HAZOP ANALYSIS

It is important to evaluate and identify the problems and hazards that cause the process parameters to
deviate from intended design. For this purpose a detailed hazard analysis is done under a multi-
disciplinary team. The more formalized hazard assessment technique is HAZOP.
HAZOP is a structured and systematic technique to assess and evaluate potential hazards in a chemical
process and identifying the operability problems that may lead to risk to personnel or equipment, or
prevent efficient operation. HAZOP is based on a theory that assumes risk events are caused by
deviations from design conditions.
HAZOP studies have been used with great success within chemical and the petroleum industry to obtain
safer, more efficient and more reliable plants. It’s a well-known and well documented study and is used
as a part of Quantitative Risk Assessment (QRA). A HAZOP analysis provides a full review of a process
system and systematically questions every part of it to establish how deviations from design intensions
might arise.

HAZOP EFFECTIVENESS:
The success or failure of HAZOP depends upon several factors:
The completeness and accuracy of drawings (P&ID) and information available to the team- the
information should be updated.
The technical skills and insights of the team
The ability of the team to concentrate on the more serious hazards identified.
The ability of the team to use the systematic approach of their imagination as an aid in visualizing
deviations, causes and consequences.

HAZOP METHODOLOGY

The HAZOP analysis is executed in four steps:

1) DEFINITION
Define scope and objectives
Define responsibilities
Select team

2) PREPARATION
Plan the study
Collect data
Estimate time Estimate time
Arrange a schedule

3) EXAMINATION
Divide the system into parts
Select a part and define design intent
Identify deviation by using guide words on each element
Identify consequences and causes
Identify whether a significant problem exists
 Identify protection, detection, and indicating mechanism
Identify possible mitigating measures
Repeat for each element and then for each part

4) DOCUMENTATION AND FOLLOW UP

Record the examination
Sign off the documentation
Produce the report of the study
Follow up that actions are implemented
Re-study ay part of the system if necessary
Produce final output report

HAZOP TERMINOLOGIES

SYSTEM: The location at which the process parameters are investigated for deviations. For example,
heat exchanger, reactor, pump, compressor, valve or pipelines.
INTENSION: The intension defines how the system is intended to operate in the absence of
deviations.
DEVIATIONS: It’s a way in which process conditions deviate from the design intentions which are
discovered by applying the guide words.
CAUSES: These are the reasons why deviations might occur. These causes can be hardware failure,
human errors or external disruption.
CONSEQUENCES: These are the results of the deviations. Consequences may comprise both
process hazards and operability problems.
GUIDE WORDS: These are the simple words applied on process parameters used to identify
possible deviations. HAZOP Analysis

GUIDE WORDS MEANINGS

No or not No part of the intent is achieved, and nothing else
occurs
Less Quantitative decrease
More Quantitative increase
Part of Qualitative decrease (i.e. only one of the two
components in a mixture )
As well as Qualitative decrease ( e.g. an impurity)
Reverse Opposite
Other than Complete substitution

STEPS IN HAZOP

The HAZOP process can be organized into the following steps:

Divide the process into sections. (i.e. reactor, heat exchanger)
Choose a study note. (i.e. line, vessel, pump)
Describe the design intent.
Select a process variable.
Apply a guide word.
 Identify the deviations of the process from the intended design
Determine possible causes of the deviations.
Evaluate consequences.
Recommend action.
Record information.
Repeat procedure for other sections of the process.

HAZOP ANALYSIS OF TUBULAR REACTOR