Variables affecting duration

• Team experience
• Complex or simple process
• Complex or simple P&IDs
• Number of nodes
• Computerized or manual recording
• Skill of the scribe
• Availability of the specialist members
• Language
• Numbers of hours of workshop per day

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HAZOP Team Expertise
• Understanding / experience with the process facility.

• Expertise in the specific discipline he/she is representing.

• Understanding experience with process safety.

• HAZOP process.

• Interested and committed

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Areas of concern
• Process engineer has insufficient experience or knowledge

• None has knowledge/experience to challenge designers

• None in the meeting knows the design basis
• Lack of operations input
• Specialist input unavailable
• Frequent change of team

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Note taking
• Only by the Scribe.

• Only directed by the team leader

• For the final version, complete sentences to be used. no abbreviations or non-

standard words.

• use the complete identification number of the equipment e.g. 12PSV251 or

23LAH561.

• If the tag numbers are unavailable, adequate descriptions of the equipment to

be provided.

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Procedure for the HAZOP Review Meeting

1. Starts with the first relevant parameter

2. apply the first relevant guide word,
3. combine to give the deviation
4. Brainstorming the credible causes.
5. Consider the consequences of deviation against each cause.
6. Assess the adequacy of available safeguards
7. If not adequate action is agreed.
8. Continue as above till node completed
9. the drawing be yellowed-off and notes made on the drawing.

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Preliminary HAZOP Example
• A cooling system is provided to remove the excess heat energy
Monom
of the exothermic reaction. Cooling
er
Coils
Feed
• In the event of cooling function is lost, the temperature of
reactor would increase.
Cooling Water
• This would lead to an increase in reaction rate leading to to Sewer
runaway reaction with pressures exceeding the bursting
pressure of the reactor.
Cooling
• The temperature within the reactor is measured and is used to Water In
control the cooling water flow rate by a valve.

T
C
Thermocou
ple

Reactor System
SLIDE No. 6 OF 32
 Preliminary HAZOP on Reactor - Example
Guide Word Deviation Causes Consequences Action
Monomer
Feed Cooling
NO No cooling Temperature
Coils
increase in
reactor
Cooling Water
REVERSE Reverse Failure of water to Sewer
cooling flow source resulting
in backward
flow Cooling
Water In
MORE More Instruct
cooling flow operators on
procedures
T
AS WELL AS Reactor Check C Thermocouple
product in maintenance
coils procedures
and schedules
OTHER THAN Sea water Desalination unit
instead of out of service
fresh water
 P&ID
• The central document during HAZOP
• Only the P&IDs reviewed, the other documents are for reference
• Represents the last step in process design.
• used to operate the process system.
• General P&ID Information Content
• Design Information
• Equipment Tag Numbers
• Information required not on the P&IDs
• vessel specifications,
• pump specifications, etc.

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PROCESS FLOW DIAGRAM (PFD)

1 2
3

4
5

6
7
9
8

10

1
1
Identification Letters and Tag Number

• single horizontal line

• double line
• absence of a line
• dotted line
• A square with a circle inside

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Vessels

3 4
2

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Lines

Data link

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ACTIVITY
What do letters and tags indicate
what kind of signal is transmitted?
Process Node Characteristics

1. Group of lines and equipment. single process operation

2. Involve critical parameter

3. Contain an active component

4. contain significant amount of hazardous materials

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 Example

P2

P1

Fuel tank Pump

Reactor
Hydrocracker

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Selecting nodes
• Select the main process flow on PFD
• With continuous plant, progress from up to downstream P&ID
• Select sections with common parameter
• Nodes numbered, marked and boundary points highlighted
• Services are considered separately and last
• Control loops go with the equipment they affect more.
• Do not overlook small branches with no line number.
• Consider different node for each operating mode

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Selecting Nodes
• Node size:
– Small nodes
• Time consuming.
• hard to see interactions between nodes.
• boredom
– Large nodes
• increase the chance of overlooked hazards.
• If node too big issues are missed owing to complexity

• Don’t omit drawings because

• Assuming there is no hazard,
• similar
• just services

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Nodes general guidance

Equipment Guidance
Major vessels Dedicated node
Process pipework Source to destination vessels, no more than 2 control
loops or branches
pumps Include in process pipework nodes
Heat exchangers Include control loop,
Nodes for process and utility
compressor Process side in pipework nodes,
separate node for seals and utilities,
split multistage machines
Loading and Procedural HAZOP
unloading

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Node Categories

• process nodes
– process sections, and additional
items based on P&IDs.
– They focus mainly on what could
happen “inside nodes”
• global node
– a single node focus on what could
happen “on other nodes”.
– Address Initiating events may affect
the entire.

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Long nodes
• Process node running into two or more P&IDs
• This should be avoided, as it is likely to miss some
probable causes and consequences.

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Node description
1. Boundaries
2. Design intent
3. Operating parameters
4. Node components.
• Others may be added
▪ Process Hazards
▪ fail position for control valves
▪ Current condition of the equipment

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Process design intent
• desired process behaviors, as intended by the designers.

• Any plant is designed with an overall purpose in mind.

– It may be to produce a certain amount of a particular chemical
– as part of the plant requirement we needed cooling system where fresh water
continuously circulated at a rate of 1500 liter per hour and initial temperature 20 C.
– What is the design intent?

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 WS

SLIDE No. 25 OF 32
1. Divide
2. Describe
 HAZOP WORK SHEET
Node No.: sheet No.: of Date:
Time:
Drawing No.
Session:
Node boundaries: Team Members:
Node components (line, equipment #):
Design intention:
Design parameters:
Operating parameters:
Parameter

Recommendations
Guideword /
Causes Consequences safeguards
Deviation

No.
Actions
Exothermic inert gas generator
• Air and hydrocarbon gas are pumped continuously into a catalytic reactor R1
where oxidation proceeds at 1300˚K and 1.2bar absolute.
• F1/F2 single stage centrifugal fan with delivery pressure of 5.8 kN/m2 gauge
The product gas is to contain no oxygen and less than 0.1% residual hydrocarbon.
• Fires or explosions could occur in process units, using the inert gas, if oxygen
leaves via line L3. Two causes could result in O2 contamination:
Lean feed mixture; or
1. Incomplete reaction (low outlet temp.)
• if the reactor temperature is less than 1100°K,
• if the residence time is too short.
– Air flow rate is obtained by setting the flow controller FC.
– FC receives air-flow signal in L1 via flow transmitter FTr1.
– Flow transmitters FTr1 and FTr2 send pneumatic signals to the flow ratio controller FrC
– FrC adjusts the hydrocarbon flow by pneumatic signal to CV2.
— Thermocouple T is located near the outlet to detect malfunction.
— The outlet temperature will be low if
▪ Feed mixture is lean or
▪ Catalyst is deactivated causing incomplete reaction.
– T operates the temperature switch TZ,
– TZ via the relay, will cause activator switch AZ to close the trip valve TV.
– Gas analyzer Q detect oxygen in the product gas and send an electrical signal to the analysis switch Qz.
– Qz sends an electrical signal through the relay to actuator switch Az. (doubted efficiency)

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Parameters
• Flow • Level
– the easiest parameter to visualise and – only relevant inside vessels.
determine change effects • Others
– Almost all causes of other parameters – Phase
caused by flow deviation.
– Composition
• Pressure – operations
– leads to many of the most common
hazards.
• Temperature
– High temperatures.
– Low temperature

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Overlap
• There may be significant overlap between deviations

– If already covered they will be excluded. A reference minute added .

• Three pairs of parameters should be reviewed sequentially:

– “Level‐flow”,
– “pressure‐temperature”, and,
– “composition-phase”.

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Identification of Causes
• The deviation happens in the node; the cause can happen anywhere.

• External effects
– deviations in the current node can create hazards in other nodes.

• Postpone the relevant discussion until the pump node is reached by

the team

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Common Human Errors in Process Plants
• Open wrong valve

• Mix wrong proportions of chemicals

• Carry out procedure in wrong sequence or miss a step

• Fail to respond to alarm or unusual condition.

• Fail to report mechanical deficiencies.

• Open up live equipment.

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