EXAMPLE

An alkene/alkane fraction containing small amounts of suspended water is continuously pumped from a bulk intermediate storage tank via a half-mile pipeline into a
buffer/settling tank where the residual water is settled out prior to passing via a feed/product heat exchanger and preheater to the reaction, is run off manually from the
settling tank at intervals. Residence time in the reaction section must be held within closely defined limits to ensure adequate conversion of the alkene and to avoid
excessive formation of polymer.
Results of Hazard and Operability Study of Proposed Olefin Dimerization Unit: Results for line section from intermediate storage to buffer/settling tank
Guide
Deviation Possible causes Consequences Action required
word
NONE No flow (1)No hydrocarbon available at Loss of feed to reaction section and reduced output. (a) Ensure good communications with intermediate storage
intermediate storage. Polymer formed in heat exchanger under no flow operator
conditions. (b)Install low level alarm on settling tank LIC.
(2)J1 pump fails (motor fault, loss of drive, As for (1) Covered by (b)
impeller corroded away etc.)
(3)Line blockage, isolation valve closed in As for (1) Covered by (b)
error, or LCV fails shut. J1 pump overheats. (c)Install kickback on J1 pump.
(d)Check design of J1 pump strainers.
(4)Line fracture As for (1) Covered by (b)
Hydrocarbon discharged into area adjacent to public (e)Institute regular patrolling & inspection of transfer line.
highway.
MORE More flow (5)LCV fails open or LCV bypass open in Settling tank overfills. (f)Install high level alarm on LIC and check sizing of relief
OF error. opposite liquid overfilling.
(g)Institute locking off procedure for LCVbypass when not in use.
Incomplete separation of water phase in tank, leading (h)Extend J2 pump suction line to 12’’ above tank base.
to problems on reaction section.
More pressure (6)Isolation valve closed in error or LCV Transfer line subjected to full pump delivery or surge (j)Covered by (c) except when kickback blocked or isolated.
loses, with J1 pump running. pressure. Check line. FQ and flange ratings and reduce stroking speed of
LCV if necessary. Install a PG upstream of LCV and an
independent PG on settling tank.
(7)Thermal expansion in an isolated valved Line fracture or flange leak. (k)Install thermal expansion relief on valved section (relief
section due to fire or strong sunlight. discharge route to be decided later in study).
More (8)High intermediate storage temperature. Higher pressure in transfer line and settling tank. (l)Check whether there is adequate warning of high temperature
temperature at intermediate storage. If not, install.
LESS OF Less flow (9)Leaking flange of valved stub not Material loss adjacent to public highway. Covered by (e) and the checks in (j).
blanked and leaking.
Less (10)Winter conditions. Water sump and drain line freeze up. (m)Lag water sump down to drain valve and steam trace drain
temperature valve and drain line downstream.
PART High water (11)High water level in intermediate Water sump fills up more quickly. Increased chance of (n)Arrange for more frequent draining off of water from
OF concentration in storage tank. water phase passing to reaction section. intermediate storage tank. Install high interface level alarm on
stream. sump.
High concen- (12)Disturbance on distillation columns Higher system pressure. (p)Check that design of settling tank and associated pipework,
tration of lower upstream of intermediate storage. including relief valve sizing, will cope with sudden ingress of
alkanes or more volatile hydrocarbons.
alkenes in
stream.
(13)As for (12) Increased rate of corrosion of tank base, sump and (q)Check suitability of materials of construction.
drain line.
OTHER Organic acids (14)Equipment failure, flange leak, etc. Line cannot be completely drained or purged. (r)Install low-point drain and N2 purge point downstream of LCV.
present Also N2 vent on settling tank.

Maintenance
ChE 62 PROCESS DESIGN AND PROJECT FEASIBILITY
Team Members: ____________________________________________________________________________________________________________ Date: ______________________
Study Title: ________________________________________________________________________________________________________________________________________________________________
PRELIMINARY HAZOP ANALYSIS: Complete the following table for hazards and operability analysis then make necessary changes in your team’s process flow diagram (i.e. install safety features). Attach the
improved process flow diagram in a separate sheet of paper.
NODE ITEM PARAMETER DEVIATION POSSIBLE CAUSES CONSEQUENCES ACTION/S REQUIRED
NODE ITEM PARAMETER DEVIATION POSSIBLE CAUSES CONSEQUENCES ACTION/S REQUIRED