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Data Requirements
Definition of steps, including process conditions, agitation / mixing, charging,
reacting, discharging etc.
Interlocks in operation during step (e.g. valves held closed)
Necessary conditions to move to next step
Details of alarms, including watchdog timers
Preparations
Leader and some members should prepare before study to understand:
Hazards of the process
Control scheme, including sequence control
Cycle of operations and main process steps
Study sections to be used
Preparations
Leader must decide how to carry out the study, after preparing the following:
A matrix showing the process steps and the study sections, and showing which
section is active in which step
A chart showing which valves, drives, pumps and instruments are active in each
step of the process
Guidewords
The standard guidewords from Process HAZOP are used
Additionally, guidewords related to the following parameters are used:
- Time
- Step
- Action
MORE TIME
LESS TIME
WRONG TIME
STEP BACKWARDS
STEP BACKWARDS
Thus, guidewords associated with the parameter STEP can be addressed by TIME
EXTRA ACTION
WRONG ACTION
10
Complete Logsheet
No
Take next active
section
Yes
Take other inactive sections
Complete Logsheet
Last Step ?
Yes
Finshed
11
Next
Step
Use all guidewords for active steps, not for inactive steps, where becomes active
is the deviation
Take each section in turn, and repeat this process
Identify and study other sections not in normal operation
12
Complete Logsheet
No
Take next step in
which
this section is
active
Yes
Take steps in which this
Section is not active
Complete Logsheet
Last Section ?
Yes
Finshed
13
Next
Section
14
V281
T1
P1
Q.R.C.
10
150#
T1
V284
V282
1.5
10 Export Line
1.5
XCV3
V78
1
V280
V283
V80
V77
To Sea
15
(1)
Cool Line
(2)
Connect
Arm
(3)
Cool Arm
Delivery Line
Recirculation
Line
Loading Arm
Sections
(4)
(5)
(6)
Load Ship Purge and Disconnect
Drain Arm
Arm
16
(1)
Cool Line
(2)
Connect
Arm
(3)
Cool Arm
V77
V80
V78
V284
XCV3
V280
XCV4
V281
QRC
Conn
Conn
Conn
Conn
V282
V283
Valves etc.
(4)
(5)
(6)
Load Ship Purge and Disconnect
Drain Arm
Arm
17
Nitrogen Purge
Solvent A
Condenser
HV-1
Reactant B
PCV-1
HV-2
Reactant C
HV-5
Coolant in
TCV-2
Catalyst D
HV-3
AV-1
HV-7
Stirrer
AG-1
HV-4
Vacuum
Vent
Receiver
R2
Heating/cooling fluid
TCV-1
Distillate
Transfer
Batch
Reactor R1
P-3
HV-6
Product discharge to storage
P-1
P-2
PCV-2
Slide 18
HV-1
HV-2
HV-3
HV-4
HV-5
HV-6
HV-7
PCV1
PCV2
AV-1
TCV1
TCV2
AG-1
P-1
P-2
P-3
Off
Off
Off
Off
1. Nitrogen Purge
Off
Off
Off
Off
2. Charging Solvent A
Off
Off
Off
Off
3. Charging Reactant B
On
Off
Off
Off
4. Charging Reactant C
On
Off
Off
Off
5. Charging Catalyst D
On
Off
Off
Off
6. Heating
On
On
Off
Off
On
On
Off
Off
8. Distillation
On
On
Off
Off
9. Break vacuum
On
On
Off
Off
10. Cooling
On
On
Off
Off
On
On
Off
On
Off
Off
On
Off
Symbols used:
C = closed
O = open
M = modulating
Slide 19
10
11
12
1. Nitrogen purge
2. Reactor
3. Jacket heating/cooling
4. Heating/cooling supply
5. Heating/cooling discharge
4. Solvent A
5. Reactant B
6. Reactant C
7. Vacuum system
8. Vent system
9. Catalyst D
12. Receiver
circulation system
Det
Norske
Veritas
AS. All
rights
22 May
2013
Slide 20
Node Description:
Step 1
Nitrogen Purge to reactor
Section
Nitrogen purging line to reactor (active for this step)
GUIDEWORD/
DEVIATION
No Flow
More
Pressure
Less Time
CAUSES
Node: 001
Page: 1
CONSEQUENCES
SAFEGUARDS
REC
#
RECOMMENDATION
R1
Provide a flowmeter in
the nitrogen supply line
to indicate nitrogen flow
to the reactor during
purging.
Operator knowledge
and training. Reliable
nitrogen supply.
As for No Flow
(above).
Det
Norske
Veritas
AS. All
rights
22 May
2013
R3
Slide 21
CAUSES
Less Flow
(Vent Line)
Node: 002
Page: 1
SAFEGUARDS
Standard pre-checks
for this process are that
reactor manway should
be bolted closed before
starting the nitrogen
purge.
Standard pre-checks
for this process are that
catalyst charge valve
should be closed
before starting the
nitrogen purge.
As before.
Operating procedures.
Catalyst charge
valve open.
As above.
Det
Norske
Veritas
AS. All
rights
22 May
2013
REC
#
RECOMMENDATION
Slide 22
Node: 003
More flow
(vacuum
line)
CAUSES
Page: 1
CONSEQUENCES
SAFEGUARDS
Det
Norske
Veritas
AS. All
rights
22 May
2013
REC
#
RECOMMENDATION
Pressure gauge on
reactor.
Slide 23
Node: 001
CAUSES
No flow
Operator forgets to
charge solvent.
Valve blocked.
More time.
Operator error.
Batch meter set
incorrectly.
Wrong
Action
Operator error.
Wrong solvent
supply routed to
reactor.
Page: 2
SAFEGUARDS
Det
Norske
Veritas
AS. All
rights
22 May
2013
REC
#
RECOMMENDATION
R4
Provide
software
interlock on batch meter
for Solvent A to ensure
that
batch
quantity
cannot be exceeded.
Operator checks
solvent quantity added
on meter upsteam.
This is entered on the
batch record sheet.
Operating procedures.
Operating procedures.
Check
what
other
solvent
could
be
mistakenly added to the
reactor
and
check
whether these could
create a hazard if they
were used instead of
Solvent A.
Slide 24
Node: 005
CAUSES
Page: 1
SAFEGUARDS
Operating procedues
and pre-start checks
that run out valve is
closed before adding
solvent. Solvent loss
would be small since P2 must be used to
remove material from
the reactor
Det
Norske
Veritas
AS. All
rights
22 May
2013
REC
#
RECOMMENDATION
Slide 25
Node: 005
Section
CAUSES
Page: 1
SAFEGUARDS
REC
#
RECOMMENDATION
No hazards identified.
Det
Norske
Veritas
AS. All
rights
22 May
2013
Slide 26
27