M03 HAZOP Study Methodology
Transcript of M03 HAZOP Study Methodology
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Overview
Learning goals – Develop an in-depth understanding of
the key principles and methodologiesassociated with executing a HAZOP
study
Topics – Deviations / uidewords
– HAZOP process
– Preparations
– !election of study sections
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How do we perform a HAZOP?
"y considering the plant section #y section$ line #y line$ item #y item
"y defining %normal operation&
"y considering deviations from normal operation
"y using guidewords to identify these deviations and to initiate the discussion
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Selecting a HAZOP Study Section/Nodes
'his is the HAZOP (eader&s responsi#ility
)hoice depends on the system and the team
olden rule is *+eep it simple,
(arge$ complex systems increase the chance of missing something
ormally follow the process flow
!tart where the line enters the P.D
)ontinue
– to next change of design intent or
– to significant change of process conditions or
– to next e0uipment item
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Selecting a HAZOP Study Section
Aim for sections which will take no more than 1 hour to study
Aim for not more than 2 causes for the first guideword
f the team needs to address the section in parts$ it is more than 1 section
HAZOP (eader and 3ecorder should study sections #efore the workshop
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Original Guideword ParametersFlow Pressure Temp Composition
No
Reverse (Wrong)
More
Less
Part of
As well as
Other than
uidewords / !eviations
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HAZOP process
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Describe design intention, operating conditions etc.
Consider first or next guide word
Identify all causes and record
Identify all consequences and record
List existing safeguards and record
Take next section
Agree any actions necessary and responsible person /org. and record
Last guide word?
Yes
No
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HAZOP / HAZ"! logsheet
Step Guideword
/ Deviation
Cause Consequence Existing
Safeguards
Finding /
Recommendation
R: Remark / A:
Action
Action
responsible
Time
1.
1.1
1.2
2.
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HAZOP / HAZ"! logsheet with ris# ran#ing
Step Guideword
/ Deviation
Cause Conseq
uence
Existing
Safeguards
P C R Finding /
Recommendati
on
R: Remark /
A: Action
Action
responsible
Time
1.
1.1
1.2
2.
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$ideo% HAZOP team in action
42 minutes
Demonstrates use of guidewords
'eam selection
5acilitator skills
)ooperation #etween facilitator and scri#e
After the video6
17 minutes with reflection / discussion6 8hat did the group do9
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HAZOP uidewords & No 'low
8rong routing
"lockage
ncorrect slip plate
ncorrectly fitted check valve
"urst pipe$ large leak
:0uipment failure ;valve$ pump$ vessel$ control system$ etc<=
ncorrect pressure differential$ isolation in error$ etc<
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HAZOP uidewords & (ess 'low
(ine restrictions
5ilter #lockage
Defective pumps
5ouling of vessels$ valves$ orifice plates
Density or viscosity changes - etc<
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HAZOP uidewords & )everse 'low
Defective check valve
ncorrect pressure differential
'wo-way flow
:mergency venting - incorrect operation
n-line spare e0uipment etc<
(eak upstream
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HAZOP uidewords & More (evel
Outlet isolated or #locked
nflow greater than outflow
)ontrol failure
5aulty level measurement
ravity li0uid #alancing etc<
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HAZOP uidewords & More Pressure
!urge pro#lems
)onnection to high pressure system
as #reakthrough ;inade0uate venting=
Defective isolation procedures for relief valves
'hermal overpressure
Positive displacement pumps
5ailed open P<)<><?s
@
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HAZOP uidewords & (ess Pressure
eneration of vacuum condition
)ondensation
as dissolving in li0uid
3estricted pump/compressor suction line
ndetected leakage
>essel drainage
"lockage of #lanket gas reducing valve
etc<
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HAZOP uidewords & More *emperature
Am#ient conditions
5ouled or failed exchanger tu#es
5ire situation
)ooling water failure
Defective control
Heater control failure
nternal fires
3eaction control failures
Heating medium leak into process
etc<
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HAZOP uidewords & (ess *emperature
Am#ient conditions
3educing pressure
5ouled or failed exchanger tu#es
(oss of heating
DepressuriBation of li0uefied gas
Coule/'hompson effect
etc<
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HAZOP uidewords & +omposition +hange
Phase change
!ettling of slurries
(eaking isolation valves$ exchanger tu#es etc<
ncorrect feedstock specification
Process control upsets
3eaction intermediates or #yproducts
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HAZOP uidewords & A,normal Operations
Purging
5lushing
!tart-up
ormal !hutdown
:mergency !hutdown
:mergency Operations
nspection of operating machines
uarding of machines
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HAZOP uidewords & Maintenance -typically covered separately.
solation Philosophy
Drainage
Purging
)leaning
Drying
!lip plates
Access
3escue plan
'raining
Pressure testing
8ork permit system
)ondition monitoring
(ifting and manual handling
etc<
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Safeguards
!afety valves
Detectors
'raining
Procedures
onitoring of critical parameters
aintenance / nspections
Heat tracing
P!D$ :!>
PP: ;last #arrier=
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HAZOP 01ample% Storage *an# 'illing
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LAH
LSH
LI
To Process
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01ample HAZOP Study Section -Node. !escription Sheet
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Project: Fuel Transfer System Revision: 0 Node: Page: 1
001
Date: 31/10/95 Time: 12:18:49
Session: 0 Team: (see below)
Node Description:
The hose connection from the road tanker to the tank including the pump and manual valves onthe pump inlet and outlet.
Leader: Recorder:
Organisation: XYZ
Location: Various
Design Intention:
To transfer petrol from the road tanker to the tank via the installed pump.
P&ID’s Rev #’s:
Normal Process Conditions (Range):
Temperature:
Pressure:Flow Rate:
Ambient
Static head from tanker, 3 Bar g maximum at pump discharge500 litres per minute
Team Members:L D RedE X Pert
R E CordO P Erator
N O FlowS I Tinn
Mal Function R N Awae
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01ample HAZOP Study (ogsheet
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Project: Mode: 001 Fuel Transfer System
Page: 2
Node Description:The hose connection from the road tanker to the tank including the pump and manual valves on the pump inlet and outlet.
GUIDEWORD/
DEVIATION
CAUSES CONSEQUENCES SAFEGUARDS REC# RECOMMENDATIONS
No Flow Manual valve on pump
inlet closed
Manual valve on pump
outlet closed
Line blocked
No transfer of fuel. Pump
starved of liquid which
could cause mechanicaldamage and possible
leakage from the pump on
to the road way.
No transfer of fuel. Pump
runs against a closed
discharge which could causeoverheating, mechanical
damage and leakage of left
for too long.
As above
Operators knowledge and
training.
Local stop which will beused by operator if pump
leaks or is noisy.
As before. Also this valve is
normally kept open.
As above. Line blockage is
unlikely since fuel deliveredis clean.
R1
R2
Provide low level/dry running
cut out for the pump to
prevent pump damage on lossof suction.
Develop a checklist for use by
the operator when carrying
out transfers. Ensure checks ofmanual valve positions are
included in this checklist for
all stages of fuel delivery.
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01ample HAZOP Study (ogsheet -+ontinued.
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Project: Mode: 001 Fuel Transfer System
Page: 3
Node Description:The hose connection from the road tanker to the tank including the pump and manual valves on the pump inlet and outlet.
GUIDEWORD/
DEVIATION
CAUSES CONSEQUENCES SAFEGUARDS REC# RECOMMENDATIONS
Reverse Flow
More Flow
Backflow of fuel whendisconnecting tanker
hose
Tanker hose or transfer
pipe rupture.
Spillage of fuel in area withpossible discharge on the
road way to the surface
water system.
Driver or operator could be
splashed with fuel when
disconnecting hose.
Discharge of fuel from hose
or pipe. Spillage locally
with potential for fire.
Discharge of fuel on the
road way and potentially to
the surface water system.
Driver would physically lifthose to check whether liquid
remains before
disconnecting.
Driver wears goggles and
gloves.
Hoses and pipework are
rated for 7 Barg pressure.
Maximum pump pressure is
3 Barg.
As above.
R3
R4
R5
R6
Install a non-return valve inthe line between the manual
valve and pump.
Ensure operator wears suitable
eye protection and gloves
Review adequacy of the fire
fighting equipment at the road
tanker unloading area.
The road tanker unloading
area should be bunded and
provided with an interceptorto prevent discharge of fuel to
the surface water system.
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