Ch.

E 405
Maintenance Engineering

LOSS PREVENTION

Sadiya Mushtaq
Loss Prevention

 The phrase loss prevention in the chemical industry is an insurance term

where the loss represents the financial loss associated with an accident.

 This loss not only represents the cost of repairing or replacing the
damaged facility and taking care of all damage claims, but also includes
the loss of earnings from lost production during the repair period and any
associated lost sales opportunities.
Rules for Loss Prevention

1. Identification and assessment of the major hazards.

2. Control of the hazards by the most appropriate means; for example,
containment, substitution, improved maintenance, etc.
3. Control of the process, i.e., prevention of hazardous conditions in process
operating variables by utilizing automatic control and relief systems, interlocks,
alarms, etc.
4. Limitation of the loss when an incident occurs.
Some Methods for Loss Prevention

1. Hazard and operability study (HAZOP)

2. Fault-tree analysis (FTA)
3. Failure mode-and-effect analysis (FMEA)
4. Safety indexes
5. Safety audits
HAZOPS Study
 What is HAZOP?
HAZOP is an acronym that stands for HAZARD and OPERABILITY Study

 The hazard and operability study, commonly referred to as. the HAZOP study, is a
systematic technique for identifying all plant or equipment hazards and operability
problems.

 In this technique, each segment (pipeline, piece of equipment, instrument, etc.) is

carefully examined and all possible deviations from normal operating conditions are
identified.
Guide Words for HAZOP Study

1. No or not-no part of the intent is achieved and nothing else occurs (e.g., no flow)
2. More-quantitative increase (e.g., higher temperature)
3. Less-quantitative decrease (e.g., lower pressure).
4. As well as-qualitative increase (e.g., an impurity)
5. Part of-qualitative decrease (e.g., only one of two components in mixture)
6. Reverse-opposite (e.g., backflow)
7. Other than-no part of the intent is achieved and something completely different occurs (e.g.,
flow of wrong material)
CASE STUDY

HAZOP Analysis
More Case Studies
 Vessel

Storage
Tank

Pumps
Assignment-2 (Presentations)
1. Fault-tree analysis (FTA), failure
2. Failure mode-and-effect analysis (FMEA)

Format: Power point

Case Study (Compulsory)
Deadline: 11th June, 2020

Note: All students should submit the assignment in ppt format. Any student will be asked to present in the
next lecture.