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OPERABILITY STUDY
Basis
•a word model, a process flow sheet (PFD) or a piping and
instrumentation diagram (P&ID)
Method
•use guide words to question every part of process to discover what deviations
from the intention of design can occur and what are their causes and
consequences may be.
PRINCIPLES OF HAZOPS
INTENTION
The intention defines how the plant is expected to operate in the absence of deviations at
the study nodes.
DEVIATIONS
These are departures from the intension which can be discovered by systematically
applying the guide words.
•Process conditions
•activities
•substances
•time
•place
GUIDE WORDS
EXAMPLE
C
The flowsheet shows that raw material streams A and B are transferred by
pump to a reactor, where they react to form product C. Assume that the
flow rate of B should not exceed that of A. Otherwise, an explosion may
occur. Let’s consider the flow of A in line 1:
NONE No flow of A
MORE Flow of A greater than design flow
LESS Flow of A less than design flow
AS WELL AS Transfer of some component additional to A
PART OF Failure to transfer a component of A
REVERSE Flow of A in a direction opposite to design direction
OTHER THAN Transfer of some material other than A
Beginning
1 Select a vessel
3 Select a line
Explain the intention of the line
4
Apply the first guide words
5
Develop a meaningful deviation
6
Examine possible causes
7
Examine consequences
8
Detect hazards
9
1 Make suitable record
0 Repeat 6-10 for all meaningful deviations derived from first guide words
1
1 Repeat 5-11 for all the guide words
1
2 Mark line as having been examined
1
3 Repeat 3-13 for each line
1
4 Select an auxiliary system (e.g. Heating system)
1
5 Explain the intention of the auxiliary system
1
6 Repeat 5-12 for auxiliary system
1
7 Mark auxiliary as having been examined
1
8 Repeat 15-18 for all auxiliaries
1
Explain intention of the vessel
9
2
Repeat 5-12
0
2 Mark vessel as completed
1
2 Repeat 1-22 for all vessels on flow sheet
2
2 Mark flow sheet as completed
3
2 Repeat 1-24 for all flow sheets
4 Figure 8.9 Hazard and operability studies : detailed sequence of examination
2
5 (Chemical Industry Safety and Health Council, 1977 Item 6)
End
HAZOP DISPLAY
EXAMPLE
An alkene/alkane fraction containing small amounts of
suspended water is continuously pumped from a bulk
intermediate storage tank via a half-mile pipeline into a
buffer/settling tank where the residual water is settled out prior
to passing via a feed/product heat exchanger and preheater to the
reaction, is run off manually from the settling tank at intervals.
Residence time in the reaction section must be held within
closely defined limits to ensure adequate conversion of the
alkene and to avoid excessive formation of polymer.
Results of hazard and operability study of proposed olefine
dimerization unit: results for line section from intermediate storage to buffer/settling tank
(1)
Results of hazard and operability study of proposed olefine
dimerization unit: results for line section from intermediate storage to buffer/settling tank
(2)
Results of hazard and operability atudy of proposed olefine
dimerization unit: results for line section from intermediate storage to buffer/settling tank
(3)
C
HAZOP PREPLANNING ISSUES
Preplanning issues addressed in a typical refinery unit HAZOP include the
following:
• Verification of as-built conditions shown on the P&IDs
• Line segment boundaries set; markup of P&IDs
• List of support documents compiled
• P&IDs (base study document)
• Process flow diagrams (PFDs)
• Process description
• Operating manuals/procedures
• Processing materials information
• Equipment and material specifications
• Tentative schedules of time to be spent per P&IDs sheet
• Recording technique (computer program or data sheet) determination
• List of standard abbreviations and acronyms compiled
• Criticality rankings devised
• HAZOP training given to all team members (one day)
• Arrange for system or process briefings for team before work begins.
HAZOP STUDY LOGISTICS