firewater ring main due to residual salt concentration following use of firewater pumps

1. Jetty facilities for replacement of jetty firewater ring main with filtered water following use of firewatre pumps

903 Pressure - High 1. Malfunction of 052-PIC-0001 on

service water pump discharge and/or pressure transmitters on service water booster pump discharge

1. Autostart of standby pump 1. Minimum flow protection on both service water and booster pump discharge (sized for single pump) 2. 052-FIC/FAL-0001 on service water to process area3. 052-FIC/FAL-0003 on service water to jetty4. Pump running light indication on DCS




907 Temperature -

High1. Thermal expansion of service water in header to jetty

1. Potential overpressure of pipework

1. 052-RO-0002 open to filtered and firewater storage tank

908 Temperature -

LowNo new issues


Zero)No new issues




HAZOP Item No.

Plant Section




HAZOP Date 12/09/2006 - 13/09/2006









916 Wrong


No new issues

917 Corrosive (As



919 Wrong Material



HAZOP Record Sheet: Potable Water Version: FinalSheet 41/125


HAZOP Item No.

Plant Section


920 Node 1 Production and storage of Potable Water

Overview 1. HAZOP of vendor packages for potable water system

R920.1 Undertake HAZOP of potable water vendor packages during detailed design

TS 3 3 7

921 Flow - High 1. Requirement to refill potable

water storage tank (on/off control)1. Flow of desalinated water from upstream reverse osmosis package discharge to potable water storage tank via treatment packages2. Potential for insufficient treatment of water in water potabilisation package and biocide dosing sytem

1. 053-FIC-0001 controls injection of calcium chloride in the water potabilisation package and sodium hypochlorite in the biocide dosing system2. 053-AIC-0001 controls pH of potable water by injection of sodium hydroxide from water potabilisation package3. Periodic operator sampling of potable water in potable water storage tank

2. Malfunction of 053-FIC-0001 on water potabilisation and biocide dosing systems

1. Potential for over-injection of chemicals into potable water system

1. Water potabilisation package and biocide dosing metering pumps are on/off type pumps2. Requirement for operator to calibrate metering pump stroke and injection flow rates using package calibration pot3. 053-AAH-0002 chlorine detector alarm on discharge of activated carbon filter package4. Daily sampling of potable water from potable water storage tank

Design intent Potable water is produced from desalinated water by addition of sodium hydroxide to control pH, calcium chloride to control hardness and sodium hypochlorite as a biocide and then stored in the potable water tank with a hold up volume of 4 days normal consumption

Node Equipment Water potabilisation package 053-U-120Biocide dosing system 053-U-122Potable water storage tank 053-T-120


Potable water is produced from desalinated water by addition of sodium hydroxide to control pH, calcium chloride to control hardness and sodium hypochlorite as a biocide. Potable water is stored in the potable water tank (hold up volume of 4 days normal consumption) and then pumped through an activated carbon filter to remove excessive free chlorine into the pressurised potable water header.




Section ID Potable water


Prepared by Arthur D Little for OK LNG



HAZOP Item No.

Plant Section







922 Flow - Low 1. Malfunction of water potabilisation and biocide dosing systems

1. Potential for insufficient treatment of potable water

1. Water potabilisation package and biocide dosing metering pumps are on/off type pumps2. Requirement for operator to calibrate metering pump stroke and injection flow rates using package calibration pot3. Daily sampling of potable water from potable water storage tank

R922.1 Review water potablisation and biocide packages to consider what DCS alarms, etc. are required to notify operator of malfunction

TS 2 2 4

923 Flow - No 1. Sufficient level in potable water

storage tank closing flow and treatment of dealinated water (on/off control)

1. 053-LIC-0001 controls potable sotrage tank inlet on/off flow2. Potential for over injection of calcium chloride, sodium hypochlorite and/or sodium hydroxide

1. 053-FIC-0001 controls injection of calcium chloride in the water potabilisation package and sodium hypochlorite in the biocide dosing system2. 053-AIC-0001 controls pH of potable water by injection of sodium hydroxide from water potabilisation package

R923.1 Ensure water potabilisation package control logic inhibits continued injection of sodium hydroxide (normally controlled by 053-AIC-0001) to prevent overinjection of sodium hydroxide during no-flow conditions (via 053-FIC-0001)

TS 2 2 4

924 Flow - Reverse 1. Reverse flow between potable

water and desalinated water storage tanks

1. Potential for loss of potable water and/or contamination of desalinated water storage tank

1. Opening of inlet 053-LV-0001 on potable water storage tank and/or 051-LV-0001 on desalinated water storage tank initiates start of reverse osmosis package pumps, minimising potential for reverse flow

R924.1 Consider provision of check valve on inlet to potable water storage tank and desalinated water storage tank

TS 2 2 4

925 Loss of

Containment1. Piston seal failure on package chemical dosing pumps

1. Spray release of chemical to atmosphere and potential for operator chemical burns

1. Operator PPE and periodic inspection of area2. Spare metering dosing pump3. Chemical dosing pumps and storage tanks located within segregated kerbed areas 4. Each chemical kerbed area has operator manual valve preventing uncontrolled release to drain system




HAZOP Item No.

Plant Section







926 Pressure - High 1. Blocked discharge on metering pump

1. Potential overpressure 1. Integral PSV within metering pump




930 Temperature -

High1. Heat of dilution of concentrated caustic in the water potabilisation package

1. Vendor package is designed for safe dilution of 40% caustic to 5% caustic required for injection2. Injection of sodium hydroxide through static mixer with small heat of dilution, given injection flow rate and concentration

931 Temperature -

LowNo new issues


Zero)No new issues

933 Level - High 1. Malfunction/incorrect setpoint

053-LIC-0001 (LV-0001 FL)1. Continued flow of potable water into potable water storage tank2. Potential to overfill and overpressure potable water storage tank

1. Eight inch overflow on potable storage tank to NW sewer2. Periodic operator inspection in area

934 Level - Low 1. Malfunction/incorrect setpoint

053-LIC-0001 (LV-0001 FL)1. Loss of refilling of potable water storage tank2. Potential to loose level and cavitate potable water pumps3. Loss of pressure in potable water system

1. Independent 053-LALL-0003 trips potable water pumps and inhibits auto start of spare pump

R934.1 Consider provision of DCS level indication using 053-LALL-0003 instrument

TS 2 2 4

1. Low level in potabilisation chemical storage tanks

1. Loss of chemical for injection R934.2 See R922.1 for provision of appropriate DCS indication and alarms

TS 2 2 4





HAZOP Item No.

Plant Section










939 Wrong


1. Malfunction in water potabilisation package, biocide dosing system or downstream activated carbon filter package

1. Potential for incorrect potable water composition

1. 053-AAH-0002 chlorine detector alarm on discharge of activated carbon filter package2. 053-AIC-0001 for pH (assuming not malfunctioned)3. Daily sampling of potable water from potable water storage tank

R939.1 Ensure during detailed design that potable water sample point enables collection of representative potable water sample

TS 3 3 7

940 Corrosive (As



942 Wrong Material





HAZOP Item No.

Plant Section







943 Node 2 Potable water chilling unit, storage tank and distribution

Overview

944 Flow - High 1. High demand for potable water

in plant, e.g. peak usage for showers, etc. at change of shift

1. Decrease in level in potable water storage tank 2. Potential for decrease in pressure in potable water header

1. Potable water storage tank is refilled via on/off level control 2. Potable water storage tank has 4 days holdup capacity (LAH to LAL on tank)3. 053-FI/FAH-003 on flow to potable water distibution network 4. Potable water pumps sized for peak water consumption requirements

2. Requirement for make-up of LNG cooling water closed network system (refrigeration compressor circuit)

1. Small increase in total potable water flow rate

1. Potable water pumps sized for peak water consumption requirements and make-up to six LNG trains

R944.1 Consider relocation of potable water tie-in for CWT make-up, upstream of the activated carbon filter package, given flow rate limitation on activated carbon filter package

TS 2 2 4

Node Equipment Potable water storage tank 053-T-120Potable water pumps 053-P-120A/BActivated carbon filter package 053-U-123


2252-053-PID-00-31-02/Rev A/24-05-062252-053-PID-00-31-03/Rev A/24-05-06

Design intent Potable water from the potable water storage tank (hold up volume of 4 days normal consumption) is pumped through an activated carbon filter to remove excessive free chlorine and into the pressurised potable water header.




HAZOP Item No.

Plant Section







945 Flow - Low 1. Low demand for potable water in plant

1. Increase in potable water header pressure and potential to dead-head potable water pumps2. Increased flow through chilling unit package

1. 053-RO-0002 provides minimum flow protection for potable water pumps 2. 053-TI/TAL-0001 on potable water tank controls duty in chilling water package

2. Blockage in activated carbon filters

1. Increase in differential pressure across filter bed and reduction in flow to the potable water distribution network

1. 053-PDAH-0003 on activated carbon filter package 2. Client request for provision of full flow bypass of activated carbon filter package

946 Flow - No 1. Potable water pump trip 1. Decrease in potable water

header pressure 2. Loss of flow through chilling unit package

1. Auto-start of spare potable water pump to maintain pressure in potable water header and flow through chilling unit package2. Internal chilling unit package control logic3. 053-PI/PAL-0004 on potable water distribution network 4. Check valve on discharge of activated carbon filter package prevents depressurisation of potable water distribution header through pump minimum flow to tank

R946.1 Review during detailed design the design of chilling unit package and protections against ice formation in the event of loss of potable water flow through the chilling unit packageR946.2 Consider inclusion of chilling unit package trip in Cause and Effect in the event of 053-LALL-0003 on the potable water tank in consulation with vendor

TS 3 3 7


948 Loss of

Containment1. Pump seal failure 1. Release of potable water to

atmosphere1. Spare pump2. Periodic operator inspection of area

949 Pressure - High 1. Filling of potable water storage

tank 1. Potential for high vapour space pressure

1. 2" vent and 8" overflow

2. Low demand for potable water on site

1. Increase in potable water network pressure2. Potential overpressure of chilling unit package and activated carbon filter package

1. Minimum flow protection of potable water pump

R949.1 Review design pressure of chilling unit package and activated carbon filters

TS 2 2 4

3. High design discharge pressure of potable water pump

1. All drinking water has to be provided as direct connection to potable water header

R949.2 Review proposed potable water system distribution and design pressure, as it appears high compared with allowable user pressures

TS 2 2 4




HAZOP Item No.

Plant Section







950 Pressure - Low 1. Peak demand for potable water on site

1. Potential for low vapour space pressure in tank

1. 2" vent and 8" overflow



953 Temperature -

High1. Malfunction/incorrect setpoint of 053-TI-0001 and/or failure of chilling unit package

1. Loss of chilling to potable water and gradual increase in potable water temperature

1. Potable water network and storage tank is insulated to prevent solar radiation heating2. 053-UUA-0001 common trouble alarm on chilling unit package

954 Temperature -

Low1. Malfunction/incorrect setpoint of 053-TI-0001 and/or failure of chilling unit package

1. Excessive chilling of potable water and gradual decrease in potable water temperature

1. 053-UUA-0001 common trouble alarm on chilling unit package2. Limited chilling duty within chilling unit package

R954.1 See R946.1 for review of chilling unit package design during detailed design

TS 3 3 7


Zero)No new issues


957 Level - Low 1. Failure of 053-LIC-0001 on

potable water tank1. Decrease in level in potable water storage tank 2. Potential for loss of level and cavitation of potable water pumps

1. 053-LALL-0003 trips potable water pumps to prevent cavitation

R957.1 See R934.1 for configuration of level indication on 053-LALL-0003 instrument

TS 2 2 4








HAZOP Item No.

Plant Section








1. Malfunction in upstream sodium hypochlorite injection and/or continued operation

1. Gradual deactivation of activated carbon within the activated carbon filter2. Potential for excessive chlorine content of potable water

1. 053-AAH-0002 free chlorine analyser on discharge of activated filters2. Sizing basis for activated carbon filter package sufficient to prevent requirement for change in activated carbon within normal shutdown duration of three years3. Minimum retention time within activated carbon filter forms part of the package equipment specification

963 Corrosive (As



965 Wrong Material



HAZOP Record Sheet: Demin. Water Version: FinalSheet 49/125


HAZOP Item No.

Plant Section


966 Node 1 Production of demineralised water

Overview R966.1 Undertake HAZOP of water demineralisation package during detailed design

LALL actions in this unit are configured as DCS stop/inhibit actions, not hardwired ESD trip actions as no immediate safety impact. No SIL rating of 054-LALL-003 required by project

TS 3 3 7

967 Flow - High 1. Decrease in level in

demineralised water storage tank1. Initiation of demineralised water production via start of single desalinated water pump2. Increase in level in demineralised water storage tank

1. 054-LI/LAH-0004 on demineralised water storage tank stops desalinated water pumps and production of demineralised water2. Pump and water demineralisation package running light indication

2. Malfunction/incorrect setpoint of 054-LI-0004 on the demineralised water storage tank

1. Start of desalinated water pump and demineralised water production2. Loss of stop signal with potential to overfill and overpressurise demineralised water storage tank3. Increased demand for production of desalinated water and use of demineralisation chemicals4. Gradual decrease in level in upstream filtered water and firewater tank

1. Overflow of demineralised water storage tank 2. Pump and water demineralisation water package running light indications3. 051-LALL-0005A/B on filtered and firewater storage tank stops service water and desalinated water pumps4. Operator inspection of area

Design intent Two 100% demineralisation packages are provided for the production of demineralised water which is used for production of boiler feed water make-up for use in the LNG process plant area. The production of demineralised water is an on/off, steady flow rate operation controlled by the level in the demineralised water storage tank. At present it is assumed that a mixed bed exchanger will be used for the production of demin water. In the event of a large demand for demineralised water (e.g. startup following maintainance activities), it is possible to operate both desalinated water pumps and demineralisation package trains in parallel.

Node Equipment Desalinated water storage tank 051-T-102Desalined water pumps 051-P-101A/BWater demineralisation package 054-U-110Demineralised water storage tank 054-T-110


Desalinated water is used for the production of demineralised water which is used to produce boiler feed water and make up for the acid gas treatment amine system.




Section ID Demineralised water production





HAZOP Item No.

Plant Section







3. Operation of both desalinated water pumps and water demineralisation package trains during startup (manual operation)

1. Increased use of desalinated water2. Decrease in level in desalinated water storage tank 3. Potential for loss of level in desalinated water storage tank and cavitation of desalinated water pumps

1. 051-LALL-0013 stop desalinated water pumps in the event of low low level in the desalinated water storage tank 2. Possible to operate both reverse osmosis packages in parallel to maintain feed to desalinated water storage tank 3. Desalinated water and demineralised water storage tanks both contain 1 day normal operating capacity (2400 m3). System inventory for change of single LNG train boiler water circuit is 300 m3

968 Flow - Low 1. Malfunction in the water

demineralisation package (e.g. sequence valve failure)

1. Potential to dead-head the desalinated water pumps

1. 051-FIC/FAL-0002 on the desalinated water pumps minimum flow protection2. Water demineralisation package design pressure is same as desalinated water pump dead-head design pressure

969 Flow - No 1. Malfuction/incorrect setpoint in

054-LI-0004 on demineralised water storage tank

1. Loss of start signal for desalinated water pumps2. Gradual decrease in level of demineralised water storage tank3. Potential to cavitate demineralised water pumps

1. 054-LALL-0003 stops demineralised water pumps2. Demineralised water storage tank has 1 day hold up of demineralised water

R969.1 Consider provision of level indication on 054-LALL-0003 instrument on DCSR969.2 Consider in consultation with downstream users (Steam and Acid Gas Removal Units) whether trip of demineralised water pumps needs to initate action on downstream unit e.g. 102-P-107A/B Demin water make up metering pump. Update Cause and Effect Diagram as necessary

TS 2 2 4

970 Flow - Reverse 1. Desalinated water pump trip 1. Potential for level equalisation

between desalinated water storage tank and demineralised water storage tank via minimum flow

1. Auto start of desalinated water pump on low discharge pressure2. Demineralised water storage tank will be top-fill in vapour space




HAZOP Item No.

Plant Section








1. Pump seal failure on desalinatedwater pump

1. Release of desalinated water 1. Periodic operator inspection of the area2. Low discharge pressure auto-start standby pump

2. Pump seal failure on sodium hydroxide and sulphuric acid dosing pumps

1. Spray release of acid/caustic to atmosphere2. Potential operator hazard and chemical burns

1. Periodic operator inspection of the area2. Operator PPE3. Dedicated segregated kerbed areas for unit with appropriate surface protection to prevent acid/caustic attack

3. Loss of containment (e.g. corrosion) of concentrated acid or caustic chemical storage tanks

1. Potential operator hazard and chemical burns2. Potential for significant heat of reaction between caustic and acid solutions

1. Periodic operator inspection of the area2. Operator PPE3. Dedicated segregated kerbed areas for each chemical storage tank to minimise potential for mixing of released caustic and acid solutions

4. Corrosion of demineralised water storage tank

1. Potential for release of demineralised water

1. Desalinated water and demineralised water storage tanks are stainless steel

972 Pressure - High 1. Filling of demineralised water

storage tank in two train operation1. Potential for increase in pressure in vapour space

1. 2" atmospheric vent and 8" overflow

2. Incorrect operator setpoint of manual globe valve on demineralised water storage tank nitrogen blanket

1. Potential for increase in pressure in vapour space

1. 2" atmospheric vent and 8" overflow2. 054-RO-0001 controls maximum flow rate of nitrogen into the vapour space

R972.1 Nitrogen purge connection will be removed in subsequent version of P&ID. Boiler feed water is dosed with oxygen scavenger and tank is stainless steel

TS 2 2 4

973 Pressure - Low 1. Pump-out of demin water at high

flow rate for change of BFW circuit1. Decreased pressure in vapour space

1. 2" atmospheric vent and 8" overflow



976 Temperature -

HighNo new issues




HAZOP Item No.

Plant Section








No new issues


Zero)No new issues




982 Phase - More 1. Degradation of water

demineralisation exchanger resin 1. Potential production of resin fines

1. Water demineralisation vendor package normally contains discharge filter to prevent contamination of demineralised water storage tank



985 Wrong


1. Gradual saturation of water demineralisation package resin during operation

1. Potential breakthrough of salts into demineralised water storage tank2. Gradual formation of salts in downstream boiler steam system

1. 054-AI/AAH-0001 conductivity analyser on discharge of water demineralisation package2. High conductivity of demineralised water initiates automatic regeneration of resin and switch to standby exchanger3. Periodic operator sampling of demineralised water in demineralised water storage tank

986 Corrosive (As



988 Wrong Material





HAZOP Item No.

Plant Section







989 Node 2 Water demineralisation unit package regeneration

Overview

990 Flow - High 1. Incorrect chemical dosing pump

stroke volume 1. High addition flow rate of acid/caustic during regeneration cycle (normally timed)2. Production of acidic and/or caustic regeneration liquid

1. Individual acid and caustic calibration pots for setting pump stroke during commissioning2. 054-AIC/AAH-0002 controls the pH of the regeneration liquid automatically upon completion of regeneration sequence3. Requirement for operator test of pH and manual start of neutralisation pumps for discharge of regeneration liquid to the non-contaminated sewer

1. Some vendors will use venturi rather than metering pumps for addition of acid and caustic during regeneration

Node Equipment Water demineralisation package 054-U-110Demin. neutralisation basin 054-T-111Neutralisation pumps 054-P-111A/BDemineralised water storage tank 054-T-110


2252-054-PID-00-31-03/Rev A/24-05-062252-054-PID-00-31-05/Rev A/24-05-06

Design intent Regeneration of the mixed bed resin exchangers is initiated automatically by high conductivity of the demineralised water discharge. The mixed bed resin is regenerated using 5% sodium hydroxide solution and 3% sulphuric acid solution. The demineralised water from the downstream storage tank is used in the final stage of the regeneration for washing the resin to remove residual acid and caustic contamination. The regeneration liquid is collected in a single demin neutralisation basin, and discharged to the non-contaminated sewer following operator confirmation of liquid pH. The reverse osmosis package removes the majority of the dissolved salts upstream, reducing the salt concentration of the regeneration liquid from the water demineralisation package.




HAZOP Item No.

Plant Section







991 Flow - Low 1. Incorrect chemical dosing pump stroke volume

1. Low addition flow rate of acid/caustic during regeneration cycle (normally timed)2. Potential for incomplete regeneration of resin3. Production of acidic and/or caustic regeneration liquid

1. Individual acid and caustic calibration pots for setting pump stroke during commissioning2. 054-AI/AAH-0001 conductivity analyser initiates premature regeneration of resin in the event of previously incomplete regeneration 3. 054-AIC/AAH-0002 controls the pH of the regeneration liquid automatically 4. Requirement for operator test of pH and manual start of neutralisation pumps for discharge of regeneration liquid to the non-contaminated sewer

992 Flow - No 1. Dosing pump trip (if used) 1. Loss of chemical injection during

regeneration cycle2. Incomplete regeneration of the resin

1. 054-UUA-0002 common trouble alarm on water demineralisation package2. Spare dosing pump for both caustic and acid injection (not auto-start)

R992.1 Vendor package logic sequences will be finalised during detailed design, including action in the event of common trouble alarm, e.g. continuation of sequence, stop of sequence or restart of sequence (general recommendation for all utility vendor packages)

TS 3 3 7

2. Demineralised water washing pump trip

1. Loss of resin washing during regeneration cycle 2. Potential for contamination of demineralised water storage tank

1. 054-UUA-0002 common trouble alarm on water demineralisation package2. Spare washing water pump (not auto-start)

R992.2 Consider provision of conductivity meter in regeneration wash of the neutralisation basin

TS 3 3 7

993 Flow - Reverse 1. Incorrect sequence during

regenerationSee R992.1

994 Loss of

ContainmentSee previous node

995 Pressure - High 1. Blocked discharge on metering

pump1. Potential overpressure 1. Integral PSV within metering

pump





HAZOP Item No.

Plant Section









999 Temperature -

High1. Heat of dilution of acid and caustic solutions

1. Potential for high liquid temperatures during the dilution of concentrated acid or caustic solutions for use during regeneration

1. Vendor to provide safe and suitable dilution facilities within package

2. Heat of reaction from neutralisation

1. Potential for high liquid temperatures during the acid and caustic neutralisation in the neutralisation basin

1. Sulphuric acid and caustic solutions are dilute, reducing potential for formation of high temperatures

1000 Temperature -

LowNo new issues


Zero)No new issues

1002 Level - High 1. Simultaneous regeneration of

water demineralisation packages 1. Potential to overfill neutralisation basin

1. Water demineralisation package control logic prevents simultaneous regeneration

2. Automatic regeneration of the water demineralisation package, but requirement for manual pump out of the neutralisation basin

1. Potential to overfill neutralisation basin

R1002.1 Review proposed design and consider configuration of alarm(e.g. LAH on the neutralisation basin and/or regeneration complete alarm) to notify operator to empty neutralisation basin

TS 2 2 4

3. Operator exposure to basin 1. Potential for operator hazard 1. Neutralisation basin will be fenced to prevent operator ingress

1003 Level - Low 1. Manual pump out of

neutralisation basin 1. Decrease in level in neutralisation basin2. Potential for pump cavitation

1. Operator controlled operation2. Neutralisation pumps will be self priming pumps 3. Spare neutralisation pump

R1003.1 If level indication and alarm provided (see R1002.1), consider provision of low level stop of neutralisation pumps

TS 3 3 7






HAZOP Item No.

Plant Section









1008 Wrong


1. Ineffective mixing in neutralisation basin

1. Incorrect addition of acid or caustic neutralisation regeneration liquid2. Potential for discharge of acid or caustic effluent to non-contaminated sewer

1. Plant air sparger provided in base of neutralisation basin

R1008.1 Review requirement for sequence valve on plant air mixing sparger as neutralisation in the basin is normally part of the automatic regeneration sequence

TS 3 3 7

1. Leakage and/or valve sequence failure in water demineralisation package at start of regeneration

1. Potential for leakage of acid and/or caustic from exchanger under regeneration into normal flow of demineralised water to the demineralised water storage tank

R1008.2 Review during detailed design of vendor package HAZOP specific protections for contamination of duty mineralisation discharge during regeneration, e.g. double valving, limit switches on sequence panels, conductivity analyser on discharge of each resin bed

TS 3 3 7

1009 Corrosive (As

well as)1. Corrosion of the neutralisation basin and air sparger

1. Neutralisation basin will have chemical resistant lining2. Air sparger and air pipework in neutralisation basin is PVC

1010 Explosive No further issues

1011 Wrong Material

(Other than)1. Sizing basis for water demineralisation package

R1011.1 Water demineralisation package sizing basis will be reviewed during detailed design following reciept of raw water composition

TS 3 3 7




HAZOP Item No.

Plant Section







1012 Node 3 Demineralised water pumps and header

Overview

1013 Flow - High 1. High demand for demineralised

water1. Decrease in level in demineralised water storage tank2. Potential decrease in demineralised water header pressure

1. Demin water pumps are sized to provide normal continuous flow rate required for make-up of BFW system and acid gas treatment (amine solution make-up)2. 054-PI-0002 on demineralised water header3. Operator start of second pump if required by process unit i.e. replacement of boiler feed water in the event of condensate contamination 4. Automatic make-up of upstream demineralised water storage tank based on level on/off control

Design intent The pressure of the demineralised water distribution header is maintained by the demineralised water pumps. In the event of high demineralised water demand, such as requirement to replace boiler water circuit due to condensate contamination, it is possible to operate two demineralised water pumps to maintain header pressure.

Node Equipment Demineralised water storage tank 054-T-110Demin. Water pumps 054-P-110A/B


2252-054-PID-00-31-05/Rev A/24-05-06




HAZOP Item No.

Plant Section







1014 Flow - Low 1. Low demand for demineralised water (e.g. 2 out of 4 LNG trains operating)

1. Decrease in usage of demineralised water2. Gradual increase in header pressure3. Potential to damage demineralised water pumps

1. 054-FIC/FAL-0003 minimum flow protection on pumps2. Automatic filling of upstream demineralised water storage tank based on level in tank

2. Malfunction/incorrect setpoint 054-FIC-0003 opening minimum flow control valve

1. Increase in recycle of demineralised water to storage tank2. Decrease in flow of demineralised water for BFW makeup and acid gas treatment amine makeup3. Potential for decrease in demineralised water header pressure

1. 054-PI-0002 on demineralised water header2. Low pump discharge pressure autostart standby pump

R1014.1 Configure PAL on 054-PI-0002 on demineralised water header

TS 2 2 4

1015 Flow - No 1. Demin water pump trip 1. Decrease in header pressure

with potential loss of demineralised water make-up to process2. Potential for reverse flow and depressurisation of header via pump minimal flow protection

1. Auto-start of standby demin water pump in event of low discharge pressure

R1015.1 Consider requirement for check valve on common demineralised water header to prevent depressurisation to tank

TS 2 2 4


1017 Loss of

Containment1. Pump seal failure 1. Release of demineralised water

to atmosphere1. Periodic operator inspection of area2. Spare demin water pump3. Low discharge pressure initates auto start of standby pump

1018 Pressure - High No new issues







HAZOP Item No.

Plant Section







1022 Temperature - High

1. Thermal expansion of demineralised water in header if isolated and no flow

1. Potential overpressurisation of header pipework

1. Pipework thermal expansion loops 2. Thermal relief valves will be considered in detailed design

1023 Temperature -

LowNo new issues


Zero)No new issues







1031 Wrong


No new issues

1032 Corrosive (As

well as) No new issues


1034 Wrong Material

(Other than) No new issues


HAZOP Record Sheet: Hot Oil Version: Final60/125


HAZOP Item No.

Plant Section


1035 Node 1 Hot oil circuit

Overview 1. HAZOP of fired furnace vendor package

R1035.1 HAZOP of fired furnace vendor package to be undertaken during detailed design

TS 3 3 7

1036 Flow - High 1. Malfunction/incorrect setting of

heater master flow controller1. Individual heater flow control valves would tend to open due to reset from 017-FY-0001A/B/C2. Gradual decrease in temperature of hot oil from hot oil furnaces and feed to downstream users3. Potential for insufficient heat duty in downstream exchangers4. Gradual decrease in hot oil header distribution pressure

1. Each individual user has temperature controlled TV which controls duty in exchanger2. Temperature controller on discharge of each furnace 017-TI-0008A/B/C 3. 017-TIC-0014 controls temperature and duty in hot oil trim air cooler 4. 017-TI/TAH-0002A/B furnace firebox temperature

Design intent The hot oil system is a closed system using speciality thermal oil for use as a heating medium. Hot oil from the hot oil expansion drum is pumped through three hot oil furnaces during normal operation and then used as a heating medium for the condensate stabiliser reboilers. The heating oil is then cooled in the hot oil trim air cooler for use in the inlet facility gas and anti-hydrate heaters before returning back to the hot oil expansion drum.

Node Equipment Hot oil expansion drum 017-V-101Hot oil circulation pumps 017-P-101Filter 017-FL-101Hot oil furnace 017-H-101A/B/CHot oil trim air cooler 017-A-101


Hot oil system is used as a heating medium for various process heat duties such as anti-hydrate and condensate stabiliser reboilers. The system is a closed circuit system with two separate controlled temperatures. The heating oil return is pumped through three parallel hot oil furnaces which control the discharge temperature at 280 degrees C for use in condensate stabiliser reboilers. Feed to second temperature stage is then controlled by hot oil trim air cooler to 210 degrees C as feed to the anti-hydrate heaters. The total circulating mass flow rate of hot oil in the system is 1280 tonnes/hr. To maintain clean service, a slipstream of approx. 40 tonnes/hr flows through a filter for removal of any cracking coke solids.




Section ID Hot oil system





HAZOP Item No.

Plant Section







2. Malfunction/incorrect setting of individual furnace pass flow controller

1. Increase in flow rate through individual furnace pass 2. Decrease in flow through remaining passes to that furnace3. Potential for high radiant section coil temperatures and possible coke formation in remaining furnace passes

1. 017-FY-0001A/B/C total furnace flow ratio controller controls total flow through each furnace 2. 017-FIC/FAL-0003** indication on remaining furnace passes3. 017-TI/TAH-0005** furnace coil skin thermocouple temperature indication and alarms4. 017-TI/TAH-0003** individual furnace pass discharge temperature5. 017-FALL-0004** low low flow on individual pass

R1036.1 Undertake complete review of furnace vendor package control, trip functions, cause & effect and flow control configuration to individual passes during detailed design

TS 3 3 7

3. Malfunction/incorrect setting of individual hot oil user temperature control valve

1. Increase in flow through individual user2. Potential for upset on process side due to increased heat duty3. Potential for upset to other users in network

1. Process side indication and alarms2. 017-FQI-0006/7/8/9 provide indication of total flow to individual user branches

R1036.2 Consider configuration of FI and FQI to enable operator monitoring of flow to individual condensate stabilisers and gas heaters

TS 5 5 10

4. Clean filter following startup 1. Reduced dP over filter and high recirculation flow of hot oil through filter

1. 017-FI-0011 on slipstream flow through filter

R1036.3 Consider provision of manual globe valve to enable operator regulation of flow through filter, especially when clean

TS 4 4 9




HAZOP Item No.

Plant Section







1037 Flow - Low 1. Malfunction/incorrect setpoint of heater master flow controller

1. Reduced total flow through hot oil furnaces 2. Gradual increase in discharge temperature of furnaces 3. Reduced duty in downstream user exchanges. Potential for insufficient heat duty in anti-hydrate heaters4. Potential for low flow conditions in individual passes and coke formation

1. 017-FY-0001A/B/C total furnace flow ratio controller controls total flow through each furnace 2. 017-FIC/FAL-0003** indication on furnace passes3. 017-TI/TAH-0005** furnace coil skin thermocouple temperature indication and alarms4. 017-TI/TAH-0003** individual furnace pass discharge temperature5. 017-TI-0008A/B/C controls firing in individual furnaces6. 017-FALL-0004** low low flow on individual pass7. 017-TI-0014 controls bypass of hot oil trim air cooler and temperature to the anti-hydrate heaters8. 014-TIC/TAL-0015 on shell inlet facility anti-hydrate heater discharge

2. Malfunction/incorrect setpoint of individual pass flow controller (independent pass FV are FC)

1. Potential for loss of flow through single pass of furnace2. Potential cracking and coke formation in coil3. Potential hot-spotting and premature tube failure

1. 017-FIC/FAL-0003** on flow control through individual pass (if not cause for scenario)2. 017-FALL-0004** on individual pass

R1037.1 Review during vendor package HAZOP furnace protections for low and/or no flow on individual passes

TS 3 3 7




HAZOP Item No.

Plant Section







3. Low demand for hot oil in network, e.g. one condensate stabiliser or train in maintainance

1. Reduced heat removal from hot oil system

1. 017-TIC-0014 controls temperature in second stage of hot oil system and heat removal in hot oil trim air cooler2. Operating manual will contain indications for heaters master flow controller setpoints for various operating conditions in the plant3. 017-TI-0008A/B/C controls firing in individual furnaces4. 017-TI-0011 on combined temperature from three furnaces resets firing ratio controller 017-TI-0007A/B/C

4. Plant startup 1. Reduced requirement for hot oil system duty

1. Operating manual will provide guidance for number of furances and operating hot oil circulation pumps required for providing necessary hot oil duty in the network 2. Circulating hot oil pump design considers circulation of hot oil at ambient conditions3. 017-TI-0011 would continue to control on operating furnace as temperature reset

5. Gradual formation of coke in furnace and blockage of hot oil filter

1. Reduced flow through filter2. Reduced removal of coke particles from hot oil 3. Potential to overpressure filter

1. Filter design pressure same as circulating pump design pressure2. 017-PDI/PDAH-0021 provides indication of filter performance if flow control element provided in slipstream

R1037.2 See Reccomendation R1036.3 for provision of flow control element in slipstream

TS 4 4 9

6. Malfunction of 017-FV-0001 on the discharge of the hot oil trim cooler

1. Potential for loss of circulation of hot oil through the furnaces

1. 017-FV-0001 is FO valve R1037.3 Review with furnace vendor whether 017-FV-0001 is required given master flow controller of individual inlet flow controllers.

TS 3 3 7




HAZOP Item No.

Plant Section







7. Circulating oil pump trip 1. Potential for reduction of hot oil flow and heat duty availability

1. Hot circulation pumps have individual single electrical feeder supplies. Hot oil unit has two independent electrical feeders which prevent loss of all hot oil circulating pumps simultaneously 2. Hot oil circulating pump discharge 017-PI-0017 auto starts standby circulating pump to maintain circulation3. 017-PIC-0015 would tend to close to maintain hot oil header pressure



1040 Loss of

Containment1. Pump seal failure on hot oil circulating pump

1. Spray release of oil to atmosphere2. Gradual decrease in hot oil inventory in system3. Potential for loss of hot oil inventory and cavitation of circulating pumps

1. Periodic operator inspection of the area 2. 017-LI-0004 on hot oil expansion drum 3. 017-LALL-0001 trip on hot oil circulating pumps

R1040.1 Configure LAL on 017-LI-0004 to act as pre-alarm before circulating pump trip

TS 3 3 7

2. Furnace pinhole leak - tube failure

1. Release of hot oil into furnace firebox2. Potential for fire in base of hot oil furnace

1. Periodic operator inspection of furnace2. Coil skin thermocouples provide indication of high skin temperatures, e.g. coke formation in tube3. 017-AI-0001A/B/C excess oxygen indication in stack 4. High soot content of furnace emissions from stack

3. Pinhole tube leak on hot oil trim air cooler

1. Spray release of oil to atmosphere2. Gradual decrease in hot oil inventory in system3. Potential for loss of hot oil inventory and cavitation of circulating pumps

1. Periodic operator inspection of the area 2. 017-LI-0004 on hot oil expansion drum 3. 017-LALL-0001 trip on hot oil circulating pumps

R1040.2 See R1040.1 for configuration of LAL

TS 3 3 7




HAZOP Item No.

Plant Section







4. Maintenance on hot oil circulating filter

1. Potential exposure of operator to hot circulating oil (approx 200 degrees C)

1. Operating procedures R1040.3 Ensure piping layout enables draining of hot oil to drum for maintenance activities

TS 4 4 9

1041 Pressure - High 1. Fire in vicinity of hot oil

expansion drum 1. Potential for overpressure of hot oil expansion drum

1. 017-PIC/PAH opens PV-0019A to flare on expansion drum 2. 017-PSV-0002A/B

2. Fire in vicinity of hot oil filter 1. Potential for overpressure of hot oil filter

1. Filter is normally open to hot oil expansion drum. However, single manual isolation valve may prevent depressurising via hot oil expansion drum

R1041.1 Confirm against code requirements whether dedicated PSV required for filter vessel sized for fire, or CSO manual isolation valve to ensure protection via expansion drum pressure relief

TS 3 3 7

3. Malfunction/incorrect setpoint of 017-PV-0019B nitrogen blanket on expansion drum

1. Gradual pressurisation of expansion drum

1. Nitrogen pressure lower than design pressure of hot oil system

4. Tube failure in high pressure inlet facility anti-hydrate and feed gas heaters

1. Potential for high pressure gas breakthrough and overpressure of hot oil system

1. Dedicated PSV on exchanger hot oil headers prevents overpressure of hot oil system

1042 Pressure - Low 1. Malfunction/incorrect setpoint

017-PIC-0015 (017-PV-0015 FO)1. Decrease in hot oil circulating header pressure2. Potential for insufficient flow through hot oil exchangers with potential for process upset

1. Process side instrumentation and alarms

R1042.1 Consider handwheel, if not already provided, on 017-PV-0015 to enable continued operation with manual control

TS 3 3 7

2. Malfunction/incorrect setpoint 017-PIC-0019

1. 017-PV-0019A opens to flare, reducing pressure in the hot oil expansion drum

1. Hot oil circulating drum elevation approx 10 m. No anticipated problem with hot oil circulating pump operation

1043 Vacuum 1. Operator error during steam-out of hot oil expansion drum and/or filter

1. Potential formation of vacuum 1. Hot oil expansion drum designed for vacuum





HAZOP Item No.

Plant Section








1. Operator incorrect setpoint 017-TIC-0014

1. Increased flow through hot oil trim air cooler bypass 2. Increase in temperature of hot oil feed to gas heaters and anti-hydrate heater exchangers3. Potential increase in return temperature to hot oil expansion drum and filter

1. Feed gas heaters and anti-hydrate heater exchangers have design temperature of 320 degrees C

R1045.1 Review design temperature of hot oil exchangers to match hot oil unit design temperatureR1045.2 Review design temperature of hot oil expansion drum

TS 2 2 4

1046 Temperature -

Low1. Malfuction/incorrect setpoint 017-TIC-0014

1. Increased flow through hot oil trim air cooler2. Decrease in temperature of hot oil feed to hot oil exchangers and gas heaters

1. Process side temperature indication and alarms2. 017-TI-0017 on hot oil return to expansion drum

2. Continued operation of fixed speed hot oil cooler fin fans with nohot oil flow

1. System and pump hot oil circulating pump design considers pumping of high viscous thermal oilduring startup at atmospheric temperatures2. Potential for operator to stop fin fan motors if considered necessary


Zero)No new issues










HAZOP Item No.

Plant Section








1. Ageing of hot oil 1. Requirement for manual purging and replacement of determined volume during maintainance on an annual programme

1055 Corrosive (As



1057 Wrong Material





HAZOP Item No.

Plant Section







1058 Node 2 Furnace firing and firebox

Overview

1059 Flow - High No new issues

1060 Flow - Low No new issues



1063 Loss of

Containment1. Leakage of fuel gas into firebox in standby mode

1. Potential for firebox explosion during ignition sequence

1. Burner management and firing control system 2. Double block and bleed isolation of main fuel gas to furnace during shutdown3. Double block and bleed isolation on pilot fuel gas feed during furnace shutdown

R1063.1 Confirm during vendor package HAZOP provision of firebox venting and purge requirements prior to ignition

TS 3 3 7

2. Tube leakage and/or tube failure in individual furnace

1. Potential for pool fire in the bas of the furnace firebox

1. Temperature indication on the furance firebox2. Oxygen anlyser on the flue gas3. Increase in soot content of the flue gas from the furnace

R1063.2 Confirm with vendor proposed simultaneous isolation of both fuel gas to the furnace and flow of hot oil through the furnace tubes. Ensure tube design temperature sufficient for residual heat in the firebox and no flow condition

TS 3 3 7

Node Equipment Hot oil furnace 017-H-101A/B/C



Design intent Hot oil is heated in a fuel gas fired natural draft furnace to maintain a normal operating discharge temperature of 280 degrees C.




HAZOP Item No.

Plant Section







1064 Pressure - High 1. Malfunction/incorrect setpoint 017-PIC-0009A/B/C

1. Increase in fuel gas flow to main burner tip 2. Potential for flame lift-off 3. Potential for re-ignition on hot refractory lining and potential for explosion

1. Flame detectors on main burners in furnace

2. Malfunction/incorrect setpoint 017-PIC-0006A/B/C

1. Increase in fuel gas flow to pilot burner tip 2. Potential for flame lift-off 3. Potential for loss of pilot

R1064.1 Review during detailed vendor package HAZOP flame protection and flame-out protection, including trip actions

TS 3 3 7

3. Variation in fuel gas pressure 1. Potential for increased firing in furnace firebox2. Gradual increase in discharge temperature of the fire furnace

1. 017-PIC-0009A/B/C controls fuelgas pressure to main burners2. 017-TI/TAH-0008A/B/C controls firing in furnace to maintain set discharge temperature

4. Incorrect setpoint and position of damper

1. Potential increase in firebox pressure with potential for substoichiometric combustion

1. 017-AI-001A/B/C excess oxygen analyser on flue gas2. 017-PI/PAH-0002A/B/C and017-PI/PAH-4A/B/C firebox pressure indication




HAZOP Item No.

Plant Section







1065 Pressure - Low 1. Malfunction/incorrect setpoint 017-PIC-0006A/B/C

1. Loss of fuel gas flow to pilot burner2. Loss of pilot in furnace

1. 017-PALL-0008A/B/C on pilot gas

R1065.1 See R1064.1 TS 3 3 7

2. Malfunction/incorrect setpoint 017-PIC-0009A/B/C

1. Loss of fuel gas flow to main burners2. Loss of firing in furnace of main gas burners3. Gradual decrease in temperature of process side discharge from furnace

1. 017-PALL-0010A/B/C on main fuel gas2. Flame detectors on main fuel gas burners

3. Low fuel gas pressure and/or blockage of inlet fuel gas filter

1. Decrease in flow of natural gas to both pilot and main gas burners2. Potential for flameout of furnace

1. 017-PALL-0008A/B/C on pilot gas2. 017-PALL-0010A/B/C on main fuel gas017/PDI/PAH-017A/B/C over inlet gas filters


1067 Partial Pressure 1. Variation in fuel gas composition 1. Potential for variation in burner

performance 1. Burner tip design takes into account anticipated variations in fuel gas composition




HAZOP Item No.

Plant Section








1. Malfunction/incorrect setpoint 017-TI-0008A/B/C

1. Increased firing in the individual fired heater 2. Increase in discharge temperature from furnace3. Potential for flame impingement on furnace tubes4. Potential for cracking reactions in coil and coke formation5. Potential for coil rupture

1. 017-TI-0011 on common hot oil discharge from all three furnaces resets 017-TY-0008A/B/C2. 017-TI/TAH-0005** coil skin temperature thermocouples3. 017-TI/TAH-0002 radiant zone firebox temperature4. 017-TI/TAH-0003** individual discharge temperatures5. 017-TAHH-0009A/B/C on common furnace discharge

R1068.1 Detailed furnace design to confirm potential for flame impingment and protection against over-firing in furnace

TS 3 3 7

1. Malfunction/incorrect setpoint of 017-TI-0011

1. Increased firing in the all fired heaters2. Increase in discharge temperature from furnace3. Potential for flame impingement4. Potential for cracking reactions in coil and coke formation5. Potential for coil rupture

1. 017-TIC-0014 controls cooling in hot oil trim air cooler2. 017-TI/TAH-0005** coil skin temperature thermocouples3. 017-TI/TAH-0002 radiant zone firebox temperature4. 017-TI/TAH-0003** individual discharge temperatures5. 017-TAHH-0009A/B/C on common furnace discharge

1069 Temperature -

Low1. Malfunction/incorrect setpoint 017-TI-0008A/B/C

1. Decreased firing in the individual fired heater 2. Decrease in discharge temperature from furnace

1. 017-TI-0011 on common hot oil discharge from all three furnaces resets 017-TY-0008A/B/C2. 017-TI-0002 radiant zone fireboxtemperature3. 017-TI-0003** individual discharge temperatures

1. Malfunction/incorrect setpoint of 017-TI-0011

1. Decreased firing in all fired heaters2. Decrease in discharge temperature from furnace

1. 017-TI-0008A/B/C on common hot oil discharge from all three furnaces resets 017-TY-0008A/B/C2. 017-TI-0002 radiant zone fireboxtemperature3. 017-TI-0003** individual discharge temperatures4. 017-TI-0004 controls cooling in hot oil trim air cooler




HAZOP Item No.

Plant Section







1070 Cryogenic (Sub - Zero)

No new issues




1074 Phase - More 1. Potential condensate formation

in fuel gas network1. Potential for upset in furnace during initial startup

1. Central KO drum in fuel gas unit R1074.1 Evaluate the need for KO drum provision on common fuel gas to Unit 17 furnaces to minimisepotential for furnace upset (general recommendation)

TS 3 3 7



1077 Wrong


No new issues

1078 Corrosive (As


1079 Explosive 1. Incorrect ignition sequence for

furnace1. Sequence controlled ignition of furnace

1080 Wrong Material





HAZOP Item No.

Plant Section







1081 Node 3 Hot oil sump

Overview

1082 Flow - High 1. Transfer of thermal oil from

sump to hot oil circuit expansion drum

1. Gradual increase in level of the thermal expansion drum with potential to overfill

1. Manually operated control procedure2. 017-LI-0004 on hot oil expansion drum3. 017-LALL-0005/6 initiates trip of transfer pump



1085 Flow - Reverse 1. Pump trip and/or normal standby

condition1. Potential for reverse flow of hot oil to sump

1. Check valve on discharge of sump pump2. Check valve on connections for addition of new thermal oil3. Hot thermal oil injection connection to expansion drum inlet pipework normally manually closed and isolated from system

1086 Loss of

Containment1. Corrosion of hot oil sump 1. Potential leakage of hot oil into

concrete pits1. Hot oil sumps are carbon steel and painted to minimise potential for external corrosion

Design intent Hot oil sumps (individual for NS and NCB systems) are designed to have sufficient total volume for the hot oil inventory for use during maintainance and startup operations The hot oil sumps can also be used for purging of hot oil inventory from the systems and venting of light ends to flare formed from gradual cracking and decomposition of the thermal oil. Facilities are also provided for the injection and makeup of hot thermal oil inventory from external third party drums, etc.

Node Equipment 017-V-102/3 hot oil sumps017-P-103/4 sump pumps


2252-017-PID-00-31-06/Rev A/25-08-062252-017-PID-00-31-05/Rev A/25-08-06




HAZOP Item No.

Plant Section







1087 Pressure - High 1. Operator error closing globe valve on nitrogen purge of hot oil sump

1. Potential to overpressure hot oil sump

R1087.1 Consider relocation of manual globe valve to inlet of hot oil sump to control purging flow R1087.2 Add note to P&ID to state that pressure gauge should be visible from nitrogen purge manual globe valve

TS 4 4 9

2. Draining of hot oil to sump 1. Potential to exceed sump design pressure

1. 3" vent to flare on vapour space of hot oil sump considered sufficient for normal nitrogen purge and maximum hot oil draining flow rate

1088 Pressure - Low 1. Pump out of thermal oil from hot

oil sump to hot oil expansion drum1. Potential for decrease in vapour space pressure in hot oil sump2. Potential for damage to drum

R1088.1 Ensure nitrogen purge sizing basis and local indication is sufficient to prevent formation of vacuum in sump during pump out conditions

TS 4 4 9


1090 Partial Pressure 1. Flashing of light ends in hot oil

sump1. Potential for formation of flammable atmospheres in hot oil sump

1. Nitrogen purge of the vapour space of hot oil sump to flare

1091 Temperature -

HighNo new issues

1092 Temperature -

Low1. Decrease in temperature of hot oil inventory in sump

1. Potential for problems in operating sump pump

1. Pumps designed for pumping both atmospheric temperature and hot thermal oil


Zero)No new issues




HAZOP Item No.

Plant Section







1094 Level - High 1. Draining of hot oil inventory during maintainance

1. Potential to overfill sump 1. Hot oil sumps (NS and NCB) are sized to hold total hot oil inventory in system 2. 017-LI/LAH-0009/0010 level indication on hot oil sumps3. Local level indication gauges on sumps

2. Collection of rainwater in hot oil pits during rainy season

1. Potential for drum to float since normally no liquid inventory

1. Hot oil sumps are anchored to pit2. 017-LI/LAH-0013/14 level indication on pit 3. Operator action to pump out hot oil sump pits during rainy conditions as necessary






1100 Wrong


No new issues

1101 Corrosive (As

well as)1. Corrosion of internals of hot oil sumps

1. Potential contamination of hot oil with corrosion products

1. Nitrogen blanket/purge of hot oil sump


1103 Wrong Material



HAZOP Record Sheet: Diesel Oil Version: Final76/125


HAZOP Item No.

Plant Section


1104 Node 1 Diesel oil system

Overview 1. HAZOP of diesel oil station R1104.1 Undertake vendor package HAZOP during detailed design

TS 3 3 7

1105 Flow - High 1. Import of diesel oil from harbour 1. Increase in level in diesel oil

storage tank2. Potential to overflow diesel oil storage tank3. Increase in vapour space pressure and overpressure of atmospheric storage tank

1. 046-LI/LAH-0002 with control signal to harbour loading facility2. 4" vent sized for maximum filling rate3. Management of diesel oil purchase and inventory control during import activities

2. Export of diesel oil to distribution truck

1. Gradual decrease in level in diesel oil storage tank 2. Low pressure in vapour space

1. 046-LI/LAL-0002 for inventory management in diesel oil tank2. 4" vent

R1105.1 Consider provision of pump to enable filling of diesel truck for onsite distribution

TS 2 2 4

1106 Flow - Low 1. Gradual blockage of diesel inlet

and/or outlet filters1. Increased duration for filling and transfer of diesel oil

1. Manual operation


1108 Flow - Reverse 1. Pump trip during import of diesel

from harbour1. Potential for reverse flow of diesel

1. Loading is a manual operation R1108.1 Consider provision of check valve at harbour to prevent reverse flow

TS 2 2 4

1109 Loss of

Containment1. Overfilling of diesel oil storage tank during loading via overfill connection

1. Potential contamination of bund area

1. 046-LI/LAH-0002 with control signal to harbour loading facility2. Management of diesel oil purchase and inventory control during import activities

R1109.1 Evaluate requirement for overflow on diesel oil storage tank, given potential environmental aspects associated with the overflow of diesel oil to bunded area

TS 2 2 4


Design intent Single diesel oil storage tank is provided for import and storage of diesel for use within plant facilities for vehicles, emergency generators, fire pumps, etc.

Node Equipment Diesel oil inlet filters 046-F-101A/BDiesel oil storage tank 046-T-101Diesel oil outlet filters 046-F-102A/BDiesel oil station 046-U-101


Single diesel oil storage tank is provided for import and storage of diesel for use within plant facilities for vehicles, emergency generators, fire pumps, etc.


2252-046-PID-00-31-01/Rev A/23-05-06


Section ID Diesel oil system





HAZOP Item No.

Plant Section










1114 Temperature -

HighNo new issues

1115 Temperature -

LowNo new issues


Zero)No new issues




1120 Phase - More 1. Contamination of diesel oil with

water1. Potential collection of water in diesel oil storage tank2. Potential collection of water in site emergency fuel tanks, e.g. diesel firewater pump

1. Sample collection on diesel oil storage tank2. Water removal drain on diesel oil storage tank3. Cone-up type bottom diesel oil storage tank4. Water drain connections on site user diesel systems



1123 Wrong


No new issues

1124 Corrosive (As

well as)1. Corrosion at water interface in base of tank

1. Potential for ground contamination

1. Bund design2. 3mm corrosion allowance in tank




HAZOP Item No.

Plant Section








1126 Wrong Material (Other than)

No new issues


HAZOP Record Sheet: Jetty Facilities Version: Final79/125


HAZOP Item No.

Plant Section


1127 Node 1 Nitrogen supply

Overview





1132 Loss of

ContainmentNo new issues


1134 Pressure - Low 1. Purging of loading arm following

loading activities1. Use of nitrogen2. Gradual decrease of pressure in nitrogen buffer vessel

1. Connected to site nitrogen system for recharging in the event of decrease in pressure due to high usage flow rates2. 031-PI/PAL-0004 on jetty nitrogen header

2. Malfunction in nitrogen generation system upstream

1. Potential for temporary loss of nitrogen supply to jetty

1. Nitrogen buffer vessel on jetty2. Check valve on inlet to nitrogen buffer vessel to protect volume in event of loss of nitrogen supply header pressure3. Buffer vessel sized for single loading operation purge4. 031-PI/PAL-0004 on jetty nitrogen header


Company TECHNIPFacility OK LNG Facility FEED StudyHAZOP Date 14-Sep-06

Section ID Jetty facilitiesGeneral Section Description:

A dedicated air compression package is provided at the jetty for provision of instrument and maintainance plant air. A dedicated jetty nitrogen buffer vessel is provided with sufficient holdup volume for single loading purge sequence in the event of loss of nitrogen header from the plant nitrogen generation package unit.


2252-031-PID-00-31-01/Rev A/23-06-06

Design intent Nitrogen is buffered in a single vessel for use in purging loading arms used for transfer of LNG, LPG and HVP condensate products.

Node Equipment Jetty gaseous nitrogen reciever 031-V-101




HAZOP Item No.

Plant Section






1137 Temperature -

HighNo new issues

1138 Temperature -

LowNo new issues


Zero)No new issues







1146 Wrong


No new issues

1147 Corrosive (As

well as)1. External corrosion of nitrogen buffer vessel and pipework at jetty location

1. Potential for loss of integrity of nitrogen vessel and pipework

1. All nitrogen header pipework along trestle, jetty head and vessel will be coated to prevent external corrosion


1149 Wrong Material





HAZOP Item No.

Plant Section





1150 Node 2 Jetty compressed air system

Overview 1. HAZOP of vendor package R1150.1 Undertake vendor air compressor package HAZOP during detailed design

TS 3 3 7

1151 Flow - High 1. High demand for instrument air

and/or plant air during maintainance and/or other activites at the jetty

1. Gradual decrease in pressure in jetty drier receiver2. Potential for loss of instrument air

1. 031-PI/PAL-0005A/B autostart of jetty air compression package2. 031-PI/PAL-0003 closes jetty plant air header to protect instrument air network

1152 Flow - Low 1. Low usage of instrument and/or

plant air1. Reduced production of compressed air by compressed air package


1154 Flow - Reverse 1. Completion of air compression

operation 1. Potential for depressurisation of jetty air reciever to atmosphere

1. Check valve on inlet connection to jetty air reciever prevents depressurisation

1155 Loss of

ContainmentNo new issues

1156 Pressure - High 1. Malfunction of compressed air

control package, e.g. compressor fails to stop

1. Potential to overpressure jetty air receiver

1. Compressed air package design2. 031-PSV-0002 on jetty dry air receiver3. 031-UUA-0001A/B summarised malfunction alarm on compressed air package

Node Equipment Jetty air compression package 031-U-104Jetty dry air receiver 031-V-103

Drawing Number/Sheet Number 2252-031-PID-00-31-01/Rev A/23-06-06Design intent A dedicated compressed air package will be provided at the jetty for production of compressed air for use as plant and instrument air. The air dryer package will be heated regeneration type (electrical)




HAZOP Item No.

Plant Section





1157 Pressure - Low 1. Malfunction of compressed air control package, e.g. compressor fails to start

1. Potential for loss of jetty instrument and plant air

1. 031-PI/PAL-0003A/B on jetty air compressor package2. 031-PI/PAL-0003 on instrument air header automatically closes jetty plant air network to preserve instrument air header pressure



1160 Temperature -

HighNo new issues

1161 Temperature -

LowNo new issues


Zero)No new issues




1166 Phase - More 1. Malfunction in jetty air

compression package drier1. Potential for formation of water in jetty dry air receiver2. Potential for damage to jetty instrumentation

1. Jetty air drier summarised malfunction alarm 031-UUA-0003A/B2. Air high moisture content alarm 031-AI/AAH-0001A/B



1169 Wrong


1. Flammable vapour in vicinity of compressed air package

1. Potential for explosion 1. Jetty air compression package will be located in safe location in non-hazardous zone




HAZOP Item No.

Plant Section





1170 Corrosive (As well as)

1. External corrosion of jetty dry air receiver and pipework at jetty location

1. Potential for loss of integrity of jetty dry air receiver and pipework

1. All dry air pipework along trestle, jetty head and dry air receiver will be coated to prevent external corrosion


1172 Wrong Material



HAZOP Record Sheet: Firewater Version: FinalSheet 84/125


HAZOP Item No.

Plant Section


1173 Node 1 Process Area Firewater System

Overview


1175 Flow - Low 1. Blockage of pump inlet filter strainers

1. Potential for reduced firewater pump performance

1. Requirement for weekly performance testing on main firewater pumps. Dedicated test line provided on each individual pump and local flow indicator 055-FI-0001 to confirm pump performance 2. Decrease in firewater ring main pressure would auto start standby jockey and/or firewater pump, e.g. if duty jockey pump suction strainerblocked3. Duty jockey pump will be switched regularly to ensure availability of spare jockey pump and equal running time

Design intent Firewater for the largest fire scenario in the process area is stored in each of the filtered and firewater storage tanks. The pressure in the process area firewater main is maintained using jockey pumps with minimum flow protection back to the filtered and firewater storage tanks. In the event of decrease in pressure in the firewater ring main the main firewater pumps (1 electric and 2 diesel) autostart.

Node Equipment Filtered and firewater storage tank 051-T-101A/BFirefighting water pumps 055-P-101A/B/CJockey pumps 055-P-102A/B


Firewater for the largest fire scenario in the process area is stored in each of the filtered and firewater storage tanks. The pressure in the process area firewater main is maintained using jockey pumps with minimum flow protection back to the filtered and firewater storage tanks. In the event of decrease in pressure in the firewater ring main the main firewater pumps (three 50% pumps provided: 1 electric and 2 diesel) autostart. In the event the pressure in the main does not increase within 20 seconds a second firewater pump is started. It is only possible to stop the main firewater pumps manually. Service water booster pumps are used for maintaining the jetty firewater ring main pressurised. In the event the pressure in the jetty ring main decreases, the jetty seawater firewater pumps are started automatically (two 100% pumps: 1 electric and 1 diesel). All main process and jetty area firewater pumps will be subject to weekly manually operator performance testing and maintenance.




Section ID Firewater Systems





HAZOP Item No.

Plant Section









1178 Loss of

Containment1. Jockey and/or firewater pump seal failure

1. Weekly testing and inspection of main firefighting and jockey water pumps2. Spare pumps available to enable maintenance

1179 Pressure - High 1. Malfunction/incorrect setpoint

055-FIC-0004 jockey pump minimum flow

1. Loss of minimum flow protection 1. Minimum flow control valve will be FO2. Maximum design pressure of ring main 16 barg same as design pressure jockey and firewater pumps

2. Malfunction/incorrect setpoint 055-FIC-0003 main firewater minimum flow

1. Loss of minimum flow protection 1. Minimum flow control valve will be FO2. Maximum design pressure of ring main 16 barg same as design pressure jockey and firewater pumps

1. Overspeed of main fire pump diesel pump motor

1. Potential to exceed rated design discharge pressure and overpressure of firewater ring main

1. Governor controls maximum speed of diesel pump 2. 055-PSV-0001A/B on diesel pumps back to storage tank




HAZOP Item No.

Plant Section







1180 Pressure - Low 1. Malfunction/incorrect setpoint 055-FIC-0004 jockey pump minimum flow

1. Minimum flow opens recycling firewater to tank2. Potential decrease of pressure in firewater main

1. 055-PIC-/PAL-0006 on firewater ring main initiates autostart and switch of standby jockey firewater pump2. 055-PIC/PAL-0003 autostarts electric fire pump if ring main pressure continues to fall 3. 055-FIC/FAL-0003 opens minimum flow protection on firewater pump 4. Pump running light for firewater main pump 055-XL-0001C

2. Malfunction/incorrect setpoint 055-FIC-0003 main firewater minimum flow

1. Minimum flow opens recycling firewater to tank2. Potential decrease of pressure in firewater main

1. 055-PIC/PAL-0003 initiates autostart of first electric firewater pump. If minimum firewater ring main pressure not achieved, control system automatically autostarts second pump after 20 seconds

R1180.1 Review configuration of firewater system. Consider provision of check valve to prevent depressurisation of ring main through main firefighting pump minimum flow to tank

TS 2 2 4

3. Fire case on site 1. Ring main pressure will drop 1. 055-PIC/PAL-0003 initiates autostart of first electric firewater pump. If minimum firewater ring main pressure not achieved, control system automatically autostarts second pump after 20 seconds2. Filtered and firewater tanks hold as minimum 4 hours firefighting water at full capacity (two firewater pumps operating) in each tank, i.e. total firewater holdup is 8 hours

R1181.2 Next revision of P&IDs will remove 051-LALL-007A/B stop of main firewater pumps

TS 2 2 4




HAZOP Item No.

Plant Section







4. Leakage in main fire ring main Loss of firewater and potential for decrease in firewater ring main pressure

1. 055-PIC-/PAL-0006 on firewater ring main initiates autostart and switch of standby jockey firewater pump2. 055-PIC/PAL-0003 autostarts electric fire pump if ring main pressure continues to fall3. Underground sections of firewater system will be non-corrosive GRP, minimising potential for system leakage4. Firewater ring main is made up of a series of rings so each plant network has two independent supply connections

1181 Vacuum 1. Operation of firewater pump 1. Potential low pressure in storage

tank 1 See filtered and firewater storage tank node


1183 Temperature -

HighNo new issues

1184 Temperature -

LowNo new issues


Zero)No new issues


1187 Level - Low 1. See filtered and firewater tank

node





HAZOP Item No.

Plant Section







1189 Phase - More 1. Algal and bacterial growth in filtered and firewater storage tanks

1. Potential for fouling of firewater ring main and pump suction pipework

1. Raw water is dosed with biocide (sodium hypochlorite) upstream of inlet for raw water filtration package

No new issues 1190 Phase - Less


1192 Wrong


No new issues

1193 Corrosive (As



1195 Wrong Material





HAZOP Item No.

Plant Section







1196 Node 2 Jetty firewater system

Overview




1200 Flow - Reverse 1. Depressurisation of jetty

firewater ring main to service water system

1. Potential for reverse flow R1200.1 Next revision of P&ID will show double check valve arrangement on service water tie-in to jetty firewater ring main

TS 2 2 4

1201 Loss of

Containment1. Corrosion of jetty firewater ring main, as it uses raw filtered water and/or seawater

1. CS firewater ring main will be painted to minimise external corrosion2. Jetty firewater main can be washed using service water to remove seawater from system. Maintenance override of 031-PIC-0006 autostart of jetty firewater pumps will be permitted

R1201.1 OK LNG to review proposed design of jetty firewater pump discharge headers and minimum flow lines. Consider requirements for upgrade of proposed materials as draining of seawater from system not really appropriate due to weekly fire pump test and jetty availability issues.

OK LNG 2 2 4

Node Equipment Service water booster pumps 052-P-131A/BJetty firewater pumps 031-P-103A/B Biocide dosing system 031-U-101


2252-052-PID-00-31-01/Rev A/23-05-062252-031-PID-00-31-03/Rev A/14-07-06

Design intent Service water from the Service water booster pumps is used to maintain the pressure in the jetty firewatre ring main and provide flow for up to two utility hose connections. In the event the ring main pressure drops the jetty firewater pumps are started automatically supplying the jetty firewater ring main with seawater




HAZOP Item No.

Plant Section







1202 Pressure - High 1. Activation of 031-PSV-0003B 1. Potential to overpressure jetty firewater ring main

R1202.1 Next revision of P&ID will show discharge of 031-PSV-0003B downstream of minimum flow control valve

TS 2 2 4

1203 Pressure - Low 1. Malfunction of upstream service

water pumps and/or excessive use of water for maintenance

1. Decrease in jetty firewater header pressure 2. Potential for loss of firewater protection at jetty

1. 031-PIC-0006 autostart of jetty firewater pump2. If after 20 seconds, ring main pressure is not achieved, control system will autostart standby diesel firewater pump

2. Fire on the jetty 1. Decrease in jetty firewater header pressure

1. 031-PIC-0006 autostart of jetty firewater pump2. If after 20 seconds, ring main pressure is not achieved, control system will autostart standby diesel firewater pump

3. Firewater pump trip and/or loss of electrical supply

1. Loss of pressure in firewater main during fire case

1. 031-PIC-0006 autostart of diesel jetty firewater pump2. Dedicated diesel supply tank sized for 8 hours supply3. 031-LAL-0006B low level diesel supply in tank

1. Review underway to consider requirement for jetty emergency electrical generator (instrumentation, lighting, etc.)

4. Malfunction/incorrect setpoint of 031-FIC-0003 on minimum flow

1. Depressurisation of firewater ring main

1. Check valve prevents depressurisation of ring main via minimum flow protection of firewater pumps2. 031-PIC-0006 autostart of jetty firewater pump3. If after 20 seconds, ring main pressure is not achieved, control system will autostart standby diesel firewater pump






HAZOP Item No.

Plant Section








No new issues

1207 Temperature -

LowNo new issues


Zero)No new issues

1209 Level - High 1. Silting of firewater basin 1. Marine baseline survey currently

being undertaken and will be considered in location of jetty firewater pump



1212 Phase - More 1. Algal and/or marine growth on

firewater system1. Potential for fouling of jetty firewater system

1. Biocide dosing system for jetty firewater system

R1212.1 Next revision of P&ID will show biocide dosing connection to pump firewater basin screen

1. Dosing of inlet systems not considered a problem during discharge and firewater test to local marine environment

TS 2 2 4



1215 Wrong


1. Malfunction in biocide dosing system

1. Potential for algal and marine growth within jetty firewater ring main and equipment

R1215.1 Detailed HAZOP of vendor package during detailed design will consider alarms to notify operator of malfunction and low level biocide dosing to jetty firewater ring main

TS 3 3 7




HAZOP Item No.

Plant Section








No new issues

1217 Explosive 1. Location of jetty firewater pumps 1. Potential for source of ignition in

event of emergency at jetty1. Location of firewater pump in non-hazardous area

No new issues

1218 Wrong Material



HAZOP Record Sheet: Effluent Treatment Version: FinalSheet 93/125


HAZOP Item No.

Plant Section


1219 Node 1 Effluent treatment system

Overview

Design intent See Above

Node Equipment Boilers blowdown LNG Train 1 Collection Basin 057-BA-110Boilers blowdown LNG Train 2 Collection Basin 057-BA-111Boilers blowdown LNG Train 3 Collection Basin 057-BA-112Boilers blowdown LNG Train 4 Collection Basin 057-BA-113Boilers blowdown LNG Train 1 Lifting Pumps 057-P-110A/BBoilers blowdown LNG Train 1 Lifting Pumps 057-P-111A/BBoilers blowdown LNG Train 1 Lifting Pumps 057-P-112A/BBoilers blowdown LNG Train 1 Lifting Pumps 057-P-113A/BChemical sewer receiving pit 075-BA-120Laboratory pit 057-BA-126Chemical sewer neutralisation basins 057-BA-121A/BChemical sewer neutralisation pumps 057-P-121A/BSulphuric acid dosing package 057-U-102Sodium hydroxide dosing package 057-U-103


Effluent from LNG steam blowdown system is collected in dedicated collection basins, then pumped under level control (on/off) to a chemical sewer receiving pit. Chemical effluent from the utilities chemical storage areas is collected and flows under gravity to mix with the boiler blowdown water in the chemical sewer recieving pit. Mixed effluent from the chemical sewer recieving pit flows under gravity into either chemical sewer recieving basins, where it is mixed and neutralised before discharge to offsite. Washing effluent from the laboratory activities is stored in the single laboratory pit and then collected using a vacuum truck for treatment offsite. Specific reaction and analysis effluent from the laboratory is collected in drums for treatment offsite also.




Section ID Effluent treatment system





HAZOP Item No.

Plant Section







1220 Flow - High 1. Blowdown of LNG train boiler system (continuous and discontinuous steam drum blowdown)

1. Continuous flow of steam blowdown effluent into LNG train collection basin2. Gradual increase in level of LNG collection basin with potential to overfill

1. 057-LI/LAH-0001/2/8/9 notifies operator of requirement to start pump if pump not already operating2. 057-LI/LAH-0004/5 closes chemical sewer neutralisation basin inlet valve and initiates start of neutralisation and pump-out to offsite 3. Logic controller I-5701 is common between both chemical sewer neutralisation basins

R1220.1 Consider whether switch in chemical sewer neutralisation basin logic should wait until high alarm in duty basin before opening inlet valve on standby basin to ensure the two basins operate in sequenceR1220.2 Consider benefits for automatic start of boiler blowdown lifting pumps based on high level in collection basin, given blowdown flow rate is continous at approximately 12 m3/hr

TS 5 1 5

2. Maintenance in chemicals storage area and/or rainy season

1. Increase in flow rate of effluent from chemical sewer to chemical sewer receiving pit2. Potential for excessive flow rates into chemical sewer neutralisation basin

1. Effluent from chemical sewer receiving pit (from LNG blowdown and chemical sewer) flows by gravity into chemical sewer neutralisation basin2. Discharge of effluent from chemicals area is initiated by operator opening manual valve3. Chemicals area is sheltered, reducing potential for collection of rainwater in kerbed areas for disposal via the chemical sewer neutralisation basin (non-contaminated rainwater from the shelter roofs is routed directly to non-contaminated sewer)

3. Disposal of laboratory washing effluent to sewer

1. Increase in level in the laboratory pit2. Potential for release of untreatedeffluent to atmosphere

1. 057-LI/LAH-0003 on the laboratory pit2. Requirement for collection by vacuum truck for disposal offsite3. Laboratory pit has a nominal size of 5 m3




HAZOP Item No.

Plant Section







1221 Flow - Low 1. Pump trip in blowdown collectionbasin

1. Loss of pump-out of effluent in blowdown collection basin2. Continued increase in level in collection basin with potential to overpressure

1. 057-LI/LAH-0001/2/8/9 on blowdown collection vessel

R1221.1 In the event that R1220.2 is implemented, autostart of standby pump will occur if level does not start to decrease in the basin once start signal initiated. In the event of pump trip during pumpout, high level in basin will initiate additional pump start signal

TS 5 1 5

2. Pump trip in chemical sewer neutralisation basin

1. Loss of mixing flow in basin2. Loss of pump-out of neutralised effluent offsite

1. Chemical sewer neutralisation control logic will be configured to autostart standby pump in the event of pump trip during either neutralisation mixing and/or pump out sequence stage

3. Pump trip and/or incorrect flow rate setting on neutralisation dosing package

1. Loss on injection and/or increased duration for neutralisation of effluent in basin2. Potential for loss of neutralisation sequence step in basin

1. Summarised malfunction alarms 057-UUA-0001 and 057-UUA-0003 on neutralisation dosing packages2. Spare dosing pump provided in dosing system 3. Stroke volume is calibrated manually using calibration pot during commissioning of package

R1221.2 HAZOP of chemical dosing packages will be undertaken during detailed design

TS 3 3 7

1222 Flow - No 1. Malfunction of sequence valve,

e.g. 052-AV-0001B and/or 2B1. Loss of pump out of chemical sewer neutralisation basin2. Continued filling of standby chemical sewer neutralisation basin with potential to liquid fill bothbasins3. Release of water from intermediate chemical sewer receiving pit

1. 057-AIC-0001/2 indication of neutral pH in basin 2. Sequence valve position indication provided in DCS panel

R1222.1 Review with instrumentation group whether provision of sequence failure alarm is possible and/or necessary for the chemical sewer neutralisation basin

TS 4 3 8




HAZOP Item No.

Plant Section







1223 Flow - Reverse 1. Reverse flow from chemical sewer receiving pit to collection basin

1. Check valves on discharge pumps prevent reverse flow2. Vapour space in chemical sewer receiving pit

1224 Loss of

Containment1. Piston seal failure on dosing package

1. Potential for spillage of acid and/or caustic 2. Potential for neutralisation of chemical dosing fluids

1. Acid and causic dosing packages will be located in kerbed, segregated areas

2. Loss of containment (e.g. corrosion) of concentrated acid or caustic chemical storage tanks

1. Potential operator hazard and chemical burns2. Potential for significant heat of reaction between caustic and acid solutions

1. Periodic operator inspection of the area2. Operator PPE3. Dedicated sgregated kerbed areas for each chemical storage tank to minimise potential for mixing of released caustic and acid solutions





1229 Temperature -

High1. Heat of neutralisation and dilution in chemical sewer neutralisation basin

1. Potential for increase in effluent temperature

1. Continuous blowdown from LNG boiler system is approximately neutral does not require neutralisation2. No significant heat of neutralisation expected in basin as pumps used for circulation of mixing of effluent during neutralisation sequence




HAZOP Item No.

Plant Section








No new issues


Zero)No new issues

1232 Level - High 1. Malfunction of 057-LI-0004/5 1. Inlet valve opens in error

2. Potential to liquid fill chemcial sewer neutralisation basin

1. Discharge to offsite location is controlled by pH and not level control

1233 Level - Low 1. Malfunction of 057-LI-0004/5 1. Potential to cavitate

neutralisation pump1. Spare neutralisation pump


1235 Phase - More 1. Release of solids from BFW

system during blowdown to collection basin

1. Gradual increase in scale and mineral solids in collection basin

1. Demineralised water used for BFW production2. Blowdown collection basin and chemical sewer receiving pit are both enclosed basins, reducing contamination potential with atmospheric solids 3. Possible to remove and clean blowdown collection basins using vacuum truck, sufficient maintenance access is provided (road access and manhole)

R1235.1 Consider provision of hard pipework connection for removal of solids from bottom of blowdown collection basins using vacuum truck

TS 5 2 8



1238 Wrong


1. Incomplete mixing in neutralisation basin and/or malfunction 057-AIC-0001/2

1. Pumping of incorrect pH effluent offsite for disposal 2. Potential environmental impact

1. Operator requirement for periodic sampling of discharge effluent and recalibration of pH meter

R1238.1 Provide sample connection on discharge of chemical sewer neutralisation pumps for sampling purposes

TS 4 1 4




HAZOP Item No.

Plant Section








1. Transfer of acid/caustic liquids to chemical sewer receiving pit in the chemical sewer

1. Potential chemical attack on concrete materials

1. Appropriate materials for chemical sewer2. Chemical sewer receiving pit will be concrete with chemical resistant epoxy lining3 Chemical sewer neutralisation basin will be concrete with chemical resistant epoxy lining


1241 Wrong Material

(Other than)1. Construction of underground basins with potential for operator falling hazard

1. Underground collection basins with metal roofing designed to enable operator walking2. Chemical sewer neutralisation basin will have fencing to prevent operator ingress


HAZOP Record Sheet: Oily Water System Version: FinalSheet 99/125


HAZOP Item No.

Plant Section


1242 Node 1 Type 1 (process area) collection basin

Overview LALL actions in this unit are configured as DCS stop/inhibit actions, not hardwired ESD trip actions as no immediate safety impact. No SIL rating of 056-LALL-003 required by project


Section ID Oily water system General Section Description:

Oily contaminated waters from the process areas (e.g. process area rainwater contaminanted with surface spillage oils and process water separated in the inlet facilities during manual draining operations) are collected in dedicated collection basins and pumped to a common oily water tank. Oil is seperated and skimmed for disposal in the liquid flare. Separated water is treated in a DAF and settled in a final control basin before release to offsite water course. Sludge from the DAF is collected and pumped offsite for disposal


2252-056-PID-00-31-01/Rev A/12-09-062252-056-PID-00-31-05/Rev A/12-09-062252-056-PID-00-31-06/Rev A/12-09-062252-056-PID-00-31-07/Rev A/12-09-062252-056-PID-00-31-08/Rev A/12-09-062252-056-PID-00-31-09/Rev A/12-09-062252-056-PID-00-31-10/Rev A/12-09-062252-056-PID-00-31-11/Rev A/12-09-062252-056-PID-00-31-12/Rev A/12-09-062252-056-PID-00-31-13/Rev A/12-09-062252-056-PID-00-31-14/Rev A/12-09-062252-056-PID-00-31-17/Rev A/12-09-062252-056-PID-00-31-18/Rev A/12-09-062252-056-PID-00-31-19/Rev A/12-09-062252-056-PID-00-31-20/Rev A/12-09-062252-056-PID-00-31-21/Rev A/12-09-062252-056-PID-00-31-23/Rev A/12-09-062252-056-PID-00-31-02/Rev A/12-09-06

Design intent Oily contaminated process area surface runoff water is collected in dedicated area collection basins. The collection basins are designed such that initial contaminated surface water enters the inlet chamber and overflows a wier arrangement into the main chamber. As the level increases in the main chamber, water from the inlet chamber overflows into the normally non-contaminated sewer system for disposal without treatment, surface oil is prevented from reverse flow into the inlet chamber and non-contaminated sewer by a baffle type arrangement

Node Equipment Process area collection basins and lifting pumps




HAZOP Item No.

Plant Section





1243 Flow - High 1. Washing of process area hard standing during cleaning operations

1. Gradual increase in level in the dedicated process area collection basin 2. Potential to liquid fill collection basin3. Potential for release of untreated oily water to non-contaminated sewer

1. Each processs area collection basin is 140 m3 with pumps for manual initiated pumping of oily water to common oily water tank2. Not possible to overflow collection basins, as water flows into the non-contaminated sewer from the inlet chamber in the event of high level in the collection basin3. Operating procedures will state requirement for operator to pump out collection basins following maintaenance and cleaning activities to ensure collection basin is maintained at a low level: for correct operation, initial contaminanted water during rainfall flows into the collection basin and non contaminated rainwater flows to the non contaminated sewer as the level in the basin increases




HAZOP Item No.

Plant Section





2. High seasonal rainfall 1. Flow of oil contaminated surface water from process area to surface drains and area collection basin 2. Gradual increase in level in collection basin 3. Potential for basin overflow

1. Each processs area collection basin is 140 m3, sized for approximately 10 mins peak rainfall2. Not possible to overflow collection basins, as water flows into the non-contaminated sewer from the inlet chamber in the event of high level in the collection basin3. Requirement for operator to manually initiate collection basin lifting pumps following rain for treatment of oily water effluents in the oily water treatment system4. Assumption in design that only initial process area surface runoff water will be contaminated and runoff water from prolonged periods of rain can flow via the inlet chamber, to the non contaminated sewer without treatment

3. Pump-out of collection basin to oily water tank

1. Increase in level in oily water tank 2. Potential to overfill oily water tank

1. Oily water tank sized to hold the inventory from ten process area collection basins 2. 056-LI/LAH-0004 initiates start of oily water transfer pumps and transfer of oily water to downstream DAF treatment package3. Design flow rate of oily water transfer pumps and downstream treatment facilities is 60m3/hr, higher than individual collection basin lifting pump capacity of 40m3/hr4. Operator coordination of pump-out activities from various process areas 5. 056-LI/LAHH-0003 on oily water tank (alarm only) and overflow to oily water sewer

R1243.1 Operating procedures to recommend notification and communication with utilities area personel before starting pumpout of oily water collection basins to prevent overwhelming oily water tank and oily water treatment packages following heavy rainfall

TS 5 3 9




HAZOP Item No.

Plant Section





1244 Flow - Low 1. Lifting pump trip during pump-out operation

1. Loss of collection basin pump-out

1. Operator supervision2. In the event of motor failure, autostart of standby pump 3. Requirement for operator to switch duty and standby pump to ensure similar operating run times

1245 Flow - No 1. Normal condition 1. Loss of flow of contaminated

oily water to oily water tank and downstream treatment system

1. Oily water system is contaminated with heavy oils. Therefore, downstream oily water treatment is only DAF with no biological treatment of effluent. Therefore, on/off "slug flow" is not a problem for the treatment process

1246 Flow - Reverse 1. Normal condition with no

pumpout and/or lifting pump trip during pumpout operation

1. Potential for reverse flow from oily water header and oily water tank to collection basin

1. Check valves in discharge of all lifting pumps2. Top entry into oily water tank in vapour space, prevents reverse flow of oily water back to collection basin

1247 Loss of

Containment1. Incorrect operation of collection basin, initiating cleaning operations with level in the collection basin

1. Potential for contaminated water to run directly into non-contaminated sewer rather than over wier into collection basin

1. Operating procedures and requirement for operator to pump out collection basin to low low level pump stop before undertaking cleaning operations

1248 Pressure - High 1. Isolation of oily water tank

and/or header valve 1. Potential to dead-head lifting pump and overpressure pipework

1. Maximum design pressure on lifting pumps is common at 8.5 barg, lower than design pressure of all oily water header pipework

2. Simultaneous pump-out of collection basins to oily water tank

1. High flow rate of oily water to oily water tank2. Gradual increase in vapour space pressure

1. 4" vent2. 12" overflow

1249 Pressure - Low 1. Pump-out of oily water tank with

no inlet flow1. Gradual decrease in vapour space pressure

1. 4" vent2. 12" overflow




HAZOP Item No.

Plant Section






1251 Partial Pressure 1. Transfer of volatile organic compounds to oily water tank

1. Potential for formation of flammable atmospheres in vapour space of oily water tank

1. Oil contaminants in oily water system are heavy hydrocarbons, lubricating oils and other low vapour pressure hydrocarbons2. No potential for flammable atmospheres in vapour space of oily water tank

2. Release of flammable materials to atmosphere from process area

1. Potential for utility lifting pumps to act as ignition source

1. Collection basins in process areas will, if possible, be located in non-hazardous areas. In the event located in classified area, pump motors will be rated accordingly 2. Operator initiated pump-out of collection basins

R1251.1 Ensure appropriate flammable gas detection is provided in process area, including in vicinity of collection basins, in the event that non-ExD pumps provided. Emergency scenarios should also consider what action to take in the event of large release simultaneous with pump operation

TS 2 4 7

1252 Temperature -

HighNo new issues

1253 Temperature -

LowNo new issues


Zero)No new issues





HAZOP Item No.

Plant Section





1256 Level - Low 1. Pump-out of collection basin 1. Gradual decrease in level2. Potential for loss of level and pump cavitation

1. Operator supervision of pumping operations2. Low level stop of pumps in collection basins3. Running light indication on DCS

2. Malfunction in LT on collection basin

1. Loss of pump stop signal 2. Decrease in level with potential to damage pump

1. Standby collection basin pump 2. All collection basin pumps are identical and therefore interchangable 3. Main operational period for the oily water system is during the rainy season


1258 Phase - More 1. Gradual collection of solids in

collection basin, e.g. sand and other material

1. Potential for damage to lifting pump

1. Pump type selection 2. Normal maintenance and periodic cleaning of collection basins, DAF, etc. for removal of solids

R1258.1 Consider provision of hard piping to each collection basin to facilitate cleaning and removal of solids by vacuum truck

TS 5 2 8



1261 Wrong


1. Heavy contamination of acid gas removal unit process area with amine spillage (caustic)

1. Potential for contamination of oily water treatment system with caustic amine2. Potential for release of high COD amine to non-contaminated sewer

1. Acid gas removal unit process area is kerbed, with normally closed drain valve to oily water sewer2. Requirement for operator to assess collected water before draining to oily water system 3. In the event of heavy amine contamination of process area water, runoff water will need to be collected and disposed of at offsite facilities as no means of onsite treatment available

R1261.1 Ensure operating procedures clearly state requirements for treatment of washing waters from amine process areas following large amine spillage offsite. Neutralisation and release to oily water system is inappropriate due to high COD of effluent and no downstream biological treatment process

TS 4 3 8




HAZOP Item No.

Plant Section






1. General corrosion of carbon steel pipework

1. Potential for rust formation and leakage

1. All oily water header pipework will be painted to minimise potential for external corrosion2. Oily water header pipework has 3mm corrosion allowance 3. Oily water tank has 3mm corrosion allowance and is not lined

R1262.1 Detailed design phase will consider requirements for corrosion protection on base of tank, e.g. CP, etc.

TS 3 3 7


1264 Wrong Material





HAZOP Item No.

Plant Section





1265 Node 2 Type 2 (inlet facility) collection basin

Overview





1270 Loss of

Containment1. Draining of process unit (MP condensate seperator and/or condensate stabiliser) washing fluid to oily sewer with high level in collection basin

1. Potential for flow of contaminated water to non-contaminated sewer without treatment

1. Collection basin baffle prevents reverse flow of contaminated process water to non-contaminated sewer



Node Equipment Inlet facilities CNL/BG collection basin 056-BA-504Inlet facilities Shell collection basin 056-BA-506Inlet facilities CNL/BG lifting pumps 056-P-504A/BInlet facilities Shell lifting pumps 056-P-506A/B



Design intent Oily contaminated process area surface runoff water from the inlet facilities is collected in dedicated area collection basins. In addition to process area runoff water, washing water from the inlet facility condensate stabiliserand condensate MP seperator is also discharged to the collection basin. The collection basins are designed such that initial contaminated surface water enters the inlet chamber and overflows a wier arrangement into the main chamber. As the level increases in the main chamber, water from the inlet chamber overflows into the normally non-contaminated sewer system for disposal without treatment, surface oil is prevented from reverse flow into the inlet chamber and non-contaminated sewer by a baffle type arrangement




HAZOP Item No.

Plant Section







1275 Temperature -

HighNo new issues

1276 Temperature -

LowNo new issues


Zero)No new issues

1278 Level - High 1. Low concentration of oil

contamination in normal run-off water flow from process area

1. Gradual collection of oil on surface of collection basin water

1. Operator skimming of oil collected in each collection basin2. Road access to each collection basin to enable vacuum truck collection of skimmed oil from basins

R1278.1 Review proposed design of oily water system to consider and develop operating procedure for management of oil collected on surface of each collection basin over time

TS 4 3 8






1284 Wrong


No new issues

1285 Corrosive (As



1287 Wrong Material





HAZOP Item No.

Plant Section





1288 Node 3 Type 3 (flare area) collection basin

Overview


1290 Flow - Low 1. Flare lifting pump trip during

rainy season1. Potential for flooding of sunken flare KO drum area

1. 056-LI/LAH/LAHH-0040 on flare lifting basin2. Autostart of standby flare lifting pump by 056-PT-0041A/B

R1290.1 Review whether flare lifting pumps need to be connected to emergency power supply and/or provision of one electric and one diesel pump, given location and function

TS 2 3 6

2. Low rainfall flow rates 1. Decreased flow of rainwater into flare area collection basin and lifting basin2. Potential for on/off operation of flare lifting pumps as (A) small volume of flare lifting basin, and (B) sizing of flare lifting pumps for maximum rainfall flow rate

R1290.2 During detailed design, review proposed design following reciept of further rainfall information specific to site location. It may be necessary to consider increasing flare lifting basin size and/or revise pump configuration (three 50% pumps)

TS 2 3 6



2252-056-PID-00-31-22/Rev A/12-09-062252-056-PID-00-31-02/Rev A/12-09-06

Design intent Oily contaminated process area surface runoff water from the flare area is collected in a dedicated collection basin. The collection basin is designed such that initial contaminated surface water enters the inlet chamber and overflows a wier arrangement into the main chamber. As the level increases in the main chamber, water from the inlet chamber overflows into the flare lifting basin. The non-contaminated water is then pumped into the non-contaminated sewer for disposal without treatment. Surface oil from the flare collection basin is prevented from reverse flow into the inlet chamber and flare lifting basin by a baffle type arrangement. The flare lifting basin and pumps are required as the flare KO drum process area is located at approximately 3-4m below normal process area grade elevation, preventing gravity flow to the non-contaminated sewer.

Node Equipment Flare collection basin 056-BA-512Oily water flare lifting pumps 056-P-512A/BFlare lifting basin 056-BA-513Flare lifting pumps 056-P-513A/B




HAZOP Item No.

Plant Section







No new issues


1295 Pressure - Low 1. Location of flare collection basin

at low surface elevation, 3-4 m below normal process area grade elevation

1. Requirement to pump oily water from flare collection basin to oily water tank

1. All oily water lifting pumps are identical and designed for maximum head required for pumping of water from (A). furthest location, and (B). maximum differential elevation



1298 Temperature -

HighNo new issues

1299 Temperature -

LowNo new issues


Zero)No new issues




HAZOP Item No.

Plant Section





1301 Level - High 1. Requirement for manual start of pump out flare collection basin

1. Potential exposure of operator to high radiation levels

1. Flare collection basin is outside flare sanitary zone

2. High seasonal rainfall 1. High flow rate of surface run-off water from flare and sunken flare KO drum process areas2. Potential for overflow of flare collection basin and flare lifting basin

1. Following initial flow of contaminated rainwater into inlet chamber, continued rainfall and surface water will flow into the flare lifting basin under gravity2. Water in flare lifting basin is pumped into the non-contaminated sewer and automatic on-off level control 3. Flare lifting pumps have been sized taking into account the surface drainage area and anticipated highest rainfall conditions4. Other process area kerb and drainage arrangements prevent flow of surface water from other process areas to lower flare area

3. Malfunction/incorrect setpoint 056-LI-0040

1. Loss of pump start2. Potential to flood flare area

R1301.1 Consider requirements for independent level indication, high level alarm and high high level alarm, given potential impact on other flare area related equipment, i.e. flare KO drum condensate pump, incinerators, etc.

TS 2 3 6

1302 Level - Low 1. Malfunction/incorrect setpoint

056-LI-00401. Loss of pump stop 2. Potential for loss of level and pump damage

R1302.1 See Recommendation R1301.1, and consider provision of independent low low level pump trip to prevent pump damage

TS 2 3 6







HAZOP Item No.

Plant Section






1307 Wrong


No new issues

1308 Corrosive (As



1310 Wrong Material





HAZOP Item No.

Plant Section





1311 Node 4 Oily water treatment

Overview

1312 Flow - High 1. Transfer of oily water from

collection basins to oily water tank 1. Gradual increase in level in oily water tank2. Potential to overfill oily water tank

1. 056-LI/LAH-0004 controls transfer of oily water to DAF oily water treatment package2. Gravity flow of treated water from DAF into final control basin 3. 056-LI/LAH-0008 controls transfer of treated water to sea

2. Malfunction/incorrect setpoint 056-FIC-0001

1. High transfer flow rate of oily water to DAF treatment package 2. Potential for reduced residence times in oily water treatment package3. Potential for off spec treated water release to sea

1. Oily water transfer pumps, oily water treatment package and final control pumps all have same design flow rate capacity 2. Daily operator sampling of final control basin effluent

Node Equipment Oily water tank 056-TK-120Floating skimmer 056-Z-101Oil pit 056-BA-121Oily recovery pumps 056-P-121A/BOily water transfer pumps 056-P-150A/BOily water treatment package 056-U-101Final control basin 056-BA-122Sludge pit 056-BA-123Final control pumps 056-P-122A/BSludge pumps 056-P-123A/B



Design intent Oily water in the oily water tank is pumped under level on/off control at a constant flow rate to the oily water treatment package (DAF type). Treated water from the DAF package flows under gravity to the final control basin from where it is pumped under on/off level control to the sea.




HAZOP Item No.

Plant Section





1313 Flow - Low 1. Malfunction/incorrect setpoint 056-FIC-0001

1. Low transfer flow rate of oily water to DAF treatment package2. Potential to overfill oily water tank 3. Potential to dead-head oily water transfer pumps

1. 056-LAH-0004 and 056-LAHH-0003 on oily water tank 2. 056-LI-LAL-0008 stops final control pump 3. Pump running lights

R1313.1 Consider deletion of pump discharge flow control, if not removed, ensure 056-FV-0001 is FO

TS 5 3 9

2. Dry season operation 1. Loss of transfer of water from process area collection basins to oily water tank 2. Decrease in level in oily water tank

1. 056-LI/LAL-0004 stops oily water transfer pumps2. 056-LI/LAL-0008 stops final control pumps

R1313.2 Update P&ID to show on-off control signal from 056-LI-0004 to control panel on oily water treatment package to control injection of oily water treatment package chemicals

TS 4 3 8

3. Trip of oily water transfer pump 1. Loss of transfer of oily water to oily water treatment package

1. 056-PT-0005A/B autostart of standby pump

4. Trip of final control pumps 1. Loss of transfer of treated water to sea

1. 056-PT-0007A/B autostart of standby pump


1315 Flow - Reverse 1. Trip of final control pumps

during recycle of off-spec treated water to oily water tank

1. Potential for reverse flow, flooding final control basin

1. 056-PT-0007A/B autostart of standby pump2. Off-spec treated water recycle to oily water storage tank enters in top vapour space

1316 Loss of

Containment1. Pump seal failure on oily water transfer pumps

1. Spray release of water to atmosphere

1. Spare pump2. Operator inspection of area

2. Loss of oily water floating skimmer and/or failure of internal hose connection

1. Potential for loss of oil skimming inside oily water tank2. Gradual increase in oil interface level in tank

R1316.1 Consider provision of skimming nozzles in tank at normal operating level for use in event of failure of floating skimmer device (see acid gas removal process HAZOP)

TS 5 4 10




HAZOP Item No.

Plant Section





1317 Pressure - High 1. Malfunction of transfer pump autostart

1. Two pumps in operation2. Increase in flow of oily water to DAF treatment package

1. DCS pump running lights2. Oily water treatment package overdesign3. 056-LI/LAH-0008 on final control basin

2. Incorrect operator lineup of sludge pump

1. Potential to dead-head pump and overpressure discharge pipework

R1317.1 Consider requirement for PSV protection on sludge pump discharge since this is a positive displacement type pump

TS 4 3 8

1318 Pressure - Low 1. Loss of plant air and/or oily

water treatment package air compressor

1. Reduced DAF performance with potential for exceedance of discharge composition (high dissolved oil content)

1. 056-PI-0006 air drum pressure R1318.1 Consider configuration of low alarm on air pressure on oily water treatment packageR1318.2 Undertake HAZOP of vendor package during detailed design

TS 3 3 7



1321 Temperature -

HighNo new issues

1322 Temperature -

LowNo new issues


Zero)No new issues

1324 Level - High 1. Malfunction of 056-LI-0004 on

oily water tank1. Loss of start signal to oily water transfer pumps2. Gradual increase in level in oily water tank

1. Independent 056-LI/LAHH-0003 on oily water tank 2. 12" overflow on the tank

2. Malfunction of 056-LI-0008 on final control basin

1. Loss of start signal to treated water final control pumps2. Potential flooding of final control basin

1. Periodic operator inspection of the area




HAZOP Item No.

Plant Section





3. Malfunction of 056-LI-0005 on oil pit

1. Loss of high alarm notifying operator of requirement to start pump 2. Potential for localised flooding of area

1. Oil pit sized for collection of free oil from all collection basins (via hydrocarbon floating skimmer)2. Periodic operator inspection of area

4. Malfunction of 056-LI-0009 on sludge pit

1. Loss of high alarm notifying operator of requirement to start pump 2. Potential for localised flooding of area

1. Sludge pit sized for collection of sludge produced from treatment of all oily water from all collection basins2. Periodic operator inspection of area

1325 Level - Low 1. Malfunction of 056-LI-0004 on

oily water tank1. Loss of stop signal to oily water transfer pumps2. Gradual decrease in level in oily water tank

1. Independent 056-LI/LALL-0003 on oily water tank stops transfer pump

2. Malfunction of 056-LI-0008 on final control basin

1. Loss of stop signal to treated water final control pumps2. Potential loss of level in final control basin 3. Potential pump damage

1. Periodic operator inspection of the area 2. Spare final control pump 3. Pump DCS running light

3. Malfunction of 056-LI-0005 on oil pit

1. Loss of stop signal to oil recovery pumps2. Potential loss of level3. Potential pump damage

1. Periodic operator inspection of the area 2. Spare oil recovery pump 3. Pump DCS running light

4. Malfunction of 056-LI-0009 on sludge pit

1. Loss of stop signal to sludge pumps2. Potential loss of level in sludge pit3. Potential pump damage

1. Periodic operator inspection of the area 2. Spare sludge pump 3. Pump DCS running light

R1325.1 Ensure suitable level device is provided since dirty service

TS 5 2 8


1327 Phase - More 1. Production of sludge in oily

water treatment package1. Sludge from oily water treatment package is skimmed and stored in sludge pit for disposal offsite

2. Completion of sludge transfer operation

1. Potential for prolonged periods with no sludge pumping2. Potential for pump blockage and damage

1. Utility connections provided on sludge pump suction and discharge to enable flushing following use




HAZOP Item No.

Plant Section







1330 Wrong


1. Malfunction in injection of oily water treatment package chemicals and/or poor package performance

1. Potential contamination of treated water disposal to sea

1. Summarised malfunction alarm 056-UUA-0001 on oily water treatment package2. Final control basin 3. Operator sample and inspection of final control basin every shift4. Possible to recycle off-spec treated water from final control basin back to oily water tank

1331 Corrosive (As


1332 Explosive 1. Formation of flammable

atmospheres on oil pit1. Potential ignition via oil recovery pumps

1. Hydrocarbon contamination is heavy oil with very low vapour pressure2. Appropriate selection of oily recovery pump

1333 Wrong Material



HAZOP Record Sheet: Sewage WW Treatment Version: FinalSheet 117/125


HAZOP Item No.

Plant Section


1334 Node 1 Sanitary water collection pits

Overview LALL/LAHH actions in this unit are configured as DCS stop/inhibit and start actions, not hardwired ESD trip actions as no immediate safety impact. No SIL rating of 059-LALL-**** or 059-LAHH-**** functions required by project

Design intent Sanitary waste water from the various areas in the plant is collected in sanitary water pits (each working volume 1.2m3). In addition, oily water from the LNG trains (2.5 m3/hr continuous flow) is also collected in the LNG train sanitary water collection pits. Sanitary water is pumped from each pit under level on/off control to the sanitary water collection basin.

Node Equipment Sanitary water inlet facilities pit 059-BA-101Sanitary water inlet facilities lifting pumps 059-P-101-A/BSanitary water LNG train 1 pit 059-BA-102Sanitary water LNG train 1 lifting pumps 059-P-102A/BSanitary water LNG train 2 pit 059-BA-103Sanitary water LNG train 2 lifting pumps 059-P-103A/BSanitary water LNG train 3 pit 059-BA-104Sanitary water LNG train 3 lifting pumps 059-P-104A/BSanitary water LNG train 4 pit 059-BA-105Sanitary water LNG train 4 lifting pumps 059-P-105A/BSanitary water utilities pit 059-BA-106Sanitary water utilities lifting pumps 059-P-106A/BSanitary water collection basin 059-BA-107


Sewage is collected in various basins around the plant and pumped under on/off level control to a common sanitary water collection basin. In addition to the domestic sewage, oily water from the LNG trains flows continuously (2.5 m3/hr) into the LNG train sanitary water pits for treatment along with the sanitary waste. The sanitary waste from the common collection basin is pumped into the sanitary water biotreatment package (extended aeration type treatment). Treated water from the sanitary water treatment package flows under gravity to the sanitary water discharge basin from where it was pumped offsite for disposal. Sludge from the sanitary water treatment package is collected and dried in the drying beds before collection and disposal offsite. Separated water from the sludge drying beds is collected and pumped back to the sanitary water treatment package.




Section ID Sewage waste water treatment





HAZOP Item No.

Plant Section







1335 Flow - High 1. Malfunction in process control on continuous flow of oily water from a single LNG train

1. Increase in flow of oily water to LNG train sanitary water pit 2. Increase in level in sanitary water pit

1. 059-LT-0003/4 (7/8, 15/16 or 17/18) starts LNG train sanitary water lifting pump 2. Operating capacity of sanitary water lifting pumps is 10m3/hr versus normal flow rate of 2.5 m3/hr3. 059-LT-0009/10 starts sanitary water feeding pump for transfer of waste to sanitary water biotreatment package4. High high level in sanitary water pit starts and switches duty to standby pump (assumption that duty pump is not operating effectively)

1. Philosophy for sanitary water system is that LALL, LAL, LAH and LAHH are setpoints within sanitary water pit and not DCS indicated alarm signals

2. Pumping of sanitary water to sanitary water collection basin

1. Increase in level in sanitary water collection basin2. Potential to overflow collection basin

1. Operating capacity of sanitary water lifting pumps is 10m3/hr versus sanitary water feeding pump capacity of 30m3/hr 2. 059-LT-0009/10 starts sanitary water feeding pump for transfer of waste to sanitary water biotreatment package




HAZOP Item No.

Plant Section







3. Simultaneous pumping of sanitary water to sanitary water collection basin

1. Increase in level in sanitary water collection basin2. Potential to overflow collection basin

1. 059-LT-0009/10 starts sanitary water feeding pump for transfer of waste to sanitary water biotreatment package2. Limited production of sanitary waste in plant areas, the main building area connects directly to the sanitary water collection basin (main shower, administration and canteen flows)3. In the event of high high level in the sanitary water collection basin, standby pump is started (continued operation two pumps) to deal with peak demand 4. Negligible effect on biotreatment package, as extended aeration package with minimum 20 hrs holdup and continued operation of two pumps for a period of minutes

3. Malfunction of duty LT in sanitary water pit

1. Start of standby pump2. Loss of stop signal to pump

1. DCS indication of standby pump running2. Independent LT in each sanitary water pit will stop pump in event of low low level

1336 Flow - Low 1. Low production of sanitary waste

on site (low demand periods within the day)

1. 059-LT/LAL-0003/4 (1/2, 5/6, 7/8, 15/16 or 17/18) stops sanitary water lifting pump 2. 059-LT/LAL-0009/10 stops sanitary water feeding pump from main sanitary water collection basin

2. Malfunction of lifting pump 1. Increase in level of sanitary water in pit and potential to overflow

1. 059-LT/LAHH autostart standby sanitary water lifting pump2. DCS indication of standby pump running




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3. Malfunction of duty LT in sanitary water pit

1. Loss of start signal to standby pump2. Increase in level in pit with potential to overflow

1. DCS indication of duty pump running2. Independent LT in each sanitary water pit would start standby pump in event of high high level


1338 Flow - Reverse 1. Pump trip and/or no pump

operating1. Potential reverse flow from collection basin to pit

1. Check valve on discharge from individual sanitary water lifting pump2. Sanitary water header enters vapour space on sanitary water collection basin

1339 Loss of

Containment1. Pump seal failure 1. Reduced pump performance 1. Autostart of standby pump in

event of high high liquid level in pit2. Submerged pumps preventing release of sewage to atmosphere

2. Corrosion of underground pipework

1. Release of sewage to environment

1. Underground sanitary pipework is GRP




1343 Partial Pressure 1. Collection of light hydrocarbon in

LNG lifting pits1. Potential for formation of flammable atmospheres

1. Hydrocarbon concentration in process rundown from LNG trains is very low with no potential for formation of flammable atmospheres

1344 Temperature -

HighNo new issues

1345 Temperature -

LowNo new issues




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1346 Cryogenic (Sub - Zero)

No new issues




1350 Phase - More 1. Mixed phase sanitary water 1. Potential blockage and settling

of solid waste in pit1. Small volume of sanitary water pits ensures short residence/settling time2. Sanitary water lifting pumps also cut solid sanitary waste



1353 Wrong


1. Inappropriate residence time of sanitary water in pit

1. Potential formation of noxious odours (SO2 and ammonia)

1. Appropriate design and sizing of pit (short residence time)

R1353.1 During detailed design, review sizing basis for sanitary water pits (especially inlet facilities pit), taking into account anticipated manning levels for each area

TS 3 3 7

1354 Corrosive (As

well as)1. Formation of ammonia and/or sulphuric acid corrosion compounds

1. Potential corrosion of materials 1. Underground pipework is GRP2. Sanitary waste pits are concrete3. Short residence time in pit minimises potential for formation of corrosive compounds


1356 Wrong Material





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1357 Node 2 Sanitary water treatment

Overview

1358 Flow - High 1. Transfer of sanitary water to

sanitary water treatment package (maximum flow, two pump operation during peak demands, e.g. shift changes and/or canteen meal times)

1. Increased flow rate of sewage to sanitary water treatment package

1. Extended type sanitary water treatment package (minimum residence time 20 hrs)2. Peak flow rate from two pumps is transitory and short duration3. Daily operator sampling of effluent from sanitary water treatment package and sanitary water discharge basin

1359 Flow - Low 1. Low production of sanitary water

(off peak durations)1. Reduced transfer of sewage to sanitary water treatment package

1. No significant impact on sanitary water treatment package

Node Equipment Sanitary water collection basin 059-BA-107Sanitary water feeding pumps 059-P-107Sanitary water treatment package 059-U-101Sanitary water discharge basin 059-BA-108Sanitary water discharge pumps 059-P-108A/BDrying beds 059-BA-111A-ERecovery water pit 059-BA-112Recovery water pump 059-P-112


2252-059-PID-00-31-03/Rev A/12-09-062252-059-PID-00-31-04/Rev A/12-09-06

Design intent Sanitary water collected in sanitary water collection basin is pumped to the extended aeration sanitary water biotreatment package. The treated water for the sanitary water package flows under gravity to the sanitary water discharge basin, from where it is pumped under on/off level control offsite. Sludge from the sanitary water treatment package is transferred to the drying beds for recovery of water and separation of solids. Solids will then be disposed of offsite and recovered water transferred back to the sanitary water treatment package




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1360 Flow - No 1. Maintenance periods with no operator and/or process demand on sanitary water system

1. Potential impact on sanitary water treatment package due to no flow for prolonged periods

1. Possible to "feed" sanitary water treatment package to maintain biological system2. Once plant is operational, shutdown maintenance periods will typically result in demand on sanitary water system, i.e. maintenance use of facilities

2. Pump trip on sanitary discharge basin

2. Loss of pump out of treated water offsite

1. Auto-start of standby pump on low discharge pressure

1361 Flow - Reverse 1. Pump trip and/or no flow

durations1. Potential for reverse flow 1. Check valve on discharge of

each individual sanitary water feeding pump, discharge pump and recovery pump2. Discharge of all pumps to atmospheric vapour space

1362 Loss of

Containment1. Seal failure on submerged pump 1. Reduced pump performance 1. Standby pump

2. Submerged pump type prevents release to atmosphere

1363 Pressure - High 1. Blocked pump discharge 1. Potential system overpressure 1. Low head pumps selected, have

lower design pressure than pipework




1367 Temperature -

High1. Variation in atmospheric temperature

1. Potential impact on sanitary water treatment package

1. No extremes of atmospheric temperature at proposed location

1368 Temperature -

LowNo new issues


Zero)No new issues




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1370 Level - High 1. Malfunction in 059-LT-0009/10 on sanitary water collection basin

1. Loss of start signal to pump 2. Increase in level in basin

1. 059-LT/LAHH autostart standby sanitary water feeding pump2. DCS indication of standby pump running

2. Malfunction 059-LT-0012 on recovered water pit

1. Loss of start signal to pump 2. Increase in level in pit 3. Reduced performance in drying bed

1. Operator inspection of area 2. Limited potential for overflow from both drying bed and recovery water pit

3. Malfunction 059-LT-0013/14 on sanitary water discharge basin

1. Loss of start signal to pump 2. Increase in level in basin

1. 059-LT/LAHH autostart standby sanitary water discharge pump2. DCS indication of standby pump running

1371 Level - Low 1. Malfunction in 059-LT-0009/10

on sanitary water collection basin1. Loss of stop signal to pump 2. Decrease in level in basin 3. Potential to damage pump

1. 059-LT/LALL stops sanitary water feeding pumps2. DCS indication of pump running

2. Malfunction 059-LT-0012 on recovered water pit

1. Loss of stop signal to pump 2. Decrease in level in pit 3. Potential to damage pump

1. Operator inspection of area 2. Limited potential to damage pump due to pump design and minimum head requirement

3. Malfunction 059-LT-0013/14 on sanitary water discharge basin

1. Loss of stop signal to pump 2. Decrease in level in basin3. Potential to damage pump

1. 059-LT/LALL stops sanitary water discharge pumps2. DCS indication of pump running


1373 Phase - More 1. Production of sludge in sanitary

water treatment package1. Transfer of sludge from sanitary water treatment package to drying beds for dewatering2. Selected type of sanitary water treatment package (extended aeration) produces low volume of sludge3. Recovery water pit start/stop on level control

2. Poor performance in sanitary water treatment package

1. High dissolved solids content in treated water

1. Operator inspection and sampling of sanitary water treatment package and discharge basin, once per day




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1376 Wrong


1. Upset in hydrocarbon concentration and/or composition from LNG train

1. High concentration of benzene, toluene and/or xylene components2. Potential poisoning of sanitary water treatment package

1. Extended aeration type sanitary water treatment package residence duration is in excess of 20 hours

R1376.1 Confirm with process department potential and maximum concentration of benzene, toluene and xylene in LNG process effluent. Determine in consultation with vendor potential impact on sanitary water treatment package

TS 2 4 7

2. Poor performance in sanitary water treatment package

1. Potential exceedance of BOD, COD and/or other discharge parameters of treated water

1. Daily operator sampling of treated water effluent2. Summarised malfunction alarm 059-UUA-0001

R1376.2 Undertake HAZOP of vendor sanitary water treatment package during detailed design

TS 3 3 7

1377 Corrosive (As



1379 Wrong Material




Contents

Executive Summary1.


HAZOP Approach2.

Appendices3.

I.

AttendanceII.

Node ListIII.


HAZOP WorksheetsV.
