Example‐1
Guide Words
NONE /No e.g., NO FLOW caused by blockage; pump failure;
valve closed or jammed :
REVERSE Opposite, e.g., REVERSE FLOW caused by pump
failure
MORE Quantitative increase, e.g., MORE FLOW, Temp,
LESS Quantitative increase, e.g., LESS FLOW, Temp,
As Well As Qualitative increase, e.g. impurity.
PART OF Qualitative decrease, Change in composition high or
low concentration of mixture; additional reactions in
reactor or other location ; feed change.
Other than Nothing of the intent happen, completely different
occurs
2
HAZOP Steps
• These guide words are applied to flow, temperature, pressure,
liquid level and composition.
• Deviation of these variables from normal operation is
considered
• The consequences of these deviations on the process is then
assessed.
• The measures needed to correct these consequences are then
established
This process enables a comprehensive evaluation of
Hazard control systems and produces recommendations for any
necessary modifications. The overall result is a reduction in both
hazards and potential operational problems
HAZOP STUDY REPORT FORM
HAZOP Study Form
TITLE :
Sheet 1 of
LINE 1 :
CAUSES CONSEQUENCES EXISTING PROVISIONS ACTIONS, QUESTIONS OR
DEVIATION RECOMMENDATIONS
5
Storage Tank
To
atmosphere
Nitrogen To flare
H
RV-1
PV-2 PICA PV-1
V-8
V-7
V-5
H
From tank TIA
trucks
H
LIA L
V-1
V-2 FICA
PI
L
To process
V-4 FV-1
V-3
HAZOP Table - level
Cause Deviation Consequences Safe guard Action
Level
Less 1. Rupture Reagent release Potential fire LIA Estimate release quantity
discharge line
2. V3 open or Reagent release Potential fire LIA Estimate release quantity
broken
3. V1 open or Reagent release Potential fire LIA V1 protection
broken
4. Tank rupture Reagent release Potential fire LIA What external event
cause tank rupture
More 5. Too much truck Overfill Reagent release via LIA Does RV1 allow for
unload RV1 liquid release?
Consider high level alarm
shutoff
6. Reverse flow Overfill Reagent release via LIA Consider check valve at
from process RV1 pump discharge
Consider high level alarm
shutoff at feed
NO Same as less
HAZOP Table - pressure
Pressure
Less 9. Break in nitrogen Reagent release Potential fire PICA Consider independent
or flare line PLA
10. Lose nitrogen Tank implode Reagent release PICA Consider vacuum break
valve
11. PV2 fails closed Tank implodes Reagent release PICA Consider PAL
12. PICA fails, Tank implodes Reagent release Tank not designed for
closing PV2 vacuum
More 13. PICA fails, Reagent release via Tank rupture if RV1 PICA What PV1 and RV1
closing PV1 RV1 fails capacity
14. PV1 fails closed Reagent release via Tank rupture if RV1 PICA Consider independent
RV1 fails PAH
15. V7 closed Reagent release via Tank rupture if RV1 PICA Is V7 locked open
RV1 fails
16. Overfill tank Truck unload Tank rupture if RV1 PICA Consider second high
fails level shutoff
17. Temperature of Reagent release in Tank rupture if RV1 PICA What prevent high temp
inlet higher RV1 fails of feed
than normal Consider PAH
18. Volatile Reagent release in Tank rupture if RV1 PICA Consider PAH
impurities in RV1 fails Consider sampling before
feed unloading
Hazop Table - composition
Cause Deviation Consequences Safe guard Action
Composition
Other than 7. Wrong reagent Possible reaction Tank rupture Consider sampling before
unload
As well as 8. Impurities in Problem in reactor Are other material
reagent delivered in tank
Are unloading connection
different
HAZOP Table - Temperature
Temperature
Less 19. Temperature of Possible vacuum Thermal stress on tank What are temp limits of
inlet cooler tank
than usual
20. Low tank See 9-12 Thermal stress on tank What are pressure limits
pressure of tank
High 21. temperature of See 17 Thermal stress on tank What are temp limits on
inlet is higher tank
than usual
22. external fire Tank fails Reagent release What could cause
external fire
What are fire protection
capabilities
Is fire protection
adequate
Example‐2
Preliminary HAZOP Example
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
Cooling of reactor would increase. This would lead to an
Water In increase in reaction rate leading to additional energy
release.
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
T
C Thermocouple
12
Preliminary HAZOP on Reactor
Guide Word Deviation Causes Consequences Action
NO No cooling Cooling water valve Temperature increase in Install high temperature
malfunction reactor alarm (TAH)
REVERSE Reverse cooling Failure of water source Less cooling, possible runaway Install check valve
flow resulting in backward reaction
flow
MORE More cooling flow Control valve failure, Too much cooling, reactor cool Instruct operators
operator fails to take action on procedures
on alarm
AS WELL AS Reactor product More pressure in reactor Off-spec product Check maintenance
in coils procedures and
schedules
OTHER THAN Another material Water source May be cooling inefffective If less cooling, TAH will
besides cooling contaminated and effect on the reaction detect. If detected, isolate
water water source. Back up
water source?
13
Preliminary HAZOP on Reactor
Guide Word Deviation Causes Consequences Action
NO No cooling Cooling water valve Temperature increase in Install high temperature
malfunction reactor alarm (TAH)
REVERSE Reverse cooling Failure of water source Less cooling, possible runaway Install check valve
flow resulting in backward reaction
flow
MORE More cooling flow Control valve failure, Too much cooling, reactor cool Instruct operators
operator fails to take action on procedures
on alarm
AS WELL AS Reactor product More pressure in reactor Off-spec product Check maintenance
in coils procedures and
schedules
OTHER THAN Another material Water source May be cooling inefffective If less cooling, TAH will
besides cooling contaminated and effect on the reaction detect. If detected, isolate
water water source. Back up
water source?
14
Example‐3
Case Study – Shell & Tube Heat
Exchanger
• Using relevant guide works, perform HAZOP study on shell & tube heat exchanger
Process
fluid
Cooling water
16
HAZOP on Heat Exchanger
Guide Word Deviation Causes Consequences Action
NONE No cooling water flow Failure of inlet cooling Process fluid temperature is Install Temperature
water valve to open not lowered accordingly indicator before and after
the process fluid line
Install TAH
MORE More cooling water Failure of inlet cooling Output of Process fluid Install Temperature
flow water valve to close temperature too low indicator before and after
process fluid line
Install TAL
LESS Less cooling water Pipe leakage Process fluid temperature too Installation of flow meter
low
REVERSE Reverse process fluid Failure of process fluid inlet Product off set Install check valve (whether
flow valve it is crucial have to check?)
CONTAMINATION Process fluid Contamination in cooling Outlet temperature too low Proper maintenance and
contamination water operator alert
17
HAZOP on Heat Exchanger
Guide Word Deviation Causes Consequences Action
NONE No cooling water flow Failure of inlet cooling Process fluid temperature is Install Temperature
water valve to open not lowered accordingly indicator before and after
the process fluid line
Install TAH
MORE More cooling water Failure of inlet cooling Output of Process fluid Install Temperature
flow water valve to close temperature too low indicator before and after
process fluid line
Install TAL
LESS Less cooling water Pipe leakage Process fluid temperature too Installation of flow meter
low
REVERSE Reverse process fluid Failure of process fluid inlet Product off set Install check valve (whether
flow valve it is crucial have to check?)
CONTAMINATION Process fluid Contamination in cooling Outlet temperature too low Proper maintenance and
contamination water operator alert
18
