Hazard Identification and

Evaluation in Process Industry

Dr. Syeda Sultana Razia

Professor
Hazard Identification

What are the hazards?

What can go wrong?
What are the chances?
What are the consequences?
 Process Safety Assessment
Qualitative

◦ Hazard identification: identification of Hazards and taking

measures to minimize the negative consequences of hazards.
Quantitative

◦ Risk assessment: determination of the events that can produce an

accident, the probability of those events and the consequences-
known as quantitative risk analysis (QRA).
◦ QRA expresses the risk in numbers and asks for modifications in
process/plants/operations/emergency responses that reduces the
risk to a lower acceptable number.
Hazard identification and Risk assessment can be
performed independently or carried out together
 Hazard Identification and Risk
Assessment Procedure
System description

Hazard identification

Scenario identification

Accident probability Accident consequences

Risk determination

Modify
no 1. process or plant
Risk and/or hazard 2. process operation
acceptance 3 emergency response
4 other
yes

Build and/or operate

system
Hazard Identification Methodologies
Factors Affecting Selection of Methods
Classical Limitations of Hazard
Evaluation Studies
HAZARD Surveys
A hazards survey can be simple or
complicated
Simple: inventory of hazardous materials
in a facility
Rigorous: the Dow Fire and Explosion
Index
Process Safety Checklist
 DOW F & EI

Material factor = MF
General process hazard factor = F1
Special process hazard factor = F2
F3=F1XF2
F & EI= F3X MF
Loss Control Credit Factor
Process Control credit factor C1
Material Isolation credit factor C2
Fire protection credit factor C3

LCCF=C1XC2XC3
Hazards and Operability (HAZOP)
Studies
Documents: PFD, P&ID, Plant Layout
 Begin with a detailed flow sheet and break the flow sheet in to a
number of process units
 Choose a study node (Vessel, line etc.)
 Pick a process parameter: flow, level, T, P, concentration, pH,
viscosity , reaction etc
 Apply a guide word to suggest possible deviation
 If the deviation is applicable determine possible causes and note
any protective system
 Evaluate the consequences
 Recommend action
 Record all information
 HAZOP Table
Study node:
Param Guide Possible Possible Existing Required actions/
eter word causes consequences safeguards recommendations
(deviation)
           
 
 
 
 
 
 
 
 
 
 Example of HAZOP Matrix
Guide
word
No Low High Part of Also Other than Reverse

Process-
variable
No Low High Missing Wrong Reverse
Flow flow flow flow ingredients Impurities material flow

Low High Low High - -

Level Empty interface interface
level level

Open to Low High - - -

Pressure atmosphere pressure pressure Vacuum

Temperature Low High - - - Auto

Freezing temp. temp. refrigeration

No Poor Excessive Irregular- Foaming - Phase

Agitation mixing mixing
agitation mixing separation

No Slow "Runaway Partial Side Wrong Decom-

Reaction reaction
reaction reaction reaction" reaction reaction position

Utility External External - - Start-up -

Other Shutdown
failure leak rupture
Maintenance
Example: DAP Process
HAZOP Analysis Worksheet-I
HAZOP Analysis Worksheet-II
 Example: Cooling
 Consider the reactor system shown in Figure 10-8. The reaction
is exothermic, so a cooling system is provided to remove the
excess energy of reaction. In the event that the cooling function
is lost, the temperature of the reactor would increase. This
would lead to an increase in reaction rate, leading to additional
energy release. The result would be a runaway reaction with
pressures exceeding the bursting pressure of the reactor vessel.
The temperature within the reactor is measured and is used to
control the cooling water flowrate by a valve.
 Perform a HAZOP study on this unit to improve the safety of
the process. Use as study nodes the cooling coil (process
parameters: flow and temperature) and the stirrer (process
parameter: agitation).
Example: Cooling
HAZOP Analysis Worksheet-I
Examples
Storage Tanks
◦ Parameters: Level ,Temperature, Pressure
◦ Action: Relief valve (to flare)
Distillation column
◦ Parameters: Level ,Temperature, Pressure
◦ Action: Relief valve (to flare)
 Volatile solvent heating system
A heat exchanger is used to heat
flammable, volatile solvents, as shown
in Figure 10-15. The temperature of
the outlet stream is measured by a
thermocouple, and a controller valve
manipulates the amount of steam to
the heat exchanger to achieve the
desired set point temperature.
◦ Identify the study nodes of the process
◦ Perform a HAZOP study on the intention
"hot solvent from heat exchanger."
Recommend possible modifications to
improve the safety of the process.
HAZOP
Study nodes: volatile solvent outlet from
heat exchanger
Recommendations
◦ Relief valve connected to flare
 Tank filling problem
A standard atmospheric storage
tank containing a flammable liquid
(see the figure below) is filled from
a tanker; after the filling up, the
liquid is pumped to the process as
needed. Consider the following
hazards:
◦ overfilling of the storage tank and
release of liquid into the surrounding
leading to vapor cloud explosion
◦ overpressure of the tank due to inflow
of liquid.
Carry out a HAZOP study to
recommend preventive measures to
safeguard the storage tank
Solution