UNIVERSITAS INDONESIA

HEAT REFLECTIVE PAINT NurCoolant

GROUP 5 LIST OF MEMBERS: ARIZ KIANSYAHNUR H. (1006679453) FEBRIAN TRI ADHI W.(1006679586) FIRDHAUZI KUSUMA R. (1006679592) NATHANAEL SANDY (1006773300)

FACULTY OF ENGINEERING DEPARTMENT OF CHEMICAL ENGINEERING DEPOK MAY 2013

Definition The HAZOP (Hazard and Operability Study) method is technique used to identify the hazards on process facilities and prepare the system safety of potential hazards occurring in the operation. Even those who are not familiar with the hazards analysis process will often have heard of the term HAZOP, even if they are not really sure what it means. It has happened when the Process Safety Management (PSM) regulations in the United States were being promulgated in the early 1990s it was not unknown for a plant manager to say, "I know what PSM is, it's HAZOPs!" In fact the HAZOP method is just one of the many types of Process Hazards Analysis (PHA) techniques that are available, and PHAs are just one element of a PSM program. Nevertheless, these managers were somewhat justified in what they said because they knew that, unless they could identify the hazards on their facilities, they could not reduce risk. The goals of HAZOP are to figure out: The potential hazards, especially the most dangerous ones for human being and environment Some various operability problems in each process because of some deviations toward the design intent in plant, both active one or about to begin one. Furthermore, both regulators and legal advisors generally support the use of the HAZOP technique because of its reputation and because it is so thorough. The use of the HAZOP technique is very defensible if a company is challenged regarding its safety performance, particularly in a legal dispute. As a result of its widespread use and acceptance, large numbers of process safety practitioners are now trained in the use of the HAZOP method, and many of those are also trained as leaders/facilitators. Furthermore, a substantial HAZOP infrastructure has developed. Many consulting companies offer HAZOP facilitation services special-purpose software.

Technique A HAZOP is organized by dividing the unit to be analyzed into nodes. A node represents a section of the process where a significant process change takes place. For example, a node might cover the transfer of material from one vessel to another through a pump. In this case the process change is the increase in pressure and flow that occurs across the node. Another node might include an overhead air-cooler on a distillation column. Here

temperature and phase are the process variables that change. The HAZOP team would systematically examine a proposed process design by asking questions using guidewords representing deviations from the intended parameters of the process which can be seen in table below:

Table . Guide Words and the Meaning

Guide Words No or None More Less As Well As Part Of Reverse Other Than

Meaning The negation of the intention (e.g.: no flow) A quantitative increase (e.g.: high pressure) A quantitative decrease (e.g.: low pressure) In addition to (e.g.: impurity) A qualitative decrease (e.g.: only one of two components present) The opposite of the intention (e.g.: back flow) Complete substitution (e.g.: wrong material)

Table . Type of Problems Indication

Deviation No Flow Reverse Flow More Temp More Press Less Flow Less Temp Less Press As Well As

Typical Problems Blockage, pump failure, suction vessel empty, vapor lock, control failure, etc. Pump failure, pump reversed, over pressurization, etc. Blockage, loss of control, reaction, explosion, valve closed, etc.

Pump failure, leak, partial blockage, sediment, cavitation, etc. Heat loss, vaporization, leak, imbalance of input and output, etc.

Presence of contaminants, e.g.: water, air, lubrication oil, etc.

Although the strength of the HAZOP method lies in its clear organization, it is important not to allow the analysis to become too rigid. If the team finds that it is talking about "Reverse Flow" even though the current guideword is "High Flow", the leader should probably let the discussion continue. If he or she were to postpone the discussion until the "right" guideword, the current thinking and creativity may be lost. On the other hand, the leader must also keep the discussion focused on the issue at hand, and should prevent too many digressions.

1. 2. 3. 4.

Select a node, define its purpose and determine the process safe limits. Select a process guideword. Identify the hazards and their causes using the deviation guidewords. Determine how the hazard is "announced", i.e., how the operator knows a safe limit has been exceeded.

5. 6. 7. 8. 9.

Estimate the consequences (safety, environmental, economic) of each identified hazard. Identify the safeguards. Estimate the frequency of occurrence of the hazard. Risk rank the hazard, with and without safeguards. Develop findings and potential recommendations.

10. Move on to the next process guideword, or to the next node if the guideword discussion is complete.

Some mistakes might happen in assessing HAZOP are: 1. Failing to establish a "safe" environment for team members. 2. Consequences of events not carried to conclusion. 3. Taking unwarranted credit for 4. Too little credit given for safeguards 5. Making recommendations as specific as possible 6. Poor recording of HAZOPS 7. Failure to HAZOP start-up and shut-down procedures 8. Poorly up-dated P&IDs 9. A HAZOP is performed in lieu of properly executed design reviews 10. Wrong technique for system being.

Table . HAZOP Sheet for Weigh Tank

Weigh Tank Deviation No. 1. Guide Word Less Parameter Level Cause The amount of ingredients put into the weigh tank is too few The amount of ingredients put into the weigh tank is too many Wrong substance delivered and human error Consequences Safeguards Action Required By designing the weigh tank with alarm for low level occurring By designing the weigh tank with alarm for high level occurring By ensuring the engineers to distinguish each ingredients used Action Assigned to Engineer

2.

More

Level

3.

Other Than Specification

Feed Ingredients

The ingredients will Rechecking run out earlier inspection/maintenance before they come regime done by into mixer engineers to prevent any problems The ingredients will Rechecking be over capacity inspection/maintenance regime done by engineers to prevent any problems Possible reaction Reviewing Question will occur since it and Answer procedures will affect the work done by engineers to system of any solve the problems equipment

Engineer

Engineer

Table . HAZOP Sheet for Energy Efficient Mixer 1

Energy Efficient Mixer 1 Deviation No. 1. Guide Word Other Than Specification Parameter Flow in (Feed) Cause The flow inlet has obstacle to go through mixer or even no flow coming in Consequences The composition to mix the materials needed will be imperfect, not suitable toward the Safeguards Checking the materials coming to the mixer for batch system done by engineers Action Required By designing the center flow control as well Action Assigned to Engineer

2.

Other Than Specification

Flow out (Feed)

Wrong substance delivered and pollutant coming through the flow

3.

Less

Level

Mixture of ingredients needed is lower than the capacity of mixture tank Mixture of ingredients needed is higher than the capacity of mixture tank

4.

More

Level

safety standard, and not fulfill the specification of market The composition to mix the materials needed will be imperfect, not suitable toward the safety standard, and not fulfill the specification of market Impeller in mixer will run faster then there will be friction between impeller and mixer and economic loss The overcapacity of tank will be hard to make impeller run and economic loss

Checking the materials coming to the mixer for batch system and the filter used

By designing the optimal performance of the filter

Engineer

Rechecking inspection/maintenance regime done by engineers to prevent any problems Rechecking inspection/maintenance regime done by engineers to prevent any problems

By ensuring the capacity and composition of the mixture is suitable with the procedure By installing safety control where machine wont be on if overcapacity happens like alarm

Engineer

Engineer

Table . HAZOP Sheet for Grinding Machine

Grinding Machine Deviation No. 1. Guide Word Other Than Parameter Flow in (Feed) Cause The mixture coming Consequences The cutter in Safeguards Rechecking the Action Required By ensuring the Action Assigned to Engineer

Specification

from previous mixer tank is too hard to be cut and crushed to get paste form of paint or can be said its not perfectly mixed

grinding machine is hard to run and motor of transfer will be broken fast

performance of equipment, standard operating system, and viscosity of the mixture coming from previous mixer tank

cutter in grinding machine is sharp and the mixture of ingredients has the best quality

Table . HAZOP Sheet for Energy Efficient Mixer 2

Energy Efficient Mixer 2 Deviation No. 1. Guide Word Other Than Specification Parameter Flow in (Feed) Cause The flow inlet has obstacle to go through mixer or even no flow coming in Consequences The composition to mix the materials needed will be imperfect, not suitable toward the safety standard, and not fulfill the specification of market The composition to mix the materials needed will be imperfect, not suitable toward the safety standard, and not fulfill the specification of market Safeguards Checking the materials coming to the mixer for batch system done by engineers Action Required By designing the center flow control as well Action Assigned to Engineer

2.

Other Than Specification

Flow out (Feed)

Wrong substance delivered and pollutant coming through the flow

Checking the materials coming to the mixer for batch system and the filter used

By designing the optimal performance of the filter

Engineer

3.

Less

Level

4.

More

Level

Mixture of ingredients needed is lower than the capacity of mixture tank and operator error Mixture of ingredients needed is higher than the capacity of mixture tank and operator error

Impeller in mixer will run faster then there will be friction between impeller and mixer and economic loss The overcapacity of tank will be hard to make impeller run and economic loss

Rechecking inspection/maintenance regime done by engineers to prevent any problems Rechecking inspection/maintenance regime done by engineers to prevent any problems

By ensuring the capacity and composition of the mixture is suitable with the procedure By installing safety control where machine wont be on if overcapacity happens like alarm and drain valve to purge the higher mixture of solvent and previous mixture

Engineer

Engineer

Table . HAZOP Sheet for Pump

Pump Deviation No. 1. Guide Word Less Parameter Level Cause The flow inlet is too low then there will also be air coming in to the pump and operator error Consequences Pump failure and cavitation occurs Safeguards Rechecking inspection/maintenance regime done by engineers to prevent any problems Action Required By designing the level alarm system and installing gas detector Action Assigned to Engineer

Table . HAZOP Sheet for Paint Filling Machine

Paint Filling Machine Deviation No. 1. Guide Word Less Parameter Level Cause Consequences Safeguards Action Required By ensuring the final capacity of products, automatically processing the previous stream, and reviewing the upstream equipment done by supervisor By doing daily inspection to all belt conveyors after production has finished Action Assigned to Engineer, Technician

2.

No

Level

The flow inlet has The product is not Rechecking obstacle to go complete and can inspection/maintenance through mixer from danger the safety regime and feed previous mixer tank also can distract the flowing has been and operator error next process and completed even economic loss since the target of production is not achieved Distraction of Economic loss as Checking the belt stream in belt the production conveyor in a good conveyor because stops from this spot condition to use the pollutant stuck to the downstream in wheel of production conveyor
Table . HAZOP Sheet for Automatic Packaging Machine

Technician

Automatic Packaging Machine Deviation No. 1. Guide Word Other Than Specification Parameter Tin Feed Cause The tin can be broken or not qualify the standard from the vendor as long as the delivery Consequences Safeguards Action Required By ensuring the product coming out of the machine and mapping the off spec product (separation) Action Assigned to Engineer, Technician

The product will be Rechecking off spec, not inspection/maintenance qualify the standard regime of tin will be operating system, suitable toward the and can affect the specification

or loading process

2.

Other Than Specification

Carton Feed

The carton can be broken or not qualify the standard from the vendor as long as the delivery or loading process

3.

No

Level

Distraction of stream in belt conveyor because the pollutant stuck in wheel of conveyor

safety of loading and inventory process The product will be Rechecking off spec, not inspection/maintenance qualify the standard regime of tin will be operating system, suitable toward the and can affect the specification safety of loading and inventory process Economic loss as Checking the belt the production conveyor in a good stops from this spot condition to use to the downstream production

By ensuring the product coming out of the machine and mapping the off spec product (separation)

Engineer, Technician

By doing daily inspection to all belt conveyors after production has finished

Technician

References

Chemical Industries Health and Safety Council. 1977. Hazard and Operability Studies. London: Chemical Industries Association. Lees, F. P. 1981. Some Features of and Activities in HAZOP Studies. The Chemical Engineer. Kletz, T. A. 1986. Notes on the Identification and Assessment of Hazard. London: The Institution of Chemical Engineers.