12_hazop

CHAPTER NO. 12

HAZOP Study

HAZOP STUDY 12.1 Introduction: A HAZOP survey is one of the most common and widely accepted methods of systematic qualitative hazard analysis. It is used for both new or existing facilities and can be applied to a whole plant, a production unit, or a piece of equipment It uses as its database the usual sort of plant and process information and relies on the judgment of engineering and safety experts in the areas with which they are most familiar. The end result is, therefore reliable in terms of engineering and operational expectations, but it is not quantitative and may not consider the consequences of complex sequences of human errors. The objectives of a HAZOP study can be summarized as follows: 

To identify (areas of the design that may possess a significant hazard potential.

 To identify and study features of the design that influence the probability of a hazardous incident occurring. 

To familiarize the study team with the design information available.

 To ensure that a systematic study is made of the areas of significant hazard potential. 

To identify pertinent design information not currently available to the team.

 To provide a mechanism for feedback to the client of the study teams detailed comments.

12.2 Steps Conducted In HAZOP Study: 

Specify the purpose, objective, and scope of the study. The purpose may be

the analysis of a yet to be built plant or a review of the risk of unexisting unit. Given the purpose and the circumstances of the study, the objectives listed above can he made more specific. The scope of the study is the boundaries of the physical unit, and also the range of events and variables considered. For example, at one time HAZOP's were mainly focused on fire and explosion endpoints, while now the scope usually includes toxic 203

CHAPTER NO. 12

HAZOP Study

release, offensive odor, and environmental end-points. The initial establishment of purpose, objectives, and scope is very important and should be precisely set down so that it will be clear, now and in the future, what was and was not included in the study. These decisions need to be made by an appropriate level of responsible management. 

Select the HAZOP study team. The team leader should be skilled in HAZOP

and in interpersonal techniques to facilitate successful group interaction. As many other experts should be included in the team to cover all aspects of design, operation, process chemistry, and safety. The team leader should instruct the team in the HAZOP procedure and should emphasize that the end objective of a HAZOP survey is hazard identification; solutions to problems are a separate effort. Collect data. Theodore 16 has listed the following materials that are usually needed. 

Process description.



Process flow sheets.



Data on the chemical, physical and toxicological properties of all raw materials, intermediates, and products.



Piping and instrument diagrams (P&IDs).



Equipment, piping, and instrument specifications.



Process control logic diagrams.



Layout drawings.



Operating procedures.

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Maintenance procedures.

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Emergency response procedures.



Safety and training manuals.

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CHAPTER NO. 12

HAZOP Study

12.2.1 HAZOP Guide Words and Meanings: 205

CHAPTER NO. 12 Guide Words



HAZOP Study

No

Meaning Negation of design intent

Less

Quantitative decrease

More

Quantitative increase

Part of

Qualitative decrease

As well as

Qualitative Increase

Reverse

Logical opposite of the intent

Other than

Complete substitution

Conduct the study. Using the information collected, the unit is divided into study

"nodes" and the sequence diagrammed in Figure, is followed for each node. Nodes are points in the process where process parameters (pressure, temperature change between nodes as a result of the operation of various pieces of equipment' such as distillation columns, heat exchanges, or pumps. Various forms and work sheets have been developed to help organize the node process parameters and control logic information. 

When the nodes are identified and the parameters are identified, each node is

studied by applying the specialized guide words to each parameter. These guide words and their meanings are key elements of the HAZOP procedure. Repeated cycling through this process, which considers how and why each parameter might vary from the intended and the consequence, is the substance of the HAZOP study. 

Write the report. As much detail about events and their consequence as is

uncovered by the study should be recorded. Obviously, if the HAZOP identifies a not improbable sequence of events that would result in a disaster, appropriate follow-up action is needed. Thus, although risk reduction action is not a part of the HAZOP, the HAZOP may trigger the need for such action. The HAZOP studies are time consuming and expensive. Just getting the P & ID's up to date on an older plant may be a major engineering effort. Still, for processes with significant risk, they are cost effective when balanced against the potential loss of life,

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HAZOP Study

property, business, and even the future of the enterprise that may result from a major release.

Deviations Equipme from nt operating condition Storage tank

What event could cause this deviation

Consequenc e of this deviation from item of equipment

Addition al implicati on of this consequ ence

Proces s indicat ion

Notes and questions

level less

more

No

1.Tank run dry

Pump cavitates

Damage to pump

LIA-1 FICA1

2.Rupture discharge line

Reagent released

Potential fire

LIA-1 FICA1

3. V-3 open or broken

Reagent reeased

Potential fire

LIA-1

4.V-1 open or broken

Reagent released

Potential fire

LIA-1

Tank rupture

Reagent released

Potential fire

LIA-1

6. Unload too much from tank truck

Tank overfills

Reagent release LIA-1 via RV-1

7. Reverse flow from process

Tank overfills

Reagent release LIA-1 via RV-1

As liquid is flammable , pump may damage As flow rate is large so much quantity is released. So isolate the leak as quickly as possible Isolate leak as fas as possible Isolate leak as far as possible RV-1 designed to relieve liquid at loading rate. Check valve in the pump discharge should work properly.

Same as less 207

CHAPTER NO. 12

HAZOP Study

Composition

Other than

As well As

8. Wrong reagent

Possible reaction

9. Impurity in reagent

p-xylene contains some minor metal impurities

Possible tank ruputre

You should consuder sampling before loading. Minor impurities

Temperature

More

Temperature Reagent of inlet is release via hotter than RV-1 normal

Thermal stress on tank.

Temperature limits are 15-20 oC

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