HAZOP

Designed by
Hossam A. Hassanein
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Goals
 Basic understanding of HAZOP

 HAZOP requirements

 How it works

 Case study

 HAZOP team

 Advantage & disadvantage

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Scenario What is the

cause of the
accident?
 You and your family are on a road trip by using a car in the
middle of the night. You were driving at 100 km/h and, it was
raining heavily.
Can we be The car hits a deep hole and, one of your tire
prepared What is the
blows. You hit
before thethe brake, but due to slippery road and your car
consequence
tire thread was thin, the car skidded andofwas
accident thrown off the
the event?

road.
occurs?
Points to
Ponder

What other What can we

possible do to prevent
accidents all those
might happen things to
on the road happen in the
trip? first place?
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Definition

- Is structured technique, which may be

applied typically to a chemical production
process, identifying hazards resulting from
HAZOP potential malfunctions in the process
(Hazard &
Operability)
Study
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History

Initially prepared by
Dr. H G Lawley and
associates of ICI at
Wilton in 1960’s .
In 1977, Chemical
Industries Association
published the edited
version.
ICI expanded the
procedure called
HAZARD STUDY levels
1 to 6.
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ICI Six Levels

Project exploration / preliminary project assessment

Project definition

Design and procurement

During final stages of construction

During plant commissioning

During normal operation, some times after start-up

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REMEBER

HAZOP is an
identifying technique
and not intended as
a means of solving
problems
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Features of HAZOP Study

Subsystems of interest line and valve, etc Equipment,

Vessels

Modes of operation Normal operation

Start -up mode
Shutdown mode
Maintenance /construction /
inspection mode

Trigger events Human failure

Equipment /instrument/component
failure
Supply failure
Emergency environment event
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Features of HAZOP Study

Effects within plant Changes in chemical conditions

Changes in inventory
Change in chemical physical
conditions

Corrective actions Change of process design

Change of operating limits
Change of system reliability
Improvement of material
containment
Change control system
Add/remove materials
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Features of HAZOP Study

How would hazardous conditions During normal operation Upon

detected ? human failure
Upon component failure In other
circumstances

Contingency actions Improve isolation Improve

protection
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Documents Needed for

HAZOP Study

– Process Flow Sheet or digram ( PFS or PFD )

Preliminary
– Description of the Process
HAZOP

– Piping and Instrumentation Diagram (P & ID)

– Process Calculations
– Process Data Sheets
– Instrument Data Sheets
Detailed – Interlock Schedules
– Layout Requirements
HAZOP – Hazardous Area Classification
– Description of the Process
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Process Flow Diagram (PFD)

The PFD displays the

Is a diagram commonly used
relationship
in chemical and process
between major equipment
engineering to indicate the
of a plant facility and does
general flow of plant
not show minor details such
processes and equipment.
as piping details and
designations
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Process Flow Diagram (PFD)

Example
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P&ID

A Piping and
Instrumentation
Diagram - P&ID, is a
schematic illustration P&ID represents the
of functional last step in process
relationship of piping, design.
instrumentation and
system equipment
components.
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P&ID Example
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HAZOP Procedure
List of guide words
for generation of
process deviations

Possible Process Possible

Causes Deviations Consequences
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Definitions
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Study Nodes

The locations (on

piping and
instrumentation
drawings and
procedures) at which
the process
parameters are
investigated for
deviations.
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Intention

The intention defines

how the plant is
expected to operate
in the absence of
deviations at the
study nodes.
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Deviations

Is a way in which the

process conditions
may depart from their
design/process intent
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Causes

These are the reasons

why deviations might
occur
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Consequences

The results of the

deviation, in case it
occurs.
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Safeguards

Facilities that help to

reduce the
occurrence
frequency of the
deviation or to
mitigate its
consequences.
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Guide Words

A short word to
create the
imagination of a
deviation of the
design/process intent.
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Guide Words Used

(most 7 used)
Guide Words Meaning
No Negation of the design intend
Less Quantitative Decrease
More Quantitative Increase
Part of Qualitative Decrease
As Well As Qualitative Increase
Reverse Logical opposite of the intend
Other Than Complete Substitution
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HAZOP Deviation Guide

Guide No, Less, More, Part of As Well As, Other Than Reverse
Process Words Not, Low, High, Also
Variable None Short Long

No Flow Low Rate High Rate Missing Misdirection, Wrong Backflow

Flow I ngredient I mpurities Material
Open to Low Pressure High ____________ ____________ ____________ Vacuum
Pressure Atmosphere Pressure
Freezing Low High ____________ ____________ ____________ Auto
Temperature Temperatur Temperatur refrigeration
e e
Empty Low Level High Lev el Low High ____________ ____________
Level I nterface I nterface
No Mixing Poor Mixing Excessive Mixing Foaming, ____________ Phase
Agitation Mixing I nterruption Extra Phase Separation
No Reaction Slow Runaway Partial Side Wrong Decompositi
Reaction Reaction Reaction Reaction Reaction Reaction on
Skipped or To Short, Too Long, Action Extra Action Wrong Out of
Time Missed Step To Little Too Much Skipped (Shortcuts) Action Order,
Procedure Opposite

Stopped Too Slow Too Fast Out of ____________ Web or Belt Backward
Speed Synch Break
Utility Failure External External Tube Leak Tube Startup, ____________
Special Leak Rupture Rupture Shutdow n,
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Process Parameters
Process parameters may generally be classified into the following groups:

Physical parameters related to input medium properties

Physical parameters related to input medium conditions

Physical parameters related to system dynamics

Non-physical tangible parameters related to batch type processes

Parameters related to system operations

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Examples of Process
Parameters
Flow Pressure Composition Addition Separation Time

pH Signal Start/stop Operate Maintain Services

Communication Temperature Mixing Stirring Transfer Phase

Speed Particle size Measure Control Level Viscosity

Reaction Sequence
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Simply How does it work?

NODE: Pipe after pump and splitter

PARAMETER: Flow rate

GUIDE WORD: Less (less than normal

value)
DEVIATION: less flow than normal
A group members
CAUSE: of deviation, can be more than
focus on the same
one
issue
CONSEQUENCE: of the deviation/cause
ACTION: initial idea for correction/
prevention/mitigation
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The HAZOP Process

Select Equipment Node

Choose Deviation OR Parameters & Guide Words

Identify Causes

Associate Consequences

Apply Risk Ranking

Agree Actions To Be Taken

Monitor Actions For Completion

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Case
Study
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Case Study 1: Preliminary

HAZOP on Reactor
Cooling Water Refer to reactor system shown.
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 would lead to an increase in
reaction rate leading to additional energy
release.
The result could be a runaway reaction with
pressures exceeding the bursting pressure of
the reactor. The temperature within the
reactor is measured and is used to control
the cooling water flow rate by a valve.

Perform HAZOP Study

Case Study 1: Preliminary 33

HAZOP on Reactor
Cooling
Water

Guide Word Deviation Causes Consequences Action

No
Rev
MoreerseThan
Other
As Well As No
Rev
MoreCooling
erse
Another
Reactor cooling
cooling
material
product Cooling
Failure
Control
Water ofvwater
water
source
More pressurealve in Temperature
Less
Too
May much product Install
cooling,
be cooling
Off-spec Instruct
If high
check
less cooling,
Check operators
flow
besides
in coils cooling v alve
source
failure, resulting
contaminated
reactor operator increase
cooling,
ineffectivin
possible runaway
reactor
e and temperature
v
on
TAHalve
procedures
will detect. If
maintenance
water malfunction
in backward
fails to take flow reactor
reaction
cool on the
effect alarm
detected,(TAH)
procedures isolate
and
action on alarm reaction water
schedulessource.
Back up water
source?
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Case Study 2: Shell & Tube

Heat Exchanger

Using relevant guide words, perform

HAZOP study on shell & tube heat
exchanger
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Case Study 2: Shell & Tube
Heat Exchanger (Answer 1)

Guide Word Deviation Causes Consequences Action

Less
More
More of Less
Moreflow
More of
cooling
pressure on Pipe blockage
Failure
Failure of cooling
of of
process Temperature of of
Bursting of tube High
Low Temperature
Install high
Contamination Contamination of Leakage tube Contamination Proper
Corrosion Corrosion
cooling
flow of
water tube Hardness
water v of
alve Less cooling and
process Proper
Temperature
tube sidefluid line
process fluid cooling
and v alve process fluid
fluid Alarm
pressure alarm
maintenance
cooling water remains
crack ofconstant
decrease tube Alarm
maintainence
water goes in and operator
alert
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Case Study 2: Shell & Tube
Heat Exchanger (Answer 2)

Guide Word Deviation Causes Consequences Action

None
More No
More cooling
cooling water Failure
Failure of
of inlet
inlet Process
Output fluid Install
Less erse
Rev Less erse
Rev cooling
process Pipe leakage
Failure ofwater
process Process of
Product
Process
fluid
off set
Install
Installation
Install check of
Contamination flow
Process
water fluid
flow cooling
Contamination
cooling water in temperature
Outlet
fluid is
temperature Temperature
Proper
Temperature
water
fluid flow fluid
v inlet v alve temperature too flow
v alvemeter
contamination v alve
cooling towater
alve to open
close not lowered
temperature
too
low low too indicator
maintenance before
indicator before
accordingly
low after process
and operator
after the
process
fluid line fluid line
alert
Install
Install TAH
TAL
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HAZOP Team
Design Engineer

Process

5 to 7 members
Engineer
Operations
Supervisor
Instrument
Design Engineer

Chemist

Maintenance
Supervisor
Safety Engineer
(team leader)
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HAZOP Advantage
Easy to learn

Stimulates creativity and generates ideas

Systematic and through procedure

Participants gain valuable knowledge of process

Readily acceptable to regulatory authorities

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HAZOP Disadvantage

Time consuming

Focusing too much on solutions

Team members allowed to divert into endless

discussions of details

HAZOP is poor where multiple-combination

events can have severe effects.
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Division Into Sections

Guideline
Choices of lines–P&ID must be
divided logically. Not too
many sections.
Each section should contain
active components, which
gives rise to deviations. e.g
piping which contains control
valves can give rise to flow
deviations, heat exchangers
can cause Temp. deviations.
Section based on process and
Materials in section – contain
states of materials. Only 1
significant amount of
process operation per 1
hazardous materials.
section.

Define one line section
Define each major process
between each major process
component as a section.
component.
Define additional line sections Define a process section at
for each branches off the each connection to existing
main process flow. equipment.

Define only one line at the Define only one additional line
Define only one process
end of a series of components section if there are alternative
section for equipment in
if there are no other flow flow paths, regardless of how
identical service.
paths. many branches there are.
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