Discipline of Chemical Engineering

SAFETY AND LOSS PREVENTION (ENCH3SL)

PART I: Hazard Evaluation Procedures

Lecture 2: What-if, Checklist, HAZOP Analysis

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PART I: HAZARD EVALUATION PROCEDURES
Lecture 02
TOPIC: WHAT-IF, CHECKLIST AND HAZARD AND OPERABILITY STUDY

Objectives

 To provide an overview of what-if and checklist analysis

and hazard and operability study

 To enable the student to undertake evaluation of the

consequences, safeguards, and recommendations

 Enable participants understand procedures and format

when conducting what-if and checklist and HAZOP studies
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PART I: HAZARD EVALUATION PROCEDURES
Lecture 02
TOPIC: WHAT-IF ANALYSIS

What-if Analysis:

• Should cover everything from feed to the end of the system

• Performed by experienced persons
• Some areas may be omitted and some emphasized (personal safety, fire
protection, etc.)
• Flowsheet is required

Preparation Evaluation Documentation

Small/simple 4-8 hours 4-8 hours 1-2 days
systems
Complex/large 1-3 days 3-5 days 1-3 weeks
systems

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PART I: HAZARD EVALUATION PROCEDURES
Lecture 02
TOPIC: WHAT-IF ANALYSIS

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PART I: HAZARD EVALUATION PROCEDURES
Lecture 02
TOPIC: WHAT-IF ANALYSIS

What if?
What-If Consequence Safeguards Recommendation
the phosphoric Unreacted NH3 NH3 detector and Verify phosphoric acid
acid carryover to the alarm concentration before
concentration is DAP storage FI in phosphoric filling storage tank
too low? tank and release acid line
to the work area
valve B is closed Periodic Alarm/shutoff of
or plugged? maintenance NH3 ammonia on low flow
detector and alarm through valve B
too high FI in ammonia line Alarm/shutoff of
proportion of NH3 detector and ammonia on high flow
ammonia is alarm through valve A
supplied to the
reactor?

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PART I: HAZARD EVALUATION PROCEDURES
Lecture 02
TOPIC: WHAT-IF/CHECKLIST ANALYSIS

What-if/Checklist Analysis:

• Combination of creative, brainstorming and systematic features

• Performed by an experienced team
• Flow sheet is required
• More general checklist used (focused on sources of hazard and accidents

Preparation Evaluation Documentation

Small/simple 6-12 hours 6-12 hours 1-2 days
systems
Complex/large 1-3 days 4-7 days 1-3 weeks
systems
Format
What-if? Consequence/hazard Safeguards Recommendations/Actions

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PART I: HAZARD EVALUATION PROCEDURES
Lecture 02
TOPIC: WHAT-IF/CHECKLIST ANALYSIS

Procedure:
• Preparing for review (team leader), developing of a checklist
• What-if questions
• Use a checklist to cover any gap
• Evaluating each of the questions and issues

Purpose:
To identify hazards, consequences, existing safeguards; to suggest
alternatives for risk reduction

Results:
Questions and answers , listing of hazardous situations, their
consequences, existing safeguards, options for risk reduction

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PART I: HAZARD EVALUATION PROCEDURES
Lecture 02
TOPIC: WHAT-IF/CHECKLIST ANALYSIS

Example of a checklist for What-if/Checklist Analysis

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PART I: HAZARD EVALUATION PROCEDURES
Lecture 02
TOPIC: HAZARD AND OPERABILITY STUDY

HAZOP (Hazard and Operability Study)

 Systematic and critical examination of the process (vessel by
vessel, line by line)
 Splitting the process into sections
 Applications of “guide words”:
No or Not
More
Less
As well as
Part of
Reverse
Other than
to develop a deviation from intended operating conditions

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PART I: HAZARD EVALUATION PROCEDURES
Lecture 02
TOPIC: HAZARD AND OPERABILITY STUDY

Purpose:
• To identify and evaluate safety hazards in a process plant
• To identify operability problems during or after detailed design stage by
using “guide words”
• Systematic analysis of the process

Results:
Identification of hazards, recommendations for changes in design,
procedures, to conduct further studies

Preparation Evaluation Documentation

Small/simple 8-12 hours 1-3 days 2-6 days
systems
Complex/large 2-4 days 1-3 weeks 2-6 weeks
systems
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PART I: HAZARD EVALUATION PROCEDURES
Lecture 02
TOPIC: HAZARD AND OPERABILITY STUDY

HAZOP (Hazard and Operability Study)

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PART I: HAZARD EVALUATION PROCEDURES
Lecture 02
TOPIC: HAZARD AND OPERABILITY STUDY

HAZOP – (other) General deviations

• Leak (small release)

• Rupture (large release – process must stop)
• Loss of containment
• Reaction (autocatalytic, autodecomposition at ambient temperature)
• Ignition source

HAZOP for procedures:

• Sampling
• Testing
• Maintenance
• Start-up
• Shutdown
• Service failure

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PART I: HAZARD EVALUATION PROCEDURES
Lecture 02
TOPIC: HAZARD AND OPERABILITY STUDY

HAZOP Guidelines for sectioning continuous processes

but
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PART I: HAZARD EVALUATION PROCEDURES
Lecture 02
TOPIC: HAZARD AND OPERABILITY STUDY

9 sections or 6 sections (tank, tower, heat exchangers, 3 line sections)?

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PART I: HAZARD EVALUATION PROCEDURES
Lecture 02
TOPIC: HAZARD AND OPERABILITY STUDY

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PART I: HAZARD EVALUATION PROCEDURES
Lecture 02
TOPIC: HAZARD AND OPERABILITY STUDY

HAZOP Example:

Part of the nitric acid process

Reaction:

NH3 + O2 HNO3

If concentration of ammonia in the reactor >14% Explosion!

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PART I: HAZARD EVALUATION PROCEDURES
Lecture 02
TOPIC: HAZARD ANS OPERABILITY STUDY

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PART I: HAZARD EVALUATION PROCEDURES
Lecture 02
TOPIC: HAZARD AND OPERABILITY STUDY

HAZOP (Hazard and Operability Study)

Vessel: Air Filter Intention: to remove particles (catalyst protection)

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PART I: HAZARD EVALUATION PROCEDURES
Lecture 02
TOPIC: HAZARD AND OPERABILITY STUDY

Vessel: Vaporiser Intention: NH3(l) NH3(g) at 8 bar, 730 kg/h, 250oC

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PART I: HAZARD EVALUATION PROCEDURES
Lecture 02
TOPIC: HAZARD AND OPERABILITY STUDY

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PART I: HAZARD EVALUATION PROCEDURES
Lecture 02
TOPIC: HAZARD ANS OPERABILITY STUDY

Line P7 Intention: to transfer reactor products to waste heat boiler

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PART I: HAZARD EVALUATION PROCEDURES
Lecture 02
TOPIC: HAZARD AND OPERABILITY STUDY)

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