Beruflich Dokumente
Kultur Dokumente
Session 10
Described as a system of imaginative anticipation of hazards Differs from Functional Failure Analysis in 4 key ways:
always a team activity concentrates on deviations in flows between components uses well-defined guide words to steer analysis considers both plausible causes and possible consequences of deviations
HAZOP - 2
HAZOP procedure
Start Select a component Select a flow Suggest a deviation using a guide word Investigate and document causes Investigate and document effects
NO NO
Finish
YES
NO
All guide words considered? Record as hazard. Make recommendations for action if necessary
NO
YES
HAZOP - 4
User(s)
may be site representative, operator, maintenance crew supply information about the context in which the system will be used, e.g. site facilities ask questions, and help decide which issues affect safety
Recorder
participant in study (?) document the analysis
Expert(s)
key function is to explore
ask questions suggest deviations / causes / effects
Different teams often appropriate for different stages of the lifecycle, but continuity (e.g. same leader) usually recommended
HAZOP - 6
Physical properties
Temperature Viscosity
Flow rate
Pressure
Reaction rate
HAZOP - 7
instrumentation
control philosophy, location of instruments, alarms and trips
LC
PG
LC
Drain
PG Settling tank
Drain
To reactor Drain
HAZOP - 9
Deviation No flow
Consequences
Action Required
MORE
More flow
Transfer pump fails (motor fault, loss of power, impeller corroded etc.) Level control valve fails to open, or LCV bypassed in error Isolation valve or LCV closed when pump running High intermediate storage temperature
Loss of feed to reactor. 1) Ensure good communication Polymer formed in with storage area heat exchanger 2) Install low level alarm on settling tank As above Covered by 2)
Line subjected to full pump pressure Higher pressure in transfer line and settling tank
3) Install high level alarm 4) Check size of overflow 5) Establish locking-off procedure for LCV bypass when not in use 6) Install kickback on pumps
HAZOP - 10
Research and Process Development Process and Project Definition Project Design Procurement and Construction Commissioning
Operation
HAZOP - 11
ICI Experience
More operability problems than hazards are usually found
though difference is smaller with existing plants
Number of post-commissioning modifications to plant is reduced Time to achieve intended production rates is reduced For major plant, cost is typically about 1% of design cost
0.1 - 0.2% of total plant cost
HAZOP - 14