PAWAN YADAV

HAZOP STUDY
Introduction:

The HAZOP study is a formal procedure to identify hazards in a chemical process

facility. The procedure is effective in identifying hazards and is well accepted by
the chemical industry. The basic idea is to let the mind go free in a controlled
fashion in order to consider all the possible ways that process and operational
failures can occur. Before the HAZOP study is started, detailed information on the
process must be available. This includes up-to-date process flow diagrams (PFDs),
process and instrumentation diagrams (P&IDs), detailed equipment specifications,
materials of construction, and mass and energy balances.
The full HAZOP study requires a committee composed of a cross-section of
experienced ' plant, laboratory, technical, and safety professionals. One individual
must be a trained HAZOP leader and serves as the committee chair. This person
leads the discussion and must be experienced with the HAZOP procedure and the
chemical process under review. One individual must also be assigned the task of
recording the results, although a number of vendors provide software to perform
this function on a personal computer. The committee meets on a regular basis for a
few hours each time. The meeting duration must be short enough to ensure
continuing interest and input from all committee members. A large process might
take several months of biweekly meetings to complete the HAZOP study.
Obviously, a complete HAZOP study requires a large investment in time and
effort, but the value of the result is well worth the effort.

Success or Failure:
The success or failure of the HAZOP depends on several factors.
 The completeness and accuracy of drawings and other data used as a basis for
the study.
 The technical skills and insights of the team.

 The ability of the team to use the approach as an aid to their imagination in
visualizing deviations, causes, and consequences.

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Hazop Characteristics:
HAZOP is best suited for assessing hazards in facilities, equipment, and
processes and is capable of assessing systems from multiple perspectives:
Design:

Assessing system design capability to meet user specifications and safety

standards. Identifying weaknesses in systems
Physical and operational environments:

Assessing environment to ensure system is appropriately situated, supported,

serviced, contained, etc.
Operational and procedural controls:

Assessing engineered controls (ex: automation), sequences of operations,

procedural controls etc. Assessing different operational modes start-up, standby,
normal operation, steady & unsteady states, normal shutdown, emergency
shutdown, etc.

10.5 Advantages:

1. Helpful when confronting hazards that are difficult to quantify that is, Hazards
rooted in human performance and behaviors
 Hazards that are difficult to detect, analyze, isolate, count, predict, etc.
 Methodology doesn’t force you to explicitly rate or measure deviation
probability of occurrence, severity of impact, or ability to detect
2. Built-in brainstorming methodology.
3. Systematic & comprehensive methodology.
4. More simple and intuitive than other commonly used risk management tools.

10.6 Disadvantages:

1. No means to assess hazards involving interactions between different parts of a

system or process.
2. No risk ranking or prioritization capability. Teams may optionally build-in such
capability as required.

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3. No means to assess effectiveness of existing or proposed controls (safeguards).

May need to interface HAZOP with other risk management tools.

10.7 Effectiveness:
The effectiveness of a HAZOP will depend on:
 The accuracy of information (including P&IDs) available to the team
information
 Should be complete and up-to-date
 The skills and insights of the team members
 How well the team is able to use the systematic method as an aid to
identifying Deviations
 The maintaining of a sense of proportion in assessing the seriousness of a
hazard
 The expenditure of resources in reducing its likelihood
 The competence of the chairperson in ensuring the study team rigorously
follows Sound procedures.

Key Elements:
Key elements of a HAZOP are:
 HAZOP team.
 Full description of process.
 Relevant guide words.
 Conditions conducive to brainstorming.
 Recording of meeting.
 Follow up plan.

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Guide Words
Guide Words Meaning
No Negation of design intent
Less Quantitative decrease
More Quantitative increase
Part of Qualitative decrease
As well as Qualitative Increase
Reverse Logical opposite of the intent
Other than Complete substitution

Hazop Study on Reactor

Guide Deviation Cause Consequences Action
No Flowrate  Cleaning of
 No Feed in
line
storage tank  Level
 Feed pump Decrease in control
rupture production system
 Maintenance
 Supply pipe or no
of pipes
rupture production
 Automatic
 Valve is closed
valve
 Pump is off
 Automatic
pump
Level Decrease in  Maintenance
 Blockage in
production of pipes
line
or no  Automatic
 Valve is closed
production valve
Temperature  Fault in Decrease in
Preheater production
or no Maintenance
 Steam pipe
production of pipes
rupture
Pressure Decrease in
Fault in production Maintenance
Preheater or no of Preheater
production

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More Flowrate  Automatic

 Explosion
More valve valve
 Less
opening  Check reactor
conversion
conditions
Level
More valve
Overflow Check Valve
opening
Temperature
Fault in
Explosion Maintenance
Preheater

Pressure
Fault in Less
Check valve.
Preheater production

Less Flowrate Less  Automatic

production valve
Less of
 Temperature
opening of
control at
valves
reactor feed
preparation
Level Less of
Less
opening of Check Valve
Production
valves
Temperature
Fault in Low Temperature
Preheater Conversion Control
Pressure
Fault in Less
Maintenance
Preheater Production
As well Impurities in  Low  Quality
 Problem in
as feed stream conversion control of
raw
rate raw
material
 Decrease in material and
 Fouling in
product product
pipes
quality  Maintenance

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Part of Higher or  High More or less

Quality
Lower quality pure
control of
percentage of feed production
 Less
raw
of than material and
quality intended
Feed product
of feed
Other Replacement Wrong Better
than of Raw connection management
Explosion
Material during plant of changing
modification procedure

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Environmental Impact
Assessment Environmental Impact Assessment:
Environmental Impact Assessment (EIA) is the process of assessing the likely
environmental impacts of a proposal and identifying options to minimize
environmental damage. The main purpose of EIA is to inform decision makers of
the likely impacts of a proposal before a decision is made. EIA provides an
opportunity to identify key issues and stakeholders early in the life of a proposal so
that potentially adverse impacts can be addressed before final approval decisions
are made. The EIA also includes a description of the measures taken to avoid,
reduce or remedy these effects.

Overview:
The US Environmental Protection Agency Pioneered the use of pathway analysis
to determine the likely human health impact of environmental factors. The
technology for performing such analysis is properly called as environmental
science. The principal phenomenon or pathways of impact are:
Noise and health effects
Water pollution
impacts
Ecology impacts including endangered species assessment
Air pollution impacts
Soil contamination impacts
Geological hazards assessment

Objectives:
 Ensuring environmental factors are considered in the decision-making process.
 Ensuring that possible adverse environmental impacts are identified and
avoided or minimized.
 Informing the public about the proposal.

Advantages:
 Allows people to examine the underlying need for a project.
 Gives people the opportunity to identify problems.
 Helps a developer to design a more publicly acceptable project.

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Methanol:

Methanol, also known as methyl alcohol among others, is a chemical with the
formula CH3OH.. Methanol acquired the name wood alcohol because it was once
produced chiefly as a byproduct of the destructive distillation of wood. Today,
industrial methanol is produced in a catalytic process directly from carbon
monoxide, carbon dioxide, and hydrogen. Methanol is a colorless liquid that boils
at 64.96 °C (148.93 °F) and solidifies at −93.9 °C (−137 °F). It forms explosive
mixtures with air and burns with a no luminous flame. It is completely miscible in
water.
Methanol has an odor that is similar to ethyl alcohol, the intoxicant of alcoholic
beverages, but is a dangerous poison; many cases of blindness or death have been
caused by drinking mixtures containing it.

Hazard:
Fire Hazards:
Highly flammable in presence of open flames and sparks, of heat. Non-flammable
in presence of shocks. Risks of explosion of the product in presence of
mechanical impact: Not available. Explosive in presence of open flames and
sparks, of heat.
Flammable liquid, soluble or dispersed in water. Small Fire Use Dry chemical
powder. Large Fire: Use alcohol foam, water spray or fog. Explosive in the form of
vapor when exposed to heat or flame. Forms an explosive mixture with air due to
its low flash point. Explosive when mixed with Chloroform, sodium methoxide
and diethyl zinc. It boils violently and explodes.

Health Hazard
Hazardous in case of skin contact, of eye contact (irritant), of ingestion, of
inhalation. Slightly hazardous in case of skin contact (permeator). Severe over-
exposure can result in death. The substance is toxic to eyes. The substance may be
toxic to blood, kidneys, liver, brain, peripheral nervous system, upper respiratory
tract, skin, central nervous system (CNS), optic nerve. Repeated or prolonged
exposure to the substance can produce target organs damage.

Protective measures

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Eye Protection:

Check for and remove any contact lenses. Immediately flush eyes with running
water for at least 15 minutes, keeping eyelids open. Cold water may be used. Get
medical attention.
Skin Contact:

Wear chemical protective clothing e.g. gloves, aprons, boots. In some operations
wear a chemical protective, full-body encapsulating suit and self-contained
breathing apparatus (SCBA).In case of contact, immediately flush skin with plenty
of water for at least 15 minutes while removing contaminated clothing and shoes.
Cover the irritated skin with an emollient.
Inhalation Protection:

If inhaled, remove to fresh air. If not breathing, give artificial respiration. If

breathing is difficult, give oxygen. Get medical attention immediately.
Spills and emergencies
Dilute with water and mop up, or absorb with an inert dry material and place in an
appropriate waste disposal container. Flammable liquid. Poisonous liquid. Keep
away from heat. Keep away from sources of ignition. Stop leak if without risk.
Absorb with Dry earth, sand or other noncombustible material. Do not get water
inside container. Do not touch spilled material [13].

Formaldehyde:

Formaldehyde (systematic name methanal), is a naturally occurring organic

compound with the formula CH2O (H-CHO). It is the simplest of the aldehydes.
Formaldehyde is a colorless poisonous gas synthesized by the oxidation of
methanol and used as an antiseptic, disinfectant, histologic fixative, and general-
purpose chemical reagent for laboratory applications. Formaldehyde is readily
soluble in water and is commonly distributed as a 37% solution in water; formalin,
a 10% solution of formaldehyde in water, is used as a disinfectant and to preserve
biological specimens. Environmentally, formaldehyde may be found in the
atmosphere, smoke from fires, automobile exhaust and cigarette smoke. Small
amounts are produced during normal metabolic processes in most organisms,
including humans.

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Hazards:
Fire Hazards:
Formaldehyde becomes a fire or explosion hazard in the presence of heat, flames
or other sources of ignition. Upon ignition, the chemical decomposes into carbon
oxides (i.e. carbon monoxide, carbon dioxide), which can be hazardous to humans.
Use dry Chemical, CO2, water spray or alcohol resistant foam as extinguisher
agents. Use water spray to reduce the vapors.

Health Hazard:
Formaldehyde can be highly toxic if swallowed, inhaled or absorbed though skin.
Ingestion of as little as 30 mL of a solution containing 37% formaldehyde has been
reported to cause death in adults. Formaldehyde is classified as a suspected human
carcinogen, based on evidence obtained from human and/or animal studies.
Exposure to formaldehyde can lead to allergic reactions in certain individuals.
Sensitization is an immune response. Formaldehyde can become irritating to the
eyes at low concentrations. Irreversible damage. At concentrations near 0.1 parts
per million (ppm), exposure to formaldehyde can be irritating to the skin, eyes and
respiratory tract. Symptoms of exposure include coughing, wheezing, dermatitis,
headaches, watery eyes, nausea, chest tightness and burning sensations in the eyes,
nose and throat. Long-term exposure can result in headaches, insomnia,
depression, mood changes, attention deficit and impairment of dexterity, memory
and equilibrium.
Protective measures
1 Eye Protection:
Tight-fitting safety goggles or a full face shield (8-inch minimum) should be worn
when handling formaldehyde.

2 Foot Protection:
Closed-toed footwear is required in all laboratories with hazardous chemicals.

3 Hand Protection:
Concentrated formaldehyde solutions (i.e. 10% or greater) should be handled with
medium or heavyweight nitrile, neoprene, natural rubber or PVC gloves.

4 Skin and Body Protection:

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In most laboratories, a lab coat or chemical-resistant apron should be worn when

handling formaldehyde. Further protection for the body may be necessary
depending on the concentrations of formaldehyde being used and operations being
performed.

5.Respiratory Protection:
Researchers working in labs with formaldehyde that have exceeded the OSHA
action level, permissible exposure limit or short-term exposure limit may be
required to wear respiratory protection. All employees required to wear respirators
in laboratories must have a medical evaluation, training and a fit test prior to use.

Spills and emergencies:

Evacuate the personal and secure and control entrance to area. Eliminate all the
ignition source. Absorb liquids in vermiculite, dry sand, earth, or a similar
material and place into sealed container for disposal. Ventilate and wash area after
clean-up is complete

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