HAZOP
Designed by
Hossam A. Hassanein
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Goals
Basic understanding of HAZOP
HAZOP requirements
How it works
Case study
HAZOP team
Advantage & disadvantage
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Scenario What is the
cause of the
accident?
You and your family are on a road trip by using a car in the
middle of the night. You were driving at 100 km/h and, it was
raining heavily.
Can we be The car hits a deep hole and, one of your tire
prepared What is the
blows. You hit
before thethe brake, but due to slippery road and your car
consequence
tire thread was thin, the car skidded andofwas
accident thrown off the
the event?
road.
occurs?
Points to
Ponder
What other What can we
possible do to prevent
accidents all those
might happen things to
on the road happen in the
trip? first place?
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Definition
- Is structured technique, which may be
applied typically to a chemical production
process, identifying hazards resulting from
HAZOP potential malfunctions in the process
(Hazard &
Operability)
Study
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History
Initially prepared by
Dr. H G Lawley and
associates of ICI at
Wilton in 1960s .
In 1977, Chemical
Industries Association
published the edited
version.
ICI expanded the
procedure called
HAZARD STUDY levels
1 to 6.
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ICI Six Levels
Project exploration / preliminary project assessment
Project definition
Design and procurement
During final stages of construction
During plant commissioning
During normal operation, some times after start-up
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REMEBER
HAZOP is an
identifying technique
and not intended as
a means of solving
problems
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Features of HAZOP Study
Subsystems of interest line and valve, etc Equipment,
Vessels
Modes of operation Normal operation
Start -up mode
Shutdown mode
Maintenance /construction /
inspection mode
Trigger events Human failure
Equipment /instrument/component
failure
Supply failure
Emergency environment event
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Features of HAZOP Study
Effects within plant Changes in chemical conditions
Changes in inventory
Change in chemical physical
conditions
Corrective actions Change of process design
Change of operating limits
Change of system reliability
Improvement of material
containment
Change control system
Add/remove materials
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Features of HAZOP Study
How would hazardous conditions During normal operation Upon
detected ? human failure
Upon component failure In other
circumstances
Contingency actions Improve isolation Improve
protection
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Documents Needed for
HAZOP Study
Process Flow Sheet or digram ( PFS or PFD )
Preliminary
Description of the Process
HAZOP
Piping and Instrumentation Diagram (P & ID)
Process Calculations
Process Data Sheets
Instrument Data Sheets
Detailed Interlock Schedules
Layout Requirements
HAZOP Hazardous Area Classification
Description of the Process
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Process Flow Diagram (PFD)
The PFD displays the
Is a diagram commonly used
relationship
in chemical and process
between major equipment
engineering to indicate the
of a plant facility and does
general flow of plant
not show minor details such
processes and equipment.
as piping details and
designations
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Process Flow Diagram (PFD)
Example
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P&ID
A Piping and
Instrumentation
Diagram - P&ID, is a
schematic illustration P&ID represents the
of functional last step in process
relationship of piping, design.
instrumentation and
system equipment
components.
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P&ID Example
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HAZOP Procedure
List of guide words
for generation of
process deviations
Possible Process Possible
Causes Deviations Consequences
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Definitions
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Study Nodes
The locations (on
piping and
instrumentation
drawings and
procedures) at which
the process
parameters are
investigated for
deviations.
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Intention
The intention defines
how the plant is
expected to operate
in the absence of
deviations at the
study nodes.
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Deviations
Is a way in which the
process conditions
may depart from their
design/process intent
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Causes
These are the reasons
why deviations might
occur
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Consequences
The results of the
deviation, in case it
occurs.
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Safeguards
Facilities that help to
reduce the
occurrence
frequency of the
deviation or to
mitigate its
consequences.
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Guide Words
A short word to
create the
imagination of a
deviation of the
design/process intent.
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Guide Words Used
(most 7 used)
Guide Words Meaning
No Negation of the design intend
Less Quantitative Decrease
More Quantitative Increase
Part of Qualitative Decrease
As Well As Qualitative Increase
Reverse Logical opposite of the intend
Other Than Complete Substitution
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HAZOP Deviation Guide
Guide No, Less, More, Part of As Well As, Other Than Reverse
Process Words Not, Low, High, Also
Variable None Short Long
Flow No Flow Low Rate High Rate Missing
Ingredient
Misdirection,
Impurities
Wrong
Material
Backflow
Pressure Open to
Atmosphere
Low Pressure High
Pressure
____________ ____________ ____________ Vacuum
Temperature Freezing Low
Temperatur
High
Temperatur
____________ ____________ ____________ Auto
refrigeration
e e
Level Empty Low Level High Level Low
Interface
High
Interface
____________ ____________
Agitation No Mixing Poor Mixing Excessive
Mixing
Mixing
Interruption
Foaming,
Extra Phase
____________ Phase
Separation
Reaction No Reaction Slow
Reaction
Runaway
Reaction
Partial
Reaction
Side
Reaction
Wrong
Reaction
Decompositi
on
Time Skipped or
Missed Step
To Short,
To Little
Too Long,
Too Much
Action
Skipped
Extra Action
(Shortcuts)
Wrong
Action
Out of
Order,
Procedure Opposite
Speed Stopped Too Slow Too Fast Out of
Synch
____________ Web or Belt
Break
Backward
Special Utility Failure External
Leak
External
Rupture
Tube Leak Tube
Rupture
Startup,
Shutdown,
____________
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Process Parameters
Process parameters may generally be classified into the following groups:
Physical parameters related to input medium properties
Physical parameters related to input medium conditions
Physical parameters related to system dynamics
Non-physical tangible parameters related to batch type processes
Parameters related to system operations
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Examples of Process
Parameters
Flow Pressure Composition Addition Separation Time
pH Signal Start/stop Operate Maintain Services
Communication Temperature Mixing Stirring Transfer Phase
Speed Particle size Measure Control Level Viscosity
Reaction Sequence
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Simply How does it work?
NODE: Pipe after pump and splitter
PARAMETER: Flow rate
GUIDE WORD: Less (less than normal
value)
DEVIATION: less flow than normal
A group members
CAUSE: of deviation, can be more than
focus on the same
one
issue
CONSEQUENCE: of the deviation/cause
ACTION: initial idea for correction/
prevention/mitigation
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The HAZOP Process
Select Equipment Node
Choose Deviation OR Parameters & Guide Words
Identify Causes
Associate Consequences
Apply Risk Ranking
Agree Actions To Be Taken
Monitor Actions For Completion
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Case
Study
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Case Study 1: Preliminary
HAZOP on Reactor
Cooling Water Refer to reactor system shown.
The reaction is exothermic. A cooling system
is provided to remove the excess energy of
reaction. In the event of cooling function is
lost, the temperature of reactor would
increase. This would lead to an increase in
reaction rate leading to additional energy
release.
The result could be a runaway reaction with
pressures exceeding the bursting pressure of
the reactor. The temperature within the
reactor is measured and is used to control
the cooling water flow rate by a valve.
Perform HAZOP Study
Case Study 1: Preliminary 33
HAZOP on Reactor
Cooling
Water
Guide Word Deviation Causes Consequences Action
No
Reverse
More
Other
As Well Than
As No
MoreCooling
Reverse
Another
Reactor cooling
cooling
material
product Cooling
Failure
Control
Water ofwater
waterin
source
valve
More pressure Temperature
Less
Too
May cooling,
much
be cooling
Off-spec product Install
Instruct
If high
check
less cooling,
Check operators
flow
besides
in coils cooling valve
source
failure, resulting
contaminated
reactoroperator increase
cooling, in and
possible runaway
ineffective
reactor temperature
valve
on
TAH procedures
will detect. If
maintenance
water malfunction
in backward
fails to take flow reactor
reaction
cool
effect on the alarm
detected,(TAH)isolate
procedures and
action on alarm reaction water
schedulessource.
Back up water
source?
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Case Study 2: Shell & Tube
Heat Exchanger
Using relevant guide words, perform
HAZOP study on shell & tube heat
exchanger
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Case Study 2: Shell & Tube
Heat Exchanger (Answer 1)
Guide Word Deviation Causes Consequences Action
Less
More
More of Less
Moreflow
More of
cooling
pressure on Pipe blockage
Failure
Failure of cooling
of of
process Temperature
Bursting of tubeof High
Low
InstallTemperature
high
Contamination Contamination of Leakage tube Contamination of Proper
Corrosion cooling
flow water
Corrosion
tube side of tube Hardness
water of
valve
fluid cooling
valve Less cooling
process fluid and Temperature
Proper
Alarm
pressure alarm
process fluid line and process fluid maintenance
cooling water remains
crack ofconstant
decrease tube Alarm
maintainence
water goes in and operator
alert
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Case Study 2: Shell & Tube
Heat Exchanger (Answer 2)
Guide Word Deviation Causes Consequences Action
None
More No
Morecooling water
cooling Failure
Failure of
of inlet
inlet Process
Output fluid
of Process Install
Install
Less
Reverse Less cooling
Reverse process Pipe
Failureleakage
ofwater
process Process
Product fluid
off set Installation
Install check of
Contamination flow
Process
water fluid
flow cooling
Contamination
cooling water in temperature
Outlet
fluid is
temperature Temperature
Proper
Temperature
water
fluid flow fluid inletopen
valve temperature too flow meter
valve
contamination valve
valve to
cooling towater
close not lowered
temperature
too low too indicator
indicator before
maintenance before
low
accordingly
low after the
and after
operatorprocess
process
alert
fluid line fluid line
Install
Install TAH
TAL
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HAZOP Team
Design Engineer
Process
5 to 7 members
Engineer
Operations
Supervisor
Instrument
Design Engineer
Chemist
Maintenance
Supervisor
Safety Engineer
(team leader)
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HAZOP Advantage
Easy to learn
Stimulates creativity and generates ideas
Systematic and through procedure
Participants gain valuable knowledge of process
Readily acceptable to regulatory authorities
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HAZOP Disadvantage
Time consuming
Focusing too much on solutions
Team members allowed to divert into endless
discussions of details
HAZOP is poor where multiple-combination
events can have severe effects.
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Division Into Sections
Guideline
Each section should contain
active components, which
Section based on process and
Choices of linesP&ID must be gives rise to deviations. e.g Materials in section contain
states of materials. Only 1
divided logically. Not too piping which contains control significant amount of
process operation per 1
many sections. valves can give rise to flow hazardous materials.
section.
deviations, heat exchangers
can cause Temp. deviations.
Define one line section Define additional line sections Define a process section at
Define each major process
between each major process for each branches off the each connection to existing
component as a section.
component. main process flow. equipment.
Define only one line at the Define only one additional line
Define only one process
end of a series of components section if there are alternative
section for equipment in
if there are no other flow flow paths, regardless of how
identical service.
paths. many branches there are.
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