ADVANCES in NATURAL and APPLIED SCIENCES

ISSN: 1995-0772 Published BYAENSI Publication EISSN: 1998-1090 http://www.aensiweb.com/ANAS

2017 May 11(7): pages 724-726 Open Access Journal

ToCite ThisArticle: Hariprasath. M, Sathyanathan. M, K. Visagavel, PSS Srinivasan., Risk Analysis (HAZOP Study) for a Hazardous Chemical Storage Plant. Advances in Natural and Applied Sciences. 11(7); Pages: 724-726

Risk Analysis (HAZOP Study) for a Hazardous Chemical Storage Plant

1Hariprasath. M, 2Sathyanathan. M, 3K. Visagavel, 4PSS Srinivasan

1PG Scholar, Industrial Safety Engineering, Knowledge Institute of Technology, Salem ,Tamilnadu, India. 2,3,4 Professor, Mechanical Engineering, Knowledge Institute of Technology, Salem , Tamilnadu, India.

Received 28 January 2017; Accepted 22 April 2017; Available online 12 May 2017

Address For Correspondence: Hariprasath. M, PG Scholar, Industrial Safety Engineering, Knowledge Institute of Technology, Salem ,Tamilnadu, India.

Copyright © 2017 by authors and American-Eurasian Network for ScientificInformation (AENSI Publication). This work is licensed under the Creative Commons Attribution International License (CC BY). http://creativecommons.org/licenses/by/4.0/

ABSTRACT The hazard and operability (HAZOP) study is being used increasingly in the chemical and petrochemical industry as a tool for discovering safety problems in existing plants or in plants just designed or under construction. The aim of this (HAZOP) hazard operability study risk assessment method is to highlighting the safety aspect while decanting Road Tanker to Underground Storage Tank as well as Underground storage tank to barrel filling unit. The Toluene is highly flammable and have potential hazard of explosion, (BLEVE) boiling liquid expanding vapor explosion. this explosion may cause to fatality and heavy property damage so that we have applied this risk assessment (HAZOP) method to find out all relevant potential risk to it and also given required control measure to reduce or eliminate risk of fire and explosion in order to make the decanting the toluene to the Underground storage and to the dispatch unit safe. KEYWORDS: Hazop study, Bleve, Static electricity.

INTRODUCTION

Toluene is an aromatic hydrocarbon that is principally used as a solvent, industrial feedstock, and as an

additive to gasoline to boost octane ratings. It is a colorless liquid that is sparingly soluble in water. To make this

material available in the plant transportation and decanting process is required which is having risk of spill,

leakage, and also one more risk in the decanting process is the developing the electrical charge in tanker which

can be cause of source of ignition. Because of this fire can takes place and this fire can create the Explosion or

Boiling liquid expanding vapor explosion (BLEVE).This would have different-different effect according to

quantity, Flow speed, Method of filling in the decanting process. In some cases it turns in major accident and

cause heavy property damage, loss of lives, harm to environment. In order to prevent these accident it is important

to look for all risk related to operation so that suitable control measure can be suggested. In order of this (HAZOP)

hazard operability study (risk assessment method) plays significant role. To provide the workplace safe the

HAZOP study was proposed for the Toluene decanting process.

Method:

The hazard operability method is careful examination which is performed by multi-disciplinary team to

collect necessary information related to process so as to find out all potential hazard involve in the process.

HAZOP is quantitative risk assessment method which can be performed to make sure that existing design

and operating process is safe. It is also performed to improve safety of existing facility most importantly it is

conducted to find out deviation in typical operation and operational failure.

This method involves several steps which are:-

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1) Select Node of process on which HAZOP is performed.

2) Identify normal operating process of segment.

3) Find out the deviation by setting or apply appropriate guide word.

4) Identify all possible causes of failure of system.

5) Identify all possible consequence of deviation.

6) Identify what action taken and action required to avoid Deviation / accident.

Guide word Deviation

No No forward flow/ reverse flow

More of More of any relevant physical property there than should be Eg: higher flow , higher temperature, higher viscosity, higher pressure

Less of less of any relevant physical property there than should be Eg: lower flow , lower temperature, lower viscosity,

lower pressure

Part of Composition of system different from what it should be Eg; change in ratio of component or component missing etc

As well as A transfer of some component in addition to the intended component. Eg: transfer of water with benzene in the

transfer line.

More than More component present in the system

Not If something is not operating Eg: control valve

Other than What else can apart from normal operation Eg; static electricity

Process Description:

In this paper I have described hazardous process involve in decanting and storage of highly flammable

Toluene and how it is done safely. Detail process description:-

1) Transfer of Material from Shore Tank to Road Tanker

2) Transportation of Material from the dispatcher to receiving plant.

3) Transfer of Material from road tanker to Underground Storage

4) Transfer of Material from underground storage to Barrels

HAZOP Work Sheet:

Node1: Transfer of material from Road tanker to Storage tank

Guide word Deviation Cause Consequences Action Required

No No Flow Master Valve Failed to open Manifold valve Failed to

open

Blockage in Manifold valve

Delay in dispatch Material evaporation

from underground

storage tank

Install and maintain No flow interlock system

More of More Flow There is no logical Sequence There is no

consequence

No action required

Other than Static Electricity 1.Road Tanker not earthed

2.Bonding not given between the Joints

3.Escape of material through

cracks of Flange joints.

Ignition of vapour leads

to fire and explosion

Ensure the integrity of joints

and earthing continuity across flange joints

Node 2: Transfer of Material from Storage tanker to Dispatch unit.

Guide word Deviation Cause Consequences Action Required

NO

No flow

ball Valve closed The pipe line will be blasted due to the pressure

build up

Direction of closing and opening of the valve should be indicate

Provide the interlock system

726 Hariprasath. M et al., 2017/Advances in Natural and Applied Sciences. 11(7) May 2017, Pages: 724-726

Periodic maintenance of valves,

Pipelines.

Transfer pump failure Toluene cannot be transferred to the storage

tank

Pump should be inspected and maintained periodically

pipe rupture Fire hazard due to the release of Toluene to the

atmosphere

High Quality pipe should be used and maintained properly

Main power failure Transfer pump does not

run

Generator arrangement is provided

as back up

LESS

Less Flow

Valve is partially

opened

There is a chance of pipe

rupture due to high

Before start of Process Check and

ensure all valves are opened

MORE OF More Flow Pump Speed is high Static electricity will be

formed highly

Maintain the less flow and

discharge the static electricity through proper earth connection

NOT Valve Not

functioning

Valve Failed to

operate

Huge pressure will be

generated in the pipe lines

Tripping system to be

implemented

Recommendation:

From this Hazop study the following recommendations are suggested to reduce the consequences of the

deviations.

1. The Road tanker must have a spark arrestor

2. Proper earthing system to be provided while decanting the Toluene to the Storage tank as well as

decanting from the storage tank to dispatch unit.

3. Emergency plan should be always available while decanting the material

4. Periodic Maintenance should be Done and it should be recorded

5. Ensure that there is no source of ignition before start of Decanting process

6. Standard operating procedure should be displayed

7. Decanting process must be performed under competent person

Conclusion:

In this paper the hazard operability study (HAZOP) method to identify unexpected deviation while decanting

and storage of toluene and action required reducing risk are suggested and implemented. The hazard operability

study is basically performed at design stage. it is qualitative analysis and helps to identify The possibility of

failures and consequences

This method helps to identify potential hazard related any system or process and contributes to recommend

control measures.

REFERENCES

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6. The Factories Act 1948 / The Tamilnadu Factories Rules 1950.