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Introduction To Hazardous Evaluation Techniques
Introduction To Hazardous Evaluation Techniques
Evaluation Techniques
• Guidelines for Hazardous Evaluation
Procedures (1992 by AIChE).
• Second Edition with Worked Examples.
• Center for Chemical Process Safety
(CCPS).
• American Institute of Chemical
Engineers (AIChE).
Hazard Evaluation Techniques
1960 - 2001 1960 - 2001 1965 - 2001 1970 - 2001 1972 - 1974 1974 - 2001
Safety Check Lists Relative PHA What if HAZOP
Review Ranking
HAZOP
Review By Documentation Follow-up
Team
Table
Sheet
intention process sections
Identify existing
safeguards to
prevent deviation
Hazop Pitfalls
Poor understanding by management of the HAZOP procedure
An Ethylene plant has 100 P&IDs, 625 equip't items. 625 items
Consider 5 variables, Pressure, Temperature, Flow
Composition and Function. 5 variables
Consider 6 Guidewords, None, More of, Less of
Part of, More than and Other than. 6 guide words
Questions to be answered = 18750 questions
Consider 5 minutes per question = 5 min./question
Time for ethylene plant HAZOP study = 93750 minutes
4 hour, 240 minutes sessions per day = 250 minutes/day
No. working of days = 375 days
Days per week = 5 days/week
No. of weeks to complete HAZOP for plant = 75 weeks
Other Pitfalls
• Inexperienced HAZOP team.
• Inadequately trained or in-experienced
leader.
Common Hazop Mistakes
• Failing to establish a "safe" environment
for team members.
• Consequences of events not carried to
conclusion.
• Taking unwarranted credit for
safeguards.
• Too little credit given for safeguards.
Hazop Mistakes Cont’d
• Failure to make recommendations as
specific as possible.
• Poor record keeping of HAZOPS.
• Failure to HAZOP start-up and shut-
down procedures.
• P&IDs not up-dated or poorly
constructed.
Hazop Mistakes Cont’d
• A HAZOP is performed in lieu of
properly executed design reviews.
• Wrong technique for system being
reviewed (See spreadsheet titled Fig
5.3).
HAZOP Example
To Compressor Inlet
LAH
FV Teams tend to quickly identify alarms, shut-downs
1 and controls, and claim them for safeguards.
Intention The intent is to transfer 150,000 lb/hr of C2/C2= mix at 300 psig and at -30 °F for the startup period.
Possible Causes
1 FV-1 Wide open
2 Line break.
3
Consequences
1 High level in KO pot with liquid carry-over to compressor with serious damage to rotor. Potential hydrocarbons release.
2 Potential hydrocarbon release.
3
Safeguards
1 High level alarm LAH-1
2 High - High level alarm HHLA - 1 shutdown.
3 Vessel inspection yearly.
Recommendation / Actions Respib By Date
1 Consider limiting flow orifice, auto SD trip on High-High level, smart check valve. 1 JB 01-Jan-99
2 Determine extent of typical hydrocarbon release. 2 PM 15-Jan-99
3 Set-up vessel inspection yearly. 3 FD 30-Jan-99
Check List Example
1 Changes In Quantity a High Flow 1 Pump racing, delivery vessel pressure lost, Loss of automatic
suction pressurized, scale dislodged, leak in control
heat exchanger
b Low Flow 2 Pump failure, scaling of delivery, presence of Operator error
foreign body, poor suction condition,
cavitation, leak in heat exchanger, drain
leak, valve jammed
c No Flow 3 Pump failure, delivery vessel Failure of joint, pipe,
overpressurized, gas blockage, presence of valve, trap, bursting
foreign body, scale, sediment, suction vessel disc, relief valve.
empty.
d Reverse Flow 4 Pump failure, pump reversed, delivery vessel
over pressurized, poor isolation, gas locking,
surging, back siphoning.
Check List Cont’d
2 Changes in physical a High or Low 1 Boiling, cavitation, freezing, chemical
condition pressure breakdown, flashing, condensation,
sedimentation, scaling, foaming, gas
release, priming, exploding, imploding.
Changes in viscosity, density. External Fire,
Weather conditions, Hammer.
b High or Low 2 same as 1
Temperature
Check List Cont’d
3 Changes in chemical a High or Low 1 Changes in proportion of mixture, in water or
condition Conentration solvent content.
b Contaminants 2 Ingress of air, water, steam, fuel, lubricant,
corrosion products, other process materials
from high pressure system, leakage through
heat exchangers. gas entrainment, spray,
mist.