Hazop Training Presentation
Hazop Training Presentation
Hazop Training Presentation
Fundamental
16/11/21
A scenario…
You and your family are on a road trip by using a car in the middle of
the night. You were replying a text message while driving at 100
km/h and it was raining heavily. The car hits a deep hole and one of
your tire blows. You hit the brake, but due to slippery road and your
car tire thread was thin, the car skidded and was thrown off the road.
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Points to ponder
What can we do to prevent all those things to happen in the first place?
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What other possible accidents might happen on the
road trip?
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Can we make it more systematic?
Car speed Too fast Rushing Skidded when - Slow down -ABS brake system
Too slow emergency brake - Speed up -Safety belt
- Air bag
Tire No thread Tire too old, often Car skidded - Check frequently
Less thread speeding and - Have spare tire
emergency break
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What is HAZOP?
• Systematic technique to IDENTIFY potential HAZard and
OPerating problems
• A formal systematic rigorous examination to the process and
engineering facets of a production facility
• A qualitative technique based on “guide-words” to help provoke
thoughts about the way deviations from the intended operating
conditions can lead to hazardous situations or operability problems
• HAZOP is basically for safety
- Hazards are the main concern
- Operability problems degrade plant performance (product quality,
production rate, profit)
• Considerable engineering insight is required - engineers working
independently could develop different results
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Origin of HAZOP
Initially prepared by Dr H G Lawley and associates of
ICI at Wilton in 1960’s.
Subsequently C J Bullock and A J D Jenning from ChE
Dept. Teeside Polytechnic under supervision of T.A.
Kletz applied the method at higher institution (post-
graduate level).
In 1977, Chemical Industries Association published the
edited version.
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Later Development - HAZOP
ICI expanded the procedure called HAZARD STUDY steps 1 to
6.
The ICI six steps :
Project exploration / preliminary project assessment – to identify
inherent hazards of process chemicals, site suitability and probable
environmental impact.
Project definition – to identify and reduce significant hazards
associated with items and areas, check conformity with relevant
standards and codes of practices.
USE CHECK LISTS
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Later Development - HAZOP
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Later Development - HAZOP
During normal operation, some time after start-up – especially
if any modification been made. To check if changes in
operation has not invalidated the HAZOP report of step iii by
introducing new hazards.
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Objective of HAZOP
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How and Why HAZOP is Used
• HAZOP identifies potential hazards , failures and operability
problems.
• Its use is recommended as a principal method by professional
institutions and legislators on the basis of proven capabilities for
over 40 years.
• It is most effective as a team effort consists of plant and prices
designers, operating personnel, control and instrumentation
engineer etc.
• It encourages creativity in design concept evaluation.
• Its use results in fewer commissioning and operational problems
and better informed personnel, thus confirming overall cost
effectiveness improvement.
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How and Why HAZOP is Used
• Necessary changes to a system for eliminating or reducing the
probability of operating deviations are suggested by the analytical
procedure.
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How and Why HAZOP is Used
• HAZOP technique is now used by most major companies handling
and processing hazardous material, especially those where
engineering practice involves elevated operating parameters :
- oil and gas production
- flammable and toxic chemicals
- pharmaceuticals etc
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Purpose of HAZOP
• It emphasizes upon the operating integrity of a system, thereby
leading methodically to most potential and detectable deviations
which could conceivably arise in the course of normal operating
routine
- including "start-up " and "shut-down" procedures
- as well as steady-state operations.
• It is important to remember at all times that HAZOP is an
identifying technique and not intended as a means of solving
problems nor is the method intended to be used solely as an
undisciplined means of searching for hazardous scenarios.
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HAZOP - Hazard and operability
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Relevant Question About HAZOP
Separate consideration is demanded for other operating modes,
such as commissioning, emergency shut-down procedures and
isolation of equipment for maintenance or modification.
' Operability' must also consider the human factors involved as well
as the prediction of equipment behavior.
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Relevant Question About HAZOP
Apart from the uniformity of day-to-day activities , hazards which
could cause major production interruptions and loss, possibly
leading to costly incidents, need to be identified :
• Are there chemicals used in the plant which have not been
classified as hazard because they are handled in small quantities,
are assumed harmless, or are not considered to have long-term
toxic effect upon employees?
• What hazardous materials are transported to or from the site ?
• What routes are taken ?
• What would be the consequences of accidental release?
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Relevant Question About HAZOP
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Features of HAZOP Study
Subsystems of interest line and valve, etc
Equipment, Vessels
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Features of HAZOP Study
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Features of HAZOP Study
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Documents Needed for HAZOP Study
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Before Detailed HAZOP
The development of the detailed P&I Diagram is the last stage of
the process design.
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P&ID
A Piping and Instrumentation Diagram - P&ID, is a schematic illustration of functional
relationship of piping, instrumentation and system equipment components.
P&ID shows all of piping including the physical sequence of branches, reducers,
valves, equipment, instrumentation and control interlocks.
P&ID is normally developed from process flow diagram (PFD).
The P&ID are used to operate the process system.
A process cannot be adequately designed without proper P&ID.
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P&I D
A P&ID should include: (Basically every mechanical aspect of the plant with some exceptions)
Instrumentation and designations
Mechanical equipment with names and numbers
All valves and their identifications
Process piping, sizes and identification
Miscellaneous - vents, drains, special fittings, sampling lines, reducers, increasers and swagers
Permanent start-up and flush lines
Flow directions
Interconnections references
Control inputs and outputs, interlocks
Interfaces for class changes
Seismic category
Quality level
Annunciation inputs
Computer control system input
Vendor and contractor interfaces
Identification of components and subsystems delivered by others
Intended physical sequence of the equipment
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P&I D
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P&ID and Safety
P&I Diagram
ISA Standard
DIN Standard
Layers of protection
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HAZOP Study Procedure
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HAZOP Study Flow Chart
Select Line
Select deviation
e. g more flow
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Guidelines for Division into Sections
General guidelines :
Define each major process component as a section. Usually
anything assigned equipment number should be considered a major
process component.
Define one line section between each major process component.
Define additional line sections for each branches off the main
process flow.
Define a process section at each connection to existing equipment.
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Guidelines for Division into Sections
Supplementary guidelines
Define only one process section for equipment in identical service.
However, pumps in different service with a common spare must be
treated separately.
Define only one line at the end of a series of components if there are no
other flow paths.
Define only one additional line section if there are alternative flow
paths, regardless of how many branches there are.
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Guidelines for Division into Sections
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HAZOP Study Procedure
GUIDE WORDS *
CONSEQUENCES
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Guide Words
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Guide Words
NONE e.g., NO FLOW caused by blockage; pump failure;
valve closed or jammed : leak: valve open ;suction
vessel empty; delivery side over - pressurized :
vapor lock ; control failure
REVERSE e.g., REVERSE FLOW caused by pump failure : NRV
failure or wrongly inserted ; wrong routing; delivery
over pressured; back- siphoning ; pump reversed
MORE OF e.g., MORE FLOW caused by reduced delivery
head ; surging ; suction pressurised ; controller
failure ; valve stuck open leak ; incorrect instrument
reading.
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Guide Words
MORE OF MORE TEMPERATURE, pressure caused by external
fires; blockage ; shot spots; loss of control ; foaming;
gas release; reaction;explosion; valve closed; loss of
level in heater; sun.
LESS OF e.g., LESS FLOW caused by pump failure; leak; scale in
delivery; partial blockage ; sediments ; poor suction
head; process turndown.
LESS e.g., low temperature, pressure caused by Heat loss;
vaporisation ; ambient conditions; rain ; imbalance of
input and output ; sealing ; blocked vent .
PART OF Change in composition high or low concentration of
mixture; additional reactions in reactor or other
location ; feed change.
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Guide Words
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HAZOP STUDY REPORT FORM
TITLE :
Sheet 1 of
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HAZOP Study
HAZOP study are applied during :
• Normal operation
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Strength of HAZOP
• HAZOP is a systematic, reasonably comprehensive and flexible.
• It is suitable mainly for team use whereby it is possible to
incorporate the general experience available.
• It gives good identification of cause and excellent identification
of critical deviations.
• The use of keywords is effective and the whole group is able to
participate.
• HAZOP is an excellent well-proven method for studying large
plant in a specific manner.
• HAZOP identifies virtually all significant deviations on the plant,
all major accidents should be identified but not necessarily their
causes.
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Weakness of HAZOP
• HAZOP is very time consuming and can be laborious with a
tendency for boredom for analysts.
• It tends to be hardware-oriented and process-oriented, although
the technique should be amenable to human error application.
• It tends to generate many failure events with insignificance
consequences and generate many failure events which have the
same consequences.
• It stifles brainstorming although this is not required at the late
stage of design when it is normally applied.
• HAZOP does not identify all causes of deviations and therefore
omits many scenarios.
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Weakness of HAZOP
• It takes little account of the probabilities of events or
consequences, although quantitative assessment are sometime
added. The group generally let their collective experiences decide
whether deviations are meaningful.
• HAZOP is poor where multiple-combination events can have
severe effects.
• It tends to assume defects or deterioration of materials of
construction will not arise.
• When identifying consequences, HAZOP tends to encourage
listing these as resulting in action by emergency control measures
without considering that such action might fail. It tends to ignore
the contribution which can be made by operator interventions
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Managing HAZOP
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Preliminary HAZOP Example
Cooling Coils
Refer to reactor system shown.
Monomer
Feed 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
Cooling Water to Sewer would lead to an increase in reaction rate leading to additional
energy release.
T
C Thermocouple
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Preliminary HAZOP on Reactor - Example
Guide Word Deviation Causes Consequences Action
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Preliminary HAZOP on Reactor – Answer
Guide Word Deviation Causes Consequences Action
NO No cooling Cooling water valve malfunction Temperature increase in Install high temperature alarm
reactor (TAH)
REVERSE Reverse cooling flow Failure of water source Less cooling, possible runaway Install check valve
resulting in backward flow reaction
MORE More cooling flow Control valve failure, operator Too much cooling, reactor cool Instruct operators on
fails to take action on alarm procedures
AS WELL AS Reactor product in More pressure in reactor Off-spec product Check maintenance
coils procedures and
schedules
OTHER THAN Another material Water source May be cooling inefffective and If less cooling, TAH will
besides cooling contaminated effect on the reaction detect. If detected, isolate
water water source. Back up water
source?
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Case Study – Shell & Tube Heat Exchanger
Using relevant guide works, perform HAZOP study on shell & tube heat exchanger
Process
fluid
Cooling water
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HAZOP on Heat Exchanger – Answer 1
Guide Word Deviation Causes Consequences Action
Less Less flow of cooling Pipe blockage Temperature of process fluid High Temperature Alarm
water remains constant
More More cooling flow Failure of cooling water Temperature of process fluid Low Temperature Alarm
valve decrease
More of More pressure on tube Failure of process fluid Bursting of tube Install high pressure alarm
side valve
Contamination Contamination of Leakage of tube and Contamination of process fluid Proper maintainance and
process fluid line cooling water goes in operator alert
Corrosion Corrosion of tube Hardness of cooling water Less cooling and crack of tube Proper maintainence
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HAZOP on Heat Exchanger – Answer 2
Guide Word Deviation Causes Consequences Action
NONE No cooling water flow Failure of inlet cooling water Process fluid temperature is not Install Temperature indicator
valve to open lowered accordingly before and after the process fluid
line
Install TAH
MORE More cooling water flow Failure of inlet cooling water Output of Process fluid temperature Install Temperature indicator
valve to close too low before and after process fluid line
Install TAL
LESS Less cooling water Pipe leakage Process fluid temperature too low Installation of flow meter
REVERSE Reverse process fluid flow Failure of process fluid inlet Product off set Install check valve (whether it is
valve crucial have to check?)
CONTAMINATION Process fluid contamination Contamination in cooling water Outlet temperature too low Proper maintenance and operator
alert
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HAZOP - Hazard and Operability
ATTITUDE CHECK
Guide
Nodes HA
ZO
P words
Parameters
Deviation
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I suppose that I
should have done that
HAZOP Study!
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HAZOP - Hazard and Operability
You are
responsible for the
safety team.
Without HAZOP
How will you focus all
members of a team on the
key issues in a systematic
manner?
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HAZOP Management
08.01.2012
Planning for HAZOP Study
What is required?
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Planning for HAZOP
• Prepare for the study. Need sufficient information :
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Planning for HAZOP
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Planning for HAZOP
Carry out the study
Record the results (may need a secretary)
Follow-up of actions noted
final report contain resolution of all recommended actions
must appoint someone as leader to check progress of action
team may meet again if answers to questions do not simply lead
to an action
team may meet again if significant design changes in interim
report
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Team Characteristics
Members share common objectives.
Everybody contributes and knows his/her roles, not leader
dependent too much.
Each members values and respects contribution of others.
Members learn while they work.
Over a period of time, individual contribution level are more or less
equal.
Disagreement are worked through by discussion.
The use of voting procedures is sparing and normally only last
resort if highly necessary.
Members enjoy team meetings.
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Questioning Techniques
Open questions
Help person being asked to think – use words how, what and
why.
Closed questions
To focus on an issue or problem. Start with words who, when,
where.
Required answer yes or no only.
Question mix
Mix between open and closed questions.
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Questioning Techniques
Things to avoid
Ambiguous or vague questions.
Double barelled/multiple questions.
Long complicated questions.
Interrogation type of questions.
A loaded questions – implied judgement.
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Responsibility of HAZOP Team Members
HAZOP leader
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Checklist for HAZOP Leader
If conflict arises, handle with care.
Avoid long discussions by recording areas which need
to be resolved outside meeting.
Leader must be strong, yet diplomatic.
Speak clearly. Make you point.
Better have experience working as team member
previously.
Do not skip anything….some time small things may
cause big accident.
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Responsibility of HAZOP Team Members
HAZOP Secretary
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Responsibility of HAZOP Team Members
Process Engineer
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Responsibility of HAZOP Team Members
Instrument Engineer
Chemist
Project Engineer