Upload
ng-joshua
View
219
Download
0
Embed Size (px)
Citation preview
8/12/2019 Basics of HAZOP
http://slidepdf.com/reader/full/basics-of-hazop 1/26
Basics of HAZOP 6 1
C H P T E R 6
Basics of HAZOPWhat Did we Do Before HAZOP Came Along
We relied upon:
Good enginee ring practices
Codes of practice such as ASME API NFPA etc.
Informal safety reviews
So what slips through the cracks?
Interface problem s between equipment and systems
Abnormal conditions not envisioned during design
Human error in design operation maintenance
How Do We Know If a Plant Is Safe
Historical record of plant incidents and near misses
History of inciden ts on similar plants
Record of onstream time
Can apply som e risk ranking e.g., Dow/Mond indices
Ask: What guarantee d o we have that there isn t a serious accident about to happen?
If there is O guarantee:
What can w e do about it?
=3 Increase Hazards Risk Awareness
by:
Process Safety Management Program .
© 2003 by CRC Prcss LLC
8/12/2019 Basics of HAZOP
http://slidepdf.com/reader/full/basics-of-hazop 2/26
Basics of HAZOP -2
HAZOP Methodology
HAZOP
Acronym for HAZards and Operability Analysis.
Originated by Imperial Chem ical Industries ICI) in Mond Division.
Basic Concept
Simulate abnormal behavior by considering deviations and disturbances due to causes
likely to impact immediate and surrounding plant resulting in consequences. Then decide
whether the design has adequate features i.e., safeguards that can prevent occurrence or
limit the consequential effects. If no such safeguards exist, then con sider what actions are
needed to remedy the situation.
High Deviation
Normal Design Intention)
Low Deviation
Other D eviations typically include:
Reverse of what was intended.
What else can happen?
System only partially functions.
What additional things can occur?
© 2003 by CRC Prcss LLC
8/12/2019 Basics of HAZOP
http://slidepdf.com/reader/full/basics-of-hazop 3/26
Basics of HAZO P 3
Methodology for Generating Deviations
G u i d e W o r d P r o p e r t y = D e v i a t i o n
For example
When Property = Parameter
High Flow
Low PressureMore Reaction
When Property = Operation
No Transfer
Less Empty
When Property = Material
No Steam
More iluent
High Flow
Low PressureGreater R eactivity
No Transfer
Residue Remaining
No Steam
More iluent
YADEM
© 2003 by CRC Prcss LLC
8/12/2019 Basics of HAZOP
http://slidepdf.com/reader/full/basics-of-hazop 4/26
Basicsof HAZOP 6 4
hat Type of HAZOP Should You Use
Parametric Deviation e.g., High pressure, Low temperature, etc.)
Good for continuous processes.
Most widely used in world today.
Critical Examination
The approach examines:
Material
Activities
Sources and Destinations
Good for batch operations, start-up, shut down.
Procedural Methodology
Useful far HAZOPing:
Operating manuals, procedures
Batch operations
Start-up, shut down
Knowledge Based HAZOP (more like What i f with established Checklist)
Mainly applicable to:
Well established continuous) processes
Organizations with very high quality engineering practices standards
© 2003 by CRC Prcss LLC
8/12/2019 Basics of HAZOP
http://slidepdf.com/reader/full/basics-of-hazop 5/26
Basics of HAZOP 6 5
Steps in the H ZOP Process
1 Preparation
Assemble:
P IDs (Full size and reduced copies for the team)
PFDs plus material and ene rgy balances
Equipment specifications
Layout drawings
2 Facilitator and Process E ngineer
Break P IDs down into Nodes.
Nodes are equipment items (or numbers of items).
If nodes are too small you can loose sense of analysis and incur excessive
repetition.
If nodes are too large, hard to handle, becomes confusing.
Questio n: How d o you size a node?
Answ er: Based on system function.
Example: Reactor feed system may consist of Pump Line Exchanger
3 Prepare HAZOP Outline with List of Deviations
4 Assemble HAZOP Team
YADEM
© 2003 by CRC Prcss LLC
8/12/2019 Basics of HAZOP
http://slidepdf.com/reader/full/basics-of-hazop 6/26
5. Facilitator Explains
The facilitator or one of the team members explains the purpose and scope of the
HAZOP and sets the rules for the study
6. Process Engineer Explains
Process in general
Immediate Node being HAZOPed
7. HAZUP Each Node Using Deviations Listed in Outline Working Throughthe P ZD.
Produce HAZOP worksheet recording the following:
Causes
Consequences
Safeguards
Actions/Recommendations
Remarks
8 At the End of HAZOP, the Facilitator Issues Preliminary HAZOP Report(issuance is optional) consisting of
Attendance
Outline
Detail Report
Action/Recommendations Register
9. Issue Final Report Giving Full Details
A sample of table of conten ts is given in page 6 11
© 2003 by CRC Prcss LLC
8/12/2019 Basics of HAZOP
http://slidepdf.com/reader/full/basics-of-hazop 7/26
Basics of HAZOP 6 7
Variations in HAZOP Types
Thre e basic types:
Guide Word HA ZOP
Knowledge Based HAZO P
Creative Checklist
The Guide Word method is the most accepted method. The re are five main variations:
Cause-by-cause
Consequence-by-consequenceDeviation-by-deviation
Exception only
Action/Recommendation item only
Cause By Cause Methodology
Correlates Consequences, Safeguards and Actions to each particular Cause of a Deviation.
Precise method
Reduces ambiguity
Detail print-out can be followed, is fully auditable
Example: Deviation: Line Rupture
Cause-By-Cause p rovides ull cross-referencing.
Action
Check fire protection
Action
Check fire protection
Action
Provide crash barrier
Safeguard
Pipe stress analysis
Safeguard
Charpee tested steel
Safeguard
None
Cause ILine overstressed
Cause 2
Brittle fracture
Cause 3
Vehicular impact
Consequence
Flammable release fire
Consequence
Flammable release fire
Consequence
Flammable release fire
© 2003 by CRC Prcss LLC
8/12/2019 Basics of HAZOP
http://slidepdf.com/reader/full/basics-of-hazop 8/26
asicsof HAZOP 6 8
Consequence By Consequence ethodology
Correlates Consequences Safeguards and Actions to each particular Consequence o a
Deviation.Precise method
Reduces ambiguity
Detail print-out can be followed is fully auditable
Example: Deviation: Line Rupture
Consequence-By-Consequence providesfull cross-referencing.
Cause I
Line overstressed
Cause 2
Brittlefracture
Cause 3
Vehicularimpact
Deviation By DeviationMethodology
All Causes Consequences Safeguards and Actions are related only to a particular
Deviation.
Consequence
Flammable release
Fire
Consequence
Flammable release
Fire
Consequence
Flammable release
Fire
Fairly simple to execute
Some ambiguity
Fairly rapid
Detail print-out hard to follow
Safeguard
Pipe stress analysis
Safeguard
Charpee tested steel
Safeguard
None
ction
Check ire protection
ction
CheckJre protection
Action
Provide crash burrier
Check ire protection
© 2003 by CRC Prcss LLC
8/12/2019 Basics of HAZOP
http://slidepdf.com/reader/full/basics-of-hazop 9/26
Basics o HAZOP 6 9
Example: Deviation: Line Rupture
Deviation-By-Deviation provides no cross-referencing.
Exception Only Methodology Not Recommended)
Causes
Line overstressed
Brittle fiacture
Vehicular impact
Includes only those deviations for which team believes there are credible causes.
Safeguards
Pipe stress analysis
Charpee tested steel
Consequences
Flammable release, fire
Reduces time
Cannot be audited
Actions
Check ire protection
Provide crash barrier
Citations have been issued by OSH A in the U SA against covered facilities using this
method.
ActiorulCecommendations Item O nly Methodo logy Not Recomm ended)
Only suggestions that team makes for action items are recorded. No proper analysis).
Not auditable
YADEM
© 2003 by CRC Prcss LLC
8/12/2019 Basics of HAZOP
http://slidepdf.com/reader/full/basics-of-hazop 10/26
Basics of HAZOP 6 10
Preparation of HAZOP Reports
asic Report Should Consist of
1 HAZO P O utline
Nodes
Deviations
Guide Words
Parameters
Design Intent
Design Conditions
2 Detail Report
Lists output of session s.
For each No de and Deviation lists:
Causes
Consequences + Risk Ranking)
Safeguards
Actions/Recommendations
Remarks
3 Attendance Register
Facility, Unit
Location
Team members and expertise
Attendanc e Present/Absent/N ot required/Part-time)
Y A D E M
© 2003 by CRC Prcss LLC
8/12/2019 Basics of HAZOP
http://slidepdf.com/reader/full/basics-of-hazop 11/26
Basics of HAZOP 6 11
4. Action/Recommendations Register
Action/Recomm endations Item
Person s) responsible for follow-up
Prioritization
Status
Target date for completion Resolution)
Other
Risk ranking
Categorization
Final Report
1 Executive Summary
2. Introduction
3 Process Description
4. Hazards of the process
5. Hazard and Operability Methodology
6. Conclusions and Recomm endations
ppendices
o Outline of Hazard and Operability Study
o Drawings
o Project Information Report
o Drawing Report
o Team Mem bers Report
o Risk Matrix Report
o Worksheet Report
o Action~RecommendationsReport
o Computer files
YADEM
© 2003 by CRC Prcss LLC
8/12/2019 Basics of HAZOP
http://slidepdf.com/reader/full/basics-of-hazop 12/26
Basics of HAZOP 6 12
HAZOP Example
Table 6-1: Scope ofHAZOP and Process Description
E?&&pslqkXY rocessing Corporationt
LPenibw b y p l a c e
Pm a3 IR: A X W l
Start Date: If2IReMI;I;
end'rnk 1r
C-t: LIGHT ENDS RECOVERY UNIT (See Figures 6- 1 and 6-2)
To muam th li hta pottion of a liquid feed stream containing 50 , by weight, of ight 4 s s& a
d m M 6 m t ~ . he eed rate is 100,000 lbhour and the intent is ta r-wr 81 af the light em ,kh in orderto prpduue a1W h y weight, light ends distillate.
RYP ess Description:
The lmit isW QX aq uptream &d dnxm V- 101. Liquid feed is sqpplied at ab t w@ Mpdgdat 22Q P. The f Is pre-heated by heat exchange with the light mis wippwrbmggp m @ QQF, inth t M m ~~b EX-101, before it enters the light ends stripper, C-101..
The light end t@l~per -Q l , s a 22 plate fractionation column, u s h g valve-type h y s w l i h b ~ P m d ImWdon plate 12.
Overhead vapors from the light ends stripper, C- 101, pass to the light ends condenser, EX-102, which is watercooled. Fluids from this condenser flow to the reflux drum, V-102. Non condensible vapors entering the refluxdrum V-102, are vented to the flare system while the condensed liquids pass to the reflux pump, P-101 or spare.The total distillate is split so that product distillate is sent directly to storage while the main portioo is reflusedbaakto the top of the light ends stripper,C-101.
At the base of the light ends stripper, C-10 1, there is a vertical thermosiphonreboiler, EX-103 hich is heated by3 psig steam on the shell side. Bottoms liquid from the base of the light ends stripper, C-101, is pumped by abottoms pump, P-102 or spare, to the tube side of the feedhottoms exchanger, EX-101, in which it is cooled by feed
before passing to storage.
Process Controls:
The feed to column is under flow control via loop FRC-10 1.
The reflux flow is under flow control via loop FRC-116.
Distillate withdrawal is under level control via loop LlC-107, from the reflux drum level.
Non-condensibles bleed off under pressure control via loop PIC- 106 based on the overheads column pressure
> YADEM
© 2003 by CRC Prcss LLC
8/12/2019 Basics of HAZOP
http://slidepdf.com/reader/full/basics-of-hazop 13/26
Basics of HAZOP 6 1
The rate of bottoms withdrawal is under level control via loop LIC-119 based on the column bottom level.
The steam flow to the reboiler is under composition control via temperature control loop TRC-126 based on the
process side of the reboiler outlet.
Protective Devices:
Relief valve PSV-105, protects against overpressuring of the light ends stripper and connected components.
Relief valve, PSV-106, protects against thermal expansion on the cooling water side of the light ends condenser.
High and low level conditions, LAH -120, LAL-12 1 and LAH LAL -107, are alarmed respectively on the lightends stripper and the reflux drum. The low level condition, LSL-12 1, on the stripper is also interlock ed to stop the
bottoms pump. The low low level condition on the reflux drum stops the reflux pump.
In even t of failure of the bottoms pump, the spare pum p is started by a low low pressu re switch, PSLL -125. The
same arrangement, for the reflux pump, is also supplied by a low low pressure switch, PSLL-109.
High or low column pressures are alarmed by PAH PAL- 106 respectively.
Loss of reflux is alarm ed by FAL- 116.
Loss of steam to the reboiler is alarmed by TAL - 126.
A minimum flow bypass on the bottoms pump protects against the no flow condition.
Remotely operable motor operated valve, MOV-122, can be manually initiated in an emergency, such as bottomsline leaklfiacture, to prevent significant flamm ables inventory loss and fire.
The instrume nt air failure positions of the control valves a re indicated as F.C. (fail close) or F.O. (fail open).
Car seal open (CSO) valves are as indicated.
Assumptions:
During a normal HAZOP you would normally have access to full equipment specifications, plant layout drawings,
piping specifications, line lists, tie points and other pertinent docum ents. As this samp le demonstrates PHA -Pro,rather than being an exercise in design, such documents are not included. Therefore make whatever assumptions
you think reasonable if you wish to modify or extend the HAZOP as shown.
Normal Operating Conditions:
Stream 1, Feed 220 F, 90 PSIG, 100,000 LbIHour, 50% Light EndsStream 2, Overhead 200 F, 75 PSIG, 135,000 LbIHour, 90.2% Light Ends
Stream 3, Bottoms 300 F, 120 PSIG, 50,000 LbIHour, 9.5% Light EndsStream 4, Reflux 200 F, 75 PSIG, 85,000 LbIHour, 90% Light Ends
Stream 5, Non Condensibles 200 F, 75 PSIG, 5,000 LbM our, 95% Light EndsStream 6, Distillate 200 F, 150 PSIG, 45,000 LbIH our, 90% L ight Ends
Stream 7, Reboiler Feed 300 F, 80 PSIG, 185,000 LbIHour, 9.5% Light Ends
Stream 8, Steam Flow 420 F, 300 PSIG, 25,000 LbIHour
YADEM
© 2003 by CRC Prcss LLC
8/12/2019 Basics of HAZOP
http://slidepdf.com/reader/full/basics-of-hazop 14/26
Basics of H ZOP 6 14
T . ,---. . l .l... ..
Heat Exchanger Duties
Condenser EX- 102: 19.5 MMB TUIHR
FeedlBottoms Exchanger EX -] 01 1.9 MM BTUIHR
Reboiler EX-103: 19.9 MM BTUIHR
Y DE M
© 2003 by CRC Prcss LLC
8/12/2019 Basics of HAZOP
http://slidepdf.com/reader/full/basics-of-hazop 15/26
Basics of HAZOP 6 15
Figure 6-1: P ID of Light Ends Process
YADEM
© 2003 by CRC Prcss LLC
8/12/2019 Basics of HAZOP
http://slidepdf.com/reader/full/basics-of-hazop 16/26
Basics of HAZOP 6 1
Figure 6 2: Process Flow Diagram
FOR L I G H T S W O V E B Y m
HE T ONDENSER 19 5 MMBTUl?W
FEEDIBCYITOMSEXCHANGER 1 9 MM TUlRR
REBOILER 19 9 MM TUIISR
© 2003 by CRC Prcss LLC
8/12/2019 Basics of HAZOP
http://slidepdf.com/reader/full/basics-of-hazop 17/26
Basics of HAZOP 6 17
Table 6 2: List of Dev iations
Node: 1. Light Ends Recovery Unit Drawings: 1. Process Flow Sketch of Light EndsI Recovery Unit; 2. Piping Instrumentation Dia gra~
Types: Centrifugal Pump Column Heat Exchanger Line PCD-A1Maintenance problems Vessel
' ~ ~ u i ~ r n e n tD: Distillation unit with heat recovery from
bottoms heating feedstream
Design ConditionsIParameters: Design conditions are listedin Process Flow Sketch of Light Ends Recovery Unit~ r o v i d e d
Deviation
1.1. High Flow
1.2. LowIN o Flow
1.3. ReverseJMisdirected Flow
1.4. Other than Flow
1.5. High Temperature
1.6. Low Temperature
1.7. High Pressure
1.8. Low Pressure
1.9. High L evel
1.10. Low L evel
1.1 1. Cavitation
1.12. Column Flooding
---
1 13 Low Tray Level
1.14. High Concentration of
Impuritiest
1.15. Leak
Guid e Word Parameter Sessio Revision Design Intent
High Flow
In
1 As per Process Flow
DiagramILowIN o As per Process Flow
Diagram
ReverseIMisdirecte Flow I oAs per Process Flow
d Diagram
Other than
--7 -7;As per Process Flow
Diagram
YADEM
© 2003 by CRC Prcss LLC
8/12/2019 Basics of HAZOP
http://slidepdf.com/reader/full/basics-of-hazop 18/26
Basics of HAZOP 6-18
. - - -
D e v ~ a t i o n G u ~ d eWord
I
1.16. Rupture I Other than
I-- - - -
l Parameter Sessio Revision De sign Intent
, DYADEM
1.17. Start-~ip1Shutdown I Other than start- 0 As per Op erating
Hazards ~~plshutdown Ins t ruc t ions. .
1.18.Maintenance Hazards Other than Maintenance 12 O1As per Maintenance
Data2-w-sik- &> bSa-& @&~&&SYR~&QSI>a3k b d k , It L 53 wLk%**~~Q, SI - $-&&V. ~V& fik bbAi3ba2&.& *& &&~-~t & *>ihaw- k 2
© 2003 by CRC Prcss LLC
8/12/2019 Basics of HAZOP
http://slidepdf.com/reader/full/basics-of-hazop 19/26
Basics of HAZOP 6 19
Table 6 3: Sam ple Worksheet
Node: 1. Light Ends Recovery Unit Drawings: 1. Process
ypes: Centrifugal Pump, Column, Heat Exchanger, Line, Flow Sketch of LightEnds Recovery Unit,
Equipme nt ID: Distillation unit with heat recovery from bottoms heating feedstream 2. PipingInstrumentation
Design ConditionslParameters: Design conditions are listed in Process Flow S ketch ofDiagram PCD-A
Light Ends Recovery Unit provided
1 1 High Flow
2. Investigate recyclingline and/or additional
101 dwg. no. PCD-AA1) to trip FV- 101
closed using solenoid
3?DYADEM
© 2003 by CRC Prcss LLC
8/12/2019 Basics of HAZOP
http://slidepdf.com/reader/full/basics-of-hazop 20/26
Basics of HAZOP 6 20
- -- -.- *-
Causes Consequen ces Safeguards S
room monitored as
opposed to local device
and add high
temperature switch and
control v alve TV- 126
so that on fill1 open ing
column will be in likely
to flood due to excess
vapor flow
Responsible
4. Control j 4.1. High bottoms 14.1. PSV-105 j I ' Tom Volkevalve or ' temperature Ifails CV ' i ; f f - spe c P roduc ts
ITV-126 Iopen or
bypass leftPhillip
Smithpen j I I
I1 ,
14.3. Over-pressuring 14.2. TI- 1 17
of column
8. Add high
temperature alarm,
TAH - 126
To111 Volke
of c o l ~ ~ m n- - i
5 Cont ro l 5 . 1 Colum n will 15.1. PAL-10 6 I 9. Add independent
pressure monitor on
column overheads with
high and low pressure
switches and a la r~n s
Tom Volke
valve or i depressure to flare / (provided 1controller ; w -
fails CV, 5.2. Loss of products
PV- 106 5.3. Off-spec products /open or ibypass left
open- --- -" - - -- - - - - II ---- -
6. Control 6.1. Loss of products 6.1. L AL- 12 1
-- --16.1.
SafegilardsfI are I.<r9
, [adequa te
I $.9
I =,
Ii i
k1
;:
1.:I
i\s
iII
18.1, dSafeguards
are
adequate '
ik A A ,4 &< W 2 h A, - & *
, v a l v e or - - - - -
I6.2. Off-spec prodi~ctscontroller ,
falls CV
LV- 107
open or -
bypass left 6.3. Low level in
6.2. LSL- I2
trips P-1021s
ope n c olumn c o ~ ~ l d II
I bottoms pumps P-
, 1021s- -
7. Control 7.1. Excess reflux to 7.1. None 4 10. Add h igh flow
alarm to FR C- I 16
1. Consider
monitoring steam flow
to column by addingi flow indicator on 3"-S-
i 10 as check on energy
, consumption
valve or column i II controller
I
I 7.2. Unecononiical
CV performance 1FV-116open or ;bypass leftopen I
I
8. PSV-10 5 8.1. Column will
fails open depressure to flare
8.1. Block
and bypass
' due to valves I8.2. Loss of products PSV
spring . .-failure ,8. 3. Off-spec products nl ~l r I 4
Y A D E M
© 2003 by CRC Prcss LLC
8/12/2019 Basics of HAZOP
http://slidepdf.com/reader/full/basics-of-hazop 21/26
Basics of HAZOP 6 2 1
auses
. Steamtrap on 3 -S-102 sticksopen
Consequences Safeguards
8 4 [Failure too for manualinfrequent to raise pressuresignificant concerns] relief when
PSV-105 isremoved for
repair
9.1. Steam wastage 9.1. None
9.2. Uneconomical
Recommendations
1 1. Consider
monitoring steam flowto column by addingflow indicator on 3 -S-10 1 as check on energyconsumption
Responsible
Tom Volke
CarlHanks
Remarks
1.2. Low/No Flow
Imaintenance inspection offlow devices, such as FE-
system to make up in the
event of sudden loss ofsteam to reboiler
YADEM
© 2003 by CRC Prcss LLC
8/12/2019 Basics of HAZOP
http://slidepdf.com/reader/full/basics-of-hazop 22/26
Basics o HAZOP 6 22
--- .-
Causes
-- 1 - -Conseq~~ences Safeguards
4.2. Poss~ble " -I
L ' R R Responsible , Remarks- - -- --
Tom Volkelosed 14. Interlock reflux return,
FV- 16, and feed, FV- I0
to close wh en PA L- 106 is
act uated
1 vacuum in I
column causing
tray dam age
I -5. Control 5. I . Column will 15. I. PAH-106
- -Tom Volke. Add independent
pressure m onitor on
column overheads with
high and low pressure
switches and alarms
valve or
controller
fails CV PV-
106 closed
overpressure (provided
P1C- 106 is
f i~nc tonal).2. Loss of
products
- - 16. Control 16.1. Loss of 6. I . LAH - 107 15. Add high level switch
and alarm on reflux drumv - 102
Tom Volke
valve or products 1 (providedcontroller
fails CV
LV- 107
closed. - -7. Control
valve or
' controller
fails CV FV-
16 closed
- - - .
7.1. Loss of 17 .1 . AL- I16
. . -1. Consider monitoring
st ea m flo w to c o l ~ ~ m ny
adding flow indicator on
3 -S- 10 as check on
16. Add independent
pressure mo nitor onco1~11nnverheads w ith
high and low pressure
switches and alarms
Tom Volke
& Carl
Hanks
reflux to column 1 (provided- - "
' F I C - 1 1 6 i s7 .2 Off-spec fLlnctional)products
Tom Volke
. -
1 7.3. Over-
/ columnf - --
8.1. None 1. Consider monitoring
steam flow to column by
adding flow indicator on
3 -S-101 as check on
energy consumption- - - -
Tom Volke
& Carl
Hanks02 sticks 8.2 Lois of
closed 1 products
' 9 . 1 .
Safegnards
l are
I ' - __" -9. Bottom s 19.1. No
pump P- withdrawal of
1021s stops j bottoms product- . .19.2. Loss of 9.2. Spare
products
9.3. High level in
base of column" .
10.1. Loss of
9.3. LG- 8
10. Reflux
pump P-
o IS stops
10.1. FAL-
116
j 10.1.
1 Safeguardseflux to column; are
10.2. PSV-
105t asP&42- :,34 w
productsE had
Y ADE M
© 2003 by CRC Prcss LLC
8/12/2019 Basics of HAZOP
http://slidepdf.com/reader/full/basics-of-hazop 23/26
Basics o HAZOP6 23
auses1
1 MOV-122 fails
closed
12.Temporarystrainers on
P-1011s
plugged13. Loss ofoverheadcondenser.
pressuring ofcolumn
wouldcavitateldamagebottoms pumps P-1021s
wouldcavitateldamage
bottoms pumps P-
1021s13.1.Overpressuring ofcolumn to reliefcondition.
10.3. Spare
11.1.Interlock on
MOV-122positionerstops bottomspumps whenvalve closes
13.1. Low 2 3flow alarmFAL-116 onloss of reflux.
13.2. Pressurerelief valve
106 PV-106 opening
to flare.
MOV- 122 positioner ZC-
122 to stop bottoms pumpswhen MOV - 122 valve
closes
strainers on P- 10 1 S arecleaned and removed whenno longer required
19. Check PSV-105 forcontrolling case for sizingvalve. Must handle firecase tube rupture inreboiler total loss of refluxloss of cooling medium
instrument or controllerfailure instrument air
failure power failure etc.
20. PV-106 to be checkedfor maximum discharge
flow in event of coolingwater failure to EX-102.
Responsible Remarks
Phillip
Smith
1.3. ReverseIMisdirected F low
1.1. Possible explosive
YADEM
© 2003 by CRC Prcss LLC
8/12/2019 Basics of HAZOP
http://slidepdf.com/reader/full/basics-of-hazop 24/26
Basics of H ZOP 6 24
Table 6 4: List of Recommen dations
- . . .- ...
. .. . . .
nsider monitoring stea
3 -S-101 as check on
/ _._
17. Provide interlock on M
nu discharge flow in event of
Y DE M
© 2003 by CRC Prcss LLC
8/12/2019 Basics of HAZOP
http://slidepdf.com/reader/full/basics-of-hazop 25/26
Basics of HAZOP 6 25
Recomm endation Resp Status
22. Check on flow regime in 6 -P-113 to
slugging'23. Check that line 3 -P-104 is both self-ven ting and is not pocketed Phillip ~ m i t h Fr24. Evaluate need for emergency depressuring to prevent BLEVE in Phillip Smith Study
event of fire
25. Provide sample point on inlet feed. Also consider need for on-line Tom Volke Incomplete
analyzer for column feed.
' 26.1 Provide quality control check o n feed stream to column Carl Hanks 1 Study
Add high temperature alarm on overheads to indicate trend towards Tom Volke Incomplete
off-spec distillate
TR- 103 only Phillip Smith Incomplete
29.1 Add low temperature alarm to TR- 103. Tom Volke
30. Consider adding independent high high level switch and alarm on Tom Volkereflux rum
Incomplete
Study
1. Check sizing of control valve TV-126 s o that CV is not oversized Phillip Smithand could cause column flooding when fully open. If necessary Tomconsider adding upper limit stop on control valve. Volke
Study
Check as to whether upstream water separationRecon vene meeting if not met.
33. Provide bolt torquing procedure as part of34. Consider need for environmental monitors. Mary Incomplete
Patterson
Add isolation valve immediately upstream of stripper on reflux line
2 -P- 110.
36. Make valve on 3 -P-102 feed to column car seal open. Phillip Smith Incomplete
37. Add check valve to 3 -P-102 , close to stripper feed inlet. Allen Brown Incomplete
rm that C-101 a
Pri Place(sUsed
7 1.4.1
YADEM
© 2003 by CRC Prcss LLC
8/12/2019 Basics of HAZOP
http://slidepdf.com/reader/full/basics-of-hazop 26/26
Basics of HAZOP 6-26
SUGGE STED READING URLs current at time of publication
"Guidelines for Hazard Evaluation Procedures" by A IChE , CCP S, 2"d edition, 1992 plus
"Guidelines for Hazard Evaluation Procedures" by AlCh E, CC PS, I st edition, 1985
w w w . a i c h e . o r r / p u L > c a t / s e a d t l . a s ~ ' ? A c ~ k 4 i n = 2 i ~
"HAZOP and HAZAN" by T.Kletz, published by IChemE, 1992
www icl1e1ne or~/framesetsiia1~o~1ti1~S~iiii~estt n ~
"Size u p plant hazards tllis way" by H .G.Lawley, H ydrocarbon Processing, April 1976, pages
247 to 258
www.livdrocarbon~~rocessin~.co~n~conte~~ts/pul~lcatiotis,:'hp/
"Eliminating Potential Process Hazards" by T.Kletz, Chem ical Eng ineering, April 1, 1985, pages
48 to 59www.che.com/
"An Introduction to Hazard and Operability Studies Th e Guid e Word Approach" by
R.E.Know lton, published by Che metic s International, 198 1
www vaerner.co~n/co~i~pa~~ics co~iipanesdcta i I.asp'?id::.::.79(i
"A Manual of Hazard & Operability Studies Th e Creative Identification of Deviations and
Disturbances", published by Chemetics International, 1992
w~vw.kvae1ner.con1/co11i~.~atii~s/~o1ii~~ai1iesdetai.asp~ id=796
"Some Features of and Activities in Hazard and Operability (Hazop ) Studies", by J.R .Roach andF.P.Lees, Th e Chemical Engineer,October, 198 1, pages 456 to 462
\vwcv.ichenie.or~/fr~1111esets/i1bo~1tus f ra~nese ttln
"HAZOP: Guide to best practice" by F .Crawley, M.Preston, B.Tyler, IChernE, 2000
~vww icherne o~/fi amesets/aboutusframesct l~t~n
"The HAZOP (Hazard and Operability) Method" (Website)
w~\~\\ .acusafc.co~n/Iazard_A~ialysis/l AZ0 PTcc lir iiquc.pd f
"Hazard and Operability Studies", by M.Lihou (Website)
M M W. l i l ~ o i ~ t e c I ~ . c o ~ ~ i / h ~ pfi.m.htm
"Hazard and Operability Studies", University of Florida, (Web site)
litt~:l.'pie.clie.i~fl.edi~/~i~ideslhazopiindex.litn~l
"Process H azards Analysis" by I.Sutton, published by SW ISutton & Associates, 2002
litt~~://ww~~~ swbooks co~i~/bool~~/bo~~k~~~prI~~tslitml