PROCESS SAFETY STUDIES

Introduction

A hazard is something which may cause harm and is an undesired event. It includes
any sources, situations, or acts with a potential damage, harm (property, workplace, and
environment), injury or adverse health effects (human health). Therefore, these hazards
need to be identified first before any operation could begin. There are various approaches
to hazard identification such as the following:
Process hazards checklist or checklist based reviews

Hazards and Operability study (HAZOP)

Job Safety /Hazard Analysis

Failure Modes and Effects Analysis (FMEA)

What If reviews

The hazard identification stated above is done by experienced or skilled workers by

mainly through observation. A hazard and operability study is being chosen as a tool in
hazard identification in this study because HAZOP is widely used method of analysis used
in the process industries. Moreover, it is recommended for use by legislators, regulators,
and the engineering institution.

A hazard and operability study or known as HAZOP is a formal systematic

examination of a processing plant for identifying hazards, failures and operability
problems, and assessing the consequences from such mal-operation or malfunction of
individual items of equipment and the consequential effects on the facility as a whole. In
other words, HAZOP is a systematic method of uncovering if a process can cope with
deviations from indented design goal.
 The purpose of HAZOP is to identify potential hazards and operability problems
caused by deviations from the design intent of both new and existing process plants (Lihou,
2003). In other words, the aim is to investigate how a plant might deviate from its design
purpose. Hence, the consequences of these deviations on the process are then assessed, and
control measure needed to detect deviations is then established.

In order to establish HAZOP, an approach of a multidisciplinary team consists of five

to seven people from a team of engineering based are required. They are operation
personnel, production and maintenance personnel, procurement personnel, production
control (purchasing), safety, health and environment personnel, and supplier. The
implementation of HAZOP requires a thorough examination of process-flow diagrams &
piping and instrumentation diagrams.

Advantages and Disadvantages of HAZOP

HAZOP provide many advantages to the manufacturing and production industries.

However every method or tools has its own limitations. Table 12.1 below shows the
advantages and disadvantages of HAZOP.

Table 1 Advantages and disadvantages of HAZOP

Advantage Disadvantage

Process Flow Diagram (PFD) are Excessive time required in review; hence
examined line by line by multidiscipline target time date cannot be achieved
team

Potential problem areas of the design can Unmanageable of board documentation,

be identified to allow early design especially for a complex system
modification
 Promotes extensive dialogue between Increase in the total capital cost; due to
designers and operators; hence better additional / modification design or
understanding. equipment
requested by the HAZOP team

Prevent any potential harm and serious Tedious to apply, requiring considerable
damage manpower and time

HAZOP Procedure

The HAZOP procedure uses the following steps to complete an analysis:

1. Begin with a detailed flow sheet. Break the flow sheet into a number of process units.
Thus, the reactor area might be one unit, and the storage tanks another. Select a unit for
study.

2. Choose a study node (vessel, line, operating instruction).

3. Describe the design intent of the study node. For example, vessel V-1 is designed to
store the benzene feedstock and provide it on demand to the reactor.

4. Pick a process parameter: e.g. flow, level, temperature, pressure, concentration, pH,
viscosity, state (solid, liquid, or gas), agitation volume, reaction, sample, component, start,
stop, stability, power, inert.

5. Apply a guide word to the process parameter to suggest possible deviation. A list of
guides

6. If deviation is applicable, determine the possible causes and note any protective systems.

7. Evaluate the consequences of the deviation (if any).

8. Recommend action. (what? By whom? By when?)

9. Record all information.

10. Repeat steps 5 through 9 until all applicable guide words have been applied to the
chosen process parameter.
The fig. 1 below illustrates a HAZOP flowchart which can be understood in a simpler way.

Fig. 1 HAZOP study flowchart

HAZOP Studies
HAZOP Guide Words and Parameters

Utilize parameters and guide words to suggest deviations of process variables and
their causes and to screen all possible causes. Guidewords are applied to various process
parameters and Table 12.2 shows a guide words used in HAZOP studies.

Table 2 Guide words used for the HAZOP procedure

HAZOP Worksheet
 Seed Fermenter and Batch Fermenter

Parameter Guide Deviation Causes Consequences Actions

Temperature LESS Temperature of the a) Valve that The decrease in a) An
mixture broth controls the temperature emergency
found to be lower flow of hot which exceeded valve is
from its ideal value. water into the the tolerance level installed in
jacket is of the mammalian parallel to the
blocked. cell culture will operating
disrupt the valve.
b) Centrifugal reaction, thus b)Backup
pump, which causing the pump is
pumps the hot desired product installed, also
water from the cannot be in parallel to
reservoir harvested during the operating
malfunctioned. downstream pump.
processing.
Temperature inside a) Blockage of The fermentation a) Install
MORE the vessel the pipeline due process within the additional
increases, to the damaged vessel will be valve in
exceeding the valve. disrupted due to parallel to the
tolerance level. the high operating
b) Centrifugal temperature that valve.
pump that destabilized the
pumps hot cells culture. b) Install
water from the backup pump
reservoir in parallel to
malfunctioned. the operating
pump.
pH The pH of the broth Valve that The cells cannot Install
LESS is getting acidic. controls the survive beyond emergency
amount of the range of the valve in
caustic solution ideal pH, therefore parallel to the
malfunctions. the product cannot operating
be harvested. valve.
MORE The pH of the broth Valve that The cells dies due Install the
is getting alkaline. controls the to the intolerance backup valve
amount of over the shifted in parallel to
acidic solution pH values. the operating
malfunctions. valve.
Dissolved MORE The concentration a) Valve that The conditions Install both
oxygen (dO2) of dissolved controls the disfavour the emergency
oxygen in the flow of carbon optimised valve and
mixture become dioxide is reaction, thus compressor in
saturated damaged. slowing the parallel with
process down. the operating
b) The equipment.
compressor
which pumps
carbon dioxide
from supply
malfunctions.
LESS or Low concentration Either or both The concentration Install backup
NO of dissolved the compressor of dissolved valve and
oxygen detected. and valve that oxygen will compressor in
controls the become rate- parallel to the
flowrate of limiting factor in operating
oxygen the reaction, valve and
malfunction. which will affect compressor.
 the performance
of the process.

MORE Pressure increase Pressure Risk of explosion a) Install high

beyond acceptable control system and chemical and pressure
level. malfunctioning. biological leakage alarm.
to the
surrounding. b) Install
additional
pressure relief
valve on the
Pressure vessel.
LESS Pressure decreases, Pressure Risk of a) Install low
creating control system contamination pressure
backpressure failure. from surrounding alarm.
condition. environment into b) Install
the vessel. additional
compressor to
pressurize the
tank.
LESS Low flowrate a) Flow a) Reduce the a) Install low
controller efficiency of the flow alarm.
malfunctioning. process within
vessel. b) Regular
b) Leakage inspection and
Flow from the b) Release of maintenance.
pipeline. harmful chemicals
or biological
c) Level materials to the
indicator surrounding.
failure.
 MORE High flowrate Valve and /or Pressure build-up a) Install
pump failure. within the vessel. backup valve
or pump in
parallel with
the operating
equipment.

b) Install high
flow alarm.

Centrifuge

Process parameter Guide Deviation Possible Possible Recommendation

words Causes Consequences

Flow No No flow of a) Valve a) No a) Connect the level

water fully closed separation indicator and flow
b) Line b) Centrifuge indicator to an alarm
fracture rotor breaks system
c) Out of down
stock in the
storage
More More citric Valve fully Undesired Connect the flow
acid in the open product indicator to an alarm
reactor system

Less Less citric a) Valve is Product Set the minimum flow

acid in the partly output is low rate
reactor closed
b) Leaking
line
Temperature More High Cooling Damages the Perform schedule
temperature system fail product maintenance

Less Low Heater a) Low rate of Set the minimum

temperature malfunction separation temperature
b) Consume
more time
Agitation Higher Faster Speed Volume Install high speed alarm
agitation controller overflow
speed fail from the
centrifuge
Lower Slower Speed Slower rate of Perform schedule
agitation controller separation maintenance
speed fail

Ultrafiltration

Process parameter Guide Deviation Possible Possible Recommendation

words Causes Consequences

Flow More More water Valve fully a) Undesired Connect the flow
in the open product indicator to an alarm
reactor b) Diluted system
reactant
Less Less water a) Valve is a) Cake a) Set the minimum flow
in the partly thickness rate
reactor closed increase b) Apply bypass line
b) Leaking b) Undesired system
line product
Pressure Higher Higher Speed a) Tank a) Set pressure limit
pressure controller explode b) Design with material
applied fail b)Temperature that can stand high
increases pressure

Lower Lower Speed Unable to Perform schedule

pressure controller pump material maintenance
applied fail to the filter

Ion exchange chromatography

Parameter Guide Deviation Causes Consequences Actions

Temperature More More a) Failure of a) The monoclonal Indicate by
temperature temperature antibody will temperature
transmitter. disintegrate at controller alarm
b) Disturbance high to maintain
in the temperature. temperature at
heating b) Less purity of 37.
system product
Less Less a) Failure of Effect the Indicate by
temperature temperature concentration of temperature
transmitter. product form controller alarm
b) Disturbance
in the
heating
system
Flow rate No Outlet flow a) Pipeline a) Contamination a) Install a LOW
leakage b) Less product LEVEL
b) Pipeline form ALARM to
blockage c) No product alert operator.
form
 c) Pump b) Install LOW
failure LEVEL
ALARM shut
down pump
to stop the
process
More Flow rate a) Valve a) High chances of a) Install HIGH
failure contamination to LEVEL
b) Pump occur. ALARM
failure b) Causes b) 2. Install
disturbance to HIGH
other equipment. LEVEL
c) The purity of ALARM shut
monoclonal down pump
antibodies will to stop the
be affected. process

Less Flow rate a) Leakage in a) High chances of a)Regular

pipeline. contamination to patrolling and
b) Blockage in occur if there is inspection at the
the pipeline. leakage. pipe line
c) Fouled resin b) Reduction in the a) Test sample
bed production rate. resin for
Flow rate d) Broken resin analysis
bed b) Regular
maintenance
of the
controller
Pressure More More pressure a) Blockage of a) Low Indicate by
resin productivity pressure alarm
b) High yield
viscous flow b) Low purity
rates

Less Less pressure a) Fouled resin a) Effect the a) Indicate by

bed concentration of pressure
b) Broken resin product form alarm
bed b) High percentage b) Measure
of impurities pressure drop
Low flow rate outlet and sample
resin for
analysis.

Crystallization

Process parameter Guide Deviation Possible Possible Recommendation

words Causes Consequences

Flow More More citric Valve fully a) Undesired Connect the flow
acid in the open product indicator to an alarm
reactor b) Reactant system
overflow
Less Less citric a) Valve is a) Equipment a) Set the minimum flow
acid in the partly efficiency rate
reactor closed decrease b) Apply bypass line
b) Leaking b) Undesired system
line product
Temperature More High Cooling a)Degradation Install temperature
temperature system fail of reactant indicator
 b)No product
Less Low Heater a)Low rate of Set the minimum
temperature malfunction reaction temperature
b)Consume
more time

Rotary Dryer

Process parameter Guide Deviation Possible Possible Recommendation

words Causes Consequences

Flow More More citric Valve fully a) Undesired Connect the flow
acid in the open product indicator to an alarm
reactor b) Reactant system
overflow
Less Less citric a) Valve is a) Equipment a) Set the minimum flow
acid in the partly efficiency rate
reactor closed decrease b) Apply bypass line
b) Leaking b) Undesired system
line product
Temperature More High Cooling a) Install temperature
temperature system fail Degradation indicator
of reactant
b) No product
Less Low Heater a) Low rate of Set the minimum
temperature malfunction drying temperature
b) Consume
more time
c) Reactant
not fully dried
Procedure for Plant Starts Up And Shut Down
 After a plant has been built, it is essential for the plant to have a smooth start up to
begin the process. In order to ensure that a plant undergoes a smooth startup, it is important
that the last phase of mechanical completion and the preparatory activities for
commissioning are thoroughly performed. These include such activities as: cleaning, and
leak-testing pipelines and vessels; loading lubricants, chemicals and catalysts; installing
mechanical seals, and column and vessel internals; removing temporary bracings; aligning
rotating equipment; and inerting the system. Other activities include closing (box-up) of
columns and vessels, test runs of rotating equipment, and many more.
A plant must have a good ventilation system to release unharmed gas to the atmosphere.
Ventilation are called column. Generally, a column startup usually consists of the following
steps:
1. Commissioning
2. Pressure-up
3. Column Heating (and/or cooling)
4. Introduction of feed
5. Introducing heating and cooling sources
6. Bringing column to desired operating conditions
Similarly, column shutdown usually consists of the following steps:
1. Reducing column rates
2. Shutting down heating and cooling sources
3. Stopping feed
4. Draining liquids
5. Cooling (or heating) the column
6. Bringing the column to atmospheric pressure
7. Eliminating undesirable materials
8. Preparing for opening to atmosphere

In a nutshell, the citric acid production plant is a continuous process. Therefore, it

is must for a plant to rest or in other term is temporary shutdown. Shutdowns are highly
susceptible to scope creep. It is common to discover additional work that needs to be done
once systems are disassembled or equipment is more accessible. The best interval of time
is to shut down once in 6 months for a year.