Group SD1 HAZOP Recording and Action Sheet

Node Identification and Intentions

Nodes have been selected from within process areas (labelled in large numbers on PID), and the
streams around these nodes have been analysed in the tables below. The nodes selected are as
follows:
NODE 1
Node 1 has been selected from process area 2 as
the circulating fluidised bed gasification vessel,
unit R101. The purpose of this unit is to take the
RDF (Refuse-Derived Fuel) from stream 201 and
perform gasification reactions at a temperature of
870oC and a pressure of 20 bar. The reaction
takes place in an oxygen deficient environment,
with oxygen being fed in the form of air through
streams 205 and 206. The product of gasification
is syngas; a mixture of gases, mainly hydrogen,
carbon monoxide, nitrogen and carbon dioxide.
These leave the vessel in stream 207, which leads
to gas-solid separation in the cyclone set C101.

Figure 1. Extract of P&ID for Node 1

NODE 2
Node 2 has been selected from process area 3 as the heat exchanger H101. This unit is key, as it takes
the syngas from the tar cracking fluidised bed, R102, and reduces its temperature using water as the
cooling agent, from 900oC to 400oC, in order to make it suitable for use particulate removal in candle
filter B102.

Figure 2. Extract of P&ID for Node 2

 Page 2
NODE 3
Node 3 has been selected from process area 4 as the COS hydrolysis reactor vessel, R103. This unit
hydrolyses COS in stream 404 to form H2S, operating at 150oC and atmospheric pressure. The
conversion of COS is 99.9% so only traces remain when the syngas leaves the reactor in stream 405.

Figure 3. Extract of P&ID for Node 3

 Group SD1 HAZOP Recording and Action Sheet

Node 1
Leader: David Cole Flowsheet No: 1
Date 23rd February 2017 Node 1 Page 1 of 3
Scribe: Daiki Kusano Team: Impact Consultants Ltd.
Line identification and intention: 201
Delivers RDF from storage tank T102 into screw feeder SF101, which then feeds the circulating fluidised bed gasifier, R101 with RDF fuel.

Guide Hazard Action

Deviation Causes Consequences Safeguards Action By
word no. no.
Rotary feeder RF201 No RDF in the gasifier; No Flow Indicator 1 Check suitability of rotary Process
closure syngas produced. feed / Consider Engineer
1
Temperature surge in the installation of fail open
gasifier. valve
No Flow
Screw feeder SF201 No RDF in the gasifier; No None 2 Consider emergency Process
jammed syngas produced. bypass installation around Engineer
2
Temperature surge in the the screw feeder
gasifier.
Rotary feeder RF201 Less RDF in the gasifier; less Flow Indicator Refer to action no. 1
partially closed syngas produced; slight
Less Flow 3
increase in gasifier
temperature.
Rotary feeder RF201 More RDF entering gasifier; Flow Indicator 3 Check suitability of valve Process
stuck open reduction in gasifier Engineer
temperature causing
More Flow 4
decrease in reaction rate;
increase in gas impurities for
output syngas
Pressure build up in Potential damage to valve Pressure control on gasifier 4 Leak detectors Operator
R101 and screw feeder. Leakage
Reverse Flow 5 of combustible substances in
stream 201 and potentially
atmosphere
Rotary feeder RF201 Reduction in solid circulation Pressure control on gasifier Refer to action 3
Less Pressure 6 failure and gas velocity; less syngas
and reduced quality
Rotary feeder RF201 Potential gasifier explosion. Pressure control / 5 Consider additional Operator
More Pressure 7 stuck open Emergency Pressure Relief emergency automatic
Valves shutdown
 Page 4

Leader: David Cole Flowsheet No: 1

Date 23rd February 2017 Node 1 Page 2 of 3
Scribe: Daiki Kusano Team: Impact Consultants Ltd.
Line identification and intention: 205/206
Air is compressed in each stream, from atmospheric pressure to 20bar. The air is then fed into R101 via the base of the bed and through a secondary air-port
above the dense bed within the reactor.
Guide Hazard Action
Deviation Causes Consequences Safeguards Action By
word no. no.
Compressor No air flow into the gasifier; Flow Indicator 1 Check suitability of Process
COMP201/202 failure no syngas produced; compressor Engineer
1
temperature surge in the
gasifier.
No Flow
Valve CV201/202 No air flow into the gasifier; Flow Indicator 2 Check suitability of valve Process
closure no syngas produced; Engineer
2
temperature surge in the
gasifier.
Valve CV201/202 Less air flow into the gasifier; Flow Indicator Refer to action 2.
partially closed less syngas produced;1 slight
Less Flow 3
increase in gasifier
temperature.
Valve CV201/202 Excess air flow; gasification Flow Indicator 3 Check suitability of valve / Process
stuck open reduces and can lead to Consider installation of fail Engineer
More Flow 4 combustion; product gases close valve; Consider
become unsuitable; pressure additional automatic
build up can lead to explosion emergency shutdown
Compressor COMP Potential leakage of syngas Pressure indicator on R101 4 Leak detectors Operator
Reverse Flow 5 201/202 failure to atmosphere; Pressure Leak alarms
drop in R101
Valve CV201/202 Reduction in solid circulation Pressure control on R101 Refer to action 2.
Less Pressure 6 closure and gas velocity; less syngas
and reduced quality
Valve CV201/202 Potential gasifier explosion. Pressure control / 5 Consider additional Operator
More Pressure 7 stuck open Emergency Pressure Relief automatic emergency
Valves shutdown
 Page 5

Leader: David Cole Flowsheet No: 1

Date 23rd February 2017 Node 1 Page 3 of 3
Scribe: Daiki Kusano Team: Impact Consultants Ltd.
Line identification and intention: 207
Sends the products of gasification at 870℃ and 20 bar out of R101 and into C101 for 99.9% gas-solid separation.

Guide Hazard Action

Deviation Causes Consequences Safeguards Action By
word no. no.
Valve CV203 closure Syngas output becomes Pressure relief valve 1 Fail open valve Operator
zero; Pressure build up in the High pressure alarm
No Flow 1
gasifier and can lead to
explosions
Valve CV203 partially Less syngas output; Reduced Pressure relief valve Refer to action 1.
closure electricity production;
Less Flow 2 Pressure build up in the
gasifier and can lead to
explosions
Valve CV203 fully Too much pressure reduction Flow indicator 2 Low pressure alarm in Operator
More Flow 3 opened in gasifier gasifier

Overly fast reaction Pipe rupture / valve damage Flow rate control on Refer to action 1.
More Pressure 4 rate in R101 compressor

Valve CV204 failure in Tar condensing in the None 3 Low temperature alarm; Operator
steam heating coil; cyclone; cause blockage in
reducing reactor valve, pipe, cyclone; high
Low Temperature 5 temperature and utility cost in unit R102;
therefore rate. reduce reaction rate and
heating value of syngas
output
Inherent in a process R101 temperature not None 4 Develop system to Process
plant. reaching 870oC before RDF preheat reactor using Engineer
Other Start Up 6 is fed in; incomplete reaction, steam coil currently
poor syngas quality and employed.
wasted fuel in stream 207.
 Page 6

Node 2
Leader: David Cole Flowsheet No: 2
Date 23rd February 2017 Node 2 Page 1 of 2
Scribe: Daiki Kusano Team: Impact Consultants Ltd.
Line identification and intention: Line 306
Delivers reduced tar content syngas from unit R102, through blower BL302 and non-return valve NRV303, into H101 heat exchanger at 900℃ and 1 bar.

Guide Hazard Action

Deviation Causes Consequences Safeguards Action By
word no. no.
Non-return valve Pressure build up in R102 Pressure indicator 1 Flow indicator on stream Operator
NRV303 closure No syngas output 306
Pipe rupture; Potential pump High pressure alarm in
No Flow 1
damage R102
Trip blower BL302 off

Partially closed valve Less syngas output; Less Pressure indicator Refer to action 1.
NRV303 electricity; Excessive syngas
cooling causes tar to
2
condense; Potential pipe
blockage; Potential pump
Less Flow damage
Pump failure / head Less syngas output; Less Pressure indicator 2 Flow indicator on stream Operator
loss BL302 electricity; Excessive syngas 306
3 cooling causes tar to High pressure alarm in
condense; Potential pipe R102
blockage
Valve NRV303 fully Higher temperature in stream None Refer to action 2
open 307 as a result of higher
flowrate through heat
More Flow 4
exchanger H101. Higher
temperature will not be
suitable for wet scrubbing.
Excessive blowing in Higher temperature in stream Pressure indicator 3 Flow indicator on stream Operator
BL302 307 as a result of higher Temperature control on 306
flowrate through heat H101
High Pressure 5 exchanger H101. Higher
temperature will not be
suitable for S108 operating
temperature1.
 Page 7

Guide Hazard Action

Deviation Causes Consequences Safeguards Action By
word no. no.
Low temperature from Potential condensation of tar; Temperature control on Current safeguard
stream 304 Pump damage; Pipe H101 sufficient
Low Temperature 6 blockage; Low temperature in
stream 307, not suitable for
B102 operating temperature.
High temperature from Higher temperature in stream Temperature control on Current safeguard
stream 304 307. Higher temperature will H101 sufficient
High Temperature 7 not be suitable for B102
operating temperature of
400oC.
 Page 8

Leader: David Cole Flowsheet No: 2

Date 23rd February 2017 Node 2 Page 2 of 2
Scribe: Daiki Kusano Team: Impact Consultants Ltd.
Line identification and intention: Line 307a / 307b
Pumps cooling water into the heat exchanger at 20℃ to decrease temperature of incoming syngas down to 400℃ from 900℃ by converting water into steam.

Guide Hazard Action

Deviation Causes Consequences Safeguards Action By
word no. no.
1 Valve CV304 closure Syngas temperature remains Temperature indicator 1 Consider installation of fail Operator
No Flow at 900℃; unsuitable for open valve
particulate removal in B102. Flow indicator
2 Valve CV304 partially Reduced cooling causes high Temperature indicator Refer to action 1.
closed temperature in stream 307;
Less Flow
unsuitable for B102 operating
temperature
3 Valve CV304 fully Increased cooling causes Temperature indicator 2 Flow indicator Operator
open lower temperature in stream
More Flow 307; unsuitable for B102
operating temperature;
Potential tar condensation
4 Feed water Excessive cooling causes Temperature control Current safeguard
temperature lower than lower temperature in stream sufficient
Low Temperature
expected 307; unsuitable for B102
operating temperature
5 Feed water Reduced cooling causes high Temperature control Current safeguard
temperature higher temperature in stream 307; sufficient
High Temperature
than expected unsuitable for B102 operating
temperature
 Page 9

Node 3
Leader: David Cole Flowsheet No: 2
Date 23rd February 2017 Node 3 Page 1 of 2
Scribe: Daiki Kusano Team: Impact Consultants Ltd.
Line identification and intention: Line 404
Delivers particulate-free syngas into the COS hydrolysis reactor, R103, at 150℃ and 1 bar.

Guide Hazard Action

Deviation Causes Consequences Safeguards Action By
word no. no.
1 Valve CV401 closure Pressure build up in S108 Pressure indicator on S108 1 High pressure alarm in Operator
Pipe rupture Pressure relief valve on S108
No Flow
No electricity production S108 Flow rate indicator on
stream 404
2 Valve CV401 partially Pressure build up in S108 Pressure indicator on S108 Refer to action 1
closed Pipe rupture / Pump damage Pressure relief valve on
Reduction in overall S108
electricity production
Less Flow
3 Blower BL401 failure Pressure build up in S108 Pressure indicator on S108 Refer to action 1
Pipe rupture Pressure relief valve on
Reduction in overall S108
electricity production
4 Valve CV401 fully Potentially incomplete Motor control on blower to 2 Consider installation of Operator
opened reaction; reduced reaction limit excessive flow composition detector on
efficiency; COS carry over stream 405
into R104; Break Industrial
Emissions Directive set by
the EU
More Flow
5 Excessive blowing by Potentially incomplete None 3 Pressure indicator Operator
BL401 reaction; reduced reaction
efficiency; COS carry over
into R104; Break Industrial
Emissions Directive set by
the EU; Valve damage
6 High temperature from Shifts COS hydrolysis Temperature control in Current safeguard
H101 reaction equilibrium towards H101 sufficient
unfavourable side; High COS
High Temperature concentration continuing
downstream; Break Industrial
Emissions Directive set by
the EU