HAZOP

(Hazard and operability study)

Chemical Process Design
Universidad del Valle
G. Bolaos

This document shows some information helpful for developing HAZOP

studies. It includes common deviations from the process intention, and
specific causes for some of them. We have included links to different parts of
the document, so that it can be used directly on a computer during a HAZOP
session.
This material has been condensed from a couple of sources. The reader can
use freely this information for his or her own education in this important tool
for improving safety in chemical process design.

HAZOP List of Common Deviations

Parameter

Guideword

Deviation

Flow

No
More

No flow
Higher flow rate
More quantity flowed
Lower flow rate
Less quantity flowed
Chemical reaction
Polimerization
Foaming
Formation of an emulsion
Reverse flow
Misdirected flow
Boiling
Freezing

Less
As well as

Reverse
Other than

Temperature

More
Less

Higher temperature
Lower temperature

Pressure

No
More
Less

Zero pressure (gauge)

Higher pressure
Lower pressure

Viscosity

More
Less

Higher viscosity
Lower viscosity

Reaction

No
More
Less
As well as
Reverse
Other than

Reaction does not occur

Reaction proceeds further or at a faster rate than desired
Reaction incomplete or proceeds at a slower rate than desired
Something else occurs
Back reaction occurs
Something different occurs

Composition

No
More
Less
As well as
Part of
Other than

No material
Higher mole weight
Lower mole weight
Contaminant
Missing component
Incorrect material

Phase

More
Less
Reverse

Additional phase
Missing phase
Emulsification
Phase inversion

No
More
Less

Empty
Higher level
Lower level

Level

HAZOP List of Common Deviations (2)

Parameter

Guideword

Deviation

Addition

No
More
Less
As well as
Part of
Reverse
Other than

No material
More material added
Less material added
Something else is done
Addition operation is incomplete
Wrong order of material addition
Something different is done

Maintenance

No
More
Less
As well as
Part of
Reverse
Other than

Non performed
Performed more frequently than desired
Performed less frequently than desired
Something else done
Incomplete operation
Operation done in opposite order
Something different is done

Testing

No
More
Less
As well as
Part of
Reverse
Other than

None performed
Performed more frequently than desired
Performed less frequently than desired
Something else done
Incomplete operation
Operation done in opposite order
Something different is done

Specific causes - FLOW

Parameter:
Guideword:
Deviation:

Flow
No
No flow

Control valve fails closed

Control valve closes due to incorrect signal
Pump fails off

electric failure

steam turbine failure

engine failure

breakage of drive shaft/coupling

Line plugged / blocked
Manual block valve mechanically fails closed
Supply tank empty
No flow upstream
Line ruptured upstream
Motor operated valve accidentally closed
Manual block valve accidentally closed
Operator inputs incorrect control valve set point
Back

Parameter:
Guideword:
Deviation:

Flow
More
More flow

Control valve fails open

Control valve opens wide due to controller failure
High pressure difference
Line rupture downstream
Control valve bypass accidentally opened or not closed tightly

Back
Parameter:
Guideword:
Deviation:

Flow
Less
Less flow

Leak
Partial plugging / blockage
Valve partially closed
Operator inputs incorret control valve set point

Back

Parameter:
Guideword:
Deviation:

Flow
As well as
Chemical reaction

Contamination
Elevated temperature
Catalyst present
Off-specification material
Wrong material
Long residence time

Back
Parameter:
Guideword:
Deviation:

Flow
Reverse
Reverse flow

Line rupture upstream

Reaction upstream creating high pressure
Backpressure
Back

Parameter:
Guideword:
Deviation:

Flow
Other than
Flow to wrong place

Bypass open
Cross tie open
Sample line open
Back

Specific causes - TEMPERATURE

Parameter:
Guideword:
Deviation:

Temperature
More
More temperature

Overfiring of fired heater/furnace/reboiler

Steam/condensate control fails open
Exothermic / runaway reaction
Failure of forced/induced draft fan
Plugging of heat exchanger tubes
Operator inputs incorret control valve setting
Fire exposure
High ambient temperatures
Loss of cooling medium
Back

Parameter:
Guideword:
Deviation:

Temperature
Less
Low temperature

Shutdown of fired heater/furnace/reboiler

Steam/condensate control valve fails closed
Endothermic reaction
Loss of heating medium
Auto-refrigeration
Plugging of heat exchanger tubes
Operator inputs incorret control valve set point
Low ambient temperatures
Back

Specific causes - PRESSURE

Parameter:
Guideword:
Deviation:

Pressure
More
High pressure

Control valve fails closed downstream

Control valve fails open upstream
Manual block valve mechanically fails closed
Blockage / plugging of line downstream
Overspeed of compressor / pump internal combustion engine or steam turbine
Gas blowby
Reaction
Manual block valve accidentally closed
Pump / compressor inadvertely started
Cross connection between high/low pressure system open or leaking
Incorrect impeller installed in pump
Remote operated valve closed accidentally
Operator inputs incorrect control set point
High temperature
Back

Parameter:
Guideword:
Deviation:

Pressure
Less
Low pressure

Back pressure control valve fails open

Backpressure control valve opens due to control signal failure
Blockage/plugging of line upstream
Underspeed of compressor/pump internal combustion engine driver or steam turbine
Pressure relief valve fails open
Depressuring valve fails open
Depressuring valve accidentally opened
Incorrect impeller installed in pump
Operator inputs incorrect control set point
Low temperature
Back

Specific causes - REACTION

Parameter:
Guideword:
Deviation:

Reaction
No
No reaction

Inadequate heat
Inadequate pressure
Incorrect or no catalyst
Back

Parameter:
Guideword:
Deviation:

Reaction
More
More reaction

Incorrect temperature
Incorrect reaction pressure
Incorrect catalyst installed
Back

Parameter:
Guideword:
Deviation:

Reaction
Less
Less reaction

Incorrect temperature
Incorrect reaction pressure
Incorrect catalyst installed
Back

Parameter:
Guideword:
Deviation:

Reaction
As well as
Additional reactiion

Incorrect temperature
Incorrect pressure
Contaminant
Incorrect catalyst
Operator fails to stop reaction when complete
Back

Parameter:
Guideword:
Deviation:

Reaction
Part of
Incomplete reaction

Incorrect temperature
Incorrect pressure
Contaminant
Incorrect catalyst
Operator stops reaction too soon
Back

Parameter:
Guideword:
Deviation:

Reaction
Other than
Incorrect reaction

Incorrect materials charged to reactor

Incorrect catalyst
Contaminant
Back

Specific causes - COMPOSITION

Parameter:
Guideword:
Deviation:

Composition
More
Increase in component ratios

More feed from one component stream

Change in feedstock
Incorrect mixing operation
Back

Parameter:
Guideword:
Deviation:

Composition
Less
Decrease in component ratios

Loss of feed from one component stream

Change in feedstock
Incorrect mixing operation
Back

Parameter:
Guideword:
Deviation:

Composition
As well as
Contamination

Block valve leaking on another line

Byproduct or incorrect reaction conditions
Incompatible seal fluid
Incorrect material charged to process
Block valve opened, or left opened, on another line
Back

Parameter:
Guideword:
Deviation:

Composition
Part of
Missing component

Incorrect mixing operation

Back

Parameter:
Guideword:
Deviation:

Composition
Other than
Incorrect material

Incorrect material charged to process

Incorrect block valve opened on feed suply manifold
Back

Specific causes - PHASE

Parameter:
Guideword:
Deviation:

Phase
More
Additional phase present

Liquid carryover into vapor line

Condensation in vapor line
Byproducts of reaction forming additional phase
Gas blowby in liquid outlet
Boiling in liquid line
Solids carried over in liquid/vapor line
Damage/erosion to catalyst producing solid particles
Back

Parameter:
Guideword:
Deviation:

Phase
Less
Missing phase

Loss of feed from one component stream

Vaporization of liquid phase in two-phase line
Loss of condensing medium in overhead line
Back

Specific causes - LEVEL

Parameter:
Guideword:
Deviation:

Level
More
High level

Liquid outlet control valve fails closed

Inflow exceeds outlet capacity
Low temperature resulting in less vapor generation
Blockage / plugging of outlet
Level control indtrumentation fails low
Plugging of tower trays
Level control instrumentation improperly calibrated
Operator overfills vessel / tank
Operator inputs incorrect control set point
Back

Parameter:
Guideword:
Deviation:

Level
Less
No/low level

Liquid outlet control valve fails open

Bypass on outlet control valve leaking
Low inlet flow
Level control instrumentation fails high
Leaks in tower trays/draw box
Leak in vessel
Block valve on drain leaking
Level control instrumentation improperly calibrated
Operator inputs incorrect control set point
Drain valve accidentally opened or not shut
Bypass on outlet control valve accidentally opened or not closed
Back