HAZOP Case Studies Example 1

Cooling Coils
Monomer
Feed

. Refer to reactor system shown

Cooling Water to Sewer

The reaction is exothermic. A cooling system is

provided to remove the excess energy of
reaction. In the event of cooling function is lost,
the temperature of reactor would increase. This
would lead to an increase in reaction rate
. leading to additional energy release

Cooling
Water In

T
C

Thermocouple

The result could be a runaway reaction with

pressures exceeding the bursting pressure of
the reactor. The temperature within the reactor
is measured and is used to control the cooling
.water flow rate by a valve
Perform HAZOP Study

Process Risk Seminar 22nd Dec

2009 - Workshop Session

Preliminary HAZOP on Reactor Example fill in the

gaps

Guide Word

Deviation

Causes

Consequences

Action

NO

No cooling

REVERSE

Reverse cooling
flow

MORE

More cooling
flow

Instruct operators
on procedures

AS WELL AS

Reactor product
in coils

Check maintenance
procedures and
schedules

OTHER THAN

Another
material besides
cooling water

Temperature increase
in reactor
Failure of water
source resulting in
backward flow

Water source
contaminated

Process Risk Seminar 22nd Dec

2009 - Workshop Session

Case Study Shell & Tube Heat

Exchanger
Using relevant guide works, perform HAZOP study on shell & tube
heat exchanger

Process
fluid

Coolingwater
3

Process Risk Seminar 22nd Dec

2009 - Workshop Session

HAZOP Study Form

HAZOP STUDY REPORT FORM
Sheet 1 of
: LINE 1

TITLE :

CAUSES

CONSEQUENCES

DEVIATION

Process Risk Seminar 22nd Dec

2009 - Workshop Session

ACTIONS, QUESTIONS OR
RECOMMENDATIONS