CHAPTER 1

Hazard and Operability Analysis for the Vacuum Pan

Boiler
The Hazard and Operability Analysis is carried out by considering the most
influential nodes of an equipment. Thus the whole equipment is
considered in sections so that the least risk of a non-significant failure
would also be recognized and the study becomes precise. The following
drawing shows the major concerns with the vacuum pan boiler.

Figure 1.1: Considered nodes of the vacuum pan boiler

1. Inlet flow rate
Table 1.1: HAZOP analysis for the inlet flow rate
Guide
word +
Deviation
No Flow

Consequences

Internal
Overheating
Internal
pressure rise

Causes

Total pipe
blockage
Total pipe leakage
Totally closed

Suggestions

Install a no-flow
alarm
Regular
maintenance of

Low Flow

Internal
Overheating
Internal
pressure rise

More
Flow

Internal
temperature
drops and
pressure
disorders
Can damage
vacuum pan

valves
Partial pipe
blockage
Partial pipe
leakage
Partially closed
valves
More input feed
to the system
Malfunctioning of
control valves

the pipe lines

Install a low-flow
alarm
Regular
maintenance of
the pipe lines
Install more flow
alarm
Regular checking
and maintenance

2. Steam output flow rate

Table 1.2: HAZOP analysis for the stem output flow rate
Guide
word +
Deviation
No Flow

Low Flow

More
Flow

Consequences

Internal
pressure rise
and may lead
to explosions
Internal
pressure rise
and
malfunctioning
of vacuum pan
Product quality
is affected
Directly affects
the product
quality
More output of
the unit and
total process
will be affected

Causes

Suggestions

Total pipe
blockage
Leakage of
vacuum pan
Totally closed
valves
Partial pipe
blockage
Partial leakage of
vacuum pan
Partially closed
valves

Install a no-flow
alarm
Regular
maintenance of
the pipe lines

More input feed

to the system
Malfunctioning of
control valves

Install more flow

alarm
Regular checking
and maintenance

Install a low-flow
alarm
Regular
maintenance of
the pipe lines

3. Product output flow rate

Table 1.3: HAZOP analysis for the product output flow rate
Guide

Consequences

Causes

Suggestions

word +
Deviation
No Flow

Internal
pressure rise
and may lead
to explosions

Low Flow

Internal
pressure rise
and
malfunctioning
of vacuum pan
Product quality
is affected

More
Flow

Directly affects
the product
quality
Process break

Total pipe
blockage
Leakage of
vacuum pan
Totally closed
valves
No feed to the
system
Partial pipe
blockage
Partial leakage of
vacuum pan
Partially closed
valves
Partial feed to the
unit
More input feed
to the system
Malfunctioning of
control valves

Install a no-flow
alarm
Regular
maintenance of
the pipe lines

Install a low-flow
alarm
Regular
maintenance of
the pipe lines

Install more flow

alarm
Regular checking
and maintenance

4. Steam output temperature

Table 1.4: HAZOP analysis for the stem output temperature
Guide
word +
Deviation
Low
Temperat
ure

High
Temperat
ure

Consequences

Low product
quality
Internal
pressure
disorders

Low product
quality
Internal
pressure
disorders

Causes

Suggestions

Low feed
temperature
Steam supply
system
malfunctioning
Burning chamber
failure
High feed
temperature
Steam supply
disorder

Fix low
temperature
alarm
Fix pressure
maintenance
valve to vacuum
pan
Fix high
temperature
alarm
Fix pressure
maintenance
valve to vacuum
pan

5. Inlet flow temperature

Table 1.5: HAZOP analysis for the inlet flow temperature

Guide
word +
Deviation
Low
Temperat
ure

High
Temperat
ure

Consequences

Low product
quality
Internal
pressure
disorders
Steam output
disorders
Low product
quality
Internal
pressure
disorders
Steam output
disorders

Causes

Suggestions

More input feed

to the system
Malfunctioning in
evaporators

Fix low
temperature
alarm
Fix pressure
maintenance
valve to vacuum
pan
Fix high
temperature
alarm
Fix pressure
maintenance
valve to vacuum
pan

Low input feed to

the system
Malfunctioning in
evaporators

CHAPTER 2
Cost Analysis of the Vacuum Pan Boiler
Production and installation cost analysis of an equipment is almost a kind
of prediction thus an evaluation of money with its increasing value should
be done in coordination with the cost analysis. This is an attempt to get its
cost analyzed with the highest possible accuracy and precision.