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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 Limited


Science Park, Milton Road
Cambridge CB4 0XL
United Kingdom
Telephone +44 (0)870 336 6700
Fax +44 (0)870 336 6701
www.adlittle.uk.com
Reference 21184
TechnipItaly/21184/023rep

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 reports 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.

TechnipItaly/21184/023rep

Contents

1.

Executive Summary

2.

HAZOP Approach

3.

Appendices
I.

FEED HAZOP procedure

II.

Attendance

III.

Node List

IV.

HAZOP Recommendations

V.

HAZOP Worksheets

VI.

HAZOP Master P&IDs


TechnipItaly/21184/023rep

Executive Summary Introduction

Arthur D. Little has completed the FEED HAZOP review for Technips 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

TechnipItaly/21184/023rep

Executive Summary Overview of recommendations

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
TechnipItaly/21184/023rep

Contents

1.

Executive Summary

2.

HAZOP Approach

3.

Appendices
I.

FEED HAZOP procedure

II.

Attendance

III.

Node List

IV.

HAZOP Recommendations

V.

HAZOP Worksheets

VI.

HAZOP Master P&IDs


TechnipItaly/21184/023rep

Study Approach

Arthur D. Little conducted a HAZOP review as part of Technips 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

TechnipItaly/21184/023rep

Team Composition

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

TechnipItaly/21184/023rep

List of P&IDs

The Gas Treatment Units review studied 65 Process & Instrumentation


Diagrams
Unit
Unit 3

Drawing Number
(PID)
2252-003-P ID-00-31-01

Unit 17

Drawing Number
(PID)
2252-017-P ID-00-31-01

Unit 17
Unit 17
Unit 17

Unit

Revision
A

Revision

Date

Sheet Description

23-Ma y-06 We ll Wa te r P umping

Date

Sheet Description

25-Aug-06 Hot Oil Furna ce (017-H-101 A)

2252-017-P ID-00-31-02

25-Aug-06 Hot Oil Furna ce (017-H-101 B)

2252-017-P ID-00-31-03

25-Aug-06 Hot Oil Furna ce (017-H-101 C)

2252-017-P ID-00-31-04

25-Aug-06 Hot Oil Dis tribution

Unit 17

2252-017-P ID-00-31-05

25-Aug-06 Expa ns ion Drum & Circula tion P umps

Unit 17

2252-017-P ID-00-31-06

25-Aug-06 Hot Oil Dra ina ge S ys te m

Unit 31

Drawing Number
(PID)
2252-031-P ID-00-31-01

Unit 31

2252-031-P ID-00-31-02

Unit

Revision

Date

23-J un-06

J e tty Air S ys te m a nd Nitroge n Re ce ive r

Sheet Description

14-J ul-06

J e tty Fire Fighting S ys te m

Revision

Date

Unit 41

Drawing Number
(PID)
2252-041-P ID-00-31-01

23-Ma y-06 Air Compre s s ors P a cka ge

Unit 41

2252-041-P ID-00-31-02

23-Ma y-06 Air Drying P a cka ge

Unit 41

2252-041-P ID-00-31-04

23-Ma y-06 Air Compre s s ors P a cka ge

Unit 41

2252-041-P ID-00-31-04

24-Ma y-06 Eme rge ncy Compre s s or a nd P la nt Air Re ce ive r

Unit 41

2252-041-P ID-00-31-05

24-Ma y-06 Ins trume nt Air Re ce ive rs

Unit 41

2252-041-P ID-00-31-06

24-Ma y-06 Ins trume nt Air Re ce ive rs

Unit 41

2252-041-P ID-00-31-07

24-Ma y-06 Ins trume nt Air Re ce ive rs

Unit

Sheet Description

TechnipItaly/21184/023rep

List of P&IDs

The Gas Treatment Units review studied 65 Process & Instrumentation


Diagrams (continued)

Unit 43

Drawing Number
(PID)
2252-043-P ID-00-31-01

Unit 43

2252-043-P ID-00-31-02

Unit

Unit
Unit 46

Drawing Number
(PID)
2252-046-P ID-00-31-01

Unit 51

Drawing Number
(PID)
2252-051-P ID-00-31-01

Unit 51
Unit 51

Unit

Revision

Date

Sheet Description

23-Ma y-06 Nitroge n Ge ne ra tion P a cka ge

23-Ma y-06 Nitroge n S tora ge a nd Va poris a tion

Revision
A

Revision

Date

Sheet Description

23-Ma y-06 Die s e l Oil S ys te m

Date

Sheet Description

23-Ma y-06 Ra w Wa te r Filtra tion S ys te m

2252-051-P ID-00-31-02

24-Ma y-06 Filte re d a nd Fire Wa te r S tora ge

2252-051-P ID-00-31-03

24-Ma y-06 Filte re d a nd Fire Wa te r S tora ge

Unit 51

2252-051-P ID-00-31-04

23-Ma y-06 Re ve rs e Os mos is S ys te m

Unit 51

2252-051-P ID-00-31-05

24-Ma y-06 De s a lina te d Wa te r S tora ge a nd P umping

Unit
Unit 52

Drawing Number
(PID)
2252-052-P ID-00-31-01

Revision
A

Date

Sheet Description

23-Ma y-06 S e rvice Wa te r P umping

Unit 53

Drawing Number
(PID)
2252-053-P ID-00-31-01

24-Ma y-06 De s a lina te d Wa te r P ota bilis a tion

Unit 53

2252-053-P ID-00-31-02

24-Ma y-06 P ota ble Wa te r S tora ge a nd P umping

Unit 53

2252-053-P ID-00-31-03

24-Ma y-06 P ota ble Wa te r A.C. Filte rs S e ction

Unit

Unit 54

Drawing Number
(PID)
2252-054-P ID-00-31-03

Unit 54

2252-054-P ID-00-31-05

Unit

Revision

Revision

Date

Date

Sheet Description

Sheet Description

24-Ma y-06 De min. Wa te r P a cka ge

24-Ma y-06 De min. Wa te r S tora ge a nd P umping

TechnipItaly/21184/023rep

10

List of P&IDs

The Gas Treatment Units review studied 65 Process & Instrumentation


Diagrams (continued)

Unit 55

Drawing Number
(PID)
2252-055-P ID-00-31-01

Unit 55

2252-055-P ID-00-31-02

Unit

Revision

Date

14-J ul-06

Fire Wa te r S ys te m

Sheet Description

14-J ul-06

Fire Wa te r S ys te m

Revision

Date

Unit 56

Drawing Number
(PID)
2252-056-P ID-00-31-01

Unit 56

2252-056-P ID-00-31-02

12-S e p-06 Oily Wa te r Equa lis a tion a nd P umping

Unit 56

2252-056-P ID-00-31-03

12-S e p-06 Oily Wa tte r Tre a tme nt

Unit 56

2252-056-P ID-00-31-04

12-S e p-06 Tre a te d Oily Wa te r Dis cha rge

Unit 56

2252-056-P ID-00-31-05

12-S e p-06 Colle ction Ba s in

Unit 56

2252-056-P ID-00-31-06

12-S e p-06 Colle ction Ba s in

Unit 56

2252-056-P ID-00-31-07

12-S e p-06 Colle ction Ba s in

Unit 56

2252-056-P ID-00-31-08

12-S e p-06 Colle ction Ba s in

Unit 56

2252-056-P ID-00-31-09

12-S e p-06 Colle ction Ba s in

Unit 56

2252-056-P ID-00-31-10

12-S e p-06 Colle ction Ba s in

Unit 56

2252-056-P ID-00-31-11

12-S e p-06 Colle ction Ba s in

Unit 56

2252-056-P ID-00-31-12

12-S e p-06 Colle ction Ba s in

Unit 56

2252-056-P ID-00-31-13

12-S e p-06 Colle ction Ba s in

Unit 56

2252-056-P ID-00-31-14

12-S e p-06 Colle ction Ba s in

Unit 56

2252-056-P ID-00-31-15

12-S e p-06 Inle t Fa cilitie s Colle ction Ba s in

Unit 56

2252-056-P ID-00-31-16

12-S e p-06 Inle t Fa cilitie s Colle ction Ba s in

Unit 56

2252-056-P ID-00-31-17

12-S e p-06 Colle ction Ba s in

Unit 56

2252-056-P ID-00-31-18

12-S e p-06 Colle ction Ba s in

Unit 56

2252-056-P ID-00-31-19

12-S e p-06 Colle ction Ba s in

Unit 56

2252-056-P ID-00-31-20

12-S e p-06 Colle ction Ba s in

Unit 56

2252-056-P ID-00-31-21

12-S e p-06 Colle ction Ba s in

Unit 56

2252-056-P ID-00-31-22

12-S e p-06 Fla re Colle ction Ba s in

Unit 56

2252-056-P ID-00-31-23

12-S e p-06 Colle ction Ba s in

Unit

Sheet Description

12-S e p-06 Colle ction Ba s in

TechnipItaly/21184/023rep

11

List of P&IDs

The Gas Treatment Units review studied 65 Process & Instrumentation


Diagrams (continued)

Unit 57

Drawing Number
(PID)
2252-057-P ID-00-31-03

Unit 57
Unit 57

Unit

Revision

Date

Sheet Description

12-S e p-06 LNG Tra in 1 & 2 Boile rs Blow Down Colle ction Ba s ins

2252-057-P ID-00-31-05

12-S e p-06 La bora tory a nd Che mica l S e we r Re ce iving P it

2252-057-P ID-00-31-06

12-S e p-06 Che mica l Wa te r Ne utra lis a tion

Unit 57

2252-057-P ID-00-31-07

12-S e p-06 Nue tra lis a tion Dos ing S ys te m

Unit 57

2252-057-P ID-00-31-08

12-S e p-06 LNG Tra in 3 & 4 Boile rs Blow Down Colle ction Ba s ins

Unit 59

Drawing Number
(PID)
2252-059-P ID-00-31-01

Unit 59

2252-059-P ID-00-31-02

Unit

Revision

Date

Sheet Description

12-S e p-06 S a nita ry Wa te r Colle ction P its

12-S e p-06 S a nita ry Wa te r Colle ction P its

Unit 59

2252-059-P ID-00-31-03

12-S e p-06 S a nita ry Wa te r Tre a tme nt

Unit 59

2252-059-P ID-00-31-04

12-S e p-06 S a nita ry Wa te r Dis cha rge a nd Drying Be ds

Unit 59

2252-059-P ID-00-31-05

12-S e p-06 S a nita ry Wa te r Colle ction P its

TechnipItaly/21184/023rep

12

Reference Documents

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

TechnipItaly/21184/023rep

13

HAZOP Record

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

TechnipItaly/21184/023rep

14

Contents

1.

Executive Summary

2.

HAZOP Approach

3.

Appendices
I.

FEED HAZOP procedure

II.

Attendance

III.

Node List

IV.

HAZOP Recommendations

V.

HAZOP Worksheets

VI.

HAZOP Master P&IDs


TechnipItaly/21184/023rep

15

Project N Unit

W - Mod. 1809/E Type A - Rev. A

The present document or drawing is property of TECHNIP ITALY S.p.A. and shall not, under any circumstances, be totally or partially, directly or undirectly, transferred, reproduced, copied, disclosed or used, without its prior written consent, for any
purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.

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Document Code

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Serial N

202

Rev.

Page

1/11

OK LNG DEVELOPMENT PROJECT


FRONT END ENGINEERING DESIGN WP1

HAZOP REVIEW PROCEDURE

16/06/06

ISSUED FOR FEED

A.SCALESSE

C. SCALA F.GIOPPO

PAESANI / HONORE

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

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FRONT END ENGINEERING DESIGN WP1
HAZOP REVIEW PROCEDURE

TABLE OF CONTENTS

1.

PURPOSE ................................................................................................................................. 3

2.

REFERENCE DOCUMENTS .................................................................................................... 3

3.

ORGANIZATION....................................................................................................................... 3

4.

5.

3.1.

Responsabilities .............................................................................................................. 3

3.2.

Timing............................................................................................................................... 4

METHODOLOGY ...................................................................................................................... 5
4.1.

Risk Ranking .................................................................................................................... 7

4.2.

Recommendations ........................................................................................................ 10

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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The present document or drawing is property of TECHNIP ITALY S.p.A. and shall not, under any circumstances, be totally or partially, directly or undirectly, transferred, reproduced, copied, disclosed or used, without its prior written consent, for any
purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.

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Project N Unit

The present document or drawing is property of TECHNIP ITALY S.p.A. and shall not, under any circumstances, be totally or partially, directly or undirectly, transferred, reproduced, copied, disclosed or used, without its prior written consent, for any
purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.

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FRONT END ENGINEERING DESIGN WP1
HAZOP REVIEW PROCEDURE

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:

W - Mod. 1809/E Type A - Rev. A

Rev.

Chairman
Scribe
JV Process Engineer
Other JV discipline engineers on call as required

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HAZOP REVIEW PROCEDURE

Clients 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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purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.

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Project N Unit

W - Mod. 1809/E Type A - Rev. A

The present document or drawing is property of TECHNIP ITALY S.p.A. and shall not, under any circumstances, be totally or partially, directly or undirectly, transferred, reproduced, copied, disclosed or used, without its prior written consent, for any
purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.

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FRONT END ENGINEERING DESIGN WP1
HAZOP REVIEW PROCEDURE

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

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

Project N Unit

W - Mod. 1809/E Type A - Rev. A

The present document or drawing is property of TECHNIP ITALY S.p.A. and shall not, under any circumstances, be totally or partially, directly or undirectly, transferred, reproduced, copied, disclosed or used, without its prior written consent, for any
purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.

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FRONT END ENGINEERING DESIGN WP1
HAZOP REVIEW PROCEDURE

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.

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

Project N Unit

W - Mod. 1809/E Type A - Rev. A

The present document or drawing is property of TECHNIP ITALY S.p.A. and shall not, under any circumstances, be totally or partially, directly or undirectly, transferred, reproduced, copied, disclosed or used, without its prior written consent, for any
purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.

2252

000

Document Code

PP

Serial N

202

Rev.

Page

7/11

OK LNG DEVELOPMENT PROJECT


FRONT END ENGINEERING DESIGN WP1
HAZOP REVIEW PROCEDURE

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
More
Less
None
Reverse
More
Less
None
More
Less
As well as
More
Less
None
More
Less
Reverse
Part of
As well as
Other than
More
As well as
Other than

DEVIATIONS
high flow
low flow
no flow
reverse flow
high pressure
low pressure
vacuum
high temperature
low temperature
cryogenic
high level
low level
no level
additional phase
loss of phase
change of state
off-spec composition
contaminants
corrosive concentration
runway reaction
side reaction
explosion

Other than

loss of

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

FLOW

PRESSURE

TEMPERATURE

LEVEL

STATE/
COMPOSITION

REACTION
UTILITY: power, air,
steam, nitrogen,
cooling water
UNSTEADY
OPERATION: startup,
shutdown,
maintenance,
sampling, drainage

4.1.

Risk Ranking

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

Project N Unit

000

Document Code

PP

Serial N

202

Rev.

Page

8/11

OK LNG DEVELOPMENT PROJECT


FRONT END ENGINEERING DESIGN WP1
HAZOP REVIEW PROCEDURE

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

1. Very High

Level

Severity
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

3. Medium

Employee injuries
Minor public injuries
Moderate property damage
Moderate environmental impact
Moderately adverse public reaction

4. Low

5. Insignificant

Minor employee injuries


No public injuries
Minor property damage
Minor environmental impact
No adverse public reaction
Operational Upset
No employee injuries
No public injuries
No property damage
No environmental impact
No adverse public reaction

W - Mod. 1809/E Type A - Rev. A

The present document or drawing is property of TECHNIP ITALY S.p.A. and shall not, under any circumstances, be totally or partially, directly or undirectly, transferred, reproduced, copied, disclosed or used, without its prior written consent, for any
purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.

2252

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

Project N Unit

Document Code

000

PP

Serial N

202

OK LNG DEVELOPMENT PROJECT


FRONT END ENGINEERING DESIGN WP1
HAZOP REVIEW PROCEDURE

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

10

Level

Likelihood

10

10

W - Mod. 1809/E Type A - Rev. A

The present document or drawing is property of TECHNIP ITALY S.p.A. and shall not, under any circumstances, be totally or partially, directly or undirectly, transferred, reproduced, copied, disclosed or used, without its prior written consent, for any
purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.

2252

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

Rev.

Page

9/11

Project N Unit

000

Document Code

PP

Serial N

202

Rev.

Page

10/11

OK LNG DEVELOPMENT PROJECT


FRONT END ENGINEERING DESIGN WP1
HAZOP REVIEW PROCEDURE

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
Chairmans 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

W - Mod. 1809/E Type A - Rev. A

The present document or drawing is property of TECHNIP ITALY S.p.A. and shall not, under any circumstances, be totally or partially, directly or undirectly, transferred, reproduced, copied, disclosed or used, without its prior written consent, for any
purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.

2252

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

Project N Unit

000

Document Code

PP

Serial N

202

Rev.

Page

11/11

OK LNG DEVELOPMENT PROJECT


FRONT END ENGINEERING DESIGN WP1
HAZOP REVIEW PROCEDURE

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.

W - Mod. 1809/E Type A - Rev. A

The present document or drawing is property of TECHNIP ITALY S.p.A. and shall not, under any circumstances, be totally or partially, directly or undirectly, transferred, reproduced, copied, disclosed or used, without its prior written consent, for any
purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.

2252

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

Contents

1.

Executive Summary

2.

HAZOP Approach

3.

Appendices
I.

FEED HAZOP procedure

II.

Attendance

III.

Node List

IV.

HAZOP Recommendations

V.

HAZOP Worksheets

VI.

HAZOP Master P&IDs


TechnipItaly/21184/023rep

27

Appendix II Attendance

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


HAZOP

Name
Mr James Perry
Mr Philip Webster
Mr Francesco Mussetto
Mr Luciano Vanneschi
Mrs Lorena Rosa
Mr Christian Scala
Mr Alfonso Ricciardi
Mr Fred Preston
Mr Eric Holland

Department
Arthur D Little - HAZOP Leader
Arthur D Little - HAZOP Scribe
Snamprogetti SpA
Snamprogetti SpA
Snamprogetti SpA
Technip
Snamprogetti SpA
OK LNG
OK LNG

11/09/2006
Monday

12/09/2006
Tuesday

Y
Y
Y
Y
Y
Y (am)

Y
Y
Y
Y
Y

13/09/2006 14/09/2006 15/09/2006


Wednesday Thursday
Friday
Y
Y
Y
Y
Y

Y
Y
Y

Y
Y

Y
Y
Y
Y
Y

18/09/2006
Monday
Y
Y
Y
Y
Y

Y
Y (am)

TechnipItaly/21184/023rep

28

Contents

1.

Executive Summary

2.

HAZOP Approach

3.

Appendices
I.

FEED HAZOP procedure

II.

Attendance

III.

Node List

IV.

HAZOP Recommendations

V.

HAZOP Worksheets

VI.

HAZOP Master P&IDs


TechnipItaly/21184/023rep

29

Appendix III Node List Air Compressors Package & Nitrogen

Unit

Drawing Number
(PID)

Revision

Date

Sheet Description

Unit 41

2252-041-P ID-00-31-01

23-Ma y-06 Air Compre s s ors P a cka ge

Unit 41

2252-041-P ID-00-31-02

Unit 41

2252-041-P ID-00-31-04

Unit 41

2252-041-P ID-00-31-02

23-Ma y-06 Air Drying P a cka ge


Eme rge ncy Compre s s or a nd P la nt
24-Ma y-06
Air Re ce ive r
23-Ma y-06 Air Drying P a cka ge

Unit 41

2252-041-P ID-00-31-05

24-Ma y-06 Ins trume nt Air Re ce ive rs

Unit 41

2252-041-P ID-00-31-06

24-Ma y-06 Ins trume nt Air Re ce ive rs

Unit 41

2252-041-P ID-00-31-07

24-Ma y-06 Ins trume nt Air Re ce ive rs

Unit

Drawing Number
(PID)

Revision

Date

Sheet Description

Unit 43

2252-043-P ID-00-31-01

23-Ma y-06 Nitroge n Ge ne ra tion P a cka ge

Unit 43

2252-043-P ID-00-31-02

23-Ma y-06 Nitroge n S tora ge a nd Va poris a tion

Node
(FEED)
1

Node
(FEED)
1

Node Description

Equipment

Day

Air Compression Package 041-U-101


041-V-101

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

Node Description
Nitrogen System

Equipment
043-U-101
043-U-102

TechnipItaly/21184/023rep

Day
1

30

Appendix III Node List Raw and Service Water

Unit

Drawing Number
(PID)

Revision

Date

Sheet Description

Unit 3

2252-003-P ID-00-31-01

23-Ma y-06 We ll Wa te r P umping

Unit 51

2252-051-P ID-00-31-01

23-Ma y-06 Ra w Wa te r Filtra tion S ys te m

Unit 51

2252-051-P ID-00-31-02

24-Ma y-06 Filte re d a nd Fire Wa te r S tora ge

Unit 51

2252-051-P ID-00-31-03

24-Ma y-06 Filte re d a nd Fire Wa te r S tora ge

Unit 51

2252-051-P ID-00-31-01

23-Ma y-06 Ra w Wa te r Filtra tion S ys te m

Unit 51

2252-051-P ID-00-31-02

24-Ma y-06 Filte re d a nd Fire Wa te r S tora ge

Unit 51

2252-051-P ID-00-31-02

24-Ma y-06 Filte re d a nd Fire Wa te r S tora ge

Unit 51

2252-051-P ID-00-31-03

24-Ma y-06 Filte re d a nd Fire Wa te r S tora ge

Unit 51

2252-051-P ID-00-31-04

Unit 51

2252-051-P ID-00-31-05

24-Ma y-06

Unit 53

2252-053-P ID-00-31-02

24-Ma y-06 P ota ble Wa te r S tora ge a nd P umping

Unit 51

2252-051-P ID-00-31-02

24-Ma y-06 Filte re d a nd Fire Wa te r S tora ge

Unit 51

2252-051-P ID-00-31-03

24-Ma y-06 Filte re d a nd Fire Wa te r S tora ge

Unit 52

2252-052-P ID-00-31-01

23-Ma y-06 S e rvice Wa te r P umping

Node
(FEED)
1

23-Ma y-06 Re ve rs e Os mos is S ys te m


De s a lina te d Wa te r S tora ge a nd
P umping

Node Description

Equipment

Well Water Pumps and Raw 003-P-101A-C


Water Filtration
051-U-101
051-T-101A/B

Raw water sterilisation


package

051-U-102

Re ve rs e os mos is pa cka ge 051-T-101A/B


a nd de s a lina te d wa te r
051-U-103
s tora ge ta nk
051-T-102
053-T-120

S e rvice wa te r s ys te m

051-T-101A/B
052-P -130A/B
052-P -131A/B

TechnipItaly/21184/023rep

Day
2

31

Appendix III Node List Potable & Demin. Water

Un it

D ra win g N u m b e r
( P ID )

R e v is io n

D a te

S h e e t D e s c rip t io n

Unit 53

2252-053-P ID-00-31-01

24-M a y-06 De s a lina te d Wa te r P o ta bilis a tio n

Unit 53

2252-053-P ID-00-31-02

24-M a y-06

Unit 53

2252-053-P ID-00-31-03

24-M a y-06 P o ta ble Wa te r A.C . F ilte rs S e c tio n

Unit 53

2252-053-P ID-00-31-02

24-M a y-06

Unit 53

2252-053-P ID-00-31-03

24-M a y-06 P o ta ble Wa te r A.C . F ilte rs S e c tio n

Unit

Drawing Number
(PID)

Revision

Date

N o de
(F EED )
1

P o ta ble Wa te r S to ra ge a nd
P um ping

P o ta ble Wa te r S to ra ge a nd
P um ping

Sheet Description

Unit 51

2252-051-P ID-00-31-05

Unit 54

2252-054-P ID-00-31-03

De s a lina te d Wa te r S tora ge a nd
24-Ma y-06
P umping
24-Ma y-06 De min. Wa te r P a cka ge

Unit 54

2252-054-P ID-00-31-05

24-Ma y-06 De min. Wa te r S tora ge a nd P umping

Unit 54

2252-054-P ID-00-31-03

24-Ma y-06 De min. Wa te r P a cka ge

Unit 54

2252-054-P ID-00-31-05

24-Ma y-06 De min. Wa te r S tora ge a nd P umping

Unit 54

2252-054-P ID-00-31-05

24-Ma y-06 De min. Wa te r S tora ge a nd P umping

Node
(FEED)
1

N o d e D e s c rip t io n

E q u ip m e n t

Day

P ro duc tio n a nd s to ra ge o f 053-U-120


P o ta ble Wa te r
053-U-122
053-T-120

P o ta ble wa te r c hilling unit, 053-T-120


053-P -120A/B
s to ra ge ta nk a nd
053-U-123
dis tributio n

Node Description

Equipment

Day

P roduction of de mine ra lis e d 051-T-102


wa te r
051-P -101A/B
054-U-110
054-T-110

Wa te r de mine ra lis a tion unit 054-U-110


pa cka ge re ge ne ra tion
054-T-111
054-P -111A/B
054
T 110
De mine ra lis e d wa te r pumps 054-T-110

a nd he a de r

054-P -110A/B

TechnipItaly/21184/023rep

32

Appendix III Node List Hot Oil System and Diesel Oil

Unit 17

Drawing Number
(PID)
2252-017-P ID-00-31-01

Unit 17

Unit

Revision

Date

Sheet Description

25-Aug-06 Hot Oil Furna ce (017-H-101 A)

2252-017-P ID-00-31-02

25-Aug-06 Hot Oil Furna ce (017-H-101 B)

Unit 17

2252-017-P ID-00-31-03

25-Aug-06 Hot Oil Furna ce (017-H-101 C)

Unit 17

2252-017-P ID-00-31-04

25-Aug-06 Hot Oil Dis tribution

Unit 17

2252-017-P ID-00-31-05

Unit 17

2252-017-P ID-00-31-01

Expa ns ion Drum & Circula tion


P umps
25-Aug-06 Hot Oil Furna ce (017-H-101 A)

Unit 17

2252-017-P ID-00-31-02

25-Aug-06 Hot Oil Furna ce (017-H-101 B)

Unit 17

2252-017-P ID-00-31-03

25-Aug-06 Hot Oil Furna ce (017-H-101 C)

Unit 17

2252-017-P ID-00-31-04

25-Aug-06 Hot Oil Dis tribution

Unit 17

2252-017-P ID-00-31-06

25-Aug-06 Hot Oil Dra ina ge S ys te m

Unit

Unit 46

Drawing Number
(PID)
2252-046-P ID-00-31-01

Revision

Node
(FEED)
1

Node Description

Equipment

Day

Hot oil circuit

017-V-101
017-P -101
017-FL-101
017-H-101A/B/C
017-A-101

Furna ce firing a nd fire box

017-H-101A/B/C

Hot oil sump

017-V-102/3
017-P-103/4

25-Aug-06

Date

Sheet Description

23-Ma y-06 Die s e l Oil S ys te m

Node
(FEED)
1

Node Description
Die s e l oil s ys te m

Equipment
046-F-101A/B
046-T-101
046-F-102 A/B
046-U-101

TechnipItaly/21184/023rep

Day
4

33

Appendix III Node List Jetty Facilities and Firewater

Unit
Unit 31
Unit 31

Drawing Number
(PID)
2252-031-P ID-00-31-01
2252-031-P ID-00-31-01

Unit 51

Drawing Number
(PID)
2252-051-P ID-00-31-02

Unit 51

Unit

Revision
A

Date
23-J un-06

23-J un-06

Revision

Date

Sheet Description
J e tty Air S ys te m a nd Nitroge n
Re ce ive r
J e tty Air S ys te m a nd Nitroge n
Re ce ive r

Sheet Description

24-Ma y-06 Filte re d a nd Fire Wa te r S tora ge

2252-051-P ID-00-31-03

24-Ma y-06 Filte re d a nd Fire Wa te r S tora ge

Unit 55

2252-055-P ID-00-31-01

14-J ul-06

Fire Wa te r S ys te m

Unit 55

2252-055-P ID-00-31-02

14-J ul-06

Fire Wa te r S ys te m

Unit 31

2252-031-P ID-00-31-02

14-J ul-06

J e tty Fire Fighting S ys te m

Unit 52

2252-052-P ID-00-31-01

23-Ma y-06 S e rvice Wa te r P umping

Node
(FEED)
1
2

Node
(FEED)
1

Node Description
Nitrogen supply

Equipment

Day

031-V-101

Jetty compressed air system 031-U-104


031-V-103

Node Description
P roce s s a re a fire wa te r
s ys te m

Equipment
051-T-101A/B
055-P -101A/B/C
055-P -102A/B

J e tty a re a fire wa te r s ys te m 052-P -131A/B


031-P -103A/B
031-U-101

TechnipItaly/21184/023rep

Day
5

34

Appendix III Node List Oily Water System

Unit 56

Drawing Number
(PID)
2252-056-P ID-00-31-01

Unit 56

Unit

Revision

Date

Sheet Description

12-S e p-06 Colle ction Ba s in

2252-056-P ID-00-31-02

12-S e p-06 Oily Wa te r Equa lis a tion a nd P umping

Unit 56

2252-056-P ID-00-31-05

12-S e p-06 Colle ction Ba s in

Unit 56

2252-056-P ID-00-31-06

12-S e p-06 Colle ction Ba s in

Unit 56

2252-056-P ID-00-31-07

12-S e p-06 Colle ction Ba s in

Unit 56

2252-056-P ID-00-31-08

12-S e p-06 Colle ction Ba s in

Unit 56

2252-056-P ID-00-31-09

12-S e p-06 Colle ction Ba s in

Unit 56

2252-056-P ID-00-31-10

12-S e p-06 Colle ction Ba s in

Unit 56

2252-056-P ID-00-31-11

12-S e p-06 Colle ction Ba s in

Unit 56

2252-056-P ID-00-31-12

12-S e p-06 Colle ction Ba s in

Unit 56

2252-056-P ID-00-31-13

12-S e p-06 Colle ction Ba s in

Unit 56

2252-056-P ID-00-31-14

12-S e p-06 Colle ction Ba s in

Unit 56

2252-056-P ID-00-31-17

12-S e p-06 Colle ction Ba s in

Unit 56

2252-056-P ID-00-31-18

12-S e p-06 Colle ction Ba s in

Unit 56

2252-056-P ID-00-31-19

12-S e p-06 Colle ction Ba s in

Unit 56

2252-056-P ID-00-31-20

12-S e p-06 Colle ction Ba s in

Unit 56

2252-056-P ID-00-31-21

12-S e p-06 Colle ction Ba s in

Unit 56

2252-056-P ID-00-31-23

12-S e p-06 Colle ction Ba s in

Unit 56

2252-056-P ID-00-31-02

12-S e p-06 Oily Wa te r Equa lis a tion a nd P umping

Unit 56

2252-056-P ID-00-31-15

12-S e p-06 Inle t Fa cilitie s Colle ction Ba s in

Unit 56

2252-056-P ID-00-31-16

12-S e p-06 Inle t Fa cilitie s Colle ction Ba s in

Unit 56

2252-056-P ID-00-31-22

12-S e p-06 Fla re Colle ction Ba s in

Unit 56

2252-056-P ID-00-31-02

12-S e p-06 Oily Wa te r Equa lis a tion a nd P umping

Unit 56

2252-056-P ID-00-31-02

12-S e p-06 Oily Wa te r Equa lis a tion a nd P umping

Unit 56

2252-056-P ID-00-31-03

12-S e p-06 Oily Wa te r Tre a tme nt

Unit 56

2252-056-P ID-00-31-04

12-S e p-06 Tre a te d Oily Wa te r Dis cha rge

Node
(FEED)
1

Node Description
Type 1 (proce s s a re a )
colle ction ba s in

Equipment

Day

P roce s s a re a colle ction ba s ins a nd


lifting pumps

056-BA-504
056-BA-506
056-P -504A/B
056-P -506A/B

Type 3 (fla re a re a ) colle ction 056-BA-512


ba s in
056-P -512A/B
056-BA-513
056-P -513A/B

Type 2 (inle t fa cility)


colle ction ba s in

Oily wa te r tre a tme nt

056-TK-120
056-Z-101
056-BA-121
056-P -121A/B
056-P -150A/B
056-U-101
056-BA-122
056-BA-123
056-P -122A/B
056-P -123A/B

TechnipItaly/21184/023rep

35

Appendix III Node List Effluent Facilities

Unit

Drawing Number
(PID)

Revision

Date

Sheet Description

Unit 57

2252-057-P ID-00-31-03

Unit 57

2252-057-P ID-00-31-05

Unit 57

2252-057-P ID-00-31-06

LNG Tra in 1 & 2 Boile rs Blow Down


12-S e p-06
Colle ction Ba s ins
La bora tory a nd Che mica l S e we r
12-S e p-06
Re ce iving P it
12-S e p-06 Che mica l Wa te r Ne utra lis a tion

Unit 57

2252-057-P ID-00-31-07

12-S e p-06 Ne utra lis a tion Dos ing S ys te m

Unit 57

2252-057-P ID-00-31-08

12-S e p-06

Revision

Date

Node Description
Efflue nt tre a tme nt s ys te m

LNG Tra in 3 & 4 Boile rs Blow Down


Colle ction Ba s ins

Unit 59

Drawing Number
(PID)
2252-059-P ID-00-31-01

12-S e p-06 S a nita ry Wa te r Colle ction P its

Unit 59

2252-059-P ID-00-31-02

12-S e p-06 S a nita ry Wa te r Colle ction P its

Unit 59

2252-059-P ID-00-31-05

12-S e p-06 S a nita ry Wa te r Colle ction P its

Unit 59

2252-059-P ID-00-31-03

12-S e p-06 S a nita ry Wa te r Tre a tme nt

Unit 59

2252-059-P ID-00-31-04

12-S e p-06

Unit

Node
(FEED)
1

Sheet Description

S a nita ry Wa te r Dis cha rge a nd Drying


Be ds

Node
(FEED)
1

Node Description

Equipment
057-BA-110
057-BA-111
057-BA-112
057-BA-113
057-P -110A/B
057-P -111A/B
057-P -112A/B
057-P -113A/B
075-BA-120
057-BA-126
057-BA-121A/B
057-P -121A/B
057-U-102
057-U-103

Equipment

S a nita ry wa te r colle ction pits 059-BA-101


059-P -101-A/B
059-BA-102
059-P -102A/B
059-BA-103
059-P -103A/B
059-BA-104
059-P -104A/B
059-BA-105
059-P -105A/B
059-BA-106
059-P -106A/B
059-BA-107
S a nita ry wa te r tre a tme nt

S a nita ry wa te r colle ction ba s in 059-BA107


S a nita ry wa te r fe e ding pumps 059-P 107
S a nita ry wa te r tre a tme nt pa cka ge 059U-101
S a nita ry wa te r dis cha rge ba s in 059-BA108
S a nita ry wa te r dis cha rge pumps 059-P 108A/B
Drying be ds 059-BA-111A-E
Re cove ry wa te r pit 059-BA-112
Re cove ry wa te r pump 059-P -112

TechnipItaly/21184/023rep

Day
5

Day
6

36

Contents

1.

Executive Summary

2.

HAZOP Approach

3.

Appendices
I.

FEED HAZOP procedure

II.

Attendance

III.

Node List

IV.

HAZOP Recommendations

V.

HAZOP Worksheets

VI.

HAZOP Master P&IDs


TechnipItaly/21184/023rep

37

Appendix IV HAZOP Recommendations Air Compressors Package

HAZOP
Node
Item No.
759
Node 1
761

Node 1

761

Node 1

761

Node 1

763

Node 1

764
765

Node 1
Node 1

769

Node 1

769

Node 1

778

Node 1

784

Node 2

787

Node 2

788

Node 2

791

Node 2

798

Node 2

798

Node 2

801

Node 2

804

Node 2

Recommendations

Action by:

R759.1 Consider requirement for vendor package HAZOP during detailed


design
R761.1 Consider requirements for redundancy in electrical feeders to the air
compressor packages, to enable distribution of air compressors over multiple
electrical feeders.
R761.2 Consider requirements for dP indication and PDAH alarm on
interstage and discharge filters on the air compressor packages
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
R763.1 Confirm requirements for check valves and configuration of air
compressor package and start-up compressor and drier with vendor
R764.1 Update P&ID to show internal baffle plate on wet air vessel
R765.1 Consider vapourisation of water collected in wet air vessel in sizing
basis for 041-PSV-0001
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
R778.1 Consider requirements for flammable gas detection in vicinity of the air
compressor package as located downwind of the LNG process area
R784.1 Provide DCS pressure indication and low pressure alarm on each
individual instrument receiver
R787.1 See R784.1 for provision of DCS PI and PAL indication on individual
instrument air receivers
R788.1 Consider and confirm requirements for PSV on each air drying
package vessel
R791.1 Ensure operating manual highlights moisture breakthrough alarm has
no trip and/or sequence action
R798.1 Consider requirements for dP indication on air drier filter elements in
discussion with vendor
R798.2 Ensure operating manual requires operator check and draining of free
water from the compressor casing before start-up
R801.1 Consider requirement for flammable gas detection on start-up
compressor inlet
R804.1 P&ID will be updated to remove instrument air header to jetty given
dedicated jetty air compressor

Action resolution

TS

TS

TS

TS

TS

TS
TS

2
3

2
4

4
8

TS

TS

TS

TS

TS

TS

TS

TS

TS

TS

TS

TechnipItaly/21184/023rep

38

Appendix IV HAZOP Recommendations Nitrogen

HAZOP
Node
Item No.
805
Node 1
806

Node 1

806

Node 1

806

Node 1

806

Node 1

807
814

Node 1
Node 1

816

Node 1

818

Node 1

818

Node 1

819

Node 1

Recommendations

Action by:

R805.1 Consider requirement for vendor package HAZOP during detailed


design
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
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
vendor
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
R807.1 Ensure atmospheric vent for nitrogen is at safe location
R814.1 Investigate whether additional requirement for oxygen analyser on
liquid nitrogen production to prevent contamination of liquid nitrogen storage
R816.1 Discuss during vendor package HAZOP protections against
exceedance of vapouriser gaseous discharge pipework specification
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
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

Action resolution

TS

TS

TS

TS

TS

TS
TS

3
3

3
3

7
7

TS

TS

TS

TS

TechnipItaly/21184/023rep

39

Appendix IV HAZOP Recommendations Raw and Service Water

HAZOP
Node
Item No.
828
Node 1
828
Node 1
829

Node 1

829

Node 1

829

Node 1

830

Node 1

830

Node 1

831

Node 1

832

Node 1

833

Node 1

833

Node 1

834

Node 1

834

Node 1

835

Node 1

842

Node 1

844

Node 1

Recommendations

Action by:

R828.1 Consider HAZOP of vendor package during detailed design


R828.2 Review all utility water storage tanks and provide maintenance blinds
and/or spacers to enable isolation of tanks for maintenance
R829.1 Update P&ID to show correct relative location of 051-LALL-0005A/B
vs non firewater nozzles
R829.2 Consider whether DCS panel alarms 051-LAH-0006A/B and 051-LAH0004A/B are required as these will be nuisance alarms during normal
operating conditions and tank levels
R829.3 During detailed design, following selection of well water pump type
and filter capacity, consider requirement for minimum flow protection on well
pumps
R830.1 Consider during detailed design whether permissive of well water
pump operating is required to commence the backwash cleaning sequence
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
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
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
R833.1 Detailed design to consider requirement for external protection of
water tanks floors via CP or coating
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)
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
R834.2 Review requirement for thermal relief on raw water pipework from well
during detailed design
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
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
R844.1 Consider during detailed design and reciept of raw water composition
implications on proposed filtration package configuration and design

Action resolution

TS
TS

3
2

3
2

7
4

TS

TS

TS

TS

TS

TS

TS

TS

TS

TS

TS

TS

TS

TS

TechnipItaly/21184/023rep

40

Appendix IV HAZOP Recommendations Raw and Service Water

HAZOP
Node
Item No.
844
Node 1

847

Node 1

847

Node 1

847

Node 1

851
853

Node 2
Node 2

855

Node 2

856

Node 2

861

Node 2

874
875

Node 3
Node 3

878

Node 3

890

Node 3

900

Node 4

902

Node 4

Recommendations

Action by:

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
R847.1 See Recommendation R833.2 for review of materials following reciept
of well water composition during detailed design
R847.2 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)
R851.1 Consider HAZOP of vendor package during detailed design
R853.1 Consider provision raw water sterilisation package sodium
hypochlorite storage DCS level indication
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
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
R861.1 Recommend provision of shelter for raw water sterilisation package
(shade, not enclosed building)
R874.1 Consider HAZOP of vendor package during detailed design
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
R878.1 Consider requirement for tank inlet check valve in the event bottom
filling
R890.1 Consider requirements for DCS dP indication and PDAH on the
reverse osmosis package inlet filters
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
R902.1 See R833.2 for review of filtered water specification during detailed
design upon confirmation of well water composition

Action resolution

TS

TS

TS

TS

TS
TS

3
2

3
2

7
4

TS

TS

TS

TS
TS

3
3

3
3

7
7

TS

TS

TS

TS

TechnipItaly/21184/023rep

41

Appendix IV HAZOP Recommendations Potable Water

HAZOP
Node
Item No.
920
Node 1
922

Node 1

923

Node 1

924

Node 1

934

Node 1

934

Node 1

939

Node 1

944

Node 2

946

Node 2

946

Node 2

949

Node 2

949

Node 2

954

Node 2

957

Node 2

Recommendations

Action by:

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


design
R922.1 Review water potablisation and biocide packages to consider what
DCS alarms, etc. are required to notify operator of malfunction
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-FIC0001)
R924.1 Consider provision of check valve on inlet to potable water storage
tank and desalinated water storage tank
R934.1 Consider provision of DCS level indication using 053-LALL-0003
instrument
R934.2 See R922.1 for provision of appropriate DCS indication and alarms
R939.1 Ensure during detailed design that potable water sample point enables
collection of representative potable water sample
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
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
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
R949.1 Review design pressure of chilling unit package and activated carbon
filters
R949.2 Review proposed potable water system distribution and design
pressure, as it appears high compared with allowable user pressures
R954.1 See R946.1 for review of chilling unit package design during detailed
design
R957.1 See R934.1 for configuration of level indication on 053-LALL-0003
instrument

Action resolution

TS

TS

TS

TS

TS

TS

TS

TS

TS

TS

TS

TS

TS

TS

TechnipItaly/21184/023rep

42

Appendix IV HAZOP Recommendations Potable Water

HAZOP
Node
Item No.
966
Node 1
969

Node 1

969

Node 1

972

Node 1

992

Node 2

992

Node 2

1002

Node 2

1003

Node 2

1008

Node 2

1008

Node 2

1011

Node 2

1014
1015

Node 3
Node 3

Recommendations

Action by:

R966.1 Undertake HAZOP of water demineralisation package during detailed


design
R969.1 Consider provision of level indication on 054-LALL-0003 instrument on
DCS
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
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
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)
R992.2 Consider provision of conductivity meter in regeneration wash of the
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
R1003.1 If level indication and alarm provided (see R1002.1), consider
provision of low level stop of neutralisation pumps
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
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
R1011.1 Water demineralisation package sizing basis will be reviewed during
detailed design following reciept of raw water composition
R1014.1 Configure PAL on 054-PI-0002 on demineralised water header
R1015.1 Consider requirement for check valve on common demineralised
water header to prevent depressurisation to tank

Action resolution

TS

TS

TS

TS

TS

TS

TS

TS

TS

TS

TS

TS
TS

2
2

2
2

4
4

TechnipItaly/21184/023rep

43

Appendix IV HAZOP Recommendations Hot Oil

HAZOP
Node
Item No.
1035
Node 1
1036

Node 1

1036

Node 1

1036

Node 1

1037

Node 1

1037

Node 1

1037

Node 1

1040

Node 1

1040
1040

Node 1
Node 1

1041

Node 1

1042

Node 1

1045

Node 1

1045
1063

Node 1
Node 2

1063

Node 2

Recommendations

Action by:

R1035.1 HAZOP of fired furnace vendor package to be undertaken during


detailed design
R1036.1 Undertake complete review of furnace vendor package control, trip
functions, cause & effect and flow control configuration to individual passes
during detailed design
R1036.2 Consider configuration of FI and FQI to enable operator monitoring of
flow to individual condensate stabilisers and gas heaters
R1036.3 Consider provision of manual globe valve to enable operator
regulation of flow through filter, especially when clean
R1037.1 Review during vendor package HAZOP furnace protections for low
and/or no flow on individual passes
R1037.2 See Reccomendation R1036.3 for provision of flow control element
in slipstream
R1037.3 Review with furnace vendor whether 017-FV-0001 is required given
master flow controller of individual inlet flow controllers.
R1040.1 Configure LAL on 017-LI-0004 to act as pre-alarm before circulating
pump trip
R1040.2 See R1040.1 for configuration of LAL
R1040.3 Ensure piping layout enables draining of hot oil to drum for
maintenance activities
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
R1042.1 Consider handwheel, if not already provided, on 017-PV-0015 to
enable continued operation with manual control
R1045.1 Review design temperature of hot oil exchangers to match hot oil unit
design temperature
R1045.2 Review design temperature of hot oil expansion drum
R1063.1 Confirm during vendor package HAZOP provision of firebox venting
and purge requirements prior to ignition
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

Action resolution

TS

TS

TS

10

TS

TS

TS

TS

TS

TS
TS

3
4

3
4

7
9

TS

TS

TS

TS
TS

2
3

2
3

4
7

TS

TechnipItaly/21184/023rep

44

Appendix IV HAZOP Recommendations Hot Oil

HAZOP
Node
Item No.
1064
Node 2
1065
1068

Node 2
Node 2

1074

Node 2

1087

Node 3

1087

Node 3

1088

Node 3

Recommendations

Action by:

R1064.1 Review during detailed vendor package HAZOP flame protection and
flame-out protection, including trip actions
R1065.1 See R1064.1
R1068.1 Detailed furnace design to confirm potential for flame impingment
and protection against over-firing in furnace
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)
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
R1088.1 Ensure nitrogen purge sizing basis and local indication is sufficient to
prevent formation of vacuum in sump during pump out conditions

Action resolution

TS

TS
TS

3
3

3
3

7
7

TS

TS

TS

TS

TechnipItaly/21184/023rep

45

Appendix IV HAZOP Recommendations Diesel Oil & Jetty Air Compressor

HAZOP
Node
Item No.
1104
Node 1
1105
Node 1
1108

Node 1

1109

Node 1

HAZOP
Node
Item No.
1150
Node 2

Recommendations

Action by:

R1104.1 Undertake vendor package HAZOP during detailed design


R1105.1 Consider provision of pump to enable filling of diesel truck for onsite
distribution
R1108.1 Consider provision of check valve at harbour to prevent reverse flow
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

Recommendations
R1150.1 Undertake vendor air compressor package HAZOP during detailed
design

TS
TS

3
2

3
2

7
4

TS

TS

Action by:
TS

Action resolution

Action resolution

TechnipItaly/21184/023rep

46

Appendix IV HAZOP Recommendations Plant and Jetty Firewater

HAZOP
Node
Item No.
1180
Node 1

1180

Node 1

1200

Node 2

1201

Node 2

1202

Node 2

1212

Node 2

1215

Node 2

Recommendations

Action by:

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
R1181.2 Next revision of P&IDs will remove 051-LALL-007A/B stop of main
firewater pumps
R1200.1 Next revision of P&ID will show double check valve arrangement on
service water tie-in to jetty firewater ring main
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.
R1202.1 Next revision of P&ID will show discharge of 031-PSV-0003B
downstream of minimum flow control valve
R1212.1 Next revision of P&ID will show biocide dosing connection to pump
firewater basin screen
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

Action resolution

TS

TS

TS

OK LNG

TS

TS

TS

TechnipItaly/21184/023rep

47

Appendix IV HAZOP Recommendations Effluent Treatment

HAZOP
Node
Item No.
1220
Node 1

1220

Node 1

1221

Node 1

1221

Node 1

1222

Node 1

1235

Node 1

1238

Node 1

Recommendations

Action by:

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
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
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
R1221.2 HAZOP of chemical dosing packages will be undertaken during
detailed design
R1222.1 Review with instrumentation group whether provision of sequence
failure alarm is possible and/or necessary for the chemical sewer
neutralisation basin
R1235.1 Consider provision of hard pipework connection for removal of solids
from bottom of blowdown collection basins using vacuum truck
R1238.1 Provide sample connection on discharge of chemical sewer
neutralisation pumps for sampling purposes

Action resolution

TS

TS

TS

TS

TS

TS

TS

TechnipItaly/21184/023rep

48

Appendix IV HAZOP Recommendations Oily Water

HAZOP
Node
Item No.
1243
Node 1

1251

Node 1

1258

Node 1

1261

Node 1

1262

Node 1

1278

Node 2

1290

Node 3

1290

Node 3

1301

Node 3

1302

Node 3

Recommendations

Action by:

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
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

TS

R1258.1 Consider provision of hard piping to each collection basin to facilitate


cleaning and removal of solids by vacuum truck
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

TS

R1262.1 Detailed design phase will consider requirements for corrosion


protection on base of tank, e.g. CP, etc.
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
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
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)
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

TS

TS

TS

TS

TS

R1302.1 See Recommendation R1301.1, and consider provision of


independent low low level pump trip to prevent pump damage

Action resolution

TechnipItaly/21184/023rep

49

Appendix IV HAZOP Recommendations Oily Water

HAZOP
Node
Item No.
1313
Node 4
1313

Node 4

1316

Node 4

1317

Node 4

1318

Node 4

1318
1325

Node 4
Node 4

Recommendations
R1313.1 Consider deletion of pump discharge flow control, if not removed,
ensure 056-FV-0001 is FO
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
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)
R1317.1 Consider requirement for PSV protection on sludge pump discharge
since this is a positive displacement type pump
R1318.1 Consider configuration of low alarm on air pressure on oily water
treatment package
R1318.2 Undertake HAZOP of vendor package during detailed design
R1325.1 Ensure suitable level device is provided since dirty service

Action by:

Action resolution

TS

TS

TS

10

TS

TS

TS
TS

3
5

3
2

7
8

TechnipItaly/21184/023rep

50

Appendix IV HAZOP Recommendations Sanitary Waste Water Treatment

HAZOP
Node
Item No.
1353
Node 1

1376

Node 2

1376

Node 2

Recommendations

Action by:

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

Action resolution

TS

TS

TS

TechnipItaly/21184/023rep

51

Contents

1.

Executive Summary

2.

HAZOP Approach

3.

Appendices
I.

FEED HAZOP procedure

II.

Attendance

III.

Node List

IV.

HAZOP Recommendations

V.

HAZOP Worksheets

VI.

HAZOP Master P&IDs


TechnipItaly/21184/023rep

52

Version: Final
Sheet 1/125

HAZOP Record Sheet: Air Compression Package

Company
Facility
HAZOP Date
Section ID
General Section
Description:

TECHNIP
OK LNG Facility FEED Study
11-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

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

HAZOP
Plant
Item No. Section

Deviation

Causes

Consequences

Safeguards

Recommendations

Remarks

Action by:

Action resolution

Drawing Number/Sheet Number 2252-041-PID-00-31-01/Rev A/23-05-06


/Rev.Number/Date 2252-041-PID-00-31-02/Rev A/23-05-06
2252-041-PID-00-31-04/Rev A/24-05-06
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-101
Wet air vessel 041-V-101
759

760

Node 1

Air
compression
package

Overview

1. HAZOP of air compressor and


drier packages

Flow - High

1. Large demand in downstream


nitrogen, plant or instrument air
systems

R759.1 Consider requirement for


vendor package HAZOP during
detailed design
1. Gradual decrease in pressure in
downstream discharge of air
compressor
2. Increased flow of instrument air
and demand on air drying package
3. 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-FI0003 on flow to instrument air
2. 041-PIC/PAL-0005 controls the
air compression, increasing output
from air compression packages
3. 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 system
4. 041-PAL-0006 closes 041-SDV0001 to plant air. 041-PALL-0006
closes 043-SDV-0001 on nitrogen
air generation package inlet. 041PALL-0007 activates unit 41 alarm
only, manual operator hand switch
trip of air compressor package 041U-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
air
6. 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.

TS

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.

Prepared by Arthur D. Little for OK LNG

Version: Final
Sheet 2/125

HAZOP Record Sheet: Air Compression Package

Company
Facility
HAZOP Date
Section ID
General Section
Description:

HAZOP
Plant
Item No. Section

TECHNIP
OK LNG Facility FEED Study
11-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

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

Deviation

Causes
2. Maintenance in plant requiring
high flow of plant air

Consequences

Safeguards

1. Increase in demand of dried air 1. 041-FI/FAH-0002 on flow to


for plant utility service
plant air, 041-FI-0001on flow to
2. Potential for gradual decrease in nitrogen generation and 041-FIpressure in instrument air system 0003 on flow to instrument air
2. 041-PIC/PAL-0005 controls the
air compression, increasing output
from air compression packages
3. 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 system
4. 041-PAL-0006 closes 041-SDV0001 to plant air. 041-PALL-0006
closes 043-SDV-0001 on nitrogen
air generation package inlet. 041PALL-0007 activates unit 41 alarm
only, manual operator hand switch
trip of air compressor package 041U-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
air
6. 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.

Recommendations

Remarks

Action by:

Action resolution

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

Prepared by Arthur D. Little for OK LNG

Version: Final
Sheet 3/125

HAZOP Record Sheet: Air Compression Package

Company
Facility
HAZOP Date
Section ID
General Section
Description:

HAZOP
Plant
Item No. Section

761

TECHNIP
OK LNG Facility FEED Study
11-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

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

Deviation

Flow - Low

Causes

Consequences

Safeguards

3. Malfunction/incorrect set point of 1. Increase in compressor flow


041-PIC-0005
rate
2. Gradual increase in dried air
pressure
3. 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 packages
3. Individual air compressor
package recycle and anti-surge
protection, in the event of low
actual demand for instrument/plant
air
4. 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 manually
6. Dedicated PSVs on discharge of
individual air compressors and 041PSV-0001 on wet air vessel

1. Low demand in downstream


1. Gradual increase in pressure in
instrument air, nitrogen generation the discharge of the air
and/or plant air
compressor packages
2. Potential for overpressure of
upstream equipment

1. Design pressure of air


compressors and downstream
equipment is 10 barg
2. 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 operation
5. 041-PI/PAH-0001A/B/C/D on
discharge of each individual air
compressor package
6. 041-XL-0001A/B/C/D running
status indication for each air
compressor package

Recommendations

Remarks

Action by:

Action resolution

Prepared by Arthur D. Little for OK LNG

Version: Final
Sheet 4/125

HAZOP Record Sheet: Air Compression Package

Company
Facility
HAZOP Date
Section ID
General Section
Description:

HAZOP
Plant
Item No. Section

TECHNIP
OK LNG Facility FEED Study
11-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

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

Deviation

Causes

Consequences

Safeguards

Recommendations

Remarks

Action by:

Action resolution

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
pressure
3. Potential for downstream
process equipment trips due to
loss of instrument air and/or
nitrogen

R761.1 Consider requirements for


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

TS

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 compressor
3. Potential for decrease in
pressure in downstream
instrument air/nitrogen generation
systems

1. 041-PIC-0005 controls the


R761.2 Consider requirements for
number of duty air compressors
dP indication and PDAH alarm on
(start stand-by compressor)
interstage and discharge filters on
2. 041-PAL-0006 closes 041-SDV- the air compressor packages
0001 to plant air. 041-PALL-0006
closes 043-SDV-0001 on nitrogen
air generation package inlet. 041PALL-0007 activates unit 41 alarm
only, manual operator hand switch
trip of air compressor package 041U-101 and start of 041-U-103
startup compressor and drier.

TS

Prepared by Arthur D. Little for OK LNG

Version: Final
Sheet 5/125

HAZOP Record Sheet: Air Compression Package

Company
Facility
HAZOP Date
Section ID
General Section
Description:

HAZOP
Plant
Item No. Section

TECHNIP
OK LNG Facility FEED Study
11-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

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

Deviation

Causes

Consequences

4. Malfunction or incorrect set point 1. 041-PIC-0005 staged shutdown


of 041-PIC-0005
of online air compressors
2. Gradual decrease in dried air
pressure
3. Potential for loss of instrument
air supply to process

762

Flow - No

763

Flow - Reverse

Safeguards

Recommendations

1. Independent 041-PIC-0008
controls feed to plant air system
2. 041-XL-0001A/B/C/D running
indication on individual air
compression packages
3. 041-PAL-0006 on feed to
instrument air system
4. Possible for operator to override
041-PIC-0005 and start air
compressors manually
5. 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

Remarks

Action by:

Action resolution

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

TS

No new issues
1. Standby air compressor

1. Potential for reverse flow


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

2. Trip of air compressor

1. Potential for reverse flow from


instrument air recievers with
damage to air drying package
2. Potential for loss of buffer air
pressure in instrument air
receivers

R763.1 Confirm requirements for


check valves and configuration of
air compressor package and startup compressor and drier with
vendor
1. Common check valve on inlet to
plant air receiver 041-V-103
2. Check valve on inlet to each
individual instrument air receiver

Prepared by Arthur D. Little for OK LNG

Version: Final
Sheet 6/125

HAZOP Record Sheet: Air Compression Package

Company
Facility
HAZOP Date
Section ID
General Section
Description:

HAZOP
Plant
Item No. Section
764

765

TECHNIP
OK LNG Facility FEED Study
11-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

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

Deviation
Loss of
Containment

Causes

Consequences

Safeguards

Recommendations

1. Compressor seal failure

1. Release of instrument air to


atmosphere
2. Reduced performance in
individual compressor

1. 041-PI/PAL-001A/B/C/D on
individual air compressor
discharge
2. 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 atmosphere
2. Potential for increased duty on
air compressors

1. Wet air system is carbon steel R764.1 Update P&ID to show


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

1. Potential overpressure of
compressed air system

1. 041-PSV-0001 sized for fire on R765.1 Consider vapourisation of


wet air vessel
water collected in wet air vessel in
sizing basis for 041-PSV-0001

1. Blocked discharge of air


compressor package resulting in
increase in discharge pressure
2. Loss of flow of dried air to
instrument air and plant air
distribution network
3. Gradual decrease in pressure
downstream of plant air receiver
4. 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
package
2. Individual surge control on each
air compressor
3. Individual compressor discharge
PSV sized for full design capacity
of compressor

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

2. Sequence failure in the air


drying package

766

Pressure - Low

No new issues

767

Vacuum

No new issues

Remarks

Action by:

Action resolution

1. HAZOP team does not


TS
consider requirement for dP
indication over demister
necessary given provision
of inlet baffle

TS

Prepared by Arthur D. Little for OK LNG

Version: Final
Sheet 7/125

HAZOP Record Sheet: Air Compression Package

Company
Facility
HAZOP Date
Section ID
General Section
Description:

HAZOP
Plant
Item No. Section
768

TECHNIP
OK LNG Facility FEED Study
11-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

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

Deviation

Causes

Partial Pressure 1. Changes in air humidity

Consequences

Safeguards

1. Increased generation of water in


discharge from air compressor
package
2. Potential for increased load on
air drying package
3. 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 drums
2. Wet air vessel with 041-LAH001 and operator manual draining
prevents free water ingress into air
drying package (no normal level)

Recommendations

769

Temperature High

1. Malfunction in air compressor


1. Increase in discharge
package (e.g. loss of interstage or temperature from air compressor
afterstage cooling)
package
2. Increased duty on downstream
air drying package

1. 041-TI/TAH-003/A/B/C/D on
discharge of each air compressor
package
2. 041-AI-0001A/B moisture
indication on downstream air
drying package
3. Dedicated drier package on inlet
to nitrogen generation package
unit

770

Temperature Low

1. Low ambient temperature

1. Minimum design temperature


for location is 4 degrees C

771

Cryogenic (Sub Zero)

772

Level - High

1. Malfunction in upstream
compressor discharge K/O drum
level control

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

1. Potential for ice formation

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-AI0001A/B to warn operator of water
breakthrough to instrument air
system

Remarks

Action by:

TS

Action resolution

No new issues

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-LAH0001 requires manual operator


draining
2. Dehydration package within
nitrogen generation package

Prepared by Arthur D. Little for OK LNG

Version: Final
Sheet 8/125

HAZOP Record Sheet: Air Compression Package

Company
Facility
HAZOP Date
Section ID
General Section
Description:

HAZOP
Plant
Item No. Section
778

TECHNIP
OK LNG Facility FEED Study
11-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

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

Deviation
Wrong
Concentration
(Part of)

Causes
1. Ingress of flammable gas into
air compressor package

Consequences
1. Potential for explosion in air
compressor package

Safeguards

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

779

Corrosive (As
well as)

No new issues

780

Explosive

No new issues

781

Wrong Material
(Other than)

No new issues

Remarks

Action by:
TS

Action resolution

Prepared by Arthur D. Little for OK LNG

Version: Final
Sheet 9/125

HAZOP Record Sheet: Air Compression Package

Company
Facility
HAZOP Date
Section ID
General Section
Description:

TECHNIP
OK LNG Facility FEED Study
11-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

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

HAZOP
Plant
Item No. Section

Deviation

Causes

Consequences

Safeguards

Recommendations

Remarks

Action by:

Action resolution

Drawing Number/Sheet Number 2252-041-PID-00-31-02/Rev A/23-05-06


/Rev.Number/Date 2252-041-PID-00-31-04/Rev A/24-05-06
2252-041-PID-00-31-05/Rev A/24-05-06
2252-041-PID-00-31-06/Rev A/24-05-06
2252-041-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.
Node Equipment 041-U-102 Air drying package
041-U-103 Startup compressor and drier
041-V-103 Plant air reciever
041-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)
782

783

Node 2

Compressed
air drier
package and
downstream
instrument air
receivers

Overview

Flow - High

See Node 1

Prepared by Arthur D. Little for OK LNG

Version: Final
Sheet 10/125

HAZOP Record Sheet: Air Compression Package

Company
Facility
HAZOP Date
Section ID
General Section
Description:

HAZOP
Plant
Item No. Section
784

TECHNIP
OK LNG Facility FEED Study
11-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

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

Deviation
Flow - Low

Causes

Consequences

Safeguards

1. Operator error in lineup of


instrument air receivers

1. Loss of instrument air supply to 1. Operating procedures


individual plant area

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

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

Remarks

Action by:
TS

Action resolution

1. Individual air drier package


common trouble alarm 041-UUA0003A/B, drier status 041-XL0002A/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 antisurge control and discharge PSV
prevent overpressure of upstream
systems
4. 100% spare air drier package
provided, requiring operator action
to bring online

Prepared by Arthur D. Little for OK LNG

Version: Final
Sheet 11/125

HAZOP Record Sheet: Air Compression Package

Company
Facility
HAZOP Date
Section ID
General Section
Description:

HAZOP
Plant
Item No. Section

TECHNIP
OK LNG Facility FEED Study
11-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

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

Deviation

Causes

Consequences

Safeguards

Recommendations

Remarks

Action by:

Action resolution

3. Blockage of the plant air drier


1. Reduced throughput in air drying 1. Individual air drier package
desiccant packings with corrosion package
common trouble alarm 041-UUAscale
2. Potential for decrease in
0003A/B would be initiated in the
pressure in downstream plant and event of high differential pressure
instrument air systems due to
over the packing
reduced drying capacity
2. Each individual instrument air
receiver has 15 mins holdup
capacity
3. 041-PAL-0006 isolates plant air,
041-PALL-006 isolates wet air feed
to nitrogen generation package to
protect feed of dried, compressed
air to the instrument air headers
4. Individual compressor antisurge control and discharge PSV
prevent overpressure of upstream
systems
5. 100% spare air drier package
provided, requiring operator action
to bring online
6. Requirement for complete
charge of desiccant for individual
air drying package to be stored in
warehouse

785

Flow - No

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 unit
3. Main air compressor package
will be commissioned to supply
feed required for single train LNG
operation

1. Local electrical failure

1. All control sequence valves are


pneumatic
2. Electrical supply for control
panel is connected to emergency
power supply

1. Loss of electricity to main air


drying package

Prepared by Arthur D. Little for OK LNG

Version: Final
Sheet 12/125

HAZOP Record Sheet: Air Compression Package

Company
Facility
HAZOP Date
Section ID
General Section
Description:

HAZOP
Plant
Item No. Section
786

787

TECHNIP
OK LNG Facility FEED Study
11-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

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

Deviation

Causes

Consequences

Safeguards

Recommendations

Remarks

Action by:

Action resolution

Flow - Reverse

1. Reverse flow of dry air during air


drying package regeneration

1. Normal operating condition


during regeneration
2. Check valves provided in the
regeneration pipework to prevent
flow of high moisture content air
into the downstream instrument air
system

Loss of
Containment

1. Regeneration of air drying


package desiccant

1. Use of dried air to regenerate


the package desiccant
2. 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


R787.1 See R784.1 for provision
(downstream of air drying package of DCS PI and PAL indication on
041-U-102) is galvanized steel,
individual instrument air receivers
minimising potential for scale
formation
2. Instrument air receivers are
carbon steel and epoxy lined
3. Corrosion and leakage flow rate
would be small in comparison with
capacity of the network
4. 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

TS

1. Potential for overpressure

1. PSV fire protection on each


individual instrument air receiver
and upstream plant air receiver

TS

788

Pressure - High 1. Fire in vicinity of instrument air


receiver

R788.1 Consider and confirm


requirements for PSV on each air
drying package vessel

789

Pressure - Low

No new issues

790

Vacuum

No new issues

Prepared by Arthur D. Little for OK LNG

Version: Final
Sheet 13/125

HAZOP Record Sheet: Air Compression Package

Company
Facility
HAZOP Date
Section ID
General Section
Description:

HAZOP
Plant
Item No. Section
791

TECHNIP
OK LNG Facility FEED Study
11-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

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

Safeguards

Recommendations

Partial Pressure 1. Incorrect sequence timing on air 1. Potential for insufficient


drying package
regeneration time and/or
exceedance of drying capacity
within the desiccant, resulting in
moisture breakthrough

Deviation

Causes

1. 041-AI-0001A/B on each drying


air package
2. 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

792

Temperature High

1. 041-TI/TAH-0006 on discharge
of the startup air compressor
package
2. 041-AI/AAH-0002 moisture
indication on downstream startup
air drying package

793

Temperature Low

No new issues

794

Cryogenic (Sub Zero)

No new issues

795

Level - High

796

Level - Low

No new issues

797

Level - No

No new issues

1. Malfunction in startup air


compressor package (e.g. loss of
afterstage cooling)

1. Malfunction of main air drying


package and/or startup drier

Consequences

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

1. Increase in moisture content of


instrument air
2. Potential for formation of
condensate, corrosion and
instrumentation damage
downstream

Remarks

Action by:
TS

Action resolution

1. 041-AI-0001A/B on discharge of
main air drier package
2. 0041-AI/AAH-0002 on discharge
of startup drier
3. 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

Prepared by Arthur D. Little for OK LNG

Version: Final
Sheet 14/125

HAZOP Record Sheet: Air Compression Package

Company
Facility
HAZOP Date
Section ID
General Section
Description:

HAZOP
Plant
Item No. Section
798

TECHNIP
OK LNG Facility FEED Study
11-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

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

Deviation
Phase - More

Causes

Consequences

Safeguards

Recommendations

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 shelter
2. Local start of startup air
compressor

TS

TS

TS

R798.2 Ensure operating manual


requires operator check and
draining of free water from the
compressor casing before start-up

No new issues

801

Wrong
Concentration
(Part of)

Wrong Material
(Other than)

No new issues

804

Change of State

Explosive

TS

Phase - Less

803

Action resolution

1. Integral filter element will be


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

800

Corrosive (As
well as)

Action by:

1. Blockage in downstream
instrument air fittings

799

802

Remarks

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

1. Contamination of instrument air


with hydrocarbon from the air
compressor packages
2. Ingress of flammable gas into
1. Potential for explosion
startup compressor

1. Requirement for vendor supply


of oil free instrument air
1. Compressor only used during
start-up

R801.1 Consider requirement for


flammable gas detection on startup compressor inlet
No new issues

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

Prepared by Arthur D. Little for OK LNG

Version: Final
Sheet 15/125

HAZOP Record Sheet: Nitrogen

Company
Facility
HAZOP Date
Section ID
General Section
Description:

TECHNIP
OK LNG Facility FEED Study
11-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Nitrogen system
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.

HAZOP
Plant
Deviation
Causes
Item No. Section
Drawing Number/Sheet Number 2252-043-PID-00-31-01/Rev A/23-05-06
/Rev.Number/Date 2252-043-PID-00-31-02/Rev A/23-05-06

Consequences

Safeguards

Recommendations

Remarks

Action by:

Action resolution

Design intent See section description


Node Equipment 043-V-101 Nitrogen generation package
043-V-102 Nitrogen storage and vapourising package
805

806

Node 1

Nitrogen Overview
System

Flow - High

1. HAZOP of nitrogen generation,


nitrogen liquid storage and
vapouriser package unit

1. Malfunction in downstream
nitrogen user control element

R805.1 Consider requirement for


vendor package HAZOP during
detailed design

TS

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

1. Increase in requirement for GAN 1. 043-PI/PAL-0002 on common


2. Potential for decrease in
gaseous nitrogen header
nitrogen header pressure
2. 043-FI-0005 on common
gaseous nitrogen header
3. Independent 043-FI-0006A/B
from nitrogen generation unit
4. In the event of 043-PAL-002,
gaseous nitrogen is produced from
the vapourisation of liquid nitrogen
to maintain header pressure
5. 043-FI-0004A/B gaseous
nitrogen flow rate from each
vapouriser

2. Maintenance/purging of single 1. Significant increase in gaseous


LNG train with continued operation nitrogen requirement
on remaining three LNG trains
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 pressure
2. 043-PI/PAL-0002 on common
gaseous nitrogen header initiates
vapourisation of liquid nitrogen to
maintain header pressure

Prepared by Arthur D. Little for OK LNG

Version: Final
Sheet 16/125

HAZOP Record Sheet: Nitrogen

Company
Facility
HAZOP Date
Section ID
General Section
Description:

HAZOP
Plant
Item No. Section

TECHNIP
OK LNG Facility FEED Study
11-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Nitrogen system
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.
Deviation

Causes

Consequences

Safeguards

Recommendations

3. Requirement for LIN production 1. Potential decrease in GAN


(storage not full)
production

1. Nitrogen generation package


designed to enable continued
production of normal consumption
GAN and design flowrate LIN
concurrently
2. 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 vendor
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

1. Internal nitrogen generation


R807.1 Ensure atmospheric vent
package control. For single train
for nitrogen is at safe location
operation, requirement to vent
nitrogen. However, for 2 and 3
train operation, possible to regulate
nitrogen generation package at
turndown conditions
2. 043-PI-002 on gaseous nitrogen
header
3. 043-FI-0005 on gaseous
nitrogen header

807

Flow - Low

1. Reduction in gaseous nitrogen 1. Gradual increase in gaseous


requirement, e.g. 1 or 2 LNG trains nitrogen header pressure
offline
2. Potential to overpressure the
nitrogen generation package

808

Flow - No

1. Plant shutdown

Remarks

Action by:

Action resolution

TS

TS

1. Loss of gaseous nitrogen usage 1. Internal nitrogen generation


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

Prepared by Arthur D. Little for OK LNG

Version: Final
Sheet 17/125

HAZOP Record Sheet: Nitrogen

Company
Facility
HAZOP Date
Section ID
General Section
Description:

HAZOP
Plant
Item No. Section

TECHNIP
OK LNG Facility FEED Study
11-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Nitrogen system
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.
Deviation

Causes
2. High level in liquid nitrogen
storage tanks

Consequences
1. No requirement for LIN
production

Safeguards

Flow - Reverse

1. Malfunction of pressure control 1. Potential for production of


1. Internal vapouriser package
on nitrogen vapourisation package nitrogen at higher pressure than
pressure control to ensure
feed nitrogen generation package production of GAN at same
pressure as nitrogen generation
package

810

Loss of
Containment

1. Valve and/or equipment failure

811

Pressure - High 1. Thermal expansion and


vapourisation of liquid nitrogen in
isolated pipework
2. Fire in vicinity of liquid nitrogen
package units
Pressure - Low

813

Vacuum

1. Upstream air compressor trip


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

Remarks

Action by:

Action resolution

1. Possible to operate nitrogen


generation package in gaseous
nitrogen mode only with reduced
total nitrogen production

809

812

Recommendations

1. Potential for release of nitrogen 1. Equipment design


to atmosphere with the production
of nitrogen rich atmosphere

1. Overpressure of pipework and


equipment

1. Equipment design and/or


pressure relief

1. Potential for overpressure of


pipework and equipment

1. Equipment design and/or


pressure relief

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 nitrogen
3. Liquid nitrogen storage for 4
days normal consumption or purge
in one LNG train

No new issues

Prepared by Arthur D. Little for OK LNG

Version: Final
Sheet 18/125

HAZOP Record Sheet: Nitrogen

Company
Facility
HAZOP Date
Section ID
General Section
Description:

HAZOP
Plant
Item No. Section
814

TECHNIP
OK LNG Facility FEED Study
11-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Nitrogen system
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.
Deviation

Causes

Partial Pressure 1. Upset in nitrogen generation


package

1. Upset in nitrogen generation


package dehydration

815

Temperature High

816

Temperature Low

Consequences

Safeguards

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

1. 043-AI-0005 oxygen analyser on


GAN distribution header
2. 043-AI-0001A/B oxygen
analyser on nitrogen generation
control panel

1. Potential for ice formation in


nitrogen generation package and
liquid nitrogen systems

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

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

Remarks

Action by:

Action resolution

TS

R816.1 Discuss during vendor


package HAZOP protections
against exceedance of vapouriser
gaseous discharge pipework
specification

TS

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

No issues identified

1. Production of cryogenic liquid


nitrogen

1. Potential for exceedence of


1. All liquid nitrogen pipework is
material design specifications and stainless steel and designed for
brittle fracture
low temperature service

1. Malfunction in liquid nitrogen


vapouriser

1. Liquid ingress into nitrogen


header
2. Potential to exceed material
specification of gaseous nitrogen
pipework leaving nitrogen
vapourisers
3. Potential for pipework brittle
fracture

817

Cryogenic (Sub - 1. Normal condition for nitrogen


Zero)
generation, liquid storage and
vapourisers

818

Level - High

1. Flow of liquid nitrogen to liquid


nitrogen storage tanks

1. Potential to liquid fill storage


tanks
2. Potential to overpressure liquid
nitrogen storage tanks

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

Prepared by Arthur D. Little for OK LNG

Version: Final
Sheet 19/125

HAZOP Record Sheet: Nitrogen

Company
Facility
HAZOP Date
Section ID
General Section
Description:

HAZOP
Plant
Item No. Section
819

TECHNIP
OK LNG Facility FEED Study
11-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Nitrogen system
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.
Deviation
Level - Low

Causes
1. Periodic requirement for
vapourisation of liquid nitrogen to
maintain GAN header pressure

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

Safeguards

Recommendations

1. During normal GAN production R819.1 Consider configuration of


mode, the nitrogen generation
LAL at higher level in the tank (e.g.
package produces greater than
60-80% full) if no requirement to
100% normal nitrogen
have LAL at low level in the tank,
consumption requirement
e.g. for protection of pump and/or
2. Requirement for operator to
gas breakthrough from storage
manually switch nitrogen
generation package from GAN to
GAN & LIN operation mode. This is
normally manual to prevent
continual upset to air separation
column reflux and operation
3. 043-LI/LAL-001A/B on liquid
nitrogen storage

820

Level - No

No new issues

821

Phase - More

No new issues

822

Phase - Less

No new issues

823

Change of State

No new issues

824

Wrong
Concentration
(Part of)

825

Corrosive (As
well as)

No new issues

826

Explosive

No new issues

827

Wrong Material
(Other than)

No new issues

1. Upset in the nitrogen generation 1. Increase in carbon dioxide


package
concentration in nitrogen product
2. Potential for formation of solid
carbon dioxide in liquid nitrogen
system

Remarks

Action by:
TS

Action resolution

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

Prepared by Arthur D. Little for OK LNG

Version: Final
Sheet: 20/125

HAZOP Record Sheet: Raw and Service Water

Company
Facility
HAZOP Date
Section ID
General Section
Description:

TECHNIP
OK LNG Facility FEED Study
12/09/2006 - 13/09/2006

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Raw water production and treatment


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

Plant
Deviation
Causes
HAZOP
Item No. Section
Drawing Number/Sheet Number 2252-003-PID-00-31-01/Rev A/23-05-06
/Rev.Number/Date 2252-051-PID-00-31-01/Rev A/23-05-06
2252-051-PID-00-31-02/Rev A/24-05-06
2252-051-PID-00-31-03/Rev A/24-05-06

Consequences

Safeguards

Recommendations

Remarks

Action by:

Action resolution

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-C


Raw water filtration package 051-U-101
Filtered and firewater storage tank 051-T-101A/B
828

Node 1

Well Water Overview


Pumps and
Raw Water
Filtration

HAZOP of Backwash Filter Control


System and Configuration

R828.1 Consider HAZOP of


vendor package during detailed
design

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

LALL actions in these units TS


are configured as DCS
stop/inhibit actions, not
hardwired ESD trip actions
as no immediate safety
impact.
No SIL rating of 051-LALL005A/B or 051-LALL-0013
required by project

TS

Prepared by Arthur D. Little for OK LNG

Version: Final
Sheet: 21/125

HAZOP Record Sheet: Raw and Service Water

Company
Facility
HAZOP Date
Section ID
General Section
Description:

Plant
HAZOP
Item No. Section
829

TECHNIP
OK LNG Facility FEED Study
12/09/2006 - 13/09/2006

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Raw water production and treatment


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

Deviation
Flow - High

Causes

Consequences

Safeguards

Recommendations

Remarks

Action by:

Action resolution

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


pumps
2. 051-LI/LAL-0004A on filtered
storage water tank
3. 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 cavitation
5. Firewater inventory in the
filtered and firewater storage tank
is protected by elevated nonfirewater water nozzles on tank
6. 051-LI/LAL-0006A/B starts third
standby well pump to increase
filling rate to maximum flow rate
7. 051-LALL-0007A/B trips
firewater pumps to prevent
cavitation (in next revision, LALL0007A/B will only be alarm with no
trip action)

R829.1 Update P&ID to show


correct relative location of 051LALL-0005A/B vs non firewater
nozzles

TS

2. Malfunction/incorrect set point


051-LI-0006A/B

1. Loss of stop signal for well


water pumps
2. 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
tanks
4. Potential to overfill and damage
filtered and firewater storage tanks

1. 051-LI/LAHH-0004A/B stops all


operating well water pumps to
prevent overfilling
2. 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 levels
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

Prepared by Arthur D. Little for OK LNG

Version: Final
Sheet: 22/125

HAZOP Record Sheet: Raw and Service Water

Company
Facility
HAZOP Date
Section ID
General Section
Description:

Plant
HAZOP
Item No. Section
830

TECHNIP
OK LNG Facility FEED Study
12/09/2006 - 13/09/2006

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Raw water production and treatment


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

Deviation
Flow - Low

Causes

Consequences

Safeguards

Recommendations

Remarks

Action by:

Action resolution

1. Reduction in requirement for


1. Reduced flow rate from
service water and/or demin water, filtered/fire water storage tank
e.g. two train operation only
2. Reduced duty for well water
pumps and/or reduced filling time
for filtered and firewater storage
tanks
3. 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 overfilling
3. 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

2. Malfunction/incorrect setpoint in 1. Loss of start signal for two well


051-LI-0004A/B
pumps
2. Continued decrease in level in
filtered and firewater storage tanks
with loss of firewater hold up
volume
3. 051-LALL-0005A/B inhibits filter
backwash and stops service and
reverse osmosis water pumps
4. Loss of both filling and emptying
of the filtered and firewater storage
pumps
5. 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 pumps
2. 051-LIC/LAL-0011 on
downstream desalinated water
storage tank
3. 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

3. Malfunction/incorrect setpoint in 1. Loss of start signal to well water


051-LI-0006A/B
pumps during initial
commissioning activities
2. 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

Prepared by Arthur D. Little for OK LNG

Version: Final
Sheet: 23/125

HAZOP Record Sheet: Raw and Service Water

Company
Facility
HAZOP Date
Section ID
General Section
Description:

Plant
HAZOP
Item No. Section

831

TECHNIP
OK LNG Facility FEED Study
12/09/2006 - 13/09/2006

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Raw water production and treatment


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

Deviation

Flow - No

Causes

Consequences

Safeguards

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 tanks
2. Gradual reduction in level in
filtered and firewater storage tanks
3. Potential for reduction in level
and usage of firewater for normal
operating systems

1. Auto-start of standby well pump


on low discharge pressure
2. 051-LI/LAL-0004A/B on filtered
and firewater storage tanks
3. 051-LALL-0005A/B on filtered
and firewater storage tank stops
non firewater user pumps (service
water, reverse osmosis &
backwash pumps) to prevent
pump cavitation
4. Firewater inventory in the
filtered and firewater storage tank
is protected by elevated nonfirewater water nozzles on tank
5. Filtered and firewater storage
tanks combined capacity provides
five days normal operation holdup
volume

1. Failure in filter backwash


sequence and/or backwash
sequence valve

1. Loss of backwash cleaning of


single filter
2. Potential for blockage of single
filtration package filter
3. Potential impact on normal
operating flow rate to filtered and
firewater storage tanks

1. 051-PDAH-0001 common alarm


on raw water filter package
2. 051-UUA-0001 common trouble
alarm on raw water filtration
package
3. Six filters in parallel with one
filter in backwash during normal
operation
4. 051-LI/LAL-0004A/B on filtered
and firewater storage tanks

2. Operator error - closing manual 1. Potential for loss of flow of


1. Normal operating procedures
isolation valve on filtered water
filtered water to tank and/or supply
and firewater storage tank
to other service requirements
2. Potential for loss of backwash
feed to filter package

Recommendations

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

Remarks

Action by:

TS

Action resolution

Prepared by Arthur D. Little for OK LNG

Version: Final
Sheet: 24/125

HAZOP Record Sheet: Raw and Service Water

Company
Facility
HAZOP Date
Section ID
General Section
Description:

Plant
HAZOP
Item No. Section

TECHNIP
OK LNG Facility FEED Study
12/09/2006 - 13/09/2006

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Raw water production and treatment


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

Deviation

Causes

Consequences

Safeguards

3. Maintenance on filter and


firewater storage tank

1. Potential for impact on normal


process operations

1. Potential for reverse flow


1. Check valve on discharge of
through raw water filtration
each individual well water pump
package to wells via syphon and/or
hydrostatic head

832

Flow - Reverse

1. Total loss of well water pump


power supply

833

Loss of
Containment

1. Corrosion of carbon steel


1. Potential for leakage of raw
pipework and filtered and firewater water to atmosphere
storage tanks with brackish well
water

Recommendations

Remarks

Action by:

Action resolution

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

1. Filtered and firewater tankage is


completely internally epoxy lined
2. Carbon steel pipework with
3mm corrosion allowance
3. Carbon steel filters with 5mm
corrosion allowance
4. Firewater underground main is
GRP

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

R833.1 Detailed design to consider


requirement for external protection
of water tanks floors via CP or
coating
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

Prepared by Arthur D. Little for OK LNG

Version: Final
Sheet: 25/125

HAZOP Record Sheet: Raw and Service Water

Company
Facility
HAZOP Date
Section ID
General Section
Description:

Plant
HAZOP
Item No. Section
834

TECHNIP
OK LNG Facility FEED Study
12/09/2006 - 13/09/2006

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Raw water production and treatment


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

Deviation

Causes

Pressure - High 1. Blockage of filtered water inlet


pipework to the storage tank

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

Safeguards

Recommendations

Remarks

Action by:

Action resolution

1. Complete blockage of six filter


packages not considered credible,
as normal inlet and outlet
sequence valves are FO
2. 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

2. Thermal expansion of blocked 1. Potential for overpressure of


water pipework section and/or fire pipework and/or filters
in vicinity of filtration package

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. Filling of filtered and firewater


1. Potential for overpressure of
storage tank with three well water atmospheric tank
pumps operating, e.g. during initial
filling of tanks

1. 4 inch vent on each filtered and


firewater atmospheric storage
tanks sufficient
2. 12 inch overflow protection on
tank

1. Operation of two firewater


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

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

835

Pressure - Low

836

Vacuum

No new issues

837

Partial Pressure

No new issues

838

Temperature High

No new issues

839

Temperature Low

840

Cryogenic (Sub Zero)

No new issues

841

Level - High

No new issues

1. Low ambient temperatures

1. Potential for decrease in filtered


and firewater storage tank vapour
space pressure
2. Potential for filtered and
firewater storage tank collapse

1. Minimum design temperature


for location is 4 degrees C

Prepared by Arthur D. Little for OK LNG

Version: Final
Sheet: 26/125

HAZOP Record Sheet: Raw and Service Water

Company
Facility
HAZOP Date
Section ID
General Section
Description:

Plant
HAZOP
Item No. Section
842

TECHNIP
OK LNG Facility FEED Study
12/09/2006 - 13/09/2006

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Raw water production and treatment


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

Deviation
Level - Low

843

Level - No

844

Phase - More

Causes
1. Reduction in water level in site
aquifer

Consequences

Safeguards

1. Potential for loss of well water 1. 0003-LT-0001 stops well water


for LNG liquifaction terminal and/or pumps to prevent pump cavitation
damage of water water pumps
2. Five days holdup volume in
filtered and firewater storage tanks

Recommendations
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

Remarks

Action by:

Action resolution

TS

TS

TS

No new issues
1. High solids concentration in well 1. High solids loading in the raw
water
water filtration package
2. Potential for blockage of filters
3. Potential for loss of feed to
filtered and firewater storage tanks
and/or filter overpressure

1. Five days storage of filtered


R844.1 Consider during detailed
water in filtered and firewater
design and reciept of raw water
storage tanks
composition implications on
2. 051-PDAH-0001 common alarm proposed filtration package
on filter package
configuration and design
3. High dP over single filter
initiates backwash sequence
4. Six filters provided, in normal
operation five online with sixth filter
in backwash

2. High solids concentration in the 1. Potential contamination of non


filter backwash water
contaminated water sewer system
and off-site receiving waters with
high solids content water

3. Contamination of well water with 1. Contamination of downstream


hydrocarbon
potable water, demin water etc.

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

1. Raw water will be obtained from


deep water wells with no potential
for hydrocarbon contamination
2. Biocide dosing of the raw water
on the inlet to the filtration package
prevents algal/bacteria growth in
the filtered and firewater storage
tank.

845

Phase - Less

No new issues

846

Change of State

No new issues

Prepared by Arthur D. Little for OK LNG

Version: Final
Sheet: 27/125

HAZOP Record Sheet: Raw and Service Water

Company
Facility
HAZOP Date
Section ID
General Section
Description:

Plant
HAZOP
Item No. Section
847

TECHNIP
OK LNG Facility FEED Study
12/09/2006 - 13/09/2006

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Raw water production and treatment


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

Deviation
Wrong
Concentration
(Part of)

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

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

Safeguards

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

848

Corrosive (As
well as)

No new issues

849

Explosive

No new issues

850

Wrong Material
(Other than)

No new issues

Remarks

Action by:
TS

Action resolution

Prepared by Arthur D. Little for OK LNG

Version: Final
Sheet: 28/125

HAZOP Record Sheet: Raw and Service Water

Company
Facility
HAZOP Date
Section ID
General Section
Description:

TECHNIP
OK LNG Facility FEED Study
12/09/2006 - 13/09/2006

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Raw water production and treatment


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

Plant
Deviation
Causes
HAZOP
Item No. Section
Drawing Number/Sheet Number 2252-051-PID-00-31-01/Rev A/23-05-06
/Rev.Number/Date 2252-051-PID-00-31-02/Rev A/24-05-06

Consequences

Safeguards

Recommendations

Remarks

Action by:

Action resolution

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

Node Equipment Raw water sterilisation package 051-U-102


851

Node 2

Raw water Overview


sterilisation
package

HAZOP of raw water sterilisation


package

852

Flow - High

1. Malfunction/incorrect setpoint of 1. Increased usage of sodium


051-AIC-001 chlorine analyser on hypochlorite solution
inlet to storage filter tank
2. Decrease in level in sodium
hypochlorite storage vessel
3. Potential upset in downstream
reverse osmosis package unit

1. Independent 051-LAL-0001 on
sterilisation package
2. Independent calibration pot
provided on raw water sterilisation
package for calibration of metering
pumps
3. 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 1. Decreased usage of sodium


051-AIC-001 chlorine analyser on hypochlorite solution
inlet to storage filter tank
2. Potential for algal and bacterial
growth in filtered and firewater
storage tanks
3. Potential for impact on
downstream water systems

1. Independent calibration pot


provided on raw water sterilisation
package for calibration of metering
pumps
2. 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

R851.1 Consider HAZOP of


vendor package during detailed
design

TS

R853.1 Consider provision raw


water sterilisation package sodium
hypochlorite storage DCS level
indication

TS

Prepared by Arthur D. Little for OK LNG

Version: Final
Sheet: 29/125

HAZOP Record Sheet: Raw and Service Water

Company
Facility
HAZOP Date
Section ID
General Section
Description:

Plant
HAZOP
Item No. Section
854

TECHNIP
OK LNG Facility FEED Study
12/09/2006 - 13/09/2006

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Raw water production and treatment


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

Deviation

Causes

Consequences

Safeguards

Recommendations

Flow - No

1. Metering pump trip

1. Loss of sodium hypochlorite


injection
2. Potential for algal and bacterial
growth in filtered and firewater
storage tanks
3. Potential for impact on
downstream water systems

855

Flow - Reverse

1. Pump trip

1. Potential for reverse flow of raw 1. Integral check valve in metering R855.1 Next revision of P&IDs will
water into sodium hypochlorite
pump
show manual isolation valve at
storage
chemical injection tie-in. Consider
requirement for check valve given
increase in well water pump
discharge pressure

856

Loss of
Containment

1. Small bore pipework failure


1. Potential for spray release of
1. Operator PPE for use when
and/or metering pump piston seal sodium hypochlorite to atmosphere handling chemicals
failure
2. Potential for operator hazard
2. Raw water sterilisation package
and chemical burns
equipment will be contained within
a small kerbed area
2. Filling and handling of sodium
hypochlorite injection chemical

Remarks

Action by:

Action resolution

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

1. Potential for operator hazard


and chemical burns

1. Operator PPE for use when


handling chemicals

1. Potential to overpressure
pipework

1. Integral PSV protection within


metering pump

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

857

Pressure - High 1. Operator error isolating


discharge on metering pump

858

Pressure - Low

No new issues

859

Vacuum

No new issues

TS

TS

Prepared by Arthur D. Little for OK LNG

Version: Final
Sheet: 30/125

HAZOP Record Sheet: Raw and Service Water

Company
Facility
HAZOP Date
Section ID
General Section
Description:

Plant
HAZOP
Item No. Section
860

TECHNIP
OK LNG Facility FEED Study
12/09/2006 - 13/09/2006

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Raw water production and treatment


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

Deviation

Causes

Consequences

Safeguards

Partial Pressure

Recommendations

Remarks

Action by:

Action resolution

No new issues

861

Temperature High

1. Thermal radiation on sodium


hypochlorite storage

1. Potential for increased


decomposition of sodium
hypochlorite producing free
chlorine

862

Temperature Low

No new issues

863

Cryogenic (Sub Zero)

No new issues

864

Level - High

No new issues

865

Level - Low

866

Level - No

No new issues

867

Phase - More

No new issues

868

Phase - Less

No new issues

869

Change of State

No new issues

870

Wrong
Concentration
(Part of)

No new issues

871

Corrosive (As
well as)

No new issues

872

Explosive

No new issues

873

Wrong Material
(Other than)

No new issues

1. Injection of sodium hypochlorite 1. Gradual decrease in level in


solution
sodium hypochlorite tank

R861.1 Recommend provision of


shelter for raw water sterilisation
package (shade, not enclosed
building)

TS

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

Prepared by Arthur D. Little for OK LNG

Version: Final
Sheet: 31/125

HAZOP Record Sheet: Raw and Service Water

Company
Facility
HAZOP Date
Section ID
General Section
Description:

TECHNIP
OK LNG Facility FEED Study
12/09/2006 - 13/09/2006

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Raw water production and treatment


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

Plant
Deviation
Causes
HAZOP
Item No. Section
Drawing Number/Sheet Number 2252-051-PID-00-31-02/24-05-06
/Rev.Number/Date 2252-051-PID-00-31-03/24-05-06
2252-051-PID-00-31-04/23-05-06
2252-051-PID-00-31-05/24-05-06
2252-053-PID-00-31-02/24-05-06

Consequences

Safeguards

Recommendations

Remarks

Action by:

Action resolution

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/B


Reverse osmosis package 051-U-103
Desalinated water storage tank 051-T-102
Potable water storage tank 053-T-120
874

875

Node 3

Reverse
Overview
osmosis
package
and
desalinated
water
storage tank

Flow - High

HAZOP of reverse osmosis


package

1. High usage of desalinated water 1. Gradual decrease in level in the


for production of demineralised
desalinated water storage tank
water in downstream
demineralised water package

R874.1 Consider HAZOP of


vendor package during detailed
design

TS

1. 051-LIC/LAL-0011 starts reverse


osmosis 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/hr
3. 051-FIC-0002 flow rate of
desalinated water to
demineralisation water unit
4. 051-LAH-0011 closes inlet on/off
valve to desalinated water storage
tank

Prepared by Arthur D. Little for OK LNG

Version: Final
Sheet: 32/125

HAZOP Record Sheet: Raw and Service Water

Company
Facility
HAZOP Date
Section ID
General Section
Description:

Plant
HAZOP
Item No. Section

TECHNIP
OK LNG Facility FEED Study
12/09/2006 - 13/09/2006

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Raw water production and treatment


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

Deviation

Causes

Consequences

Safeguards

Recommendations

Remarks

Action by:

Action resolution

2. Increased usage of potable


1. Gradual decrease in level in the 1. 053-LIC/LAL-0001 starts reverse
water on site, e.g. maintenance or potable water storage tank
osmosis package pumps
shutdown duration
2. Reverse osmosis package
desalinated water production flow
rate is 100m3/hr whilst average
flow rate of desalinated water to
potable water unit is 15m3/hr
3. 053-FAH-0003 flow rate of
potable water to distribution
4. 053-LAH-0001 closes inlet on/off
valve 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

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
control
3. Deadhead of reverse osmosis
package pumps
4. 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 trip

1. Loss of flow of filtered water


through the reverse osmosis
package

1. 051-XL-0003 reverse osmsis


package pump run status
indication
2. 051-UUA-0005 common trouble
alarm
3. 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

TS

Prepared by Arthur D. Little for OK LNG

Version: Final
Sheet: 33/125

HAZOP Record Sheet: Raw and Service Water

Company
Facility
HAZOP Date
Section ID
General Section
Description:

Plant
HAZOP
Item No. Section

TECHNIP
OK LNG Facility FEED Study
12/09/2006 - 13/09/2006

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Raw water production and treatment


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

Deviation

Causes

Consequences

Safeguards

2. Low level in upstream filtered


and firewater storage tank

1. Potential for loss of firewater


storage inventory in upstream
filtered and firewater storage tank
2. 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 cavitation
2. Firewater inventory in the
filtered and firewater storage tank
is protected by elevated nonfirewater water nozzles on tank
3. Sufficient capacity in desalinated
water storage tank and
downstream demineralised water
storage tank to enable continued
normal process production
condition
4. 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

879

Loss of
Containment

1. Pump seal failure on reverse


osmosis package pump

1. Spray release of water to


atmosphere

1. Periodic operator inspection of


the area
2. In the event of major pump seal
failure, 051-FI-0001 on permeate
flow rate
3. 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


rate
2. 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 1. Desalinated water tank is


atmosphere
stainless steel

Recommendations

R878.1 Consider requirement for


tank inlet check valve in the event
bottom filling

Remarks

Action by:

TS

Action resolution

Prepared by Arthur D. Little for OK LNG

Version: Final
Sheet: 34/125

HAZOP Record Sheet: Raw and Service Water

Company
Facility
HAZOP Date
Section ID
General Section
Description:

Plant
HAZOP
Item No. Section

TECHNIP
OK LNG Facility FEED Study
12/09/2006 - 13/09/2006

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Raw water production and treatment


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

Deviation

Causes
4. Corrosion and leakage from
potable water storage tank

Consequences

Safeguards

Recommendations

Remarks

Action by:

Action resolution

1. Release of desalinated water to 1. Potable water tank is carbon


atmosphere
steel with epoxy lining on all
internal surfaces

880

Pressure - High 1. Filling of desalinated water


1. Potential for increase in vapour 1. Two inch vent on vapour space
and/or potable water storage tanks space pressure
for tank
2. Tanks have overflow protection

881

Pressure - Low

882

Vacuum

No new issues

883

Partial Pressure

No new issues

884

Temperature High

No new issues

885

Temperature Low

No new issues

886

Cryogenic (Sub Zero)

No new issues

887

Level - High

1. Emptying of desalinated water 1. Potential for decrease in vapour 1. Two inch vent on vapour space
and/or potable water storage tanks space pressure
for tank
with no inlet flow (on/off filling)

1. Malfunction of 051-LIC-0011 on 1. Loss of stop signal closing inlet 1. 8 inch overflow on desalinated
desalinated water tank
isolation on/off valve
water storage tank
2. Potential to liquid fill and overpressure storage tank
1. Malfunction of 053-LIC-0001 on 1. Loss of stop signal closing inlet 1. 8 inch overflow on potable water
potable water tank
isolation on/off valve
storage tank
2. Potential to liquid fill and overpressure storage tank

888

Level - Low

1. Malfunction of 051-LIC-0011 on 1. Loss of start signal for opening


desalinated water tank
inlet isolation on/off valve and
starting reverse osmosis package
pumps
2. Gradual decrease in level in
tank
3. Potential to loose liquid level
and cavitate desalinated water
pumps

1. Independent LALL-0013 stops


desalinated water pumps
2. 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

Prepared by Arthur D. Little for OK LNG

Version: Final
Sheet: 35/125

HAZOP Record Sheet: Raw and Service Water

Company
Facility
HAZOP Date
Section ID
General Section
Description:

Plant
HAZOP
Item No. Section

TECHNIP
OK LNG Facility FEED Study
12/09/2006 - 13/09/2006

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Raw water production and treatment


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

Deviation

Causes

Consequences

2. Malfunction of 053-LIC-0001 on 1. Loss of start signal for opening


potable water tank
inlet isolation on/off valve and
starting reverse osmosis package
pumps
2. Gradual decrease in level in
tank
3. Potential to loose liquid level
and cavitate potable water pumps

Safeguards

Recommendations

Remarks

Action by:

Action resolution

1. Independent LALL-0003 stops


potable water pumps
2. 053-PI/PAL-0004 on potable
water distribution header

889

Level - No

890

Phase - More

No new issues

891

Phase - Less

No new issues

892

Change of State

No new issues

893

Wrong
Concentration
(Part of)

1. Incorrect addition of reverse


1. Reduced performance of
osmosis package chemicals (anti- reverse osmosis package
scale, sulphuric acid, bisulphite)
2. Potential contamination of
desalinated water

1. 051-AI/AAH-0002 outlet
conductivity
2. 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

1. Discharge pipework from


No new issues
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

895

Explosive

No new issues

896

Wrong Material
(Other than)

No new issues

1. Carryover of solids from


upstream raw water filtration
package

1. Potential for blockage of reverse 1. Filter on inlet of reverse osmosis R890.1 Consider requirements for
osmosis membrane
package
DCS dP indication and PDAH on
the reverse osmosis package inlet
filters

Potential leakage and release of


treated water

TS

Prepared by Arthur D. Little for OK LNG

Version: Final
Sheet: 36/125

HAZOP Record Sheet: Raw and Service Water

Company
Facility
HAZOP Date
Section ID
General Section
Description:

TECHNIP
OK LNG Facility FEED Study
12/09/2006 - 13/09/2006

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Raw water production and treatment


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

Plant
Deviation
Causes
HAZOP
Item No. Section
Drawing Number/Sheet Number 2252-051-PID-00-31-02/24-05-06
/Rev.Number/Date 2252-051-PID-00-31-03/24-05-06
2252-052-PID-00-31-01/23-05-06

Consequences

Safeguards

Recommendations

Remarks

Action by:

Action resolution

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 demand
Service water is also used to maintain the jetty firewater ring main pressurised and other cleaning activities at jetty (design basis 20m3/hr).
Node Equipment Filtered and firewater storage tank 051-T-101A/B
Service water pumps 052-P-130A/B
Service water booster pumps 052-P-131A/B
897

898

Node 4

Service
water
system

Overview

Flow - High

1. Maintainance in process area


(e.g. shutdown of one LNG train)

1. Increased requirement for


service water for cleaning activities
2. Gradual decrease in service
water header pressure
3. Gradual decrease in jetty
firewater main pressure
4. 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 jetty
3. 051-LI/LAL-0004A/B on filtered
and firewater storage tank
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 cavitation
5. Firewater inventory in the
filtered and firewater storage tank
is protected by elevated nonfirewater water nozzles on tank

Prepared by Arthur D. Little for OK LNG

Version: Final
Sheet: 37/125

HAZOP Record Sheet: Raw and Service Water

Company
Facility
HAZOP Date
Section ID
General Section
Description:

Plant
HAZOP
Item No. Section

TECHNIP
OK LNG Facility FEED Study
12/09/2006 - 13/09/2006

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Raw water production and treatment


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

Deviation

Causes

Consequences

Safeguards

2. Maintainance in jetty area

1. Increased use of service water


at jetty
2. Potential for decrease in
pressure in jetty supply pipeline
3. 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 activties
2. 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 DCS
3. 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 1. Gradual pressurisation of


process area and/or jetty
service water header
2. Potential to dead-head the
service water pumps
3. 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
pumps
2. 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. 052-PIC/PAL-0001 autostart of
standby service water pump to
maintain service water header
pressure
2. Check valve at tie in of service
water header to the jetty firewatre
ring main

1. Gradual decrease in pressure in


service water header
2. Potential cavitation of service
water booster pump
3. Potential for reduction in jetty
firewater ring main

Recommendations

Remarks

Action by:

Action resolution

Prepared by Arthur D. Little for OK LNG

Version: Final
Sheet: 38/125

HAZOP Record Sheet: Raw and Service Water

Company
Facility
HAZOP Date
Section ID
General Section
Description:

Plant
HAZOP
Item No. Section

TECHNIP
OK LNG Facility FEED Study
12/09/2006 - 13/09/2006

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Raw water production and treatment


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

Deviation

Causes

Consequences

Safeguards

2. Service water booster pump trip 1. Potential for gradual reduction in 1. Autostart of stand-by service
jetty firewater ring main pressure, water booster pump
depending on service water usage 2. Check valve at tie-in of service
at jetty
water to jetty firewater ring main
2. Autostart of standby jetty
3. 031-PIC-0006 autostart of jetty
firewater pumps
firewater pumps
3. Ingress of seawater into
firewater ring main

3. Low low level in upstream


1. Stop of service water pumps
filtered and firewater storage tank 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 pumps
2. Loss of jockey pump for jetty
firewater ring main and potential
depressurisation

901

Flow - Reverse

902

Loss of
Containment

Recommendations

Remarks

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

1. Check valve at tie-in of service


water to jetty firewater ring main
2. 031-PIC-0006 autostart of jetty
firewater pumps
3. 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

Action by:
TS

Action resolution

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

No new issues
1. Service water pump seal failure 1. Spray release of filtered water to 1. Operator inspection of area
atmosphere
2. Spare service water pump with
2. Potential for reduction in
autostart on low discharge service
pressure in service water header water header pressure
2. Service water booster pump
seal failure

1. Spray release of filtered water to 1. Operator inspection of area


atmosphere
2. Spare service water booster
2. Potential for reduction in
pump with autostart on low
pressure in service water header discharge service water header
to jetty
pressure
3. Autostart of jetty firewater
pumps if jetty firewater ring main
pressure drops

Prepared by Arthur D. Little for OK LNG

Version: Final
Sheet: 39/125

HAZOP Record Sheet: Raw and Service Water

Company
Facility
HAZOP Date
Section ID
General Section
Description:

Plant
HAZOP
Item No. Section

TECHNIP
OK LNG Facility FEED Study
12/09/2006 - 13/09/2006

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Raw water production and treatment


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

Deviation

Causes

Consequences

Safeguards

3. Corrosion of carbon steel


1. Potential for spray release of
pipework due to filtered water salt service water to atmosphere
concentration

4. Corrosion of service water


header on trestle to jetty

1. Potential for spray release of


service water to atmosphere
2. Potential for decrease in
firewater ring main pressure in
event of significant release

5. Corrosion of jetty firewater ring


main due to residual salt
concentration following use of
firewater pumps

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

Action by:
TS

Action resolution

1. Service water pipework on


trestle will be painted and/or
provided with alternative anticorrosion protection

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 1. Autostart of standby pump


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

904

Pressure - Low

No new issues

905

Vacuum

No new issues

906

Partial Pressure

No new issues

907

Temperature High

908

Temperature Low

No new issues

909

Cryogenic (Sub Zero)

No new issues

1. Thermal expansion of service


water in header to jetty

Remarks

1. Potential overpressure of
pipework

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 area
3. 052-FIC/FAL-0003 on service
water to jetty
4. Pump running light indication on
DCS

1. 052-RO-0002 open to filtered


and firewater storage tank

Prepared by Arthur D. Little for OK LNG

Version: Final
Sheet: 40/125

HAZOP Record Sheet: Raw and Service Water

Company
Facility
HAZOP Date
Section ID
General Section
Description:

Plant
HAZOP
Item No. Section
910

TECHNIP
OK LNG Facility FEED Study
12/09/2006 - 13/09/2006

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Raw water production and treatment


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

Deviation

Causes

Consequences

Safeguards

Recommendations

Level - High

No new issues

911

Level - Low

No new issues

912

Level - No

No new issues

913

Phase - More

No new issues

914

Phase - Less

No new issues

915

Change of State

No new issues

916

Wrong
Concentration
(Part of)

No new issues

917

Corrosive (As
well as)

No new issues

918

Explosive

No new issues

919

Wrong Material
(Other than)

No new issues

Remarks

Action by:

Action resolution

Prepared by Arthur D. Little for OK LNG

Version: Final
Sheet 41/125

HAZOP Record Sheet: Potable Water

Company
Facility
HAZOP Date
Section ID
General Section
Description:

TECHNIP
OK LNG Facility FEED Study
13-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Potable water
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.

HAZOP
Plant
Deviation
Causes
Item No. Section
Drawing Number/Sheet Number 2252-053-PID-00-31-01/Rev A/24-05-06
/Rev.Number/Date 2252-053-PID-00-31-02/Rev A/24-05-06
2252-053-PID-00-31-03/Rev A/24-05-06

Consequences

Safeguards

Recommendations

Remarks

Action by:

Action resolution

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-120
Biocide dosing system 053-U-122
Potable water storage tank 053-T-120
920

921

Node 1

Producti Overview
on and
storage
of
Potable
Water
Flow - High

1. HAZOP of vendor packages for


potable water system

R920.1 Undertake HAZOP of


potable water vendor packages
during detailed design

1. Requirement to refill potable


1. Flow of desalinated water from
water storage tank (on/off control) upstream reverse osmosis
package discharge to potable
water storage tank via treatment
packages
2. 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 system
2. 053-AIC-0001 controls pH of
potable water by injection of
sodium hydroxide from water
potabilisation package
3. Periodic operator sampling of
potable water in potable water
storage tank

2. Malfunction of 053-FIC-0001 on 1. Potential for over-injection of


water potabilisation and biocide
chemicals into potable water
dosing systems
system

1. Water potabilisation package


and biocide dosing metering
pumps are on/off type pumps
2. Requirement for operator to
calibrate metering pump stroke
and injection flow rates using
package calibration pot
3. 053-AAH-0002 chlorine
detector alarm on discharge of
activated carbon filter package
4. Daily sampling of potable water
from potable water storage tank

TS

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 42/125

HAZOP Record Sheet: Potable Water

Company
Facility
HAZOP Date
Section ID
General Section
Description:

HAZOP
Plant
Item No. Section
922

TECHNIP
OK LNG Facility FEED Study
13-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Potable water
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.
Deviation

Causes

Consequences

Safeguards

Recommendations

Remarks

Action by:

Action resolution

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 pumps
2. Requirement for operator to
calibrate metering pump stroke
and injection flow rates using
package calibration pot
3. 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

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 flow
2. 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 system
2. 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

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

925

Loss of
Containment

1. 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 area
2. Spare metering dosing pump
3. 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

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 43/125

HAZOP Record Sheet: Potable Water

Company
Facility
HAZOP Date
Section ID
General Section
Description:

HAZOP
Plant
Item No. Section
926

TECHNIP
OK LNG Facility FEED Study
13-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Potable water
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.
Deviation

Causes

Consequences

Pressure - High 1. Blocked discharge on metering 1. Potential overpressure


pump

Safeguards

Recommendations

927

Pressure - Low

No new issues

928

Vacuum

No new issues

929

Partial Pressure

No new issues

930

Temperature High

931

Temperature Low

No new issues

932

Cryogenic (Sub 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 tank
2. Potential to overfill and
overpressure potable water
storage tank

1. Eight inch overflow on potable


storage tank to NW sewer
2. 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 tank
2. Potential to loose level and
cavitate potable water pumps
3. Loss of pressure in potable
water system

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

1. Low level in potabilisation


chemical storage tanks

1. Loss of chemical for injection

935

Level - No

1. Heat of dilution of concentrated


caustic in the water potabilisation
package

Remarks

Action by:

Action resolution

1. Integral PSV within metering


pump

1. Vendor package is designed


for safe dilution of 40% caustic to
5% caustic required for injection
2. Injection of sodium hydroxide
through static mixer with small
heat of dilution, given injection
flow rate and concentration

R934.1 Consider provision of


DCS level indication using 053LALL-0003 instrument

TS

R934.2 See R922.1 for provision


of appropriate DCS indication and
alarms

TS

No new issues

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 44/125

HAZOP Record Sheet: Potable Water

Company
Facility
HAZOP Date
Section ID
General Section
Description:

HAZOP
Plant
Item No. Section
936

TECHNIP
OK LNG Facility FEED Study
13-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Potable water
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.
Deviation

Causes

Consequences

Safeguards

Recommendations

Phase - More

No new issues

937

Phase - Less

No new issues

938

Change of State

No new issues

939

Wrong
Concentration
(Part of)

940

Corrosive (As
well as)

No new issues

941

Explosive

No new issues

942

Wrong Material
(Other than)

No new issues

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 package
2. 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

Remarks

Action by:

TS

Action resolution

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 45/125

HAZOP Record Sheet: Potable Water

Company
Facility
HAZOP Date
Section ID
General Section
Description:

TECHNIP
OK LNG Facility FEED Study
13-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Potable water
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.

HAZOP
Plant
Deviation
Causes
Item No. Section
Drawing Number/Sheet Number 2252-053-PID-00-31-02/Rev A/24-05-06
/Rev.Number/Date 2252-053-PID-00-31-03/Rev A/24-05-06

Consequences

Safeguards

Recommendations

Remarks

Action by:

Action resolution

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.
Node Equipment Potable water storage tank 053-T-120
Potable water pumps 053-P-120A/B
Activated carbon filter package 053-U-123
943

944

Node 2

Potable Overview
water
chilling
unit,
storage
tank and
distributi
on

Flow - High

1. High demand for potable water 1. Decrease in level in potable


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


1. Small increase in total potable
LNG cooling water closed network water flow rate
system (refrigeration compressor
circuit)

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

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 46/125

HAZOP Record Sheet: Potable Water

Company
Facility
HAZOP Date
Section ID
General Section
Description:

HAZOP
Plant
Item No. Section
945

TECHNIP
OK LNG Facility FEED Study
13-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Potable water
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.
Deviation
Flow - Low

Causes

Consequences

Safeguards

1. Low demand for potable water


in plant

1. Increase in potable water


header pressure and potential to
dead-head potable water pumps
2. 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

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 package
2. Internal chilling unit package
control logic
3. 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

946

Flow - No

947

Flow - Reverse

948

Loss of
Containment

949

Pressure - High 1. Filling of potable water storage


tank
2. Low demand for potable water
on site

Recommendations

Remarks

Action by:

Action resolution

TS

R949.1 Review design pressure


of chilling unit package and
activated carbon filters

TS

R949.2 Review proposed potable


water system distribution and
design pressure, as it appears
high compared with allowable
user pressures

TS

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

No new issues
1. Pump seal failure

1. Release of potable water to


atmosphere

1. Spare pump
2. Periodic operator inspection of
area

1. Potential for high vapour space 1. 2" vent and 8" overflow
pressure
1. Increase in potable water
1. Minimum flow protection of
network pressure
potable water pump
2. Potential overpressure of
chilling unit package and
activated carbon filter package

3. High design discharge pressure 1. All drinking water has to be


of potable water pump
provided as direct connection to
potable water header

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 47/125

HAZOP Record Sheet: Potable Water

Company
Facility
HAZOP Date
Section ID
General Section
Description:

HAZOP
Plant
Item No. Section
950

TECHNIP
OK LNG Facility FEED Study
13-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Potable water
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.
Deviation
Pressure - Low

Causes

Consequences

1. Peak demand for potable water 1. Potential for low vapour space
on site
pressure in tank

Safeguards

Recommendations

951

Vacuum

No new issues

952

Partial Pressure

No new issues

953

Temperature High

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

1. Loss of chilling to potable water 1. Potable water network and


and gradual increase in potable
storage tank is insulated to
water temperature
prevent solar radiation heating
2. 053-UUA-0001 common
trouble alarm on chilling unit
package

954

Temperature Low

1. 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

955

Cryogenic (Sub Zero)

No new issues

956

Level - High

No new issues

957

Level - Low

958

Level - No

No new issues

959

Phase - More

No new issues

960

Phase - Less

No new issues

961

Change of State

No new issues

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

Remarks

Action by:

Action resolution

1. 2" vent and 8" overflow

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

R954.1 See R946.1 for review of


chilling unit package design
during detailed design

1. Decrease in level in potable


1. 053-LALL-0003 trips potable
R957.1 See R934.1 for
water storage tank
water pumps to prevent cavitation configuration of level indication on
2. Potential for loss of level and
053-LALL-0003 instrument
cavitation of potable water pumps

TS

TS

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 48/125

HAZOP Record Sheet: Potable Water

Company
Facility
HAZOP Date
Section ID
General Section
Description:

HAZOP
Plant
Item No. Section
962

TECHNIP
OK LNG Facility FEED Study
13-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Potable water
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.
Deviation
Wrong
Concentration
(Part of)

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

Consequences

Safeguards

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

1. 053-AAH-0002 free chlorine


analyser on discharge of
activated filters
2. Sizing basis for activated
carbon filter package sufficient to
prevent requirement for change in
activated carbon within normal
shutdown duration of three years
3. Minimum retention time within
activated carbon filter forms part
of the package equipment
specification

Recommendations

963

Corrosive (As
well as)

No new issues

964

Explosive

No new issues

965

Wrong Material
(Other than)

No new issues

Remarks

Action by:

Action resolution

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 49/125

HAZOP Record Sheet: Demin. Water

Company
Facility
HAZOP Date

TECHNIP
OK LNG Facility FEED Study
13-Sep-06

Section ID
General Section
Description:

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.

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Demineralised water production

HAZOP
Plant
Deviation
Causes
Item No. Section
Drawing Number/Sheet Number 2252-051-PID-00-31-05/Rev A/24-05-06
/Rev.Number/Date 2252-054-PID-00-31-03/Rev A/24-05-06
2252-054-PID-00-31-05/Rev A/24-05-06

Consequences

Safeguards

Recommendations

Remarks

Action by:

Action resolution

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-102


Desalined water pumps 051-P-101A/B
Water demineralisation package 054-U-110
Demineralised water storage tank 054-T-110
966

967

Node 1

Producti Overview
on of
deminera
lised
water

Flow - High

R966.1 Undertake HAZOP of


water demineralisation package
during detailed design

1. Decrease in level in
demineralised water storage tank

1. Initiation of demineralised water


production via start of single
desalinated water pump
2. Increase in level in
demineralised water storage tank

2. Malfunction/incorrect setpoint of 1. Start of desalinated water pump


054-LI-0004 on the demineralised and demineralised water
water storage tank
production
2. Loss of stop signal with potential
to overfill and overpressurise
demineralised water storage tank
3. Increased demand for
production of desalinated water
and use of demineralisation
chemicals
4. Gradual decrease in level in
upstream filtered water and
firewater tank

LALL actions in this unit are TS


configured as DCS
stop/inhibit actions, not
hardwired ESD trip actions
as no immediate safety
impact.
No SIL rating of 054-LALL003 required by project

1. 054-LI/LAH-0004 on
demineralised water storage tank
stops desalinated water pumps
and production of demineralised
water
2. Pump and water
demineralisation package running
light indication
1. Overflow of demineralised water
storage tank
2. Pump and water
demineralisation water package
running light indications
3. 051-LALL-0005A/B on filtered
and firewater storage tank stops
service water and desalinated
water pumps
4. Operator inspection of area

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 50/125

HAZOP Record Sheet: Demin. Water

Company
Facility
HAZOP Date

TECHNIP
OK LNG Facility FEED Study
13-Sep-06

Section ID
General Section
Description:

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.

HAZOP
Plant
Item No. Section

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Demineralised water production

Deviation

Consequences

Safeguards

3. Operation of both desalinated


water pumps and water
demineralisation package trains
during startup (manual operation)

Causes

1. Increased use of desalinated


water
2. 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 protection
2. Water demineralisation package
design pressure is same as
desalinated water pump deadhead 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 pumps
2. Gradual decrease in level of
demineralised water storage tank
3. Potential to cavitate
demineralised water pumps

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

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 pressure
2. Demineralised water storage
tank will be top-fill in vapour space

Recommendations

R969.1 Consider provision of level


indication on 054-LALL-0003
instrument on DCS
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-P107A/B Demin water make up
metering pump. Update Cause
and Effect Diagram as necessary

Remarks

Action by:

TS

Action resolution

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 51/125

HAZOP Record Sheet: Demin. Water

Company
Facility
HAZOP Date

TECHNIP
OK LNG Facility FEED Study
13-Sep-06

Section ID
General Section
Description:

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.

HAZOP
Plant
Item No. Section
971

972

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Demineralised water production

Deviation
Loss of
Containment

Causes

Consequences

Safeguards

1. Pump seal failure on desalinated 1. Release of desalinated water


water pump

1. Periodic operator inspection of


the area
2. Low discharge pressure autostart standby pump

2. Pump seal failure on sodium


hydroxide and sulphuric acid
dosing pumps

1. Periodic operator inspection of


the area
2. Operator PPE
3. Dedicated segregated kerbed
areas for unit with appropriate
surface protection to prevent
acid/caustic attack

1. Spray release of acid/caustic to


atmosphere
2. Potential operator hazard and
chemical burns

3. Loss of containment (e.g.


1. Potential operator hazard and
corrosion) of concentrated acid or chemical burns
caustic chemical storage tanks
2. Potential for significant heat of
reaction between caustic and acid
solutions

1. Periodic operator inspection of


the area
2. Operator PPE
3. 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. Desalinated water and


demineralised water storage tanks
are stainless steel

1. Potential for release of


demineralised water

Pressure - High 1. Filling of demineralised water


1. Potential for increase in
storage tank in two train operation pressure in vapour space
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. Pump-out of demin water at high 1. Decreased pressure in vapour


flow rate for change of BFW circuit space

Recommendations

Remarks

Action by:

Action resolution

1. 2" atmospheric vent and 8"


overflow
1. 2" atmospheric vent and 8"
overflow
2. 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

973

Pressure - Low

974

Vacuum

No new issues

975

Partial Pressure

No new issues

976

Temperature High

No new issues

TS

1. 2" atmospheric vent and 8"


overflow

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 52/125

HAZOP Record Sheet: Demin. Water

Company
Facility
HAZOP Date

TECHNIP
OK LNG Facility FEED Study
13-Sep-06

Section ID
General Section
Description:

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.

HAZOP
Plant
Item No. Section
977

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Demineralised water production

Deviation

Causes

Consequences

Safeguards

Recommendations

Temperature Low

No new issues

978

Cryogenic (Sub Zero)

No new issues

979

Level - High

No new issues

980

Level - Low

No new issues

981

Level - No

No new issues

982

Phase - More

983

Phase - Less

No new issues

984

Change of State

No new issues

985

Wrong
Concentration
(Part of)

986

Corrosive (As
well as)

No new issues

987

Explosive

No new issues

988

Wrong Material
(Other than)

No new issues

1. Degradation of water
demineralisation exchanger resin

1. Gradual saturation of water


demineralisation package resin
during operation

1. Potential production of resin


fines

1. Potential breakthrough of salts


into demineralised water storage
tank
2. Gradual formation of salts in
downstream boiler steam system

Remarks

Action by:

Action resolution

1. Water demineralisation vendor


package normally contains
discharge filter to prevent
contamination of demineralised
water storage tank

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

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 53/125

HAZOP Record Sheet: Demin. Water

Company
Facility
HAZOP Date

TECHNIP
OK LNG Facility FEED Study
13-Sep-06

Section ID
General Section
Description:

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.

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Demineralised water production

HAZOP
Plant
Deviation
Causes
Item No. Section
Drawing Number/Sheet Number 2252-054-PID-00-31-03/Rev A/24-05-06
/Rev.Number/Date 2252-054-PID-00-31-05/Rev A/24-05-06

Consequences

Safeguards

Recommendations

Remarks

Action by:

Action resolution

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.
Node Equipment Water demineralisation package 054-U-110
Demin. neutralisation basin 054-T-111
Neutralisation pumps 054-P-111A/B
Demineralised water storage tank 054-T-110
989

990

Node 2

Water
Overview
deminera
lisation
unit
package
regenera
tion

Flow - High

1. Incorrect chemical dosing pump 1. High addition flow rate of


stroke volume
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 commissioning
2. 054-AIC/AAH-0002 controls the
pH of the regeneration liquid
automatically upon completion of
regeneration sequence
3. Requirement for operator test of
pH and manual start of
neutralisation pumps for discharge
of regeneration liquid to the noncontaminated sewer

1. Some vendors will use


venturi rather than metering
pumps for addition of acid
and caustic during
regeneration

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 54/125

HAZOP Record Sheet: Demin. Water

Company
Facility
HAZOP Date

TECHNIP
OK LNG Facility FEED Study
13-Sep-06

Section ID
General Section
Description:

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.

HAZOP
Plant
Item No. Section
991

992

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Demineralised water production

Deviation

Causes

Consequences

Safeguards

Recommendations

Remarks

Action by:

Action resolution

Flow - Low

1. Incorrect chemical dosing pump 1. Low addition flow rate of


stroke volume
acid/caustic during regeneration
cycle (normally timed)
2. Potential for incomplete
regeneration of resin
3. Production of acidic and/or
caustic regeneration liquid

1. Individual acid and caustic


calibration pots for setting pump
stroke during commissioning
2. 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 noncontaminated sewer

Flow - No

1. Dosing pump trip (if used)

1. Loss of chemical injection during


regeneration cycle
2. Incomplete regeneration of the
resin

1. 054-UUA-0002 common trouble R992.1 Vendor package logic


sequences will be finalised during
alarm on water demineralisation
detailed design, including action in
package
the event of common trouble
2. Spare dosing pump for both
caustic and acid injection (not auto- alarm, e.g. continuation of
start)
sequence, stop of sequence or
restart of sequence (general
recommendation for all utility
vendor packages)

TS

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 R992.2 Consider provision of


alarm on water demineralisation
conductivity meter in regeneration
package
wash of the neutralisation basin
2. Spare washing water pump (not
auto-start)

TS

993

Flow - Reverse

1. Incorrect sequence during


regeneration

994

Loss of
Containment

See previous node

995

Pressure - High 1. Blocked discharge on metering


pump

996

Pressure - Low

See R992.1

1. Potential overpressure

1. Integral PSV within metering


pump
No new issues

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 55/125

HAZOP Record Sheet: Demin. Water

Company
Facility
HAZOP Date

TECHNIP
OK LNG Facility FEED Study
13-Sep-06

Section ID
General Section
Description:

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.

HAZOP
Plant
Item No. Section
997

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Demineralised water production

Deviation

Causes

Consequences

Safeguards

Recommendations

Vacuum

No new issues

998

Partial Pressure

No new issues

999

Temperature High

1. Heat of dilution of acid and


caustic solutions

1. Potential for high liquid


1. Vendor to provide safe and
temperatures during the dilution of suitable dilution facilities within
concentrated acid or caustic
package
solutions for use during
regeneration

2. Heat of reaction from


neutralisation

1. Potential for high liquid


temperatures during the acid and
caustic neutralisation in the
neutralisation basin

Temperature Low

No new issues

1001

Cryogenic (Sub Zero)

No new issues

1002

Level - High

2. Automatic regeneration of the


water demineralisation package,
but requirement for manual pump
out of the neutralisation basin

Action by:

Action resolution

1. Sulphuric acid and caustic


solutions are dilute, reducing
potential for formation of high
temperatures

1000

1. Simultaneous regeneration of
water demineralisation packages

Remarks

1. Potential to overfill neutralisation 1. Water demineralisation package


basin
control logic prevents
simultaneous regeneration
1. Potential to overfill neutralisation
R1002.1 Review proposed design
basin
and consider configuration of alarm
(e.g. LAH on the neutralisation
basin and/or regeneration
complete alarm) to notify operator
to empty neutralisation basin

3. Operator exposure to basin

1. Potential for operator hazard

1. Neutralisation basin will be


fenced to prevent operator ingress

1. Manual pump out of


neutralisation basin

1. Decrease in level in
neutralisation basin
2. Potential for pump cavitation

1. Operator controlled operation


2. Neutralisation pumps will be self
priming pumps
3. Spare neutralisation pump

1003

Level - Low

R1003.1 If level indication and


alarm provided (see R1002.1),
consider provision of low level stop
of neutralisation pumps

1004

Level - No

No new issues

1005

Phase - More

No new issues

TS

TS

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 56/125

HAZOP Record Sheet: Demin. Water

Company
Facility
HAZOP Date

TECHNIP
OK LNG Facility FEED Study
13-Sep-06

Section ID
General Section
Description:

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.

HAZOP
Plant
Item No. Section
1006

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Demineralised water production

Deviation

Causes

Consequences

Safeguards

Recommendations

Phase - Less

No new issues

1007

Change of State

No new issues

1008

Wrong
Concentration
(Part of)

1. Ineffective mixing in
neutralisation basin

1. Incorrect addition of acid or


1. Plant air sparger provided in
caustic neutralisation regeneration base of neutralisation basin
liquid
2. Potential for discharge of acid or
caustic effluent to noncontaminated sewer

1. Leakage and/or valve sequence 1. Potential for leakage of acid


failure in water demineralisation
and/or caustic from exchanger
package at start of regeneration
under regeneration into normal
flow of demineralised water to the
demineralised water storage tank

1009

Corrosive (As
well as)

1010

Explosive

1011

Wrong Material
(Other than)

1. Corrosion of the neutralisation


basin and air sparger

Remarks

Action by:

Action resolution

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

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

TS

1. Neutralisation basin will have


chemical resistant lining
2. Air sparger and air pipework in
neutralisation basin is PVC
No further issues

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

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 57/125

HAZOP Record Sheet: Demin. Water

Company
Facility
HAZOP Date

TECHNIP
OK LNG Facility FEED Study
13-Sep-06

Section ID
General Section
Description:

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.

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Demineralised water production

HAZOP
Plant
Deviation
Causes
Item No. Section
Drawing Number/Sheet Number 2252-054-PID-00-31-05/Rev A/24-05-06
/Rev.Number/Date

Consequences

Safeguards

Recommendations

Remarks

Action by:

Action resolution

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-110
Demin. Water pumps 054-P-110A/B
1012

1013

Node 3

Deminer Overview
alised
water
pumps
and
header
Flow - High

1. High demand for demineralised 1. Decrease in level in


water
demineralised water storage tank
2. 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 header
3. 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

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 58/125

HAZOP Record Sheet: Demin. Water

Company
Facility
HAZOP Date

TECHNIP
OK LNG Facility FEED Study
13-Sep-06

Section ID
General Section
Description:

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.

HAZOP
Plant
Item No. Section
1014

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Demineralised water production

Deviation
Flow - Low

Causes

Consequences

Safeguards

1. Low demand for demineralised


water (e.g. 2 out of 4 LNG trains
operating)

1. Decrease in usage of
demineralised water
2. Gradual increase in header
pressure
3. Potential to damage
demineralised water pumps

1. 054-FIC/FAL-0003 minimum
flow protection on pumps
2. 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
tank
2. Decrease in flow of
demineralised water for BFW
makeup and acid gas treatment
amine makeup
3. Potential for decrease in
demineralised water header
pressure

1. 054-PI-0002 on demineralised
water header
2. Low pump discharge pressure
autostart standby pump

1. Demin water pump trip

1. Decrease in header pressure


1. Auto-start of standby demin
with potential loss of demineralised water pump in event of low
water make-up to process
discharge pressure
2. Potential for reverse flow and
depressurisation of header via
pump minimal flow protection

Recommendations

Remarks

Action by:

Action resolution

R1014.1 Configure PAL on 054-PI0002 on demineralised water


header

TS

R1015.1 Consider requirement for


check valve on common
demineralised water header to
prevent depressurisation to tank

TS

1015

Flow - No

1016

Flow - Reverse

1017

Loss of
Containment

1018

Pressure - High

No new issues

1019

Pressure - Low

No new issues

1020

Vacuum

No new issues

1021

Partial Pressure

No new issues

No new issues
1. Pump seal failure

1. Release of demineralised water 1. Periodic operator inspection of


to atmosphere
area
2. Spare demin water pump
3. Low discharge pressure initates
auto start of standby pump

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 59/125

HAZOP Record Sheet: Demin. Water

Company
Facility
HAZOP Date

TECHNIP
OK LNG Facility FEED Study
13-Sep-06

Section ID
General Section
Description:

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.

HAZOP
Plant
Item No. Section
1022

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Demineralised water production

Deviation
Temperature High

Causes
1. Thermal expansion of
demineralised water in header if
isolated and no flow

Consequences
1. Potential overpressurisation of
header pipework

Safeguards

Recommendations

Remarks

Action by:

Action resolution

1. Pipework thermal expansion


loops
2. Thermal relief valves will be
considered in detailed design

1023

Temperature Low

No new issues

1024

Cryogenic (Sub Zero)

No new issues

1025

Level - High

No new issues

1026

Level - Low

No new issues

1027

Level - No

No new issues

1028

Phase - More

No new issues

1029

Phase - Less

No new issues

1030

Change of State

No new issues

1031

Wrong
Concentration
(Part of)

No new issues

1032

Corrosive (As
well as)

No new issues

1033

Explosive

No new issues

1034

Wrong Material
(Other than)

No new issues

Prepared by Arthur D Little for OK LNG

Version: Final
60/125

HAZOP Record Sheet: Hot Oil

Company
Facility
HAZOP Date
Section ID
General Section
Description:

TECHNIP
OK LNG Facility FEED Study
14-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Hot oil system


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.

HAZOP
Plant
Deviation
Causes
Item No. Section
Drawing Number/Sheet Number 2252-017-PID-00-31-01/Rev A/25-08-06
/Rev.Number/Date 2252-017-PID-00-31-02/Rev A/25-08-06
2252-017-PID-00-31-03/Rev A/25-08-06
2252-017-PID-00-31-04/Rev A/25-08-06
2252-017-PID-00-31-05/Rev A/25-08-06

Consequences

Safeguards

Recommendations

Remarks

Action by:

Action resolution

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-101
Hot oil circulation pumps 017-P-101
Filter 017-FL-101
Hot oil furnace 017-H-101A/B/C
Hot oil trim air cooler 017-A-101
1035

1036

Node 1

Hot oil
circuit

Overview

1. HAZOP of fired furnace vendor


package

Flow - High

1. Malfunction/incorrect setting of
heater master flow controller

R1035.1 HAZOP of fired furnace


vendor package to be undertaken
during detailed design

1. Individual heater flow control


valves would tend to open due to
reset from 017-FY-0001A/B/C
2. Gradual decrease in
temperature of hot oil from hot oil
furnaces and feed to downstream
users
3. Potential for insufficient heat
duty in downstream exchangers
4. Gradual decrease in hot oil
header distribution pressure

TS

1. Each individual user has


temperature controlled TV which
controls duty in exchanger
2. Temperature controller on
discharge of each furnace 017-TI0008A/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

Prepared by Arthur D. Little for OK LNG

Version: Final
61/125

HAZOP Record Sheet: Hot Oil

Company
Facility
HAZOP Date
Section ID
General Section
Description:

HAZOP
Plant
Item No. Section

TECHNIP
OK LNG Facility FEED Study
14-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Hot oil system


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.

Deviation

Causes

Consequences

Safeguards

Recommendations

1. Increase in flow rate through


individual furnace pass
2. Decrease in flow through
remaining passes to that furnace
3. 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 passes
3. 017-TI/TAH-0005** furnace coil
skin thermocouple temperature
indication and alarms
4. 017-TI/TAH-0003** individual
furnace pass discharge
temperature
5. 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. Malfunction/incorrect setting of 1. Increase in flow through


individual hot oil user temperature individual user
control valve
2. Potential for upset on process
side due to increased heat duty
3. Potential for upset to other users
in network

1. Process side indication and


alarms
2. 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 10

1. Reduced dP over filter and high 1. 017-FI-0011 on slipstream flow


recirculation flow of hot oil through through filter
filter

R1036.3 Consider provision of


manual globe valve to enable
operator regulation of flow through
filter, especially when clean

TS

2. Malfunction/incorrect setting of
individual furnace pass flow
controller

4. Clean filter following startup

Remarks

Action by:

Action resolution

Prepared by Arthur D. Little for OK LNG

Version: Final
62/125

HAZOP Record Sheet: Hot Oil

Company
Facility
HAZOP Date
Section ID
General Section
Description:

HAZOP
Plant
Item No. Section
1037

TECHNIP
OK LNG Facility FEED Study
14-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Hot oil system


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.

Deviation
Flow - Low

Causes

Consequences

Safeguards

1. Malfunction/incorrect setpoint of 1. Reduced total flow through hot


heater master flow controller
oil furnaces
2. Gradual increase in discharge
temperature of furnaces
3. Reduced duty in downstream
user exchanges. Potential for
insufficient heat duty in antihydrate heaters
4. 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 passes
3. 017-TI/TAH-0005** furnace coil
skin thermocouple temperature
indication and alarms
4. 017-TI/TAH-0003** individual
furnace pass discharge
temperature
5. 017-TI-0008A/B/C controls firing
in individual furnaces
6. 017-FALL-0004** low low flow
on individual pass
7. 017-TI-0014 controls bypass of
hot oil trim air cooler and
temperature to the anti-hydrate
heaters
8. 014-TIC/TAL-0015 on shell inlet
facility anti-hydrate heater
discharge

2. Malfunction/incorrect setpoint of 1. Potential for loss of flow through


individual pass flow controller
single pass of furnace
(independent pass FV are FC)
2. Potential cracking and coke
formation in coil
3. 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

Recommendations

R1037.1 Review during vendor


package HAZOP furnace
protections for low and/or no flow
on individual passes

Remarks

Action by:

TS

Action resolution

Prepared by Arthur D. Little for OK LNG

Version: Final
63/125

HAZOP Record Sheet: Hot Oil

Company
Facility
HAZOP Date
Section ID
General Section
Description:

HAZOP
Plant
Item No. Section

TECHNIP
OK LNG Facility FEED Study
14-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Hot oil system


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.

Deviation

Causes

Consequences

Safeguards

3. Low demand for hot oil in


network, e.g. one condensate
stabiliser or train in maintainance

1. Reduced heat removal from hot 1. 017-TIC-0014 controls


oil system
temperature in second stage of hot
oil system and heat removal in hot
oil trim air cooler
2. Operating manual will contain
indications for heaters master flow
controller setpoints for various
operating conditions in the plant
3. 017-TI-0008A/B/C controls firing
in individual furnaces
4. 017-TI-0011 on combined
temperature from three furnaces
resets firing ratio controller 017-TI0007A/B/C

4. Plant startup

1. Reduced requirement for hot oil 1. Operating manual will provide


system duty
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 conditions
3. 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 filter


2. Reduced removal of coke
particles from hot oil
3. Potential to overpressure filter

6. Malfunction of 017-FV-0001 on
the discharge of the hot oil trim
cooler

1. Potential for loss of circulation of 1. 017-FV-0001 is FO valve


hot oil through the furnaces

1. Filter design pressure same as


circulating pump design pressure
2. 017-PDI/PDAH-0021 provides
indication of filter performance if
flow control element provided in
slipstream

Recommendations

Remarks

Action by:

Action resolution

R1037.2 See Reccomendation


R1036.3 for provision of flow
control element in slipstream

TS

R1037.3 Review with furnace


vendor whether 017-FV-0001 is
required given master flow
controller of individual inlet flow
controllers.

TS

Prepared by Arthur D. Little for OK LNG

Version: Final
64/125

HAZOP Record Sheet: Hot Oil

Company
Facility
HAZOP Date
Section ID
General Section
Description:

HAZOP
Plant
Item No. Section

TECHNIP
OK LNG Facility FEED Study
14-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Hot oil system


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.

Deviation

Causes
7. Circulating oil pump trip

Consequences

Safeguards

Recommendations

Remarks

Action by:

Action resolution

1. Potential for reduction of hot oil 1. Hot circulation pumps have


flow and heat duty availability
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 circulation
3. 017-PIC-0015 would tend to
close to maintain hot oil header
pressure

1038

Flow - No

No new issues

1039

Flow - Reverse

No new issues

1040

Loss of
Containment

1. Pump seal failure on hot oil


circulating pump

1. Spray release of oil to


atmosphere
2. Gradual decrease in hot oil
inventory in system
3. 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

2. Furnace pinhole leak - tube


failure

1. Release of hot oil into furnace


firebox
2. Potential for fire in base of hot
oil furnace

1. Periodic operator inspection of


furnace
2. Coil skin thermocouples provide
indication of high skin
temperatures, e.g. coke formation
in tube
3. 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 1. Spray release of oil to


air cooler
atmosphere
2. Gradual decrease in hot oil
inventory in system
3. 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-LI0004 to act as pre-alarm before


circulating pump trip

TS

R1040.2 See R1040.1 for


configuration of LAL

TS

Prepared by Arthur D. Little for OK LNG

Version: Final
65/125

HAZOP Record Sheet: Hot Oil

Company
Facility
HAZOP Date
Section ID
General Section
Description:

HAZOP
Plant
Item No. Section

TECHNIP
OK LNG Facility FEED Study
14-Sep-06

Team members:
Team Leader/Assistant

Hot oil system


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.

Deviation

Causes
4. Maintenance on hot oil
circulating filter

1041

Pressure - High 1. Fire in vicinity of hot oil


expansion drum

2. Fire in vicinity of hot oil filter

Consequences
1. Potential exposure of operator
to hot circulating oil (approx 200
degrees C)

Pressure - Low

1043

Vacuum

1044

Partial Pressure

Safeguards
1. Operating procedures

Recommendations

Remarks

Action by:

Action resolution

R1040.3 Ensure piping layout


enables draining of hot oil to drum
for maintenance activities

TS

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

R1042.1 Consider handwheel, if


not already provided, on 017-PV0015 to enable continued
operation with manual control

TS

1. Potential for overpressure of hot 1. 017-PIC/PAH opens PV-0019A


oil expansion drum
to flare on expansion drum
2. 017-PSV-0002A/B
1. Potential for overpressure of hot 1. Filter is normally open to hot oil
oil filter
expansion drum. However, single
manual isolation valve may
prevent depressurising via hot oil
expansion drum

3. Malfunction/incorrect setpoint of 1. Gradual pressurisation of


017-PV-0019B nitrogen blanket on expansion drum
expansion drum

1042

see attached list


Perry/Webster

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 1. Dedicated PSV on exchanger


breakthrough and overpressure of hot oil headers prevents
hot oil system
overpressure of hot oil system

1. Malfunction/incorrect setpoint
017-PIC-0015 (017-PV-0015 FO)

1. Decrease in hot oil circulating


header pressure
2. Potential for insufficient flow
through hot oil exchangers with
potential for process upset

1. Process side instrumentation


and alarms

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

1. Operator error during steam-out 1. Potential formation of vacuum


of hot oil expansion drum and/or
filter

1. Hot oil expansion drum


designed for vacuum

No new issues

Prepared by Arthur D. Little for OK LNG

Version: Final
66/125

HAZOP Record Sheet: Hot Oil

Company
Facility
HAZOP Date
Section ID
General Section
Description:

HAZOP
Plant
Item No. Section
1045

1046

TECHNIP
OK LNG Facility FEED Study
14-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Hot oil system


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.

Deviation

Causes

Consequences

Safeguards

Temperature High

1. Operator incorrect setpoint 017- 1. Increased flow through hot oil


TIC-0014
trim air cooler bypass
2. Increase in temperature of hot
oil feed to gas heaters and antihydrate heater exchangers
3. Potential increase in return
temperature to hot oil expansion
drum and filter

1. Feed gas heaters and antihydrate heater exchangers have


design temperature of 320 degrees
C

Temperature Low

1. Malfuction/incorrect setpoint 017- 1. Increased flow through hot oil


TIC-0014
trim air cooler
2. Decrease in temperature of hot
oil feed to hot oil exchangers and
gas heaters

1. Process side temperature


indication and alarms
2. 017-TI-0017 on hot oil return to
expansion drum

2. Continued operation of fixed


speed hot oil cooler fin fans with no
hot oil flow

1. System and pump hot oil


circulating pump design considers
pumping of high viscous thermal oil
during startup at atmospheric
temperatures
2. Potential for operator to stop fin
fan motors if considered necessary

Recommendations
R1045.1 Review design
temperature of hot oil exchangers
to match hot oil unit design
temperature
R1045.2 Review design
temperature of hot oil expansion
drum

1047

Cryogenic (Sub Zero)

No new issues

1048

Level - High

No new issues

1049

Level - Low

No new issues

1050

Level - No

No new issues

1051

Phase - More

No new issues

1052

Phase - Less

No new issues

1053

Change of State

No new issues

Remarks

Action by:
TS

Action resolution

Prepared by Arthur D. Little for OK LNG

Version: Final
67/125

HAZOP Record Sheet: Hot Oil

Company
Facility
HAZOP Date
Section ID
General Section
Description:

HAZOP
Plant
Item No. Section
1054

TECHNIP
OK LNG Facility FEED Study
14-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Hot oil system


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.

Deviation
Wrong
Concentration
(Part of)

Causes
1. Ageing of hot oil

Consequences

Safeguards

Recommendations

Remarks

Action by:

Action resolution

1. Requirement for manual purging


and replacement of determined
volume during maintainance on an
annual programme

1055

Corrosive (As
well as)

No new issues

1056

Explosive

No new issues

1057

Wrong Material
(Other than)

No new issues

Prepared by Arthur D. Little for OK LNG

Version: Final
68/125

HAZOP Record Sheet: Hot Oil

Company
Facility
HAZOP Date
Section ID
General Section
Description:

TECHNIP
OK LNG Facility FEED Study
14-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Hot oil system


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.

HAZOP
Plant
Deviation
Causes
Item No. Section
Drawing Number/Sheet Number 2252-017-PID-00-31-01/Rev A/25-08-06
/Rev.Number/Date 2252-017-PID-00-31-02/Rev A/25-08-06
2252-017-PID-00-31-03/Rev A/25-08-06
2252-017-PID-00-31-04/Rev A/25-08-06

Consequences

Safeguards

Recommendations

Remarks

Action by:

Action resolution

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.
Node Equipment Hot oil furnace 017-H-101A/B/C
1058

Node 2

Furnace Overview
firing and
firebox

1059

Flow - High

No new issues

1060

Flow - Low

No new issues

1061

Flow - No

No new issues

1062

Flow - Reverse

No new issues

1063

Loss of
Containment

1. Leakage of fuel gas into firebox 1. Potential for firebox explosion


in standby mode
during ignition sequence

1. Burner management and firing


control system
2. Double block and bleed isolation
of main fuel gas to furnace during
shutdown
3. Double block and bleed isolation
on pilot fuel gas feed during
furnace shutdown

2. Tube leakage and/or tube failure 1. Potential for pool fire in the bas 1. Temperature indication on the
in individual furnace
of the furnace firebox
furance firebox
2. Oxygen anlyser on the flue gas
3. Increase in soot content of the
flue gas from the furnace

R1063.1 Confirm during vendor


package HAZOP provision of
firebox venting and purge
requirements prior to ignition

TS

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

Prepared by Arthur D. Little for OK LNG

Version: Final
69/125

HAZOP Record Sheet: Hot Oil

Company
Facility
HAZOP Date
Section ID
General Section
Description:

HAZOP
Plant
Item No. Section
1064

TECHNIP
OK LNG Facility FEED Study
14-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Hot oil system


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.

Deviation

Causes

Pressure - High 1. Malfunction/incorrect setpoint


017-PIC-0009A/B/C

Consequences

Safeguards

Recommendations

Remarks

Action by:

Action resolution

1. Increase in fuel gas flow to main 1. Flame detectors on main


burner tip
burners in furnace
2. Potential for flame lift-off
3. Potential for re-ignition on hot
refractory lining and potential for
explosion

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

3. Variation in fuel gas pressure

1. Potential for increased firing in


furnace firebox
2. Gradual increase in discharge
temperature of the fire furnace

4. Incorrect setpoint and position of 1. Potential increase in firebox


damper
pressure with potential for
substoichiometric combustion

R1064.1 Review during detailed


vendor package HAZOP flame
protection and flame-out
protection, including trip actions

TS

1. 017-PIC-0009A/B/C controls fuel


gas pressure to main burners
2. 017-TI/TAH-0008A/B/C controls
firing in furnace to maintain set
discharge temperature

1. 017-AI-001A/B/C excess oxygen


analyser on flue gas
2. 017-PI/PAH-0002A/B/C and017PI/PAH-4A/B/C firebox pressure
indication

Prepared by Arthur D. Little for OK LNG

Version: Final
70/125

HAZOP Record Sheet: Hot Oil

Company
Facility
HAZOP Date
Section ID
General Section
Description:

HAZOP
Plant
Item No. Section
1065

TECHNIP
OK LNG Facility FEED Study
14-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Hot oil system


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.

Deviation
Pressure - Low

Causes
1. Malfunction/incorrect setpoint
017-PIC-0006A/B/C
2. Malfunction/incorrect setpoint
017-PIC-0009A/B/C

3. Low fuel gas pressure and/or


blockage of inlet fuel gas filter

Consequences
1. Loss of fuel gas flow to pilot
burner
2. Loss of pilot in furnace
1. Loss of fuel gas flow to main
burners
2. Loss of firing in furnace of main
gas burners
3. Gradual decrease in
temperature of process side
discharge from furnace

Safeguards
1. 017-PALL-0008A/B/C on pilot
gas

Recommendations
R1065.1 See R1064.1

Remarks

Action by:
TS

Action resolution

1. 017-PALL-0010A/B/C on main
fuel gas
2. Flame detectors on main fuel
gas burners

1. Decrease in flow of natural gas 1. 017-PALL-0008A/B/C on pilot


to both pilot and main gas burners gas
2. Potential for flameout of furnace 2. 017-PALL-0010A/B/C on main
fuel gas
017/PDI/PAH-017A/B/C over inlet
gas filters

1066

Vacuum

1067

Partial Pressure 1. Variation in fuel gas composition 1. Potential for variation in burner
performance

No new issues
1. Burner tip design takes into
account anticipated variations in
fuel gas composition

Prepared by Arthur D. Little for OK LNG

Version: Final
71/125

HAZOP Record Sheet: Hot Oil

Company
Facility
HAZOP Date
Section ID
General Section
Description:

HAZOP
Plant
Item No. Section
1068

1069

TECHNIP
OK LNG Facility FEED Study
14-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Hot oil system


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.

Deviation
Temperature High

Temperature Low

Causes
1. Malfunction/incorrect setpoint
017-TI-0008A/B/C

Consequences

Safeguards

Recommendations

1. Increased firing in the individual


fired heater
2. Increase in discharge
temperature from furnace
3. Potential for flame impingement
on furnace tubes
4. Potential for cracking reactions
in coil and coke formation
5. Potential for coil rupture

1. 017-TI-0011 on common hot oil


discharge from all three furnaces
resets 017-TY-0008A/B/C
2. 017-TI/TAH-0005** coil skin
temperature thermocouples
3. 017-TI/TAH-0002 radiant zone
firebox temperature
4. 017-TI/TAH-0003** individual
discharge temperatures
5. 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

1. Malfunction/incorrect setpoint of 1. Increased firing in the all fired


017-TI-0011
heaters
2. Increase in discharge
temperature from furnace
3. Potential for flame impingement
4. Potential for cracking reactions
in coil and coke formation
5. Potential for coil rupture

1. 017-TIC-0014 controls cooling in


hot oil trim air cooler
2. 017-TI/TAH-0005** coil skin
temperature thermocouples
3. 017-TI/TAH-0002 radiant zone
firebox temperature
4. 017-TI/TAH-0003** individual
discharge temperatures
5. 017-TAHH-0009A/B/C on
common furnace discharge

1. Malfunction/incorrect setpoint
017-TI-0008A/B/C

1. 017-TI-0011 on common hot oil


discharge from all three furnaces
resets 017-TY-0008A/B/C
2. 017-TI-0002 radiant zone firebox
temperature
3. 017-TI-0003** individual
discharge temperatures

1. Decreased firing in the individual


fired heater
2. Decrease in discharge
temperature from furnace

1. Malfunction/incorrect setpoint of 1. Decreased firing in all fired


017-TI-0011
heaters
2. Decrease in discharge
temperature from furnace

Remarks

Action by:
TS

Action resolution

1. 017-TI-0008A/B/C on common
hot oil discharge from all three
furnaces resets 017-TY-0008A/B/C
2. 017-TI-0002 radiant zone firebox
temperature
3. 017-TI-0003** individual
discharge temperatures
4. 017-TI-0004 controls cooling in
hot oil trim air cooler

Prepared by Arthur D. Little for OK LNG

Version: Final
72/125

HAZOP Record Sheet: Hot Oil

Company
Facility
HAZOP Date
Section ID
General Section
Description:

HAZOP
Plant
Item No. Section
1070

TECHNIP
OK LNG Facility FEED Study
14-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Hot oil system


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.

Deviation

Causes

Consequences

Safeguards

Recommendations

Cryogenic (Sub Zero)

No new issues

1071

Level - High

No new issues

1072

Level - Low

No new issues

1073

Level - No

No new issues

1074

Phase - More

1075

Phase - Less

No new issues

1076

Change of State

No new issues

1077

Wrong
Concentration
(Part of)

No new issues

1078

Corrosive (As
well as)

No new issues

1079

Explosive

1080

Wrong Material
(Other than)

1. Potential condensate formation 1. Potential for upset in furnace


in fuel gas network
during initial startup

1. Incorrect ignition sequence for


furnace

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 minimise
potential for furnace upset (general
recommendation)

Remarks

Action by:

TS

Action resolution

1. Sequence controlled ignition of


furnace
No new issues

Prepared by Arthur D. Little for OK LNG

Version: Final
73/125

HAZOP Record Sheet: Hot Oil

Company
Facility
HAZOP Date
Section ID
General Section
Description:

TECHNIP
OK LNG Facility FEED Study
14-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Hot oil system


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.

HAZOP
Plant
Deviation
Causes
Item No. Section
Drawing Number/Sheet Number 2252-017-PID-00-31-06/Rev A/25-08-06
/Rev.Number/Date 2252-017-PID-00-31-05/Rev A/25-08-06

Consequences

Safeguards

Recommendations

Remarks

Action by:

Action resolution

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 sumps


017-P-103/4 sump pumps
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 1. Manually operated control


thermal expansion drum with
procedure
potential to overfill
2. 017-LI-0004 on hot oil
expansion drum
3. 017-LALL-0005/6 initiates trip of
transfer pump

1083

Flow - Low

No new issues

1084

Flow - No

No new issues

1085

Flow - Reverse

1. Pump trip and/or normal standby 1. Potential for reverse flow of hot 1. Check valve on discharge of
condition
oil to sump
sump pump
2. Check valve on connections for
addition of new thermal oil
3. Hot thermal oil injection
connection to expansion drum inlet
pipework normally manually closed
and isolated from system

1086

Loss of
Containment

1. Corrosion of hot oil sump

1. Potential leakage of hot oil into


concrete pits

1. Hot oil sumps are carbon steel


and painted to minimise potential
for external corrosion

Prepared by Arthur D. Little for OK LNG

Version: Final
74/125

HAZOP Record Sheet: Hot Oil

Company
Facility
HAZOP Date
Section ID
General Section
Description:

HAZOP
Plant
Item No. Section
1087

TECHNIP
OK LNG Facility FEED Study
14-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Hot oil system


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.

Deviation

Causes

Pressure - High 1. Operator error closing globe


valve on nitrogen purge of hot oil
sump

2. Draining of hot oil to sump

1088

Pressure - Low

1089

Vacuum

1090

Partial Pressure 1. Flashing of light ends in hot oil


sump

1091

Temperature High

1092

Temperature Low

1093

Cryogenic (Sub Zero)

Consequences

Safeguards

1. Potential to overpressure hot oil


sump

Recommendations

Remarks

Action by:

Action resolution

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

R1088.1 Ensure nitrogen purge


sizing basis and local indication is
sufficient to prevent formation of
vacuum in sump during pump out
conditions

TS

1. Potential to exceed sump design 1. 3" vent to flare on vapour space


pressure
of hot oil sump considered
sufficient for normal nitrogen purge
and maximum hot oil draining flow
rate

1. Pump out of thermal oil from hot 1. Potential for decrease in vapour
oil sump to hot oil expansion drum space pressure in hot oil sump
2. Potential for damage to drum

No new issues
1. Potential for formation of
flammable atmospheres in hot oil
sump

1. Nitrogen purge of the vapour


space of hot oil sump to flare

No new issues

1. Decrease in temperature of hot 1. Potential for problems in


oil inventory in sump
operating sump pump

1. Pumps designed for pumping


both atmospheric temperature and
hot thermal oil

No new issues

Prepared by Arthur D. Little for OK LNG

Version: Final
75/125

HAZOP Record Sheet: Hot Oil

Company
Facility
HAZOP Date
Section ID
General Section
Description:

HAZOP
Plant
Item No. Section
1094

TECHNIP
OK LNG Facility FEED Study
14-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Hot oil system


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.

Deviation
Level - High

Causes
1. Draining of hot oil inventory
during maintainance

Consequences
1. Potential to overfill sump

Safeguards

Recommendations

Remarks

Action by:

Action resolution

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 sumps
3. Local level indication gauges on
sumps

2. Collection of rainwater in hot oil 1. Potential for drum to float since 1. Hot oil sumps are anchored to
pits during rainy season
normally no liquid inventory
pit
2. 017-LI/LAH-0013/14 level
indication on pit
3. Operator action to pump out hot
oil sump pits during rainy
conditions as necessary
1095

Level - Low

No new issues

1096

Level - No

No new issues

1097

Phase - More

No new issues

1098

Phase - Less

No new issues

1099

Change of State

No new issues

1100

Wrong
Concentration
(Part of)

No new issues

1101

Corrosive (As
well as)

1102

Explosive

No new issues

1103

Wrong Material
(Other than)

No new issues

1. Corrosion of internals of hot oil


sumps

1. Potential contamination of hot oil 1. Nitrogen blanket/purge of hot oil


with corrosion products
sump

Prepared by Arthur D. Little for OK LNG

Version: Final
76/125

HAZOP Record Sheet: Diesel Oil

Company
Facility
HAZOP Date

TECHNIP
OK LNG Facility FEED Study
14-Sep-06

Section ID
General Section
Description:

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.

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Diesel oil system

HAZOP
Plant
Deviation
Causes
Item No. Section
Drawing Number/Sheet Number 2252-046-PID-00-31-01/Rev A/23-05-06
/Rev.Number/Date

Consequences

Safeguards

Recommendations

Remarks

Action by:

Action resolution

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/B
Diesel oil storage tank 046-T-101
Diesel oil outlet filters 046-F-102A/B
Diesel oil station 046-U-101
1104

1105

Node 1

Diesel oil Overview


system

Flow - High

1. HAZOP of diesel oil station

1. Import of diesel oil from harbour 1. Increase in level in diesel oil


storage tank
2. Potential to overflow diesel oil
storage tank
3. Increase in vapour space
pressure and overpressure of
atmospheric storage tank

1. 046-LI/LAH-0002 with control


signal to harbour loading facility
2. 4" vent sized for maximum filling
rate
3. Management of diesel oil
purchase and inventory control
during import activities

2. Export of diesel oil to distribution 1. Gradual decrease in level in


truck
diesel oil storage tank
2. Low pressure in vapour space

1. 046-LI/LAL-0002 for inventory


management in diesel oil tank
2. 4" vent

1106

Flow - Low

1107

Flow - No

1108

Flow - Reverse

1. Pump trip during import of diesel 1. Potential for reverse flow of


from harbour
diesel

1109

Loss of
Containment

1. Overfilling of diesel oil storage


tank during loading via overfill
connection

1110

Pressure - High

R1104.1 Undertake vendor


package HAZOP during detailed
design

TS

R1105.1 Consider provision of


pump to enable filling of diesel
truck for onsite distribution

TS

R1108.1 Consider provision of


check valve at harbour to prevent
reverse flow

TS

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

1. Gradual blockage of diesel inlet 1. Increased duration for filling and 1. Manual operation
and/or outlet filters
transfer of diesel oil
No new issues
1. Loading is a manual operation

1. Potential contamination of bund 1. 046-LI/LAH-0002 with control


area
signal to harbour loading facility
2. Management of diesel oil
purchase and inventory control
during import activities

No new issues

Prepared by Arthur D. Little for OK LNG

Version: Final
77/125

HAZOP Record Sheet: Diesel Oil

Company
Facility
HAZOP Date

TECHNIP
OK LNG Facility FEED Study
14-Sep-06

Section ID
General Section
Description:

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.

HAZOP
Plant
Item No. Section
1111

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Diesel oil system

Deviation

Causes

Consequences

Safeguards

Recommendations

Pressure - Low

No new issues

1112

Vacuum

No new issues

1113

Partial Pressure

No new issues

1114

Temperature High

No new issues

1115

Temperature Low

No new issues

1116

Cryogenic (Sub Zero)

No new issues

1117

Level - High

No new issues

1118

Level - Low

No new issues

1119

Level - No

No new issues

1120

Phase - More

1121

Phase - Less

No new issues

1122

Change of State

No new issues

1123

Wrong
Concentration
(Part of)

No new issues

1124

Corrosive (As
well as)

1. Contamination of diesel oil with 1. Potential collection of water in


water
diesel oil storage tank
2. Potential collection of water in
site emergency fuel tanks, e.g.
diesel firewater pump

1. Corrosion at water interface in


base of tank

1. Potential for ground


contamination

Remarks

Action by:

Action resolution

1. Sample collection on diesel oil


storage tank
2. Water removal drain on diesel
oil storage tank
3. Cone-up type bottom diesel oil
storage tank
4. Water drain connections on site
user diesel systems

1. Bund design
2. 3mm corrosion allowance in tank

Prepared by Arthur D. Little for OK LNG

Version: Final
78/125

HAZOP Record Sheet: Diesel Oil

Company
Facility
HAZOP Date

TECHNIP
OK LNG Facility FEED Study
14-Sep-06

Section ID
General Section
Description:

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.

HAZOP
Plant
Item No. Section
1125
1126

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Diesel oil system

Deviation

Causes

Consequences

Safeguards

Recommendations

Explosive

No new issues

Wrong Material
(Other than)

No new issues

Remarks

Action by:

Action resolution

Prepared by Arthur D. Little for OK LNG

Version: Final
79/125

HAZOP Record Sheet: Jetty Facilities

Company
Facility
HAZOP Date
Section ID
General Section
Description:

TECHNIP
OK LNG Facility FEED Study
14-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Jetty facilities
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.

HAZOP
Plant
Deviation
Causes
Item No. Section
Drawing Number/Sheet Number 2252-031-PID-00-31-01/Rev A/23-06-06
/Rev.Number/Date

Consequences

Safeguards

Recommendations

Remarks

Action by:

Action resolution

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.

1127

Node 1

Node Equipment Jetty gaseous nitrogen reciever 031-V-101


Nitrogen Overview
supply

1128

Flow - High

No new issues

1129

Flow - Low

No new issues

1130

Flow - No

No new issues

1131

Flow - Reverse

No new issues

1132

Loss of
Containment

No new issues

1133

Pressure - High

No new issues

1134

Pressure - Low

1. Purging of loading arm following 1. Use of nitrogen


1. Connected to site nitrogen
loading activities
2. Gradual decrease of pressure in system for recharging in the event
nitrogen buffer vessel
of decrease in pressure due to
high usage flow rates
2. 031-PI/PAL-0004 on jetty
nitrogen header
2. Malfunction in nitrogen
generation system upstream

1135

Vacuum

1. Potential for temporary loss of


nitrogen supply to jetty

1. Nitrogen buffer vessel on jetty


2. Check valve on inlet to nitrogen
buffer vessel to protect volume in
event of loss of nitrogen supply
header pressure
3. Buffer vessel sized for single
loading operation purge
4. 031-PI/PAL-0004 on jetty
nitrogen header

No new issues

Prepared by Arthur D. Little for OK LNG

Version: Final
80/125

HAZOP Record Sheet: Jetty Facilities

Company
Facility
HAZOP Date
Section ID
General Section
Description:
HAZOP
Plant
Item No. Section
1136

TECHNIP
OK LNG Facility FEED Study
14-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Jetty facilities
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.
Deviation

Causes

Consequences

Safeguards

Recommendations

Partial Pressure

No new issues

1137

Temperature High

No new issues

1138

Temperature Low

No new issues

1139

Cryogenic (Sub Zero)

No new issues

1140

Level - High

No new issues

1141

Level - Low

No new issues

1142

Level - No

No new issues

1143

Phase - More

No new issues

1144

Phase - Less

No new issues

1145

Change of State

No new issues

1146

Wrong
Concentration
(Part of)

No new issues

1147

Corrosive (As
well as)

1148

Explosive

No new issues

1149

Wrong Material
(Other than)

No new issues

1. External corrosion of nitrogen 1. Potential for loss of integrity of


buffer vessel and pipework at jetty nitrogen vessel and pipework
location

Remarks

Action by:

Action resolution

1. All nitrogen header pipework


along trestle, jetty head and vessel
will be coated to prevent external
corrosion

Prepared by Arthur D. Little for OK LNG

Version: Final
81/125

HAZOP Record Sheet: Jetty Facilities

Company
Facility
HAZOP Date
Section ID
General Section
Description:

TECHNIP
OK LNG Facility FEED Study
14-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Jetty facilities
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.

HAZOP
Plant
Deviation
Causes
Consequences
Safeguards
Recommendations
Remarks
Action by:
Action resolution
Item No. Section
Drawing Number/Sheet Number 2252-031-PID-00-31-01/Rev A/23-06-06
Design 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)

Node Equipment Jetty air compression package 031-U-104


Jetty dry air receiver 031-V-103
1150

Node 2

Jetty
Overview
compres
sed air
system

1. HAZOP of vendor package

R1150.1 Undertake vendor air


compressor package HAZOP
during detailed design

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 receiver
2. Potential for loss of instrument
air

1152

Flow - Low

1. Low usage of instrument and/or 1. Reduced production of


plant air
compressed air by compressed air
package

1153

Flow - No

1154

Flow - Reverse

1155

Loss of
Containment

1156

Pressure - High 1. Malfunction of compressed air


control package, e.g. compressor
fails to stop

TS

1. 031-PI/PAL-0005A/B autostart
of jetty air compression package
2. 031-PI/PAL-0003 closes jetty
plant air header to protect
instrument air network

No new issues
1. Completion of air compression
operation

1. Potential for depressurisation of 1. Check valve on inlet connection


jetty air reciever to atmosphere
to jetty air reciever prevents
depressurisation
No new issues

1. Potential to overpressure jetty


air receiver

1. Compressed air package design


2. 031-PSV-0002 on jetty dry air
receiver
3. 031-UUA-0001A/B summarised
malfunction alarm on compressed
air package

Prepared by Arthur D. Little for OK LNG

Version: Final
82/125

HAZOP Record Sheet: Jetty Facilities

Company
Facility
HAZOP Date
Section ID
General Section
Description:
HAZOP
Plant
Item No. Section
1157

TECHNIP
OK LNG Facility FEED Study
14-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Jetty facilities
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.
Deviation
Pressure - Low

Causes
1. Malfunction of compressed air
control package, e.g. compressor
fails to start

Consequences
1. Potential for loss of jetty
instrument and plant air

Safeguards

Recommendations

1158

Vacuum

No new issues

1159

Partial Pressure

No new issues

1160

Temperature High

No new issues

1161

Temperature Low

No new issues

1162

Cryogenic (Sub Zero)

No new issues

1163

Level - High

No new issues

1164

Level - Low

No new issues

1165

Level - No

No new issues

1166

Phase - More

1167

Phase - Less

No new issues

1168

Change of State

No new issues

1169

Wrong
Concentration
(Part of)

1. Malfunction in jetty air


compression package drier

1. Flammable vapour in vicinity of


compressed air package

1. Potential for formation of water


in jetty dry air receiver
2. Potential for damage to jetty
instrumentation

1. Potential for explosion

Remarks

Action by:

Action resolution

1. 031-PI/PAL-0003A/B on jetty air


compressor package
2. 031-PI/PAL-0003 on instrument
air header automatically closes
jetty plant air network to preserve
instrument air header pressure

1. Jetty air drier summarised


malfunction alarm 031-UUA0003A/B
2. Air high moisture content alarm
031-AI/AAH-0001A/B

1. Jetty air compression package


will be located in safe location in
non-hazardous zone

Prepared by Arthur D. Little for OK LNG

Version: Final
83/125

HAZOP Record Sheet: Jetty Facilities

Company
Facility
HAZOP Date
Section ID
General Section
Description:
HAZOP
Plant
Item No. Section
1170

TECHNIP
OK LNG Facility FEED Study
14-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Jetty facilities
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.
Deviation
Corrosive (As
well as)

Causes
1. External corrosion of jetty dry
air receiver and pipework at jetty
location

Consequences

Safeguards

Recommendations

Remarks

Action by:

Action resolution

1. Potential for loss of integrity of 1. All dry air pipework along trestle,
jetty dry air receiver and pipework jetty head and dry air receiver will
be coated to prevent external
corrosion

1171

Explosive

No new issues

1172

Wrong Material
(Other than)

No new issues

Prepared by Arthur D. Little for OK LNG

Version: Final
Sheet 84/125

HAZOP Record Sheet: Firewater

Company
Facility
HAZOP Date

Section ID
General Section
Description:

TECHNIP
OK LNG Facility FEED Study
15-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Firewater Systems
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.

HAZOP
Plant
Deviation
Causes
Item No. Section
Drawing Number/Sheet Number 2252-051-PID-00-31-02/Rev A/24-05-06
/Rev.Number/Date 2252-051-PID-00-31-03/Rev A/24-05-06
2252-055-PID-00-31-01/Rev A/14-07-06
2252-055-PID-00-31-02/Rev A/14-07-06

Consequences

Safeguards

Recommendations

Remarks

Action by:

Action resolution

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/B


Firefighting water pumps 055-P-101A/B/C
Jockey pumps 055-P-102A/B
1173

Node 1

Process Overview
Area
Firewater
System

1174

Flow - High

1175

Flow - Low

No new issues

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 055FI-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 strainer
blocked
3. Duty jockey pump will be
switched regularly to ensure
availability of spare jockey pump
and equal running time

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 85/125

HAZOP Record Sheet: Firewater

Company
Facility
HAZOP Date

Section ID
General Section
Description:

HAZOP
Plant
Item No. Section

TECHNIP
OK LNG Facility FEED Study
15-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Firewater Systems
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.

Deviation

Causes

Consequences

Safeguards

Recommendations

1176

Flow - No

No new issues

1177

Flow - Reverse

No new issues

1178

Loss of
Containment

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 FO
2. 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 FO
2. 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 1. Governor controls maximum


discharge pressure and
speed of diesel pump
overpressure of firewater ring main 2. 055-PSV-0001A/B on diesel
pumps back to storage tank

1. Jockey and/or firewater pump


seal failure

Remarks

Action by:

Action resolution

1. Weekly testing and inspection of


main firefighting and jockey water
pumps
2. Spare pumps available to
enable maintenance

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 86/125

HAZOP Record Sheet: Firewater

Company
Facility
HAZOP Date

Section ID
General Section
Description:

HAZOP
Plant
Item No. Section
1180

TECHNIP
OK LNG Facility FEED Study
15-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Firewater Systems
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.

Deviation
Pressure - Low

Causes

Consequences

Safeguards

Recommendations

Remarks

Action by:

Action resolution

1. Malfunction/incorrect setpoint
055-FIC-0004 jockey pump
minimum flow

1. Minimum flow opens recycling


firewater to tank
2. Potential decrease of pressure
in firewater main

1. 055-PIC-/PAL-0006 on firewater
ring main initiates autostart and
switch of standby jockey firewater
pump
2. 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 tank
2. 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

3. Fire case on site

1. Ring main pressure will drop

1. 055-PIC/PAL-0003 initiates
R1181.2 Next revision of P&IDs
autostart of first electric firewater will remove 051-LALL-007A/B stop
pump. If minimum firewater ring
of main firewater pumps
main pressure not achieved,
control system automatically
autostarts second pump after 20
seconds
2. 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

TS

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 87/125

HAZOP Record Sheet: Firewater

Company
Facility
HAZOP Date

Section ID
General Section
Description:

HAZOP
Plant
Item No. Section

TECHNIP
OK LNG Facility FEED Study
15-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Firewater Systems
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.

Deviation

Causes

Consequences

Safeguards

4. Leakage in main fire ring main

Loss of firewater and potential for


decrease in firewater ring main
pressure

1. Operation of firewater pump

1. Potential low pressure in storage 1 See filtered and firewater storage


tank
tank node

Recommendations

Remarks

Action by:

Action resolution

1. 055-PIC-/PAL-0006 on firewater
ring main initiates autostart and
switch of standby jockey firewater
pump
2. 055-PIC/PAL-0003 autostarts
electric fire pump if ring main
pressure continues to fall
3. Underground sections of
firewater system will be noncorrosive GRP, minimising
potential for system leakage
4. Firewater ring main is made up
of a series of rings so each plant
network has two independent
supply connections

1181

Vacuum

1182

Partial Pressure

No new issues

1183

Temperature High

No new issues

1184

Temperature Low

No new issues

1185

Cryogenic (Sub Zero)

No new issues

1186

Level - High

No new issues

1187

Level - Low

1188

Level - No

1. See filtered and firewater tank


node
No new issues

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 88/125

HAZOP Record Sheet: Firewater

Company
Facility
HAZOP Date

Section ID
General Section
Description:

HAZOP
Plant
Item No. Section
1189

TECHNIP
OK LNG Facility FEED Study
15-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Firewater Systems
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.

Deviation
Phase - More

Causes

Consequences

Safeguards

Recommendations

Remarks

Action by:

Action resolution

1. Algal and bacterial growth in


1. Potential for fouling of firewater 1. Raw water is dosed with biocide
filtered and firewater storage tanks ring main and pump suction
(sodium hypochlorite) upstream of
pipework
inlet for raw water filtration
package
No new issues

1190

Phase - Less

1191

Change of State

No new issues

1192

Wrong
Concentration
(Part of)

No new issues

1193

Corrosive (As
well as)

No new issues

1194

Explosive

No new issues

1195

Wrong Material
(Other than)

No new issues

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 89/125

HAZOP Record Sheet: Firewater

Company
Facility
HAZOP Date

Section ID
General Section
Description:

TECHNIP
OK LNG Facility FEED Study
15-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Firewater Systems
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.

HAZOP
Plant
Deviation
Causes
Consequences
Safeguards
Recommendations
Remarks
Action by:
Item No. Section
Drawing Number/Sheet Number 2252-052-PID-00-31-01/Rev A/23-05-06
/Rev.Number/Date 2252-031-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

Action resolution

Node Equipment Service water booster pumps 052-P-131A/B


Jetty firewater pumps 031-P-103A/B
Biocide dosing system 031-U-101
1196

Node 2

Jetty
Overview
firewater
system

1197

Flow - High

No new issues

1198

Flow - Low

No new issues

1199

Flow - No

No new issues

1200

Flow - Reverse

1. Depressurisation of jetty
1. Potential for reverse flow
firewater ring main to service water
system

1201

Loss of
Containment

1. 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
corrosion
2. Jetty firewater main can be
washed using service water to
remove seawater from system.
Maintenance override of 031-PIC0006 autostart of jetty firewater
pumps will be permitted

R1200.1 Next revision of P&ID will


show double check valve
arrangement on service water tiein to jetty firewater ring main

TS

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

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 90/125

HAZOP Record Sheet: Firewater

Company
Facility
HAZOP Date

Section ID
General Section
Description:

HAZOP
Plant
Item No. Section
1202

1203

TECHNIP
OK LNG Facility FEED Study
15-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Firewater Systems
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.

Deviation

Causes

Pressure - High 1. Activation of 031-PSV-0003B

Pressure - Low

Consequences

Safeguards

1. Potential to overpressure jetty


firewater ring main

Remarks

R1202.1 Next revision of P&ID will


show discharge of 031-PSV-0003B
downstream of minimum flow
control valve

1. Malfunction of upstream service 1. Decrease in jetty firewater


water pumps and/or excessive use header pressure
of water for maintenance
2. Potential for loss of firewater
protection at jetty

1. 031-PIC-0006 autostart of jetty


firewater pump
2. If after 20 seconds, ring main
pressure is not achieved, control
system will autostart standby
diesel firewater pump

2. Fire on the jetty

1. 031-PIC-0006 autostart of jetty


firewater pump
2. If after 20 seconds, ring main
pressure is not achieved, control
system will autostart standby
diesel firewater pump

1. Decrease in jetty firewater


header pressure

Recommendations

3. Firewater pump trip and/or loss 1. Loss of pressure in firewater


of electrical supply
main during fire case

1. 031-PIC-0006 autostart of diesel


jetty firewater pump
2. Dedicated diesel supply tank
sized for 8 hours supply
3. 031-LAL-0006B low level diesel
supply in tank

4. Malfunction/incorrect setpoint of 1. Depressurisation of firewater


031-FIC-0003 on minimum flow
ring main

1. Check valve prevents


depressurisation of ring main via
minimum flow protection of
firewater pumps
2. 031-PIC-0006 autostart of jetty
firewater pump
3. If after 20 seconds, ring main
pressure is not achieved, control
system will autostart standby
diesel firewater pump

Action by:
TS

Action resolution

1. Review underway to
consider requirement for
jetty emergency electrical
generator (instrumentation,
lighting, etc.)

1204

Vacuum

No new issues

1205

Partial Pressure

No new issues

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 91/125

HAZOP Record Sheet: Firewater

Company
Facility
HAZOP Date

Section ID
General Section
Description:

HAZOP
Plant
Item No. Section
1206

TECHNIP
OK LNG Facility FEED Study
15-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Firewater Systems
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.

Deviation

Causes

Consequences

Safeguards

Recommendations

Temperature High

No new issues

1207

Temperature Low

No new issues

1208

Cryogenic (Sub Zero)

No new issues

1209

Level - High

1210

Level - Low

No new issues

1211

Level - No

No new issues

1212

Phase - More

1213

Phase - Less

No new issues

1214

Change of State

No new issues

1215

Wrong
Concentration
(Part of)

1. Silting of firewater basin

1. Algal and/or marine growth on


firewater system

1. Malfunction in biocide dosing


system

Remarks

Action by:

Action resolution

1. Marine baseline survey currently


being undertaken and will be
considered in location of jetty
firewater pump

1. Potential for fouling of jetty


firewater system

1. Potential for algal and marine


growth within jetty firewater ring
main and equipment

1. Biocide dosing system for jetty


firewater system

R1212.1 Next revision of P&ID will 1. Dosing of inlet systems TS


show biocide dosing connection to not considered a problem
pump firewater basin screen
during discharge and
firewater test to local marine
environment

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

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 92/125

HAZOP Record Sheet: Firewater

Company
Facility
HAZOP Date

Section ID
General Section
Description:

HAZOP
Plant
Item No. Section
1216

TECHNIP
OK LNG Facility FEED Study
15-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Firewater Systems
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.

Deviation

Causes

Consequences

Safeguards

Corrosive (As
well as)

1217

Explosive

1218

Wrong Material
(Other than)

Recommendations

Remarks

Action by:

Action resolution

No new issues

1. Location of jetty firewater pumps 1. Potential for source of ignition in 1. Location of firewater pump in
event of emergency at jetty
non-hazardous area

No new issues

No new issues

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 93/125

HAZOP Record Sheet: Effluent Treatment

Company
Facility
HAZOP Date

Section ID
General Section
Description:

TECHNIP
OK LNG Facility FEED Study
15-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Effluent treatment system


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.

HAZOP
Plant
Deviation
Causes
Item No. Section
Drawing Number/Sheet Number 2252-057-PID-00-31-03/Rev A/12-09-06
/Rev.Number/Date 2252-057-PID-00-31-05/Rev A/12-09-06
2252-057-PID-00-31-06/Rev A/12-09-06
2252-057-PID-00-31-07/Rev A/12-09-06
2252-057-PID-00-31-08/Rev A/12-09-06

Consequences

Safeguards

Recommendations

Remarks

Action by:

Action resolution

Design intent See Above


Node Equipment Boilers blowdown LNG Train 1 Collection Basin 057-BA-110
Boilers blowdown LNG Train 2 Collection Basin 057-BA-111
Boilers blowdown LNG Train 3 Collection Basin 057-BA-112
Boilers blowdown LNG Train 4 Collection Basin 057-BA-113
Boilers blowdown LNG Train 1 Lifting Pumps 057-P-110A/B
Boilers blowdown LNG Train 1 Lifting Pumps 057-P-111A/B
Boilers blowdown LNG Train 1 Lifting Pumps 057-P-112A/B
Boilers blowdown LNG Train 1 Lifting Pumps 057-P-113A/B
Chemical sewer receiving pit 075-BA-120
Laboratory pit 057-BA-126
Chemical sewer neutralisation basins 057-BA-121A/B
Chemical sewer neutralisation pumps 057-P-121A/B
Sulphuric acid dosing package 057-U-102
Sodium hydroxide dosing package 057-U-103
1219

Node 1

Effluent Overview
treatmen
t system

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 94/125

HAZOP Record Sheet: Effluent Treatment

Company
Facility
HAZOP Date

Section ID
General Section
Description:

HAZOP
Plant
Item No. Section
1220

TECHNIP
OK LNG Facility FEED Study
15-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Effluent treatment system


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.

Deviation
Flow - High

Causes

Consequences

Safeguards

Recommendations

1. Blowdown of LNG train boiler


system (continuous and
discontinuous steam drum
blowdown)

1. Continuous flow of steam


blowdown effluent into LNG train
collection basin
2. 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
operating
2. 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
sequence
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

2. Maintenance in chemicals
storage area and/or rainy season

1. Increase in flow rate of effluent


from chemical sewer to chemical
sewer receiving pit
2. 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 basin
2. Discharge of effluent from
chemicals area is initiated by
operator opening manual valve
3. Chemicals area is sheltered,
reducing potential for collection of
rainwater in kerbed areas for
disposal via the chemical sewer
neutralisation basin (noncontaminated 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


1. 057-LI/LAH-0003 on the
laboratory pit
laboratory pit
2. Potential for release of untreated 2. Requirement for collection by
effluent to atmosphere
vacuum truck for disposal offsite
3. Laboratory pit has a nominal
size of 5 m3

Remarks

Action by:
TS

Action resolution

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 95/125

HAZOP Record Sheet: Effluent Treatment

Company
Facility
HAZOP Date

Section ID
General Section
Description:

HAZOP
Plant
Item No. Section
1221

1222

TECHNIP
OK LNG Facility FEED Study
15-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Effluent treatment system


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.

Deviation
Flow - Low

Flow - No

Causes

Consequences

1. Pump trip in blowdown collection 1. Loss of pump-out of effluent in


basin
blowdown collection basin
2. Continued increase in level in
collection basin with potential to
overpressure

Safeguards
1. 057-LI/LAH-0001/2/8/9 on
blowdown collection vessel

Recommendations

Remarks

Action by:

Action resolution

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

1. Summarised malfunction alarms R1221.2 HAZOP of chemical


057-UUA-0001 and 057-UUA-0003 dosing packages will be
on neutralisation dosing packages undertaken during detailed design
2. Spare dosing pump provided in
dosing system
3. Stroke volume is calibrated
manually using calibration pot
during commissioning of package

TS

TS

2. Pump trip in chemical sewer


neutralisation basin

1. Loss of mixing flow in basin


1. Chemical sewer neutralisation
2. Loss of pump-out of neutralised control logic will be configured to
effluent offsite
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 basin
2. Potential for loss of
neutralisation sequence step in
basin

1. Malfunction of sequence valve,


e.g. 052-AV-0001B and/or 2B

1. Loss of pump out of chemical


1. 057-AIC-0001/2 indication of
sewer neutralisation basin
neutral pH in basin
2. Continued filling of standby
2. Sequence valve position
chemical sewer neutralisation
indication provided in DCS panel
basin with potential to liquid fill both
basins
3. Release of water from
intermediate chemical sewer
receiving pit

R1222.1 Review with


instrumentation group whether
provision of sequence failure alarm
is possible and/or necessary for
the chemical sewer neutralisation
basin

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 96/125

HAZOP Record Sheet: Effluent Treatment

Company
Facility
HAZOP Date

Section ID
General Section
Description:

HAZOP
Plant
Item No. Section
1223

1224

TECHNIP
OK LNG Facility FEED Study
15-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Effluent treatment system


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.

Deviation

Causes

Flow - Reverse

1. Reverse flow from chemical


sewer receiving pit to collection
basin

Loss of
Containment

1. Piston seal failure on dosing


package

Consequences

Safeguards

Recommendations

Action by:

Action resolution

1. Check valves on discharge


pumps prevent reverse flow
2. Vapour space in chemical sewer
receiving pit
1. Potential for spillage of acid
and/or caustic
2. Potential for neutralisation of
chemical dosing fluids

2. Loss of containment (e.g.


1. Potential operator hazard and
corrosion) of concentrated acid or chemical burns
caustic chemical storage tanks
2. Potential for significant heat of
reaction between caustic and acid
solutions

1. Acid and causic dosing


packages will be located in kerbed,
segregated areas
1. Periodic operator inspection of
the area
2. Operator PPE
3. Dedicated sgregated kerbed
areas for each chemical storage
tank to minimise potential for
mixing of released caustic and acid
solutions

1225

Pressure - High

No new issues

1226

Pressure - Low

No new issues

1227

Vacuum

No new issues

1228

Partial Pressure

No new issues

1229

Temperature High

1. Heat of neutralisation and


dilution in chemical sewer
neutralisation basin

Remarks

1. Potential for increase in effluent 1. Continuous blowdown from LNG


temperature
boiler system is approximately
neutral does not require
neutralisation
2. No significant heat of
neutralisation expected in basin as
pumps used for circulation of
mixing of effluent during
neutralisation sequence

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 97/125

HAZOP Record Sheet: Effluent Treatment

Company
Facility
HAZOP Date

Section ID
General Section
Description:

HAZOP
Plant
Item No. Section
1230

TECHNIP
OK LNG Facility FEED Study
15-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Effluent treatment system


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.

Deviation

Causes

Consequences

Safeguards

Recommendations

Temperature Low

No new issues

1231

Cryogenic (Sub 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 pump

1. Spare neutralisation pump

1234

Level - No

1235

Phase - More

1236

Phase - Less

No new issues

1237

Change of State

No new issues

1238

Wrong
Concentration
(Part of)

Remarks

Action by:

Action resolution

No new issues
1. Release of solids from BFW
system during blowdown to
collection basin

1. Incomplete mixing in
neutralisation basin and/or
malfunction 057-AIC-0001/2

1. Gradual increase in scale and


mineral solids in collection basin

1. Demineralised water used for


BFW production
2. 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)

1. Pumping of incorrect pH effluent 1. Operator requirement for


offsite for disposal
periodic sampling of discharge
2. Potential environmental impact effluent and recalibration of pH
meter

R1235.1 Consider provision of


hard pipework connection for
removal of solids from bottom of
blowdown collection basins using
vacuum truck

R1238.1 Provide sample


connection on discharge of
chemical sewer neutralisation
pumps for sampling purposes

TS

TS

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 98/125

HAZOP Record Sheet: Effluent Treatment

Company
Facility
HAZOP Date

Section ID
General Section
Description:

HAZOP
Plant
Item No. Section
1239

TECHNIP
OK LNG Facility FEED Study
15-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Effluent treatment system


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.

Deviation
Corrosive (As
well as)

1240

Explosive

1241

Wrong Material
(Other than)

Causes
1. Transfer of acid/caustic liquids
to chemical sewer receiving pit in
the chemical sewer

Consequences
1. Potential chemical attack on
concrete materials

Safeguards

Recommendations

Remarks

Action by:

Action resolution

1. Appropriate materials for


chemical sewer
2. Chemical sewer receiving pit will
be concrete with chemical resistant
epoxy lining
3 Chemical sewer neutralisation
basin will be concrete with
chemical resistant epoxy lining

No new issues
1. Construction of underground
basins with potential for operator
falling hazard

1. Underground collection basins


with metal roofing designed to
enable operator walking
2. Chemical sewer neutralisation
basin will have fencing to prevent
operator ingress

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 99/125

HAZOP Record Sheet: Oily Water System

Company
Facility
HAZOP Date

TECHNIP
OK LNG Facility FEED Study
18-Sep-06

Section ID
General Section
Description:

Oily water system

HAZOP
Item No.

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

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

Plant
Deviation
Causes
Section
Drawing Number/Sheet Number 2252-056-PID-00-31-01/Rev A/12-09-06
/Rev.Number/Date 2252-056-PID-00-31-05/Rev A/12-09-06
2252-056-PID-00-31-06/Rev A/12-09-06
2252-056-PID-00-31-07/Rev A/12-09-06
2252-056-PID-00-31-08/Rev A/12-09-06
2252-056-PID-00-31-09/Rev A/12-09-06
2252-056-PID-00-31-10/Rev A/12-09-06
2252-056-PID-00-31-11/Rev A/12-09-06
2252-056-PID-00-31-12/Rev A/12-09-06
2252-056-PID-00-31-13/Rev A/12-09-06
2252-056-PID-00-31-14/Rev A/12-09-06
2252-056-PID-00-31-17/Rev A/12-09-06
2252-056-PID-00-31-18/Rev A/12-09-06
2252-056-PID-00-31-19/Rev A/12-09-06
2252-056-PID-00-31-20/Rev A/12-09-06
2252-056-PID-00-31-21/Rev A/12-09-06
2252-056-PID-00-31-23/Rev A/12-09-06
2252-056-PID-00-31-02/Rev A/12-09-06

Consequences

Safeguards

Recommendations

Remarks

Action by:

Action resolution

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
1242

Node 1

Overview
Type 1
(process
area)
collection
basin

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-LALL003 required by project

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 100/125

HAZOP Record Sheet: Oily Water System

Company
Facility
HAZOP Date

TECHNIP
OK LNG Facility FEED Study
18-Sep-06

Section ID
General Section
Description:

Oily water system

HAZOP
Item No.
1243

Plant
Section

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

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
Deviation
Flow - High

Causes
1. Washing of process area hard
standing during cleaning
operations

Consequences
1. Gradual increase in level in the
dedicated process area collection
basin
2. Potential to liquid fill collection
basin
3. Potential for release of
untreated oily water to noncontaminated sewer

Safeguards

Recommendations

Remarks

Action by:

Action resolution

1. Each processs area collection


basin is 140 m3 with pumps for
manual initiated pumping of oily
water to common oily water tank
2. 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 basin
3. 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

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 101/125

HAZOP Record Sheet: Oily Water System

Company
Facility
HAZOP Date

TECHNIP
OK LNG Facility FEED Study
18-Sep-06

Section ID
General Section
Description:

Oily water system

HAZOP
Item No.

Plant
Section

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

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
Deviation

Consequences

Safeguards

2. High seasonal rainfall

Causes

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
rainfall
2. 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 basin
3. Requirement for operator to
manually initiate collection basin
lifting pumps following rain for
treatment of oily water effluents in
the oily water treatment system
4. 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
package
3. 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/hr
4. Operator coordination of pumpout activities from various process
areas
5. 056-LI/LAHH-0003 on oily water
tank (alarm only) and overflow to
oily water sewer

Recommendations

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

Remarks

TS

Action by:

Action resolution

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 102/125

HAZOP Record Sheet: Oily Water System

Company
Facility
HAZOP Date

TECHNIP
OK LNG Facility FEED Study
18-Sep-06

Section ID
General Section
Description:

Oily water system

HAZOP
Item No.
1244

Plant
Section

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

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
Deviation

Causes

Consequences

Safeguards

Flow - Low

1. Lifting pump trip during pumpout operation

1. Loss of collection basin pumpout

1. Operator supervision
2. 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 pumps
2. Top entry into oily water tank in
vapour space, prevents reverse
flow of oily water back to collection
basin

1247

Loss of
Containment

1. Incorrect operation of collection 1. Potential for contaminated water


basin, initiating cleaning operations to run directly into noncontaminated sewer rather than
with level in the collection basin
over wier into collection basin

1248

Pressure - High 1. Isolation of oily water tank


and/or header valve

1249

Pressure - Low

1. Potential to dead-head lifting


pump and overpressure pipework

Recommendations

Remarks

Action by:

Action resolution

1. Operating procedures and


requirement for operator to pump
out collection basin to low low level
pump stop before undertaking
cleaning operations

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
1. High flow rate of oily water to
collection basins to oily water tank oily water tank
2. Gradual increase in vapour
space pressure

1. 4" vent
2. 12" overflow

1. Pump-out of oily water tank with 1. Gradual decrease in vapour


no inlet flow
space pressure

1. 4" vent
2. 12" overflow

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 103/125

HAZOP Record Sheet: Oily Water System

Company
Facility
HAZOP Date

TECHNIP
OK LNG Facility FEED Study
18-Sep-06

Section ID
General Section
Description:

Oily water system

HAZOP
Item No.
1250
1251

Plant
Section

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

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
Deviation

Causes

Consequences

Safeguards

Vacuum

Recommendations

Remarks

Action by:

Action resolution

No new issues

Partial Pressure 1. Transfer of volatile organic


compounds to oily water tank

1. Oil contaminants in oily water


1. Potential for formation of
flammable atmospheres in vapour system are heavy hydrocarbons,
lubricating oils and other low
space of oily water tank
vapour pressure hydrocarbons
2. No potential for flammable
atmospheres in vapour space of
oily water tank

2. Release of flammable materials 1. Potential for utility lifting pumps


to atmosphere from process area 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

TS
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

1252

Temperature High

No new issues

1253

Temperature Low

No new issues

1254

Cryogenic (Sub Zero)

No new issues

1255

Level - High

No new issues

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 104/125

HAZOP Record Sheet: Oily Water System

Company
Facility
HAZOP Date

TECHNIP
OK LNG Facility FEED Study
18-Sep-06

Section ID
General Section
Description:

Oily water system

HAZOP
Item No.
1256

Plant
Section

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

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
Deviation
Level - Low

Causes

Consequences

Safeguards

1. Pump-out of collection basin

1. Gradual decrease in level


2. Potential for loss of level and
pump cavitation

1. Operator supervision of
pumping operations
2. Low level stop of pumps in
collection basins
3. 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

Recommendations

1257

Level - No

1258

Phase - More

1259

Phase - Less

No new issues

1260

Change of State

No new issues

1261

Wrong
Concentration
(Part of)

Remarks

Action by:

Action resolution

No new issues
1. Gradual collection of solids in
collection basin, e.g. sand and
other material

1. Potential for damage to lifting


pump

1. Heavy contamination of acid gas 1. Potential for contamination of


oily water treatment system with
removal unit process area with
caustic amine
amine spillage (caustic)
2. Potential for release of high
COD amine to non-contaminated
sewer

1. Pump type selection


2. Normal maintenance and
periodic cleaning of collection
basins, DAF, etc. for removal of
solids

1. Acid gas removal unit process


area is kerbed, with normally
closed drain valve to oily water
sewer
2. 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

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

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

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 105/125

HAZOP Record Sheet: Oily Water System

Company
Facility
HAZOP Date

TECHNIP
OK LNG Facility FEED Study
18-Sep-06

Section ID
General Section
Description:

Oily water system

HAZOP
Item No.
1262

Plant
Section

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

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
Deviation
Corrosive (As
well as)

Causes
1. General corrosion of carbon
steel pipework

Consequences
1. Potential for rust formation and
leakage

Safeguards
1. All oily water header pipework
will be painted to minimise
potential for external corrosion
2. Oily water header pipework has
3mm corrosion allowance
3. Oily water tank has 3mm
corrosion allowance and is not
lined

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

1263

Explosive

No new issues

1264

Wrong Material
(Other than)

No new issues

Remarks
TS

Action by:

Action resolution

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 106/125

HAZOP Record Sheet: Oily Water System

Company
Facility
HAZOP Date

TECHNIP
OK LNG Facility FEED Study
18-Sep-06

Section ID
General Section
Description:

Oily water system

HAZOP
Item No.

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

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

Plant
Deviation
Causes
Section
Drawing Number/Sheet Number 2252-056-PID-00-31-15/Rev A/12-09-06
/Rev.Number/Date 2252-056-PID-00-31-16/Rev A/12-09-06
2252-056-PID-00-31-02/Rev A/12-09-06

Consequences

Safeguards

Recommendations

Remarks

Action by:

Action resolution

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 stabiliser
and 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

Node Equipment Inlet facilities CNL/BG collection basin 056-BA-504


Inlet facilities Shell collection basin 056-BA-506
Inlet facilities CNL/BG lifting pumps 056-P-504A/B
Inlet facilities Shell lifting pumps 056-P-506A/B
1265

Node 2

Overview
Type 2
(inlet
facility)
collection
basin

1266

Flow - High

No new issues

1267

Flow - Low

No new issues

1268

Flow - No

No new issues

1269

Flow - Reverse

No new issues

1270

Loss of
Containment

1271

Pressure - High

No new issues

1272

Pressure - Low

No new issues

1. 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 noncontaminated sewer without
treatment

1. Collection basin baffle prevents


reverse flow of contaminated
process water to noncontaminated sewer

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 107/125

HAZOP Record Sheet: Oily Water System

Company
Facility
HAZOP Date

TECHNIP
OK LNG Facility FEED Study
18-Sep-06

Section ID
General Section
Description:

Oily water system

HAZOP
Item No.
1273

Plant
Section

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

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
Deviation

Causes

Consequences

Safeguards

Recommendations

Vacuum

No new issues

1274

Partial Pressure

No new issues

1275

Temperature High

No new issues

1276

Temperature Low

No new issues

1277

Cryogenic (Sub Zero)

No new issues

1278

Level - High

1279

Level - Low

No new issues

1280

Level - No

No new issues

1281

Phase - More

No new issues

1282

Phase - Less

No new issues

1283

Change of State

No new issues

1284

Wrong
Concentration
(Part of)

No new issues

1285

Corrosive (As
well as)

No new issues

1286

Explosive

No new issues

1287

Wrong Material
(Other than)

No new issues

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 basin
2. Road access to each collection
basin to enable vacuum truck
collection of skimmed oil from
basins

R1278.1 Review proposed design TS


of oily water system to consider
and develop operating procedure
for management of oil collected on
surface of each collection basin
over time

Remarks

Action by:

Action resolution

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 108/125

HAZOP Record Sheet: Oily Water System

Company
Facility
HAZOP Date

TECHNIP
OK LNG Facility FEED Study
18-Sep-06

Section ID
General Section
Description:

Oily water system

HAZOP
Item No.

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

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

Plant
Deviation
Causes
Section
Drawing Number/Sheet Number 2252-056-PID-00-31-22/Rev A/12-09-06
/Rev.Number/Date 2252-056-PID-00-31-02/Rev A/12-09-06

Consequences

Safeguards

Recommendations

Remarks

Action by:

Action resolution

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 noncontaminated 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-512


Oily water flare lifting pumps 056-P-512A/B
Flare lifting basin 056-BA-513
Flare lifting pumps 056-P-513A/B

1288

Node 3

Overview
Type 3
(flare
area)
collection
basin

1289

Flow - High

1290

Flow - Low

1291

Flow - No

No new issues
1. Flare lifting pump trip during
rainy season

1. Potential for flooding of sunken


flare KO drum area

2. Low rainfall flow rates

1. Decreased flow of rainwater into


flare area collection basin and
lifting basin
2. 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

1. 056-LI/LAH/LAHH-0040 on flare
lifting basin
2. Autostart of standby flare lifting
pump by 056-PT-0041A/B

TS
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

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)

No new issues

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 109/125

HAZOP Record Sheet: Oily Water System

Company
Facility
HAZOP Date

TECHNIP
OK LNG Facility FEED Study
18-Sep-06

Section ID
General Section
Description:

Oily water system

HAZOP
Item No.
1292

Plant
Section

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

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
Deviation

Causes

Consequences

Safeguards

Recommendations

Flow - Reverse

No new issues

1293

Loss of
Containment

No new issues

1294

Pressure - High

No new issues

1295

Pressure - Low

1296

Vacuum

No new issues

1297

Partial Pressure

No new issues

1298

Temperature High

No new issues

1299

Temperature Low

No new issues

1300

Cryogenic (Sub Zero)

No new issues

1. Location of flare collection basin 1. Requirement to pump oily water


from flare collection basin to oily
at low surface elevation, 3-4 m
below normal process area grade water tank
elevation

Remarks

Action by:

Action resolution

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

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 110/125

HAZOP Record Sheet: Oily Water System

Company
Facility
HAZOP Date

TECHNIP
OK LNG Facility FEED Study
18-Sep-06

Section ID
General Section
Description:

Oily water system

HAZOP
Item No.
1301

Plant
Section

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

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
Deviation
Level - High

Causes

Consequences

Safeguards

Recommendations

Remarks

Action by:

Action resolution

1. Requirement for manual start of 1. Potential exposure of operator


pump out flare collection basin
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 areas
2. 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 gravity
2. 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
conditions
4. 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 start


2. Potential to flood flare area

TS
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.

1. Malfunction/incorrect setpoint
056-LI-0040

1. Loss of pump stop


2. Potential for loss of level and
pump damage

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

1302

Level - Low

1303

Level - No

No new issues

1304

Phase - More

No new issues

1305

Phase - Less

No new issues

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 111/125

HAZOP Record Sheet: Oily Water System

Company
Facility
HAZOP Date

TECHNIP
OK LNG Facility FEED Study
18-Sep-06

Section ID
General Section
Description:

Oily water system

HAZOP
Item No.
1306

Plant
Section

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

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
Deviation

Causes

Consequences

Safeguards

Recommendations

Change of State

No new issues

1307

Wrong
Concentration
(Part of)

No new issues

1308

Corrosive (As
well as)

No new issues

1309

Explosive

No new issues

1310

Wrong Material
(Other than)

No new issues

Remarks

Action by:

Action resolution

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 112/125

HAZOP Record Sheet: Oily Water System

Company
Facility
HAZOP Date

TECHNIP
OK LNG Facility FEED Study
18-Sep-06

Section ID
General Section
Description:

Oily water system

HAZOP
Item No.

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

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

Plant
Deviation
Causes
Section
Drawing Number/Sheet Number 2252-056-PID-00-31-02/Rev A/12-09-06
/Rev.Number/Date 2252-056-PID-00-31-03/Rev A/12-09-06
2252-056-PID-00-31-04/Rev A/12-09-06

Consequences

Safeguards

Recommendations

Remarks

Action by:

Action resolution

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.
Node Equipment Oily water tank 056-TK-120
Floating skimmer 056-Z-101
Oil pit 056-BA-121
Oily recovery pumps 056-P-121A/B
Oily water transfer pumps 056-P-150A/B
Oily water treatment package 056-U-101
Final control basin 056-BA-122
Sludge pit 056-BA-123
Final control pumps 056-P-122A/B
Sludge pumps 056-P-123A/B
1311

1312

Node 4

Oily water Overview


treatment

Flow - High

1. Transfer of oily water from


1. Gradual increase in level in oily
collection basins to oily water tank water tank
2. Potential to overfill oily water
tank

1. 056-LI/LAH-0004 controls
transfer of oily water to DAF oily
water treatment package
2. 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. 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

1. High transfer flow rate of oily


water to DAF treatment package
2. Potential for reduced residence
times in oily water treatment
package
3. Potential for off spec treated
water release to sea

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 113/125

HAZOP Record Sheet: Oily Water System

Company
Facility
HAZOP Date

TECHNIP
OK LNG Facility FEED Study
18-Sep-06

Section ID
General Section
Description:

Oily water system

HAZOP
Item No.
1313

Plant
Section

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

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
Deviation
Flow - Low

Causes

Consequences

Safeguards

Recommendations

Remarks

Action by:

Action resolution

1. Malfunction/incorrect setpoint
056-FIC-0001

1. Low transfer flow rate of oily


water to DAF treatment package
2. Potential to overfill oily water
tank
3. Potential to dead-head oily
water transfer pumps

1. 056-LAH-0004 and 056-LAHH0003 on oily water tank


2. 056-LI-LAL-0008 stops final
control pump
3. Pump running lights

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

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 pumps
2. 056-LI/LAL-0008 stops final
control pumps

R1313.2 Update P&ID to show on- TS


off control signal from 056-LI-0004
to control panel on oily water
treatment package to control
injection of oily water treatment
package chemicals

3. Trip of oily water transfer pump

1. Loss of transfer of oily water to


oily water treatment package
1. Loss of transfer of treated water
to sea

1. 056-PT-0005A/B autostart of
standby pump
1. 056-PT-0007A/B autostart of
standby pump

4 10

4. Trip of final control pumps

1314

Flow - No

No new issues

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

1316

Loss of
Containment

1. Pump seal failure on oily water


transfer pumps
2. Loss of oily water floating
skimmer and/or failure of internal
hose connection

1. Spray release of water to


1. Spare pump
atmosphere
2. Operator inspection of area
1. Potential for loss of oil skimming
inside oily water tank
2. Gradual increase in oil interface
level in tank

1. 056-PT-0007A/B autostart of
standby pump
2. Off-spec treated water recycle
to oily water storage tank enters in
top vapour space

TS
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)

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 114/125

HAZOP Record Sheet: Oily Water System

Company
Facility
HAZOP Date

TECHNIP
OK LNG Facility FEED Study
18-Sep-06

Section ID
General Section
Description:

Oily water system

HAZOP
Item No.
1317

Plant
Section

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

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
Deviation

Causes

Pressure - High 1. Malfunction of transfer pump


autostart

Consequences
1. Two pumps in operation
2. Increase in flow of oily water to
DAF treatment package

Safeguards

Recommendations

Remarks

Action by:

Action resolution

1. DCS pump running lights


2. Oily water treatment package
overdesign
3. 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 TS


PSV protection on sludge pump
discharge since this is a positive
displacement type pump

1. Loss of plant air and/or oily


water treatment package air
compressor

1. Reduced DAF performance with 1. 056-PI-0006 air drum pressure


potential for exceedance of
discharge composition (high
dissolved oil content)

R1318.1 Consider configuration of TS


low alarm on air pressure on oily
water treatment package
R1318.2 Undertake HAZOP of
vendor package during detailed
design

1318

Pressure - Low

1319

Vacuum

No new issues

1320

Partial Pressure

No new issues

1321

Temperature High

No new issues

1322

Temperature Low

No new issues

1323

Cryogenic (Sub Zero)

No new issues

1324

Level - High

1. Malfunction of 056-LI-0004 on
oily water tank

1. Loss of start signal to oily water 1. Independent 056-LI/LAHH-0003


on oily water tank
transfer pumps
2. Gradual increase in level in oily 2. 12" overflow on the tank
water tank

2. Malfunction of 056-LI-0008 on
final control basin

1. Periodic operator inspection of


1. Loss of start signal to treated
the area
water final control pumps
2. Potential flooding of final control
basin

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 115/125

HAZOP Record Sheet: Oily Water System

Company
Facility
HAZOP Date

TECHNIP
OK LNG Facility FEED Study
18-Sep-06

Section ID
General Section
Description:

Oily water system

HAZOP
Item No.

1325

Plant
Section

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

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
Deviation

Level - Low

1326

Level - No

1327

Phase - More

Consequences

Safeguards

3. Malfunction of 056-LI-0005 on
oil pit

Causes

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
basins
2. Periodic operator inspection of
area

1. Malfunction of 056-LI-0004 on
oily water tank

1. Loss of stop signal to oily water 1. Independent 056-LI/LALL-0003


on oily water tank stops transfer
transfer pumps
2. Gradual decrease in level in oily pump
water tank

2. Malfunction of 056-LI-0008 on
final control basin

1. Loss of stop signal to treated


water final control pumps
2. 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 pumps
2. Potential loss of level
3. 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


pumps
2. Potential loss of level in sludge
pit
3. Potential pump damage

1. Periodic operator inspection of


the area
2. Spare sludge pump
3. Pump DCS running light

Recommendations

R1325.1 Ensure suitable level


device is provided since dirty
service

Remarks

TS

Action by:

Action resolution

No new issues
1. Production of sludge in oily
water treatment package

2. Completion of sludge transfer


operation

1. Sludge from oily water treatment


package is skimmed and stored in
sludge pit for disposal offsite
1. Potential for prolonged periods
with no sludge pumping
2. Potential for pump blockage and
damage

1. Utility connections provided on


sludge pump suction and
discharge to enable flushing
following use

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 116/125

HAZOP Record Sheet: Oily Water System

Company
Facility
HAZOP Date

TECHNIP
OK LNG Facility FEED Study
18-Sep-06

Section ID
General Section
Description:

Oily water system

HAZOP
Item No.
1328

Plant
Section

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

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
Deviation

Causes

Consequences

Safeguards

Recommendations

Phase - Less

No new issues

1329

Change of State

No new issues

1330

Wrong
Concentration
(Part of)

1331

Corrosive (As
well as)

1332

Explosive

1333

Wrong Material
(Other than)

1. Malfunction in injection of oily


water treatment package
chemicals and/or poor package
performance

1. Potential contamination of
treated water disposal to sea

Remarks

Action by:

Action resolution

1. Summarised malfunction alarm


056-UUA-0001 on oily water
treatment package
2. Final control basin
3. Operator sample and inspection
of final control basin every shift
4. Possible to recycle off-spec
treated water from final control
basin back to oily water tank

No new issues

1. Formation of flammable
atmospheres on oil pit

1. Potential ignition via oil recovery 1. Hydrocarbon contamination is


pumps
heavy oil with very low vapour
pressure
2. Appropriate selection of oily
recovery pump
No new issues

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 117/125

HAZOP Record Sheet: Sewage WW Treatment

Company
Facility
HAZOP Date

Section ID
General Section
Description:

HAZOP
Item No.

TECHNIP
OK LNG Facility FEED Study
18-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Sewage waste water treatment


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.

Plant
Deviation
Causes
Section
Drawing Number/Sheet Number 2252-059-PID-00-31-01/Rev A/12-09-06
/Rev.Number/Date 2252-059-PID-00-31-02/Rev A/12-09-06
2252-059-PID-00-31-05/Rev A/12-09-06

Consequences

Safeguards

Recommendations

Remarks

Action by:

Action resolution

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-101


Sanitary water inlet facilities lifting pumps 059-P-101-A/B
Sanitary water LNG train 1 pit 059-BA-102
Sanitary water LNG train 1 lifting pumps 059-P-102A/B
Sanitary water LNG train 2 pit 059-BA-103
Sanitary water LNG train 2 lifting pumps 059-P-103A/B
Sanitary water LNG train 3 pit 059-BA-104
Sanitary water LNG train 3 lifting pumps 059-P-104A/B
Sanitary water LNG train 4 pit 059-BA-105
Sanitary water LNG train 4 lifting pumps 059-P-105A/B
Sanitary water utilities pit 059-BA-106
Sanitary water utilities lifting pumps 059-P-106A/B
Sanitary water collection basin 059-BA-107

1334

Node 1

Sanitary Overview
water
collection
pits

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

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 118/125

HAZOP Record Sheet: Sewage WW Treatment

Company
Facility
HAZOP Date

Section ID
General Section
Description:

HAZOP
Item No.
1335

Plant
Section

TECHNIP
OK LNG Facility FEED Study
18-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Sewage waste water treatment


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.
Deviation
Flow - High

Causes

Consequences

Safeguards

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/hr
3. 059-LT-0009/10 starts sanitary
water feeding pump for transfer of
waste to sanitary water
biotreatment package
4. High high level in sanitary water
pit starts and switches duty to
standby pump (assumption that
duty pump is not operating
effectively)

2. Pumping of sanitary water to


sanitary water collection basin

1. Increase in level in sanitary


water collection basin
2. 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

Recommendations

Remarks

Action by:

Action resolution

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

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 119/125

HAZOP Record Sheet: Sewage WW Treatment

Company
Facility
HAZOP Date

Section ID
General Section
Description:

HAZOP
Item No.

1336

Plant
Section

TECHNIP
OK LNG Facility FEED Study
18-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Sewage waste water treatment


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.
Deviation

Flow - Low

Causes

Consequences

Safeguards

3. Simultaneous pumping of
sanitary water to sanitary water
collection basin

1. Increase in level in sanitary


water collection basin
2. Potential to overflow collection
basin

1. 059-LT-0009/10 starts sanitary


water feeding pump for transfer of
waste to sanitary water
biotreatment package
2. 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 pump


2. Loss of stop signal to pump

1. DCS indication of standby pump


running
2. Independent LT in each sanitary
water pit will stop pump in event of
low low level

1. Low production of sanitary waste


on site (low demand periods within
the day)

2. Malfunction of lifting pump

Recommendations

Remarks

Action by:

Action resolution

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
1. Increase in level of sanitary
water in pit and potential to
overflow

1. 059-LT/LAHH autostart standby


sanitary water lifting pump
2. DCS indication of standby pump
running

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 120/125

HAZOP Record Sheet: Sewage WW Treatment

Company
Facility
HAZOP Date

Section ID
General Section
Description:

HAZOP
Item No.

Plant
Section

TECHNIP
OK LNG Facility FEED Study
18-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Sewage waste water treatment


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.
Deviation

Causes

Consequences

Safeguards

3. Malfunction of duty LT in
sanitary water pit

1. Loss of start signal to standby


pump
2. Increase in level in pit with
potential to overflow

1. DCS indication of duty pump


running
2. Independent LT in each sanitary
water pit would start standby pump
in event of high high level

1337

Flow - No

1338

Flow - Reverse

1. Pump trip and/or no pump


operating

1. Potential reverse flow from


collection basin to pit

1. Check valve on discharge from


individual sanitary water lifting
pump
2. Sanitary water header enters
vapour space on sanitary water
collection basin

1339

Loss of
Containment

1. Pump seal failure

1. Reduced pump performance

1. Autostart of standby pump in


event of high high liquid level in pit
2. 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

Recommendations

Remarks

Action by:

Action resolution

No new issues

1340

Pressure - High

No new issues

1341

Pressure - Low

No new issues

1342

Vacuum

1343

Partial Pressure 1. Collection of light hydrocarbon in 1. Potential for formation of


LNG lifting pits
flammable atmospheres

1344

Temperature High

No new issues

1345

Temperature Low

No new issues

No new issues
1. Hydrocarbon concentration in
process rundown from LNG trains
is very low with no potential for
formation of flammable
atmospheres

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 121/125

HAZOP Record Sheet: Sewage WW Treatment

Company
Facility
HAZOP Date

Section ID
General Section
Description:

HAZOP
Item No.
1346

Plant
Section

TECHNIP
OK LNG Facility FEED Study
18-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Sewage waste water treatment


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.
Deviation

Causes

Consequences

Safeguards

Recommendations

Cryogenic (Sub Zero)

No new issues

1347

Level - High

No new issues

1348

Level - Low

No new issues

1349

Level - No

No new issues

1350

Phase - More

1351

Phase - Less

No new issues

1352

Change of State

No new issues

1353

Wrong
Concentration
(Part of)

1. Inappropriate residence time of


sanitary water in pit

1. Potential formation of noxious


odours (SO2 and ammonia)

TS
1. Appropriate design and sizing of R1353.1 During detailed design,
pit (short residence time)
review sizing basis for sanitary
water pits (especially inlet facilities
pit), taking into account anticipated
manning levels for each area

1354

Corrosive (As
well as)

1. Formation of ammonia and/or


sulphuric acid corrosion
compounds

1. Potential corrosion of materials

1. Underground pipework is GRP


2. Sanitary waste pits are concrete
3. Short residence time in pit
minimises potential for formation of
corrosive compounds

1355

Explosive

No new issues

1356

Wrong Material
(Other than)

No new issues

1. Mixed phase sanitary water

1. Potential blockage and settling


of solid waste in pit

Remarks

Action by:

Action resolution

1. Small volume of sanitary water


pits ensures short
residence/settling time
2. Sanitary water lifting pumps also
cut solid sanitary waste

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 122/125

HAZOP Record Sheet: Sewage WW Treatment

Company
Facility
HAZOP Date

Section ID
General Section
Description:

HAZOP
Item No.

TECHNIP
OK LNG Facility FEED Study
18-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Sewage waste water treatment


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.

Plant
Deviation
Causes
Section
Drawing Number/Sheet Number 2252-059-PID-00-31-03/Rev A/12-09-06
/Rev.Number/Date 2252-059-PID-00-31-04/Rev A/12-09-06

Consequences

Safeguards

Recommendations

Remarks

Action by:

Action resolution

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
Node Equipment Sanitary water collection basin 059-BA-107
Sanitary water feeding pumps 059-P-107
Sanitary water treatment package 059-U-101
Sanitary water discharge basin 059-BA-108
Sanitary water discharge pumps 059-P-108A/B
Drying beds 059-BA-111A-E
Recovery water pit 059-BA-112
Recovery water pump 059-P-112
1357

Node 2

Sanitary Overview
water
treatment

1. Increased flow rate of sewage to 1. Extended type sanitary water


sanitary water treatment package treatment package (minimum
residence time 20 hrs)
2. Peak flow rate from two pumps
is transitory and short duration
3. Daily operator sampling of
effluent from sanitary water
treatment package and sanitary
water discharge basin

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)

1359

Flow - Low

1. Low production of sanitary water 1. Reduced transfer of sewage to


(off peak durations)
sanitary water treatment package

1. No significant impact on sanitary


water treatment package

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 123/125

HAZOP Record Sheet: Sewage WW Treatment

Company
Facility
HAZOP Date

Section ID
General Section
Description:

HAZOP
Item No.
1360

Plant
Section

TECHNIP
OK LNG Facility FEED Study
18-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Sewage waste water treatment


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.
Deviation
Flow - No

Causes
1. Maintenance periods with no
operator and/or process demand
on sanitary water system

Consequences

Safeguards

Recommendations

Action by:

Action resolution

1. Potential impact on sanitary


1. Possible to "feed" sanitary water
water treatment package due to no treatment package to maintain
flow for prolonged periods
biological system
2. 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 2. Loss of pump out of treated


basin
water offsite

1. Auto-start of standby pump on


low discharge pressure
1. Check valve on discharge of
each individual sanitary water
feeding pump, discharge pump and
recovery pump
2. Discharge of all pumps to
atmospheric vapour space

1361

Flow - Reverse

1. Pump trip and/or no flow


durations

1362

Loss of
Containment

1. 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. Low head pumps selected, have


lower design pressure than
pipework

1364

Pressure - Low

No new issues

1365

Vacuum

No new issues

1366

Partial Pressure

No new issues

1367

Temperature High

1368

Temperature Low

No new issues

1369

Cryogenic (Sub Zero)

No new issues

1. Variation in atmospheric
temperature

Remarks

1. Potential for reverse flow

1. Potential system overpressure

1. Potential impact on sanitary


water treatment package

1. No extremes of atmospheric
temperature at proposed location

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 124/125

HAZOP Record Sheet: Sewage WW Treatment

Company
Facility
HAZOP Date

Section ID
General Section
Description:

HAZOP
Item No.
1370

1371

Plant
Section

TECHNIP
OK LNG Facility FEED Study
18-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Sewage waste water treatment


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.
Deviation
Level - High

Level - Low

1372

Level - No

1373

Phase - More

Causes

Consequences

Safeguards

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 pump
2. 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 pump
2. DCS indication of standby pump
running

1. Malfunction in 059-LT-0009/10
on sanitary water collection basin

1. 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 pumps
2. 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 basin
3. Potential to damage pump

1. 059-LT/LALL stops sanitary


water discharge pumps
2. DCS indication of pump running

Recommendations

Remarks

Action by:

Action resolution

No new issues
1. Production of sludge in sanitary
water treatment package

2. Poor performance in sanitary


water treatment package

1. Transfer of sludge from sanitary


water treatment package to drying
beds for dewatering
2. Selected type of sanitary water
treatment package (extended
aeration) produces low volume of
sludge
3. Recovery water pit start/stop on
level control
1. High dissolved solids content in
treated water

1. Operator inspection and


sampling of sanitary water
treatment package and discharge
basin, once per day

Prepared by Arthur D Little for OK LNG

Version: Final
Sheet 125/125

HAZOP Record Sheet: Sewage WW Treatment

Company
Facility
HAZOP Date

Section ID
General Section
Description:

HAZOP
Item No.
1374

Plant
Section

TECHNIP
OK LNG Facility FEED Study
18-Sep-06

Team members:
Team Leader/Assistant

see attached list


Perry/Webster

Sewage waste water treatment


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.
Deviation

Causes

Consequences

Safeguards

Recommendations

Phase - Less

No new issues

1375

Change of State

No new issues

1376

Wrong
Concentration
(Part of)

Remarks

Action by:

Action resolution

1. Upset in hydrocarbon
concentration and/or composition
from LNG train

1. High concentration of benzene, 1. Extended aeration type sanitary


toluene and/or xylene components water treatment package residence
2. Potential poisoning of sanitary
duration is in excess of 20 hours
water treatment package

TS
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

2. Poor performance in sanitary


water treatment package

1. Potential exceedance of BOD,


COD and/or other discharge
parameters of treated water

R1376.2 Undertake HAZOP of


vendor sanitary water treatment
package during detailed design

1. Daily operator sampling of


treated water effluent
2. Summarised malfunction alarm
059-UUA-0001

1377

Corrosive (As
well as)

No new issues

1378

Explosive

No new issues

1379

Wrong Material
(Other than)

No new issues

TS

Prepared by Arthur D Little for OK LNG

Contents

1.

Executive Summary

2.

HAZOP Approach

3.

Appendices
I.

FEED HAZOP procedure

II.

Attendance

III.

Node List

IV.

HAZOP Recommendations

V.

HAZOP Worksheets

VI.

HAZOP Master P&IDs


TechnipItaly/21184/023rep

178