ArcelorMittal Design & Engineering Centre (P) Ltd

HAZOP STUDY: 4TH to 8th 2024, L&T office Kolkata

ArcelorMittal Nippon Steel (AM/NS)
PROJECT : 6MTPA - Grinding & De-sliming Plant Review of Engineering & Construction
(Project Code – 222002)
 Introduction

1. What is HAZOP
2. Why HAZOP
3. Importance of HAZOP
4. HAZOP Study Process

1. What is HAZOP ?
•HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible operational
hazards in a work process/Plant/Equipment.

2. Why HAZOP ?
•Identify potential hazards in business operation;
•past incidents that had likelihood for catastrophic consequences;
•human-controlled factors;
•consequences of failure of applied control measures including the range of the possible health
and safety risks.
3. Importance of HAZOP
•proactively catch hazards
•realize risks during modification of current processes
•risk mitigation early on during the planning or design stage of projects

4.Forming a HAZOP team

4.1 Identifying & Understand the PFD, P&ID & HAZOP NODES
4.2 Consider the effect of Variation
4.3 Identify controls and establish safety monitoring
4.4. Communicate HAZOP results and improve processes
 4. HAZOP Study Process

4.1.Forming a HAZOP team

 Create a HAZOP team including people with a variety of expertise such as operations, maintenance,
instrumentation, engineering/process design.
 Expertise from L&T, AMNS Design, Project, Safety & AMDEC team involved in the HAZARD
workshop
4.2. Identifying & Understand the PFD, P&ID & HAZOP NODES
 Create a plan for the complete work process
 Understand the process flow diagrams
 Identify every individual steps in P&ID by using different NODEs
 Identify the planned operating parameters of the system at that point: flow rate, pressure, slurry
density, weight indicator, vibration etc
4.3 Consider the effect of Variation:
Variation in parameters and deviations are determined and below guide words are selected.

Examples of common HAZOP guide words:

 No or not
 More
 Less
 High
 Low
With the use of guide words, workplace hazards clearly identified as they are the deviations that go beyond
acceptable parameters or safe operating limits.

For each parameter, the team considers the effects of deviation from normal. For example, “What would happen
if the pressure at this valve was too high? What if the pressure was unexpectedly low?
for example, “What would happen if the valve was opened too early, or too late?
4.4 Identify Potential Hazard and establish safety monitoring

Example:

Potential Hazard: Potential Hazard:

1. Loss of business opportunity 1. Loss of production
2. Partial Blockage 2. Full Blockage

Deviation 1 Deviation 2
LESS FLOW NO FLOW
UPSTREAM DOWNSTREAM
NORMAL OPERATION
MORE FLOW
Deviation 3

Potential Hazard:
1. Instrument Malfunctioning
2. Variation in operating parameters
 5. Communicate HAZOP results and improve processes

 After completion of HAZOP study, HAZOP team will suggest an assessment weighing the

potential deviations, their consequences, their causes, and the protection requirements.

 When a hazardous condition is identified, recommendations may be made for process or system

modifications, or further study by a specialist may be required.

 A HAZOP study might recommend these typical actions:
 A review of existing protection system designs by a specialist/Consultant/Technology supplier
 Adding or modifying alarms that warn of deviations
 Adding or modifying relief systems
 Adding or modifying ventilation systems
 Placement of routine operator surveillance
Key points discussed by HAZOP team

1. Hydrogen Emission in Battery room- Potential Hazard

2. Discussed all the nodes for the respective process lines

3. Belt conveyer area- Fire & Gas detection system required

4. Public General Alarm system required in entire plant

5. Colour Identification of Shade/store of dosing chemicals

6. Identification on Emergency area/ Assembly point

7. First aid Area identification

Constrains

1. Vendor packages (Ball mill, Filter Press, Thickener, FDS etc. are excluded from HAZOP study
Thank you