Hazard and Operability (HAZOP)

Study

April 2009

Delivering sustainable solutions in a more competitive world

Outline of HAZOP Presentation

HAZOP/SIL Study Program
HAZOP Methodology
HAZOP Process
HAZOP Basis
HAZOP Documentation and Recording

Delivering sustainable solutions in a more competitive world

HAZOP Objectives
To identify hazards and operability issues
Not a design check or provide design alternative
Not to find solutions but identify problems
Not an optimisation study
Solutions may be proposed but will not be finalised
during the session

Actions/solutions to be reviewed by the design team

later and discussed in a separate session

Delivering sustainable solutions in a more competitive world

HAZOP Process
Node definition
Design Intent
Deviations
Causes
Consequences
Safeguards
Actions

Delivering sustainable solutions in a more competitive world

Review of Node
Describe design intention, operating conditions etc.
Consider first or next guide word
Identify all causes and record
Identify all consequences and record
No
List existing safeguards and record
Agree any actions necessary
Last guide word?
Take next section

Delivering sustainable solutions in a more competitive world

Yes

Node (sub-system) Definition

Each piping will be considered as a sub-system
Equipment will be considered as part of piping or
defined separately where significant process changes
occur in the equipment

Piping systems will be combined in some cases where

process parameters do not undergo significant change
or design intent is same

Delivering sustainable solutions in a more competitive world

Design Intent
Description of system
Design parameters and limits

Delivering sustainable solutions in a more competitive world

Deviations
Deviations generated by combining the parameter (or
property word) and the guide word

For example, Flow + None = No flow

Delivering sustainable solutions in a more competitive world

Parameters
Flow
Pressure
Temperature
Level
Composition
Phase
Corrosion / Erosion
Agitation
Rotation
Maintenance
Delivering sustainable solutions in a more competitive world

Guide-words

None

The complete negation of design intent

Less

Quantitative decrease of the associate parameter

More

Quantitative increase of the associate parameter

Reverse

Logical opposite of the design intention

As well as A qualitative increase of the associated parameter

(In addition to)

Part of

Other than Complete substitution

Composition of the system (stream) is different

than it should be (qualitative decrease)

Delivering sustainable solutions in a more competitive world

Typical Causes
Equipment failure
Control failure
Human error
Influence from other systems
External events such as fire or explosion
Extreme environmental events

Delivering sustainable solutions in a more competitive world

Consequence Assessment
Consequence to be assessed without considering safeguards
Consequence category
Immediate consequence
Delayed consequence
Impact on the node under study
Impact on other sub-systems/system/unit

Impact on
Personnel Injury
Production and Equipment
Environment

Delivering sustainable solutions in a more competitive world

Safeguards
Prevention
Design standards, basic control
Operating procedures
Indication, alarm, interlock, trip system
Mechanical protection (such as relief, material, etc)

Mitigation
Gas Detectors
Fire Fighting such as water spray system
Emergency shutdown system
Indication, alarm system, operator intervention
Evacuation/emergency plans

Delivering sustainable solutions in a more competitive world

Guidelines to Define Actions

Action category
Provide..(where there is consensus)
Consider (for further review and discussions)

Not get bogged down as to whether additional

instrument or trip is required

Assumptions on alarms/response to be agreed

alarm management

Delivering sustainable solutions in a more competitive world

HAZOP Basis
Assume single failure; double jeopardy is remote
Equipment/ machinery designed, manufactured,
inspected with no defect

Rupture of equipment will not be considered except

for tube rupture/ seal leak; however overall gas
leak/fire scenario will be reviewed

Assume plant will be well maintained

Delivering sustainable solutions in a more competitive world

HAZOP Basis (Contd)

Parallel systems or equipment will not be covered in
HAZOP

However, recommendations will apply

Interconnection issues to be examined
Simultaneous operation of parallel systems to be
reviewed

Delivering sustainable solutions in a more competitive world

Documentation Required for

HAZOP

Piping and instrument diagrams

Process and utility flow diagrams
Site and process description / design basis
Heat and material balance
Material selection diagrams
Plot plan
Cause and effect diagrams / Interlock Description
Process control narratives
Major equipment data sheets (as required)
Relief valve applicable emergency scenarios

Delivering sustainable solutions in a more competitive world

HAZOP Deliverables
HAZOP Study Report including actions, worksheets
and P&IDs
P&IDs marked up with node identification and
actions; retained as HAZOP Master
Design comments/ P&ID corrections if any will be
marked-up on P&ID but not recorded in HAZOP

Worksheets will be distributed the following

morning as draft to the HAZOP Co-ordinator

Delivering sustainable solutions in a more competitive world

HAZOP Recording Software (PHAPro7)

Delivering sustainable solutions in a more competitive world