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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
What If reviews
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
Prevent any potential harm and serious Tedious to apply, requiring considerable
damage manpower and time
HAZOP Procedure
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.
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.
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.
HAZOP Worksheet
Seed Fermenter and Batch Fermenter
b) Install high
flow alarm.
Centrifuge
Ultrafiltration
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
Crystallization
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
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