Chemical Process HAZOP and

Risk Analysis (CHE 4413)

CLO 3 - HAZOP Analysis

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 HAZOP
• HAZOP identifies potential hazards,
failures and operability problems.
• Its use is recommended as a
principal method by professional
institutions and legislators on the
basis of proven capabilities for over
40 years.
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 HAZOP
• It is most effective as a team effort consists of
process designers, operating personnel,
instrumentation and control engineers, technical
and safety professionals etc.
• It encourages creativity in design concept
evaluation.
• Its use results in fewer commissioning and
operational problems and better informed
personnel, thus confirming overall cost
effectiveness improvement. 3
 HAZOP (continued)

• Necessary changes to a system for

eliminating or reducing the probability of
operating deviations are suggested by the
analytical procedure.
• HAZOP provides a necessary management
tool and bonus in so far that it
demonstrates to insurers and inspectors
evidence of comprehensive thoroughness.
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 HAZOP (continued)

• HAZOP reports are an integral part of

plant and safety records and are also
applicable to design changes and plant
modifications, thereby containing
accountability for equipment and its
associated human interface
throughout the operating lifetime.
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 HAZOP (continued)
• HAZOP technique is now used by most
major companies handling and
processing hazardous material,
especially those where engineering
practice involves elevated operating
parameters: oil and gas production,
flammable and toxic chemicals,
pharmaceuticals etc. 6
 HAZOP (continued)
• It emphasizes upon the operating integrity
of a system, thereby leading methodically
to most potential and detectable
deviations which could conceivably arise in
the course of normal operating routine
 including "start-up " and "shut-down"
procedures
 as well as steady-state operations.
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 HAZOP (continued)
• HAZOP keeps all team members focused on
the same topic and enables them to work
as a team.
• Node: Concentrate on specific
location (vessel, line) in the process
• Intention: description of how the process is
expected to behave at the node

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 HAZOP (continued)

• Parameter: Consider each process

variable individually (F, T, L, P,
concentration, pH, viscosity etc.)
• Guide Word: Pose a series of standard
questions about deviations from
normal conditions. We assume that
we know a safe “normal” operation.
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 HAZOP (continued)
1) HAZOP committee
 A full HAZOP study requires a committee composed of
experienced plant, laboratory, technical and safety
professionals.
 One person must be a trained HAZOP leader and serves
as the committee chair.
2) HAZOP Procedure (given handout – “HAZOP Summary”)
3) Guide Words (given handout- “HAZOP Summary” ) – also
recall previous “guide words”
4) Guide Word/Process Parameters Combination
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 Common Hazard Identification Methods
Selected examples and case studies
Example 1:
An exothermic reaction controlled by cooling water.

Perform a HAZOP study on the unit (Example 1) to

improve the safety of the process.

An Exothermic
rection controlled by cooli
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 Common Hazard Identification Methods
Selected examples and case studies

Example 2: Nitric Acid Plant

Study the Example 10.2: Nitric acid plant [Towler, G.,
Sinnott, R. K. (2012), Chemical Engineering Design : Principles,
Practice and Economics of Plant and Process Design (2nd ed.),
pp. 471-474]

HAZOP_example2

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 HAZOP Study Project

For the given handout perform the following:

a) Safety checklist - Develop a safety checklist for use
before operation of this experiment
b) HAZOP Study - Perform a HAZOP study on the
process. (nodes…..etc.)
c) What specific recommendations can you make to
improve the safety of this experiment? Recommend
possible modifications to improve the safety of the
process. 13