HAZOP SUMMARY

Sno Department No of Action

Points
1 Process 20
2 Process/Projects 2
3 Piping 0
4 Mechanical (Static) 1
5 Mechanical (Static)/ 2
Procurement
6 Mechanical (Rot) 4
7 Mechanical (Rot)/Projects 24
8 Mechanical (Rot)/Process 2
9 Instrumentation/Process/Ele 1
ctrical
10 Instrumentation 3
11 Instrumentation/Process 1
12 Projects 11
13 O&M 22
A TOTAL ACTION POINTS 93
B POINTS CLOSE AS OF 18- 49
JAN-11

C POINTS LEFT FOR 5

DISCUSSION
 HAZOP STUDY REPORT

Client SO2331 CS-140-PR-47-0001 0

Annexu
re II
Plant Project Document Number Rev.
The
recomm
endatio
ns of
HAZOP
study
SNois P&ID no Recommendations Responsibility Action Target Date Status Category Resolution Post Meeting Clarification SEI Response to Action By NOCL Comment_12-Mar-11 Discipline Response
listed Responsibility PMC/NOCL Comments
below: (Dept)
Process CLOSE PID Incorporated in IFC P&ID
CS-140-PR-15-001 Provide low alarm for PC-
1 SEI
343.

Mechanical (Static) CLOSE Clarification The filter has been designed for the
pump shut-off pressure. The over
CS-140-PR-15-001, pressure is applicable only for external
CS-140-PR-15-002, Design case for overpressure fire case.
2 Vendor/SEI
CS-140-ME-E- in filter is to be reviewed.
03800002

High temperature alarm to be Process CLOSE PID Incorporated in IFC P&ID

CS-140-PR-15-001 provided on TI-107 and TI-
3 SEI
343.
Instrumentation CLOSE DCS Graphics Will be shown in graphics.(Repeat signal NOCL Reply: For incorporating in DHU graphics it NOCL/ SEI(Process)
will be provided by NOCL) should be indicated in P&ID also NOCL to indicate source of
LCO,LCGO flow rate
CS-140-PR-15-001 signals with Tag nos. However,
4 indications to be duplicated PMC/SEI
dummy Tag Nos to be
in DHU graphics.
indicated in IFC-1 P&ID by SEI.

Instrumentation CLOSE DCS Graphics Will be shown in graphics.(Repeat signal NOCL Reply: For incorporating in DHU graphics it NOCL/ SEI(Process)
will be provided by NOCL) should be indicated in P&ID also NOCL to indicate source of
Feed stream ratio indication
CS-140-PR-15-001 signals with Tag nos. However,
5 with alarm to be repeated in PMC/SEI
dummy Tag Nos to be
DHU graphics.
indicated in IFC-1 P&ID by SEI.

Process 25-Jan-11 CLOSE PID Will be incorporated in P&ID No-0005 Incorporated in 90% Model Review P&ID Will be incorporated in IFC-1 SEI (Process)
Provide TDI (TI-129 and TC- P&ID.
124)on the first bed with high
6 CS-140-PR-15-005 PMC/SEI
alarm set at differential temp.
of 30 C.

Mechanical (Static)/ 25-Jan-11 CLOSE Clarification Mail sent to TEMA on 8-Dec-10. Refer our design calculations. Internal Bolts are
Procurement Awaiting TEMA confirmation. designed for 405° C for tag no140-EE-001A/B/C/D and
430° C for tag no 140-EE-002.
MOC of the internal flange, push rods and set screws
are as under:
Push Rods:
SA453 Gr 660 B (part No 604) Mean Coeff. Of Thermal
expansion@ 6.1 in/in per deg F
Set Screws:-
SA 453 Gr 660 B (Part No 506) Mean Coeff of Thermal
expansion@ 6.1 in/in per deg F
Internal Flange :-
SA965 F321 (part NO 211) Mean Coeff of Thermal
expansion@ 6.1 in/in per deg F
Ensure proper thermal material of construction for rods, bolts and flange has
CS-140-PR-15-002, expansion in Mechanical been selected in such a way that there is no differential
7 CS-140-PR-15-003, design is considered in case SEI coefficient of expansion between these components
CS-140-PR-15-004 of depressurization temp. of which lead to development of reverse thermal
405 C for all shells. expansion force.
Also note that when designing the equipment, bolts
and push rods have been designed to take load due to
thermal expansion of the cylinder.

CLOSE O&M Will be taken care in Operating Manual.

Operating manual/SOP
CS-140-PR-15-002 SEI/NOCL
8 should ensure periodical
checking of LG-506

Manual isolation valves Process CLOSE PID Incorporated in IFC P&ID

CS-140-PR-15-002
9 downstream of FCV- SEI
407A/B,to be LO.

Operating procedure should CLOSE O&M Will be taken care in Operating Manual.
CS-140-PR-15-002 SEI/NOCL
10 ensure periodical checking of
LG-506.
Process CLOSE PID Incorporated in IFC P&ID
Provision of local temp.
CS-140-PR-15-002,
gauge to be provided for SEI/NOCL
11 CS-140-PR-15-003, ascertaining the temperature
CS-140-PR-15-004
before taking the sample.

CLOSE O&M Will be taken care in Operating Manual.

CS-140-PR-15-002, Operating procedure should
SEI/NOCL
12 CS-140-PR-15-003, ensure temp. of sampling
CS-140-PR-15-004 fluid below 80 C.

Provide low pressure alarm Process CLOSE PID Incorporated in IFC P&ID
13 CS-140-PR-15-0007 at PC-358 at 140-V-006 gas SEI
outlet.
CLOSE O&M Will be taken care in Operating Manual.
Operating procedure should
CS-140-PR-15-0004, SEI/NOCL
14 ensure safe shutdown of the
CS-140-PR-15-0006
plant.

Instrumentation/ 19-Jan-11 CLOSE PID Trip alarms already provided in P&ID No Electrical will keep the provision of motor trip
Process/ Electrical CS-140-PR-15-0027, Rev-2. These will alarm signal to DCS based on the requirement to be
also be reflected in DCS graphics. given by Instrumentation team. These signals shall be
connected to DCS through IRP panel by
Instrumentation team.However, the cable between
CS-140-PR-15-0003, HV/LV Panel to IRP Panel( at Switchhouse) shall be
CS-140-PR-15-0005, done by Elecrical through e-mail dated 19-Jan-11 from
All pump motor trip alarms to
15 CS-140-PR-15-0006, SEI electrical.
be provided in DCS.
CS-140-PR-15-0007, SEI
CS-140-PR-15-0017

Projects 25-Jan-11 CLOSE O&M To be confirmed by NOCL. Projects to NOCL Reply: Maintenance philosphy not yet Mechanical(Static)
request NOCL for same. finalised.Process inspector will inspect the finfan area
Noted. This will be
Maintenance schedule for for any abnprmal noise/vibration on a daily shift basis.
incorporated in Vendor
vibration checking is to be
16 CS-140-PR-15-0006 strictly followed on regular NOCL Manual for Air Fin Coolers
and Operating manual of
basis.
DHU unit

Process CLOSE PID Incorporated in IFC P&ID

Manual isolation valves
CS-140-PR-15-0008 downstream of FCV-
17 SEI
455A/B,to be LO.

Process 19-Jan-11 CLOSE PID Gas breakthrough while LCV-542A NOCL Reply: i) From LCV-542A to V004, Is the line is Additional supports will be Process/Piping
failure case is checked and PSV-310 designed for two phase flow? If not please incorporate. provided to take care of two-
A/B sized for the same. Ii) Safeguarding Memorandum to be updated to phase flow. Safeguarding
address this gas breakthrough for PSV-310A/B. memorandum will be updated.
CS-140-PR-15-0008, Confirm gas break through
18 CS-140-PR-15-0021 LCV-542A case is considered SEI
for PSV-310A/B

Process/ 20-Jan-11 CLOSE PID Low alarm with switch is provided (90% Low Level Alarm provided with magnetic LG in 90% Resolution was discussed Process Please provide clarification for separate shut Separate shut down valve is not
Instrumentation model review P&ID issue) on magnetic Model Review P&ID. again & agreed & accordingly down valve as recommended by PMC. required as operator has enough
LG-543 to enable operator action. NOCL Reply: Resolution by SEI not acceptable. Since recorded in the remarks time for action to close the manual
this recommendation is discussed in length and agreed column during HAZOP. Kindly isolation valve upstream of control
b/w Axens, SEI , PMC & NOCL. The recommendation also refer acceptance to CD- valve in case of low level in the
indication in the action to be implemented. SEI-0046 from PMC & NOCL. drum. The estimated hold up time
The alternate resolution proposed by SEI to be (Also refer mail to PMC dated between LLL in drum to boot top
reviewed by PMC. 8-Mar-11). is about 32 minutes which is quite
PMC Reply: Provide separate shutdown valve with an adequate for operator action.
independent level transmitter as recommended. If hydrocarbon from Stripper
Provide additional control Reflux Drum (140-V-008) is
scheme on V-008 boot with reaching to Sour Water Flash
LT (Low low level signal), Drum (140-V-004), it will increase
CS-140-PR-15-0021 SEI/ PMC/ NOCL/
19 new shutdown valve on Axens the vapour pressure resulting in
recycle water line from V-008 pop-up of 40-PSV-310A/B (on
to avoid gas break through. 140-V-004).
Also, we are proposing for force
closing of 140-LCV-542A (with
additional solenoid valve) on low
level of boot using magnetic LG-
543.

Projects 25-Jan-11 CLOSE Clarification To be confirmed by NOCL. Projects to PMC Reply: Resolution was discussed Process Please provide clarification for separate shut Separate shut down valve is not
request NOCL for same. Provide separate shut down valve on the commmon again & agreed & accordingly down valve as recommended by PMC. required as operator has enough
outlet line of V-008. This will resolve action items 19 & recorded in the remarks time for action to close the manual
20. column during HAZOP(Report isolation valve upstream of control
feed Surge drum (FF0) in downstream sour water page to be attached). Kindly valve in case of low level in the
stripper unit 1 (unit 550) has hydrocarbon skimming also refer acceptance to CD- drum. The estimated hold up time
facilities for removal of any accidental hydrocabron SEI-0046 from PMC & NOCL. between LLL in drum to boot top
contamination. (Also refer mail to PMC dated is about 32 minutes which is quite
8-Mar-11) adequate for operator action.
If hydrocarbon from Stripper
CS-140-PR-15-0003, Reflux Drum (140-V-008) is
CS-140-PR-15-0006, reaching to Sour Water Flash
CS-140-PR-15-0008, Review the impact of vapor Drum (140-V-004), it will increase
20 CS-140-PR-15-0021, break through/liquid HC in NOCL the vapour pressure resulting in
CS-140-PR-15-0022, unit 550. pop-up of 40-PSV-310A/B (on
CS-140-PR-15-0030, 140-V-004).
CS-140-PR-15-0037 Also, we are proposing for force
closing of 140-LCV-542A (with
additional solenoid valve) on low
level of boot using magnetic LG-
543.

Process CLOSE PID Incorporated in IFC P&ID Axen's answer is very clear as MP
BFW will be used in case of
stripped sour water fails. The unit
can be operated for short duration
(20 minutes), if MP BFW is also
not available. Further, the impact
of MP BFW on operation of wash
water pump 140-P-002 A/B is
checked and found no problem as
the system is already designed to
take care of high temperature.
This has been verified by vendor
CS-140-PR-15-0022 Provide low alarm for LI-560A SEI/NOCL as below,
21
at V-009 boot "Regarding the pump operation on
BFW at 128℃, it will not be a
problem since the pump will be
equipped with seal cooler".

Operating procedure should CLOSE O&M Will be taken care in Operating Manual.
CS-140-PR-15-0008 ensure periodical checking of SEI/NOCL
22
PI-
369A/B at pump suction..
Process 21-Jan-11 CLOSE PID Incorporated in IFC P&ID.
Provide high temp. Alarm at Set point is provided in Alarm Set point
CS-140-PR-15-0008 list using 5 Deg C above the maximum
23 TI-210. Axens/SEI
operating temperature.

Process 21-Jan-11 CLOSE O&M MP Boiler Feed Water is supplied as Process TQ raised to Axens does not take care of the Axen's answer is very clear as MP
back-up to the Stripped Sour water. If HAZOP recommendation. BFW will be used in case of
there is not sufficient stripped sour water Query shall be whether in absence of stripped stripped sour water fails. The unit
from unit 550 for make-up then MP BFW sour water for washing whether MP BFW at 128 can be operated for short duration
is automatically supplied. However, if deg C can be used for washing? (20 minutes), if MP BFW is also
there is not enough MP BFW then unit not available. Further, the impact
can operate for a short duration and of MP BFW on operation of wash
then must be shutdown. water pump 140-P-002 A/B is
CS-140-PR-15-0003, As per Operating Instructions section checked and found no problem as
Operating procedure to
CS-140-PR-15-0006, 10.7.5.3, Wash Water Pump failure, in the system is already designed to
ensure Increase of injection
CS-140-PR-15-0008, this situation unit can be kept running for take care of high temperature.
water flow rate and/or plant
24 CS-140-PR-15-0021, Axens/SEI 20 minutes without wash water. After 20 This has been verified by vendor
capacity to be decreased. To
CS-140-PR-15-0022, minutes, the normal shutdown as below,
be further checked for the
CS-140-PR-15-0030, feasibility of this operation. procedure is to be followed. "Regarding the pump operation on
CS-140-PR-15-0037 BFW at 128℃, it will not be a
problem since the pump will be
equipped with seal cooler".

Operating procedure should CLOSE O&M Will be taken care in Operating Manual.
25 CS-140-PR-15-0006 ensure periodical checking of SEI/NOCL
FI-
458/459/460/461
Mechanical(Rot) 20-Jan-11 CLOSE Clarification Mechanical to check with Vendor. SEI Mechanical(Rot) Mechanical to check with Vendor. Sundyne confirmed that the pump
operation on BFW at 128 ℃, will
not be a problem since the pump
Check working of P- will be equipped with seal cooler
26 CS-140-PR-15-0008 002A/B,when operating only SEI
on BFW(128 C)

CLOSE O&M Will be taken care in Operating Manual.

Operating procedure should
CS-140-PR-15-0006, ensure periodical checking of SEI/NOCL
27 CS-140-PR-15-0007
LG-515

Process CLOSE PID Incorporated in IFC P&ID

Ensure LG-515 facing with
28 CS-140-PR-15-0006 SEI
LCV-514 bypass valve

Process 21-Jan-11 CLOSE PID Low flow alarm will be provided for FC- Set points to be provided to Yukogawa.
416. The set point would be 10% below
CS-140-PR-15-0007 Consider FC-416 low alarm the minimum operating flow rate.
29 SEI / AXENS
is set below turndown flow.

Process 21-Jan-11 CLOSE PID As per Axens, the direct control of the Process In response to the TQ raised by Process (CS - As clarified by Axens, the scheme
reactor heater inlet temperature is not 140- PR- 01- 021) dated 1-Feb-11 , Axens has as presented by them is in line
required. CB&I and NOCL requested also written with CB&I/NOCL as per Basic
during the Basic Engineering that this " ............Axens does not object to changing Engineering discussions. SEI did
control be changed to instead control the back to the original control scheme where not feel any requirement to
feed/effluent exchanger hot-side outlet the heater inlet temperature is controlled change the scheme, if the same is
Consider installation of temperature. Axens agreed to the directly with the liquid feed bypass around acceptable to licensor. In case
limiting temp. controller (TI- change as the heater inlet temperature the feed/effluent exchangers. However, this PMC still feels to change the
30 CS-140-PR-15-0008 SEI / AXENS is in effect controlled indirectly. change must be done by SEI." scheme, please provide the same
120) in heater inlet.
Furthermore, the overheating of the SEI need to confirm from PMC whether the for SEI review and final
reactor feed is mitigated by the fact that control scheme to be changed as proposed in confirmation from Axens.
the Heater is also equipped with heater HAZOP or not.
outlet temperature alarms and
shutdown.

CLOSE O&M Will be taken care in Operating Manual.

SOP to address lining of
quench gas in the bottom
CS-140-PR-15-0007,
bed which will help in SEI/NOCL
31 CS-140-PR-15-0017,
reducing the reactor outlet
CS-140-PR-15-0018 temp. minimizing the
disturbance.

CLOSE Clarification Reactor Effluent temperature is 369 PMC Reply: Whether SEI considered inlet piping of Process To be checked SEI confirms that inlet line (P025)
Deg. C. In case of malfunction of TCV- EE-001A/B/C/D and EA-001 for this temperature & to 140-EE-001C/D (tube side) is
191A, 140-EE-001A/B/C/D will see this thermal expansion. designed for the temperature of
higher temperature. As per datasheet of 430 deg C.
140-EE-001A/B/C/D, shell side inlet Sufficient cooling effect is taking
temperature is considered as 371 Deg. place with 140-EE-001A/B/C/D
C. That means, this increased shell side with Gas Oil feed from
Check the impact on the inlet temperature is already considered for 140-P-001A/B.
piping and equipments due the design of EE-001A/B/C/D. Inlet line (P028) to 140-EE-001A/B
32 CS-140-PR-15-0003, to increased inlet temp. to SEI (tube side) is designed for 375 deg
CS-140-PR-15-0006 C and inlet line (P030) to 140-EA-
EE-001A/B/C/D and reactor
effluent air cooler EA-001 001 is designed for 205 deg C
considering the availability of gas
oil feed in shell side of 140-EE-
001A/B/C/D.

CLOSE Clarification If XZV-703 closes then the feed to the Process In response to the TQ raised by Process (CS - Axens reply on Process TQ dated
Stripper is also lost. Therefore, the 140- PR- 01- 021) dated 1-Feb-11 , Axens has 1-Feb-11: " If XZV-703 closes then
stripper bottoms which is on level control also written the feed to the Stripper is also lost.
will also stop. Of course, the stripper "..............Axens does not consider this case Therefore, the stripper bottoms
bottoms will not stop immediately but it for the design temperatures of all the which is on level control will also
also not run continuously. Axens does feed/bottoms shells nor the downstream stop. Of course, the stripper
not considers this case for the design product air cooler. However, Axens does not bottoms will not stop immediately
temperatures of all the feed/bottoms object to the increase of the design but it also when not run
shells nor the downstream product air temperatures for these exchnagers." continuously. Axens does not
cooler. SEI needs to confirm from PMC whether design consider this case for the design
temperature to be increased or not based on temperatures of all the
Check the impact on the inlet HAZOP recommendation. feed/bottoms shells nor the
piping and equipments due downstream product air cooler.
CS-140-PR-15-0018, However, Axens does not object to
33 to increased inlet temp. to SEI
CS-140-PR-15-0019 the increase of the design
EE-006A/B/C/D and gas oil
air cooler EA-003. temperatures for these
exchnagers."
SEI Reply: As responded by
AXENS, change in design
temperature is not mandatory.
Accordingly, no further action is
envisaged.

Process CLOSE PID Incorporated in IFC P&ID

Provide DCS PI with high
34 CS-140-PR-15-0018 alarm upstream of EE- SEI
006A/B/C/D.

Process CLOSE PID Incorporated in IFC P&ID

CS-140-PR-15-0022 Provide high alarm at
35 SEI
analyzer AI-003.

Process CLOSE PID Incorporated in IFC P&ID

CS-140-PR-15-0017 Provide high temp. alarm TI-
36 SEI
192.

Process 21-Jan-11 CLOSE PID Process to raise TQ to Axens/PMC for TQ raised by Process on 1-Feb-11 Process To be checked. Since, Axens doesn't have any
clarification. objection on this scheme (refer TQ
Consider converting TI-192 CS-140-PR-01-021 to Axens dated
CS-140-PR-15-0017 1-Feb-11), the scheme will be
37 to TC and put reflux on Axens/PMC/SEI
TC/FC cascade. incorporated in IFC-1 P&IDs.

Process 25-Jan-11 CLOSE Clarification 140-FCV-416 gas breakthrough case is SEI Process To be checked. Line upstream of TCV-191A/B and
already considered for 140-PSV-319A/B upto the stripper column is already
sizing. sized for Two Phase Flow.
And gas breakthrough case is
Check the system integrity
CS-140-PR-15-0017 already considered for 140-PSV-
38 upstream of TCV-191A/B SEI
319A/B sizing.
during gas break through.

CLOSE Clarification Reactor Effluent temperature is 369 NOCL Reply: Whether SEI considered inlet piping for Process To be checked. SEI confirms that inlet line (P025)
Deg. C. In case of malfunction of TCV- EE-001A/B/C/D & EA-001 for this temperature & to 140-EE-001C/D (tube side) is
191A, 140-EE-001A/B/C/D will see this thermal expansion. designed for the temperature of
higher temperature. As per datasheet of 430 deg C.
140-EE-001A/B/C/D, shell side inlet Sufficient cooling effect is taking
temperature is considered as 371 Deg. place with 140-EE-001A/B/C/D
C. That means, this increased shell side with Gas Oil feed from
Check the impact on the inlet temperature is already considered for 140-P-001A/B.
piping and equipments due the design of EE-001A/B/C/D. Inlet line (P028) to 140-EE-001A/B
CS-140-PR-15-0017
39 to increased inlet temp. to SEI (tube side) is designed for 375 deg
EE-001A/B/C/D and reactor C and inlet line (P030) to 140-EA-
effluent air cooler EA-001 001 is designed for 205 deg C
considering the availability of gas
oil feed in shell side of 140-EE-
001A/B/C/D.

CLOSE Clarification If XZV-703 closes then the feed to the Process In response to the TQ raised by Process Axens Axens reply on Process TQ dated
Stripper is also lost. Therefore, the has also written 1-Feb-11: "If XZV-703 closes then
stripper bottoms which is on level control "Axens does not consider this case for the the feed to the Stripper is also lost.
will also stop. Of course, the stripper design temperatures of all the feed/bottoms Therefore, the stripper bottoms
bottoms will not stop immediately but it shells nor the downstream product air cooler. which is on level control will also
also not run continuously. Axens does However, Axens does not object to the stop. Of course, the stripper
not considers this case for the design increase of the design temperatures for these bottoms will not stop immediately
temperatures of all the feed/bottoms exchnagers." but it also when not run
shells nor the downstream product air SEI needs to confirm from PMC whether design continuously. Axens does not
cooler. temperature to be increased or not based on consider this case for the design
HAZOP recommendation. temperatures of all the
Check the impact on the inlet
piping and equipments due feed/bottoms shells nor the
CS-140-PR-15-0017 downstream product air cooler.
40 to increased inlet temp. to SEI
However, Axens does not object to
EE-006A/B/C/D and gas oil
air cooler EA-003. the increase of the design
temperatures for these
exchnagers."
SEI Reply: As responded by
AXENS, change in design
temperature is not mandatory.
Accordingly, no further action is
envisaged.

Process 28-Jan-11 CLOSE Clarification Shell & tube side design pressure of
140-EE-006A/B/C/D is 15 barg (i.e.
designed for 10/13 rule). As per API
Check if downstream product 521/ISO 23251, 2007 Clause no. 5.19.2,
CS-140-PR-15-0018
41 tank can be pressurized due SEI pressure relief for tube rupture case is
to tube rupture. not required. So, downstream product
tank can not be pressurized.

Process 28-Jan-11 CLOSE Clarification Shell & tube side design pressure of
140-EE-006A/B/C/D is 15 barg (i.e.
designed for 10/13 rule). As per API
521/ISO 23251, 2007 Clause no. 5.19.2,
CS-140-PR-15-0018, Consider increase in pressure relief for tube rupture case is
42 CS-140-PR-15-0022 operating pressure of SEI not required. Therefore, downstream
product. product tank can not be pressurized. No
change in operating pressure of product.

Process 28-Jan-11 CLOSE Clarification Shell side design pressure of 140-EE-

002 is 74.5 barg and tube side design
pressure of 140-EE-002 is 96.5 barg. As
Check the overpressurization it is designed for 10/13 rule, referring to
CS-140-PR-15-0017
43 of system and confirm that SEI API 521/ISO 23251, 2007 Clause no.
PSVs are sized for this case. 5.19.2, pressure relief for tube rupture
case is not required.

CLOSE O&M Will be taken care in Operating Manual.

CS-140-PR-15-0007, Operating procedure to

CS-140-PR-15-0009, include operation of HS-822 SEI/NOCL
44 CS-140-PR-15-0010, to select FCV-423 to purge
CS-140-PR-15-0012 H2S to flare header

Process CLOSE PID Incorporated in IFC P&ID

low low suction pressure
compressor trip PZ-378 is not
45 CS-140-PR-15-0011 SEI
required as per process
reason and to be deleted.

Page 2 of 6
 HAZOP STUDY REPORT

Client SO2331 CS-140-PR-47-0001 0

Annexu
re II
Plant Project Document Number Rev.
The
recomm
endatio
ns of
HAZOP
study
SNois P&ID no Recommendations Responsibility Action Target Date Status Category Resolution Post Meeting Clarification SEI Response to Action By NOCL Comment_12-Mar-11 Discipline Response
listed Responsibility PMC/NOCL Comments
below: (Dept)
CLOSE O&M Will be taken care in Operating Manual.
Operating instruction to
include feed cut-off if system
46 CS-140-PR-15-0007 AXENS
pressure is below 80% of the
normal pressure.

Mechnical(Rot)/BHEL 25-Jan-11 CLOSE PID BHEL confirmed low low suction trip is BHEL Mechanical(Rot) Set points to be provided by SEI (80% of Normal BHEL confirmed the set-point to
required as per MOM dated 5-Jan-11. operating pressure) BHEL to confirm be 80% of suction pressure ie;
Set points to be provided by BHEL. acceptance.. 78.2*0.8=62.8 barg.
BHEL to confirm if low low
suction pressure trip is
47 CS-140-PR-15-0007 BHEL
required for machine
protection.

Ensure refinery fuel gas Projects 25-Jan-11 CLOSE Clarification To be confirmed by NOCL. Projects to PMC Reply: Fuel gas system has been designed for
composition has considered request NOCL for same. hydrogen rich purge gas from DHU
48 CS-140-PR-15-0007 NOCL
addition of hydrogen from
this unit.
Projects 25-Jan-11 CLOSE PID Indication signal is updated in IFC P&ID. Requested from NOCL/PMC on 01-Feb-11
Flow indication of hydrogen PMC to specify it in fuel gas unit in
49 CS-140-PR-15-0012 to fuel gas unit is to be NOCL/PMC OSBL. Projects to request PMC/NOCL
repeated in fuel gas unit. for same.

Move high alarm from PC- Process CLOSE PID Incorporated in IFC P&ID
50 CS-140-PR-15-0012 SEI
394 to PI-999.
Provide high alarm on PDI- Process CLOSE PID Incorporated in IFC P&ID
51 CS-140-PR-15-0011 SEI
688.
Mechanical (Rot)/ 20-Jan-11 OPEN Clarification BHEL confirmed that within 2 -3 seconds NOCL Reply: What is the guarantee 500 rpm will come Mechanical(Rot) BHEL reconfimred that within 2 -3 Email from
Projects speed will come down to 11000 rpm and with in 2-3 min closure of suction discharge XV's based seconds speed will come down to BHEL dated
further down to 500 rpm within 2-3 min . on rpm may be considered. 11000 rpm and further down to 2-Mar-11 &
Accordingly C&E will be updated for 500 rpm within 2-3 min . 14-Mar-11
closing the suction discharge XVs with a PMC reply: Timer doesnot take care of the concerns Accordingly C&E will be updated
time delay of 3 min. High high level raised by BHEL . Closing of MOVs to be based on the for closing the suction discharge
setting for recycle compressor KOD to speed of the machine. In addition this item must be XVs with a time delay of 3 min.
be lowered by 150 mm based on agreed with BHEL in writing as it impacts the safe High high level setting for recycle
BHEL recommends the discussion with BHEL/NOCL meeting operation of the compressor. We await BHEL compressor KOD to be lowered by
closing of MOVs with a time BHEL/ PMC/ SEI/ dated 5-Jan-11. BHEL to reconfirm. response. 150 mm.
52 CS-140-PR-15-0011 Also BHEL confirmed that
delay while rpm is reduced NOCL/ Axens
to 500. Machine RPM shall be the basis of
valve closure.

Mechanical (Rot)/ OPEN Clarification BHEL confirmed that small amount of NOCL Reply: Will BHEL /SEAL vendor will given Mechanical(Rot) BHEL
Projects liquid carry over to compressor is not a guarantee?
concern during the period of 2-3 PMC Reply: Do not understand the logic of 2-3
seconds. BHEL to reconfirm. seconds. SEI to provide clear reasoning in the
response. This item must be agreed with BHEL in
System to be reviewed for writing as it impacts the safe operation of the
required protection, when compressor. We await BHEL response.
53 CS-140-PR-15-0011 potential liquid carryover BHEL/ PMC/ SEI/
tocompressor as there is a NOCL/ Axens
time delay in closer of suction
MOV.

Mechanical (Static) 24-Jan-11 OPEN Clarification Mechanical to revert back. Heater tubes are made of SS347H material. As per API Mechanical(Static) To check whether N2 used for heater dry out would be
530, the limiting metal temperature for this metallurgy suitably cooled that the compressor will not trip
is 815 C. Based on Petron's experience, no cooling is because of high suction temp trip.
required during field dryout as the flue gas temperature
at the bridge wall is limited to 550 C. Though, the tube
metal temp will be higher than the flue gas temperature
during dryout, but the same is not expected to go
beyond say 650 C. Hence, it is important to monitor the
TMT with Tube skin thermocouples as well as IR
thermography /pyrometer. As long as the TMT is
Check the feasibility of adequately lower (say 750 C max) than the limiting
Nitrogen startup operation for metal temp, there is no need to introduce any cooling
CS-140-PR-15-0007, fluid through the tubes. However, if the TMT is
refractory dryout feed heater
CS-140-PR-15-0009, exceeding this limit then the cooling medium (e.g.
54 resulting in Possible high SEI
CS-140-PR-15-0010, nitrogen) can be introduced to keep the tubes cool.
suction temp. leading to high
CS-140-PR-15-0012 Additionally, the entire dryout operation shall be done
discharge temp. (higher than
current design). under supervision of an experienced field operator to
ensure the hot spots are not developed.The current
dryout procedure will be revised by Petron to include
field dryout and heating/cooling curves.
NOCL Reply: SEI to submit the procedure. Nitrogen
cooling medium used
or not. If so system capability to be checked by SEI.

Operating procedure to
monitor LG-522 for HC carry
SEI/NOCL
55 CS-140-PR-15-0010 over. When HC level builds
up it should be drained to Mechanical(Rot) CLOSE
OPEN O&M
Clarification Will beconfirmed
BHEL taken care in Operating
that the machineManual.
set NOCL Reply: How to change the set points in Temperature trip point for the Mechanical(Rot) N2 operation set point to be provided by BHEL. Selector switch provided in DCS
CBD by using Skim line. points are not to be changed whereas nitrogen / normal operation? Not addressed anywhere machine while running in N2 Logic to be developed by SEI for N2 & normal by SEI for changing modes of
the process trip set points related to both by SEI in P&ID, C&E, SISFS etc. until implemented , service will be the same as for operation. operation.
modes of operation shall be provided not closed. normal operation. BHEL to provide N2 operation set
separately by BHEL as minuted in points by 18.Apr.11.EL
meeting dated 5-Jan-11. PMC Reply: What is the difference between process
trip and machine trip.The trips are merant for machine
safeguarding only. If separate set points are required,
Confirm that the max.
then separate logics need to be developed. This item
allowable trip temp. (while
must be agreed with BHEL in writing as it impacts the
running in nitrogen service) &
safe operation of the compressor. we await BHEL
all trip set points for machine
CS-140-PR-15-0011, response.
56 safeguards for startup BHEL
CS-140-PR-15-0012
nitrogen case are not
different from the normal
operating case.

Instrumentation OPEN Clarification Please refer Point 56. Mechanical(Rot) N2 operation set point to be provided by BHEL. Selector switch provided in DCS
If set points are different Logic to be developed by SEI for N2 & normal by SEI for changing modes of
CS-140-PR-15-0011, separate modes of operation operation. operation.
57 BHEL BHEL to provide N2 operation set
CS-140-PR-15-0012 to be programmed in DCS
and in safeguarding system. points by 18.Apr.11.EL

Operating procedure to CLOSE O&M Will be taken care in Operating Manual.

include operation of HS-822 SEI/NOCL
58 CS-140-PR-15-0012
to select FCV-423 to purge
H2S to flare header.
Process CLOSE PID Incorporated in IFC P&ID

CS-140-PR-15-0003,
Considering full flow through
CS-140-PR-15-0005,
59 FCV-427, verify low-low flow SEI
CS-140-PR-15-0006,
alarm on FZ-428.
CS-140-PR-15-0011

Process CLOSE PID Incorporated in IFC P&ID

For low flow alarm FC-424

and low low trip FZ-443,trip
values are presently given as
per process point of view,
CS-140-PR-15-0009,
which needs to be verified
60 CS-140-PR-15-0010, SEI
based on pump vendor min
CS-140-PR-15-0016
flow requirement. So UZ-720
should also activate UZ-710
to trip pump (P-003A/B)-logic
to be implemented.

CLOSE O&M Will be taken care in Operating Manual.

Operating procedure should
ensure routing of off gas to
61 CS-140-PR-15-0009 flare header when there is SEI/NOCL
disturbance in lean amine
supply to C-003

Process CLOSE PID Incorporated in IFC P&ID

Provide high alarm at AI-
62 CS-140-PR-15-0016 SEI
002.

Process/Projects CLOSE Clarification PMC to confirm the suitability. (Expected PMC Reply:
H2S content is 680 Kg/Hr as per 1)Off gas from DHU is only a small part of the feed to
Process Data Book clause 3.4 (Heat & unit 350 where the feed is washed with Amine. Impact
Material Balance-C450 1400 NOCL will be minimal.
WMB SOR Rev-0, Stream No 15 & 23) if 2)When connected to fuel gas , this will result in
no H2S removal is there from absorber. increased H2S concentratin. However this flows form
only a small part of total fuel gas system, the impact
will be minimal.
3) This upset will be temporary as the DHU cannot
Check unit 350 design for operate without amine.
63 CS-140-PR-15-0016 possible increase of H2S in NOCL/PMC
feed gas from DHU.

Process CLOSE PID Incorporated in IFC P&ID

UZ-720 should activate UZ-
64 CS-140-PR-15-0009 710 to trip pump (P-003A/B) SEI

Process CLOSE PID Incorporated in IFC P&ID

Provide low alarm at TI-170.
65 CS-140-PR-15-0009 SEI

25-Jan-11 CLOSE Clarification PMC/NOCL to confirm. Projects to PMC Reply: Minimum ambient temperature os 18 deg
request PMC/NOCL for same. C. If the temperature of the amine drops due to climatic
conditions, the operator will be alarme by Low Alarm on
TI-170 (recommendation 65) and the set point of lean
amine temperature controller within the ARU will be
increased by the ARU operator to compensate. No
need for insulation.
Ensure the provision of Hot
insulation on the lean amine
66 CS-140-PR-15-0009 PMC/NOCL Projects
line coming from ARU
(Outside DHU B/L).

Process CLOSE PID Incorporated in IFC P&ID

Provide High alarm on TI-170
67 CS-140-PR-15-0009 at lean amine B.L SEI

CLOSE O&M Will be taken care in Operating Manual.

SOP to address regular
SEI/NOCL
68 CS-140-PR-15-0009 sampling of recycle gas for
CO/CO2.

Process 25-Jan-11 CLOSE PID To be incorporate in P&ID. Incorporated in 90% Model Review P&ID Recommendation was Process The point was discussed and
concluded unanimously by all agreed by all parties present as
present. PMC to recheck. Also recommendation. SEI reiterates
refer DDR CD-SEI-0046 on the that HAZOP report is reflecting
same subject. discussions correctly & completely.
Also please refer Design
Deviation Request CD-SEI-0033
for 140-C-001 for using magnetic
LG-522A/B (Magnetic type)
CS-140-PR-15-0010, type Level gauge & CD-SEI-0046
69 are to be provided with high SEI issued for the similar case which
CS-140-PR-15-0016
high alarm with switch. has been already approved by
NOCL/PMC. PMC to advise if a
specific DDR is to be issued in this
case.

Process/Projects 25-Jan-11 CLOSE Clarification PSV set pressure to be provided by PMC Reply: Noted Process/Instrumentati Process to provide relief case data.
PMC/NOCL. Process to provide Gas 1. Set pressure of the PSV on ARU Feed Drum is 6 on
Ensure this gas breakthrough break through flow rate. PSV adequacy barg.
case has been considered in to be confirmed by PMC/NOCL. 2. SEI to provide the relief case data to UMS based on
70 CS-140-PR-15-0009 design of safety valve in ARU PMC/NOCL the selected control valve.
(Receiving flash drum
vessel).

Process 25-Jan-11 CLOSE PID To be incorporate in P&ID. Incorporated in 90% Model Review P&ID Recommendation was Process The point was discussed and
concluded unanimously by all agreed by all parties present as
present. PMC to recheck. Also recommendation. SEI reiterates
refer DDR CD-SEI-0046 on the that HAZOP report is reflecting
same subject. discussions correctly & completely.
Also please refer Design
Deviation Request CD-SEI-0044
CS-140-PR-15-0021, LG-552 to be converted to for 140-V-018 for using magnetic
71 CS-140-PR-15-0016, Mag. Type with provision of SEI type Level gauge & CD-SEI-0046
CS-140-PR-15-0006 high level alarm with switch. issued for the similar case which
has been already approved by
NOCL/PMC. PMC to advise if a
specific DDR is to be issued in this
case.

CLOSE O&M Will be taken care in Operating Manual.

Periodical checking of SEI/NOCL
72 CS-140-PR-15-0016
interface in LG-533A/B/C/D.

Process CLOSE PID Incorporated in IFC P&ID

Keep the spectacle blind
CS-140-PR-15-0017, located in startup
CS-140-PR-15-0018, recirculation line in open
73 SEI
CS-140-PR-15-0019, position to maintain unit
CS-140-PR-15-0022 under circulation during upset
without loosing much time.

Process CLOSE PID Incorporated in IFC P&ID

FC-436 should be force
74 CS-140-PR-15-0017 closed when UZ-717 is SEI
activated.
Provide high alarm for FC- Process CLOSE PID Incorporated in IFC P&ID
CS-140-PR-15-0022
75 442. SEI

CS-140-PR-15-0017 Provide independent DCS Process CLOSE PID Incorporated in IFC P&ID
76 SEI
low low alarm from LZ-537
Mechanical (Static)/ 25-Jan-11 CLOSE Clarification This point has been specified in NOCL Reply: At what temperature to be confirmed? Process Temperature to be confirmed. As per vendor information, if
Procurement operational manual §3 « risk and temperature increases above 60
recommendation associated with the Deg. C., salt may result in melting
process". You can find it here below: and caking.
3.6 Salt carry over and dissolution As recommended by vendor, high
Water Trap product can not be carried temperature alarm (TI-529) with
Possibility of dissolution of over as design flow rate is respected. set point as 50 Deg.C is provided
CS-140-PR-15-0022 at salt dryer inlet.
77 salt in gas oil product is to be Vendor/SEI
confirmed. Water Trap Product is not soluble in In case of high inlet temperature,
gasoil, and can not contaminate gasoil. salt dryer is to be bypassed.
Appropriate Note is already added
in P&ID (Note-12).

Operating procedure should CLOSE O&M Will be taken care in Operating Manual.
ensure draining of salt dryer
CS-140-PR-15-0022 SEI/NOCL
78 at regular intervals by
checking LG-
554.
CLOSE O&M Will be taken care in Operating Manual.
Regular top up
CS-140-PR-15-0022 SEI/NOCL
79 procedures/schedules to be
mentioned in SOP.

Process CLOSE PID Required facility is incorporated in IFC

P&ID is to be updated for
P&ID. Operating procedure of salt dryer
CS-140-PR-15-0022 maintenance /Top up
80 SEI/VENDOR given by vendor will be taken care in
discharge/bypassing salt
dryer procedure. Operating manual.

Projects 25-Jan-11 CLOSE Clarification PMC/NOCL to confirm. Projects to Requested from NOCL/PMC on 1-Feb-11
CS-140-PR-15-0019 Confirm that hydrocarbon request PMC/NOCL for same.
81 detectors are provided in NOCL
cooling tower area.

Mechanical(Rot) 20-Jan-11 CLOSE Clarification Sulzer confirmed that the pump SEI Process Process to check the P&IDs for this minimum This pump has multiple outlets.
Minimum flow requirement for Item No. flow requirement. Minimum flow requirement of the
140-P-004 (Pump Model – ZF 40-2250) pump is ensured as all these
A/B shall be 4.8 m3/hr. outlets are not expected to be
closed simultaneously. Further the
reflux to 140-C-002 is on flow
control and its minimum process
CS-140-PR-15-0017, value is 7.38 m3/hr which is higher
TBC from vendor regarding
CS-140-PR-15-0020,
82 the requirement of min. flow SEI than the pump minimum flow
CS-140-PR-15-0021,
to avoid churning. requirement. Hence no additional
CS-140-PR-15-0023
minimum flow line is required.

Process 25-Jan-11 CLOSE PID Subsequent to this HAZOP Incorporated in 90% Model Review P&ID Will be incorporated in IFC-1 Process To be incorporated. DDR CD-SEI-0046 for similar case
recommendation this issue was P&ID. has already been approved by
Consider providing
discussed between NOCL, Axens & SEI NOCL/PMC. PMC to advise if a
independent level
and it was agreed that high level alarm separate DDR is to be issued.
83 CS-140-PR-15-0021 transmitters with high alarm SEI
will be provided on magnetic LG-541
and delete the high alarm
with switch. P&ID will be updated
from LC-540
accordingly.

Process 25-Jan-11 CLOSE PID Subsequent to this HAZOP Incorporated in 90% Model Review P&ID Will be incorporated in IFC-1 Process To be incorporated. DDR CD-SEI-0046 for similar case
recommendation this issue was P&ID. has already been approved by
Consider Providing
discussed between NOCL, Axens & SEI NOCL/PMC. PMC to advise if a
independent level
and it was agreed that high level alarm separate DDR is to be issued.
transmitters with high alarm
84 CS-140-PR-15-0021 SEI will be provided on magnetic LG-541
and delete the high alarm
with switch. P&ID will be updated
from LC-540 accordingly.

Process 25-Jan-11 CLOSE PID Subsequent to this HAZOP Incorporated in 90% Model Review P&ID Will be incorporated in IFC-1 Process To be incorporated. DDR CD-SEI-0046 for similar case
recommendation this issue was P&ID. has already been approved by
Consider Providing
discussed between NOCL, Axens & SEI NOCL/PMC. PMC to advise if a
independent level
and it was agreed that high level alarm separate DDR is to be issued.
85 CS-140-PR-15-0021 transmitters with high alarm SEI
will be provided on magnetic LG-541
and delete the high alarm
with switch. P&ID will be updated
from LC-540
accordingly.

Provide high temp alarm on Process CLOSE PID Incorporated in IFC P&ID
86 CS-140-PR-15-0017 TI-192 SEI

Projects 25-Jan-11 CLOSE Clarification To be confirmed by NOCL. Projects to PMC Reply: Hydrocarbon detectors will be provided in
Confirm that hydrocarbon request NOCL for same. Cooling Water return Line.
87 CS-140-PR-15-0020 detectors are provided in NOCL
cooling tower area.

SOP to ensure that the CLOSE O&M Will be taken care in Operating Manual.
proper dosing rate is SEI/NOCL
88 CS-140-PR-15-0023
maintained and confirmed
with proper lineup.
Process CLOSE PID Incorporated in IFC P&ID
Provide low alarm at PI-358A
89 CS-140-PR-15-0007 SEI
on separator drum.

Mechanical (Rot)/ 20-Jan-11 CLOSE Clarification Taken up with NEA. Indicated figures SEI
CS-140-PR-15-0014, Check the time required to SEI/NOCL Projects range from 15 to 45 minutes.
90
CS-140-PR-15-0015 startup spare compressor .

Process CLOSE PID Incorporated in IFC P&ID

PT with high alarm is to be
91 CS-140-PR-15-0013 provided instead of PI-953. SEI

Process CLOSE PID Incorporated in IFC P&ID

Low pressure alarm at PC-
92 CS-140-PR-15-0007 358 is to be provided on V- SEI
006.

Process CLOSE Clarification In case of total instrument air failure

140-FCV-431 will fully open and 140-XV-
Confirm that the suction 707 will fully close. Make up compressor
system can either withstand will operate on full recycle and relief will
93 CS-140-PR-15-0013 with the high suction SEI occur (Refer Doc No CS-140-PR-45-
pressure and PSV is 0002, Pg 20 of 45, Clause 2.2.13.3)
designed for the same.

Mechanical (Rot)/ 25-Jan-11 CLOSE Clarification Mechanical(Rot) To be confirmed from vendor. NEA confirmed that automatic
Projects start-up is possible from 25-100 %
NEA Reply: Please note once the loading. For 0-25% it shall be
HydroCOM vendor to clarify compressor is started in unloaded through spill back valve. NEA
for the consequences of condition any required unloading step confirmed that compressor will not
CS-140-PR-15-0013, sudden loading and how to between 25% to 100% can be selected trip in this case. If it all there is a
94 SEI/NEA
CS-140-PR-15-0014, prevent tripping of for comperssor operation. There will not sudden rise in requirement of
compressor and implement be any problem for ccomplressor loading hydrogen, then the hydrocom will
solution to provide the same. from 25% to 100% load operation. proportionately balance the flow.

Process CLOSE PID Incorporated in IFC P&ID

CS-140-PR-15-0013, Consider forced PCV-922
95 SEI
CS-140-PR-15-0014, close when compressor trips.

Projects 25-Jan-11 CLOSE Clarification To be confirmed by NOCL. Projects to PMC Reply: Hydrocarbon detectors will be provided in
Confirm that hydrocarbon request NOCL for same. Cooling Water return Line.
CS-140-PR-15-0013,
96 detectors are provided in NOCL
CS-140-PR-15-0014,
cooling tower area.

Process CLOSE PID Incorporated in IFC P&ID

97 CS-140-PR-15-0013 Provide High alarm at TI-176. SEI

Mechanical (Rot)/ 25-Jan-11 CLOSE Clarification NEA Reply: We will provide high high NOCL Reply: This resolution not reflected in P&ID/ Agreed by NEA. Revised Process/Projects Rev-4 P&IDs to be provided.
Projects level trip from LT901 instead of providing C&E/ SISFS etc to be updated. P&ID(Rev-4) will be submitted.
alarm.We feel alarm is not required as
LG is provided for monitoring &
automatic drain trap is also present for
auto draining of liquid if any.
SEI Reply: NEA to retain high level
alarm from LT-901. Also, separate LT is
Provide High high level required for high high level compressor
CS-140-PR-15-0013,
98 compressor trip for 2nd stage NEA trip for 2nd stage suction vessel.
CS-140-PR-15-0014,
suction vessel NEA Reply: NEA will provide additional
2 nozzles for LT.
NEA to submit optional price for LT.

Projects 25-Jan-11 CLOSE Clarification To be confirmed by NOCL. Projects to PMC Reply: Hydrocarbon detectors will be provided in
Confirm that hydrocarbon request NOCL for same. Cooling Water return Line.
CS-140-PR-15-0013,
99 detectors are provided in NOCL
CS-140-PR-15-0014,
cooling tower area.

Process CLOSE PID Low point drain incorporated in IFC

Provide low point drain valve P&ID.
at the shell side outlet of EE- O&M SOP to be taken care in operating
CS-140-PR-15-0013, 009 and SOP to ensure manual.
100 SEI
CS-140-PR-15-0014, checking of leakage of
cooling water after any
maintenance.

Page 3 of 6
 HAZOP STUDY REPORT

Client SO2331 CS-140-PR-47-0001 0

Annexu
re II
Plant Project Document Number Rev.
The
recomm
endatio
ns of
HAZOP
study
SNois P&ID no Recommendations Responsibility Action Target Date Status Category Resolution Post Meeting Clarification SEI Response to Action By NOCL Comment_12-Mar-11 Discipline Response
listed Responsibility PMC/NOCL Comments
below: (Dept)
Mechanical (Rot)/ 25-Jan-11 CLOSE Clarification NOCL Reply: The distance between the inspection Mechanical(Rot) NEA GA to be prvided
Inspection opening of 2nd Projects opening and vanepack separator should be clearly
stage suction vessel shall be NEA Reply: OK we will locate the same defined to close out the issue.
CS-140-PR-15-0013,
101 located closer to the SEI/NEA as closer as practically possible.
CS-140-PR-15-0014,
vanepack for inspection SEI Reply: Noted
purpose.

Process 25-Jan-11 CLOSE PID To be incorporate in P&ID. Incorporated in 90% Model Review P&ID Will be incorporated in IFC-1 Process
Venting/purge facility to flare P&ID.
CS-140-PR-15-0013
102 at EE-009 outlet is to be SEI
provided near B/L.

Process CLOSE PID Incorporated in IFC P&ID

CS-140-PR-15-0023, PI-304 to be provided with
103 SEI
CS-140-PR-15-0025 low pressure alarm.

CS-140-PR-15-0023, Ensure that blockage of NOCL OPEN O&M Will be taken care in Operating Manual. NOCL Reply: To be confirmed from carbon canister Operator to ensure periodic Mechanical(Static)
CS-140-PR-15-0025 carbon canister is not vendor if blockedhow DCS operator willl come to know. maintanance & cleaning of
possible. What is the resolution for blockage of carbon canister. carbon canister. However
vendor details will be provided.
104

Process CLOSE PID Incorporated in IFC P&ID

Provide additional flushing oil
CS-140-PR-15-0024,
105 return taping upstream of SEI
CS-140-PR-15-0026 XZV-718 M for flushing.

Damper open/close Process CLOSE PID Incorporated in IFC P&ID

indications are provided
CS-140-PR-15-0023,
106 (P&ID is to be updated SEI
CS-140-PR-15-0025
accordingly).

Process 17-Feb-11 CLOSE Required Start up and shut down over SEI Process To be incorporated.
Startup and shut down rides will be incorporated in heater
107 CS-140-PR-15-0004 overrides for damper control SEI operation control philosophy, & SISFS.
to be included in P&ID note.

Process CLOSE PID Incorporated in IFC P&ID

Low oxygen alarm at AI-004
108 CS-140-PR-15-0004 SEI
is to be provided

Projects 25-Jan-11 CLOSE Clarification To be confirmed by NOCL. Projects to PMC Reply:

request NOCL for same. 1. Do not agree that vaporization of low boiling
components in fuel oil will lead to vapor locking in
upshot firing burners.
2. Fuel oil temperature is controlled in the upstream
CS-140-PR-15-0024, Ensure that upstream unit. A high temperature alarm will be provided on 260-
109 system is properly monitored NOCL TI-043 to warn the operator in case of high
CS-140-PR-15-0026
to avoid any vaporization. temperature.

Process CLOSE PID Incorporated in IFC P&ID

MP steam for soot blower
110 CS-140-PR-15-0004 tapping to be downstream of SEI
FI-409.(P&ID to be updated).

HH pressure trip PZ- Mechanical (Rot)/ 20-Jan-11 CLOSE Clarification To be confirmed from BHEL A HH Pressure trip is required in view of machine
678A/B/C requirement is to Projects safety.
111 CS-140-PR-15-0030 be reviewed from vendor in BHEL/SEI
view of turbine back
pressure.
Process CLOSE PID Incorporated in IFC P&ID
Line from Desuperheater
downstream upto steam trap
112 CS-140-PR-15-0030 SEI
is to be designed for two
phase flow.

Mechanical (Rot)/ 20-Jan-11 CLOSE PID 345 Deg C NOCL Reply: Now where is the control on inlet steam
Projects temperature to turbine? Consider providing low steam
inlet temp trip.
PMC Reply: Low steam temp will lead to higher steam
consumption.As long as the recycle compressor
continues to recycle sufficient gas this is not a concern.
Vendor to provide min. temp.
Sufficient controls and safeguard exist for reactor
of steam acceptable at
section performance monitoring. No action required.
113 CS-140-PR-15-0030 turbine inlet, irrespective of BHEL
min. operating temp.
specified in B/L condition.

Process CLOSE PID Incorporated in IFC P&ID

TI-627 is to be provided with
114 CS-140-PR-15-0011 SEI
low temp. alarm in DCS.

CLOSE O&M Will be taken care in Operating Manual.

SOP to ensure checking of
115 CS-140-PR-15-0032 leakage of cooling water after SEI/NOCL
any maintenance.

Projects 25-Jan-11 CLOSE Clarification To be confirmed by NOCL. Projects to PMC Reply: Hydrocarbon detectors will be provided in
Confirm that hydrocarbon request NOCL for same. Cooling Water return Line.
116 CS-140-PR-15-0032 detectors are provided in NOCL
cooling tower area.

Process CLOSE PID Incorporated in IFC P&ID

Provide 3" jumpover
connection line (with valve
and spec. blind) between
cooling water supply and
117 CS-140-PR-15-0032 return headers near dead SEI
end. Jumpover will be used
for initial passivation during
commissioning.

CLOSE Clarification SEI

Ensure different connections
CS-140-PR-15-0031, For Nitrogen lines 1/2" connection
are available for air and
118 CS-140-PR-15-0033, SEI provided and for other lines 3/4"
nitrogen hose stations to
CS-140-PR-15-0034 connection provided.
avoid wrong connections.

CLOSE O&M Will be taken care in Operating Manual.

CS-140-PR-15-0037, SOP to ensure Manual
119 SEI/NOCL
CS-140-PR-15-0038 intervention of HS-908

Process CLOSE PID Incorporated in IFC P&ID

Provide high high alarm at
120 CS-140-PR-15-0044 LI-800 SEI

Process CLOSE PID Incorporated in IFC P&ID

Provide low low alarm at LI-
121 CS-140-PR-15-0044 SEI
801

Process CLOSE PID Incorporated in IFC P&ID

Provide high high alarm at
122 CS-140-PR-15-0040 SEI
LI-902

Process CLOSE PID Incorporated in IFC P&ID

Provide NRV in the flare
KOD pump discharge line no.
123 CS-140-PR-15-0038 SEI
P803 near to tie in point to
slop header.

Operating procedure should CLOSE O&M Will be taken care in Operating Manual.
prevent draining of hot
124 CS-140-PR-15-0040 SEI / NOCL
hydrocarbon in Hydrocarbon
drain drum.

Provide low low alarm at LI- Process CLOSE PID Incorporated in IFC P&ID
125 CS-140-PR-15-0040 SEI
902

Mechanical (Rot)/ 25-Jan-11 CLOSE PID

Projects

NEA Reply: The strainer provided before

aux lube oil pump is a 20mesh coarse
strainer.We are already having a
cranckcase strainer before this & after
initial flushing we do not expect any big
dirt particles which will clogg this
strainer.The complete oil system is
CS-140-PR-D- Provide differential pressure designed with SS304 piping.We have
126 gauge across the suction NEA
06600002 never provided PDI across this strainer
strainer.
& considering all above it is not required.
SEI Reply: noted and vendor shall
mention the perodical requirement of
maintenance, of strainer, in SOP.
NEA Reply: NEA to include periodical
maintenance of strainers in its SOP
document.

Mechanical (Rot)/ 25-Jan-11 CLOSE PID

Projects
NEA Reply: We do not have any project
philosophy document provided to us
which will specify 8.7barg PSV set
pressure.Also please refer API 618 4th
edition table 3, which confirm 1 barg
pressure more above operating pressure
.Hence 8 barg PSV set pressure
provided by us is correct & adequate.
SEI Reply: Document no. CC-000-PR-
Consider PSV set point 40-0004 was not part of PR (given to
900001-1-05 (NEA NEA) hence MOP+1.7 barg was
127 change to 8.7 barg as per NEA
P&ID) unknown to them .As per API 618 4th
project philosophy.
edition , 10% margin is Ok hence NEA
reply on these lines seems to be
acceptable.

Process reply: Operating pressure of the

line is 7 barg. PSV set pressure is 8.0
barg. So, there is very less margin and
PSV will pop up frequently. Therefore,
NEA to consider PSV set point change
to 8.7 barg as per project philosophy.

900001-1-05 (NEA Trip of aux. pump with time NEA Mechanical (Rot)/ 40568 CLOSE Clarification NEA Reply: Ref. the logic diagram and Ref. the logic diagram and cause & effect chart Project (To check Logic Dia. & C&E of NEA to be provided.
P&ID) delay is to be ensured when Projects cause & effect chart submitted by submitted by NEA.The aux lube oil pump is stopped whether doc been
compressor is tripped (refer NEA.The aux lube oil pump is stopped after run down timer T3 (180 Seconds) is completed sent to PMC)
vendor cause and effect after run down timer T3 (180 Seconds) is during tripping.
diagram). completed during tripping. NOCL Reply: The above said vendor documents-
SEI Reply: Noted C&E , Logic diagram, not yet provided to us by SEI to
close out this issue.
128

Mechanical (Rot)/ 25-Jan-11 CLOSE PID NEA Reply: The sampling arrangement
Projects is to be provided in SAMSUNG scope
piping as required
SEI Reply: Sample connection to be
Manual sampling provided by NEA.
900001-1-05 (NEA NEA reply: Due to space constraints with
129 arrangement is to be NEA
P&ID) LO skid the sampling arrangement is to
provided.
be provided in SAMSUNG scope piping
as required.

Mechanical (Rot)/ 25-Jan-11 OPEN Clarification NEA Reply: Please note there will be Please note there will be some oil carry over in Mechanical(Rot) SEI to ask Axens if the grade of oil used will
Projects some oil carry over in process.But we process.But we can specify only oil injected into the contaminate process gas or not? SEI REPLY :- Please note that Oil
can specify only oil injected into the compressor & not an oil carry over.For Oil injected injected into the system is
compressor & not an oil carry over.For quantity please refer utility consumption list 0.006m3 per day(ISO VG220 is oil
Oil injected quantity please refer utility NOCL Reply: The above said utility consumption list grade and per cylinder oil qunatity
consumption list not yet provided by SEI to NOCL/PMC. will be very less) moreover oil
SEI Reply: Possible leakage from NEA is What is the guarantee that the leakage of oil will not quantity going along with gas will
required. Also, NEA to provide oil contaminate the process fluid leading to off spec be still lesser hence it may not
specification including all impurities. product. Not yet answered. Is it any query raised to affect the process gas.
NEA/Axens? It may not be possible for vendor
Provide possible leakage SEI Reply: Rough order of magnitude to be confirmed to specify the oil quantity going
quantity to process gas and by NEA. along with gas because oil is used
900001-1-05 (NEA specification, including all for lubrication of cylinders and oil
130 NEA / AXENS
P&ID) impurities in the oil used for lost during lubrication cannot be
cylinder lubrication.Axens will calculated /measured. This
confirm the acceptance. happens in all the reciprocating
compressor . If required , NOCL
/CBI may contact axen for further
clarifications if required.
TQ raised by Process on 15-
Apr-11.

Mechanical (Rot)/ 25-Jan-11 CLOSE O&M NEA Reply: Please note while NOCL Reply: Whether less cooling water flow pressure During maintenance of filter for Mechanical(Rot) Possibility of dual filter to be confirmed from During maintenance of filter for
Projects maintaining the CW filter , upstream & will lead to high process gas temp or not? This is not short period possibility of low vendor. short period possibility of low flow
downstream valves need to be closed & answered. Vendor to give guarantee whether the flow through bypass is ruled through bypass is ruled out as
the filter can be process gas temp will not rise. out as bypass line size is same bypass line size is same as filter
changed/maintained.During small peroid as filter inlet line size.(to be inlet line size, hence less cooling
of time the water can flow through confirmed by NEA) water flow pressure condition
bypass line to packing. cannot occur.
NEA to include the same with SOP. Since vendor accepted the
operational continuity with filter
bypass for the period when filter
Vendor operation manual cleaning is done, no spare filter is
CS-140-PR-D-
131 should mention bypass NEA being provided by NEA. In addition
06600006 operation. to this please also note that
coolant is a closed loop circulating
system and as such clean of
dirt/debris therefore bypassing the
filter during maintenance for short
duration will not create any
problem for the compressor
operation.

Mechanical (Rot)/ 25-Jan-11 CLOSE O&M

Projects
NEA Reply: Please note the bleed
Vendor operating manual line/recirculation line valves need to be
should mention closing of open during normal operation in order to
manual isolation valve achieve the required back pressure.
900001-1-09 (NEA
132 located in pump minimum NEA SEI Reply: NEA to confirm that pump
P&ID)
circulation line in case both capacity is adequately taken care of this
compressors are in operation min. circulation.
during changeover. NEA reply: NEA confirms that the pump
capacity is adequate for this minimum.

Mechanical (Rot)/ 25-Jan-11 CLOSE PID NEA Reply: OK we can change the
Projects valve to globe type but please note API
618, PLAN-D shows the valves as gate
Gate valve in min circulation valves only & we feel the same are OK.
900001-1-09 (NEA
133 line to be changed to globe NEA SEI reply: Noted based on accpetance
P&ID)
valve. of Globe.

900001-1-09 (NEA Vendor to recheck NEA Mechanical (Rot)/ 40568 CLOSE Clarification NEA Reply: Refer the latest logic Refer the latest logic diagram as well as cause & effect TI 932 is provided with high Mechanical(Rot) to Logic Dia. & C&E of NEA to be provided.
P&ID) requirement of low temp Projects diagram as well as cause & effect chart chart submitted by NEA. TI-932 low temperature alarm temperature alarm only.(NEA confirm by 7-Mar-11.
alarmTI-932 and compressor submitted by NEA. TI-932 low & permissive is not required & hence not provided. updated C&E & P&ID to be
start permissive (refer vendor temperature alarm & permissive is not NOCL Reply: The above said vendor documents not forwarded to NOCL).
cause & effect page 4). required & hence not provided. yet provided by SEI to NOCL to close out this issue.
SEI Reply: Noted

134

Mechanical (Rot)/ 25-Jan-11 CLOSE Clarification Gas dew point is -197.6 deg C. No
900001-1-09 (NEA Gas dew point to be Projects possibility of condensation of process
135 NEA
P&ID) confirmed. gas in cylinder.
Mechanical (Rot)/ 25-Jan-11 CLOSE PID SEI will go ahead with DM water with Corrosion
Projects inhibitor as informed by PMC.

NEA confirmed to provide suitable makeup water

NEA confirmed to provide suitable
Suitable makeup water connection to cooling water tank
900001-1-09 (NEA makeup water connection to cooling
136 connection to cooling water NEA PMC Reply: Potable water is not suitable for make-up. To be discussed. Mechanical(Rot)
P&ID) water tank
tank is to be provided. It is proposed to use DM water with corrosion inhibitor
SEI reply: Noted
for make-up. This should be confirmed with NEA.

Mechanical (Rot)/ 25-Jan-11 CLOSE PID NEA Reply: We will provide tank vent NOCL Reply: P&ID CS-140-PR-D-06600006 to be
Projects connection as a TP point.SAMSUNG to updated to reflect this change.
take the same further to safe location.
Noted and Process shall look check for
any comments
Cooling water tank vent
900001-1-09 (NEA Process reply: Process requirement is to
137 P&ID) should be provided at safe NEA
location. route vent at safe location for safety
reason. Projects Team to decide whether
it is to be done by SEI piping or by NEA.

Mechanical (Rot)/ 25-Jan-11 CLOSE Clarification

Projects
NEA Reply: Please note 2 barg flare
back pressure is the maximum flare
back pressure which is an upset
condition & we do not design the PCV
set points for upset condition.We design
the same for normal flare back condition
case & the present set points of PCV are
PCV-902/903 set points to be ok considering 0.3barg normal flare back
reviewed in view of max. flare pressure.
CS-140-PR-D-
138 back pressure of 2 barg NEA / SEI SEI reply: NEA to check the impact on
06600003
(during general power seal when back pressure reached to 2
failure). barg as this may happen when
compressor is in operation.
NEA reply: NEA understands max flare
back pressure will be 1.68 barg and not
2 barg. Please note 1.68 barg is an
upset conditions for which operator can
change PCV 902/903 set points to 2
barg max in field .

Mechanical (Rot)/ 25-Jan-11 CLOSE PID NOCL Reply: P&ID CS-140-PR-D-06600003 to be

Projects NEA Reply: OK we will update the 2" updated.
900001-1-06 (NEA Isolation valve in vent line to
139 NEA size valve close to TP07 to "LO" type
P&ID) flare is to be LO.
SEI Reply: Noted

Mechanical (Rot)/ 25-Jan-11 CLOSE PID

Projects
NEA Reply: Latest P&ID rev.3 are
indicating PSV-909 & 910 discharge to
safe location NEA confirmed to show a
TP point instead of gooseneck vent at
compressor which further can be
PSV discharge and Goose connected to safe location by SEI Latest P&ID rev.3 are indicating PSV-909 & 910
SEI Reply: Noted and reply by NEA is
900001-1-06 (NEA neck provided on distance discharge to safe location NEA confirmed to show a TP
140 NEA/SEI found acceptable to MECH however
P&ID) piece, to be routed to safe point instead of gooseneck vent at compressor which
process to respond.
location. further can be connected to safe location by SEI
Process reply: i) Noted
ii) Process requirement is to route vent
at safe location for safety reason.
Projects Team to decide whether it is to
be done by SEI piping or by NEA.

Mechanical (Rot)/ 25-Jan-11 CLOSE PID

Projects NEA Reply: NEA confirmed to indicate
the drain line to be connected to CBD in NEA confirmed to indicate the drain line to be
900001-1-06 (NEA Drain line from packing drain NEA / SEI
141 P&ID. Necessary routing after TP08 to connected to CBD in P&ID. Necessary routing after
P&ID) pot to be routed to CBD
be done by SAMSUNG TP08 to be done by SAMSUNG
SEI reply: Noted

Mechanical(Rot) CLOSE PID Compressor casing drains already

CS-140-PR-15-0011, All drains to be properly indicated in seal gas P&ID and routed to
142 CS-140-PR-15-0030, routed. BHEL/SEI
CBD.
1-336-00-33049(BHEL)

Mechanical (Rot)/ 25-Jan-11 CLOSE Clarification Confirmed. SEI P&IDs updated considering this philosphy & tie-in Based on vendor confirmation Process. To be incorporated.
All condensate collections Process points all condensate discharge
having temp<70 C will be NOCL Reply: Can be closed once P&ID is updated. having temp.> 70 C will be
CS-140-PR-15-0011, routed to ND system and routed to condensate collection
143 CS-140-PR-15-0030, others having temp.> 70 C SEI system. Will be updated in IFC-
1-336-00-33049(BHEL) will be routed to condensate 1 P&ID.
collection system.

Mechanical (Rot) CLOSE Clarification BHEL confirmed that PCV 691 is falied
BHEL to confirm that PCV- to close as per meeting dated 5-Jan-11.
1-336-00-33049(BHEL
144 691 is fail to close. BHEL/SEI
P&ID)

Mechanical (Rot)/ 25-Jan-11 CLOSE Clarification Single PSV is adequate as per HAZOP
Standby PSV requirement for Projects requirements however as per Project
PSV-691 is to be checked as requirement to be taken up separately.
1-336-00-33049(BHEL
145 per project standards BHEL/SEI
P&ID)
(considering PSV-691
failure).

Mechanical (Rot)/ 25-Jan-11 CLOSE Clarification Confirmed. SEI P&IDs updated considering this philosphy & tie-in Based on vendor confirmation Process. To be incorporated.
Process points all condensate discharge
All condensate collections PMC Reply: Can be closed once P&ID is updated. having temp.> 70 C will be
having temp<70 C will be routed to condensate collection
1-336-00-33049(BHEL routed to ND system and system. Will be updated in IFC-
146 BHEL/SEI/NOCL
P&ID) others having temp.> 70 C 1 P&ID.
will be routed to condensate
collection system.

Mechanical(Rot) 20-Jan-11 CLOSE Clarification BHEL confirmed that isolation of land Isolation of land Steam Condensor is not required
SOP to ensure mentioning of Steam Condensor is not required during during start up. It is done only during maintenance,
gland steam condenser start up. It is done only during where the steam is vented through local vent.
1-336-00-33049(BHEL isolation and steam is to be maintenance, where the steam is vented BHEL
147 BHEL/SEI/NOCL
P&ID) through local vent.
vented out through local
vent.

Page 4 of 6
 STATUS OF ACTION POINTS

Total
OPEN 28
CLOSE 119
 HAZOP POINTS STATUS

Based on Comments from NOCL

ITEMS NOT YET CLOSED BY NOCL ITEMS NOT YET RECIEVED BY SEI
(Were already closed by SEI) (Action by SEI) Action already taken
Total Items: 31 Total Items: 13 Total Items: 6
Item Nos: Item Nos:
Item Nos: 24,26,27,29,30,33,37,38,40,47,57,82,107 24,29,30,33,40,82
4,5,6,16,18,19,20,32,39,48,54,56,69,71,77,83,84,8
5,94,98,101,102,104,109,113,128,130,131,134,143
,146

As per SEI Status

Total Action Points 147
Points Closed 136
Open Points related to BHEL
3
(Already raised)
Open Points related to TQs raised to Axens
1
(Already raised)
Open Points that requires PMC/NOCL
action (Already requested from 4
PMC/NOCL)
Open Points that require SEI action
3
(Design related)