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054402 Design and Analysis LECTURE 12: HAZARD AND OPERABILITY (HAZOP) STUDIES
Daniel R. Lewin Department of Chemical Engineering Technion, Haifa, Israel
12 - HAZOP
OUTLINE
This lecture, and next weeks lecture: ! Provide motivation for performing a HAZOP/HAZAN study on a process ! This lecture provides instruction on how to carry out a HAZOP analysis ! Next lecture, we will learn about the tools and methods used in a HAZAN analysis Sources:
" HAZAN is a technique for estimating the probability and consequences of a hazard. " HAZOP is a technique for identifying hazards without waiting for an accident to occur.
T. Kletz, HAZOP and HAZAN, 3rd Ed., IChemE (1992) T. Kletz, Learning from Accidents in Industry, Butterworths (1988) T. Kletz, What Went Wrong?, 2nd Ed., Gulf Publishing Co. (1988)
2 DESIGN AND ANALYSIS - (c) Daniel R. Lewin 12 - HAZOP
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$ What will be the consequences? % How often will it occur ? & How can it be prevented ? ' Is the cost of prevention justified ?
FI
PG FI TR
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FRC RF
12 - HAZOP
A HAZOP is a systematic procedure to analyze the hazards associated with each process pipeline, applying the following guide words: NONE, MORE OF, LESS OF, REVERSE, OTHER THAN, PART OF, MORE THAN.
4 DESIGN AND ANALYSIS - (c) Daniel R. Lewin 12 - HAZOP
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7. Prevention 2.
Perhaps our method of prevention has disadvantages, and better methods can be suggested. We should answer this question before a table is made and a glass ordered.
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More components present than there should be: e.g. extra phase present, or impurities. What else can happen apart from NOC: e.g. startOTHER THAN up, shut-down, failure of services
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HAZOP PROCEDURE
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HAZOP PROCEDURE
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HAZOP PROCEDURE
Note: In addition to identifying each hazard, it is important to also estimate its severity, on a scale of 1 (high) to 4 (low), and likelihood, on a scale of 1 (high) to 4 (low).
11 DESIGN AND ANALYSIS - (c) Daniel R. Lewin 12 - HAZOP
Severity Significance 1 2 3 4 High Fatality/serious injury hazard or hazard leading to loss of >6 months production or loss greater than $10M Medium High Injury hazard or hazard leading to loss of 1-6 months production or loss between $1-10M Medium Low Minor injury hazard or hazard leading to loss of 1-4 weeks production or loss between $0.1-1M Low No injury hazard or hazard leading to loss of <1 weeks production or loss less than $100,000
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Likelihood
Ranking A B Significance
2 3 4
Acceptable risk level. Almost acceptable risk level. Acceptable if suitably controlled level. by management. Should check that suitable procedures and/or control systems are in place. Undesirable risk level. Must be reduced to level B at the most level. by engineering or management control. Unacceptable risk level. Must be reduced to level B at the most by engineering or management control.
DESIGN AND ANALYSIS - (c) Daniel R. Lewin 12 - HAZOP
C D
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LECTURE TWELVE
FI
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As for (1).
(3) Line As for (1). J1 blockage, pump isolation valve overheats. closed in error, or LCV fails shut.
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MORE OF
More flow
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More pressure
2 1 (j) Covered by (c) except when kickback blocked or isolated. Check line and FI. Install a PG upstream of LCV and an independent PG on settling tank.
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More temp.
(l) Check whether there is adequate warning of high temperature at intermediate storage. If not, install.
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Less temp.
(m) Lag water sump down to drain valve and steam trace valve and drain line downstream.
4 1 A
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Higher system (p) Check that settling tank pressure. and piping, including relief valve, will cope with sudden inflow of more volatile HCs.
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OTHER
(r) Install low-point drain and N2 purge point downstream of LCV. Also N2 vent on settling tank.
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Ensure communication with CM intermediate storage operator. Install low level alarm on settling tank. Install kickback on J1 pumps. Check design on J1 pump strainers. IDE DE DE
Institute regular patrolling and CM inspection of transfer line. Install high level alarm on LIC. IDE
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SUMMARY
On completing this weeks materials, you should be able to carry out a HAZOP analysis: " Applying the guide words systematically to identify the most imporant hazards affecting each line in the process. " Categorizing each hazard according to its severity, likelyhood and cost. " Realizing that a HAZOP analysis is an ongoing process that needs to be documented and followed up. Next lecture, we will learn about the tools and methods used in a HAZAN analysis, which is a technique for estimating the probability and consequences of a hazard.
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