Hazop

SAFETY AND LOSS
PREVENTION
HAZOP
Used by the process industry for identifying possible
hazards in a system and finding operability
problems likely to lead to non-compliant products
Formal procedure to identify hazards in chemical
process facility.
Information needed :
Process flow diagrams (PFD)
Process and Instrumentation Diagrams (P&IDs)
Detailed equipment specifications
Materials of construction
Mass and energy balances
2
HAZOP PROCEDURE
Set
Set
study
study
nodes
nodes
Select
Select
study
studynode
node
to
to study
study
Select
Select
Guide
Guide
Word
Word
Cause
Cause
Conseque
Consequences
nces
Recommendations
Yes
Another
safeguard
?
No
Yes
Another
guide
word?
No
Yes
New
node?
3
Study Nodes
Study Nodes
Design Intent
Reaction of Ethylene &
R-101 to E-103
Chlorine (Direct
Chlorination)
R-202, HE-206 passing

through HE-201 to HE202
C-502 passing to E.Cond
C-502 and E.Reb C-502
Oxychlorination
Purification of VCM
NODE: R-101 to HE-103

Design Intent: Reaction of Ethylene &
Chlorine (Direct Chlorination)
Parameters: Flow, Temperature,
Pressure
Secti
on
Item
Intention
Paramete
r
Deviatio
n
No
R-101
Designed
for direct
chlorinati
on
reaction.
Flow
Blockage
or leakage
in
pipelines
Consequen
ce
Release of
toxic
chemicals
such as
ethylene and
chlorine to
the
environment
, the pipes
might
explode or
cause
drowsiness
and
dizziness to
the people in
surrounding.
More
Might lead to
explosion;
Increase in
release of
the
toxic
flowrates
chemicals to
in pipes.
environment
.
Less
Release of
toxic
chemicals
(ethylene
and
chlorine) to
environment
, the pipes
might
explode at
the blocking
point.
Cause
Blocking
or leaking
in the
pipes
Safe
guard
Action
Sensor,
alarm; flow
controller
and back
flow
preventive
device
installed.
Check the
conditions of the
inlet pipes when
there is no flow
maximum for 15
minutes
Flow
controller,,
pressure
controller
installed.
Adjust flow
control. In case
failure of the
valve, shut down
the whole
system.
Alarm, flow
controller
Alarm on when
there is less
flow; Flow
controller shut
down the
system if the
flow goes to
15%
Sectio
n
Item
Intention
Paramete
r
Deviatio
n
Reverse
Pressure
R-101
Designed
for direct
chlorinati
on
reaction.
Higher
Lower
Higher
Temperatur
e
Cause
Blocking in
outlet
stream,
failure in
controls.
Less
pressure in
stream.
Leakage in
pipelines
Increase in
inlet
flowrate or
decrease in
outlet
flowrate
Consequenc
Safe guard
e
No reaction
or product;,
possible
release
chemicals to
environment
Explosion
due to the
release of
chemicals to
environment.
Action
Immediately shut
Alarm, flow
down the system.
controller,
Check the pipes
Install
and all the
backflow
equipments.Instal
preventive
l pressure
device.
controller.
Pressure
and level
controller.
Adjust the
controller and
check the
conditions of the
system.
Immediately shut
Alarm, flow
down the system.
controller,
Check the pipes
Install
and all the
backflow
equipments.Instal
preventive
l pressure
device
controller.
Too much
Products'
Temperature
heat
composition
controller. Might
supplied
changes.
consider
Temperatur
into the
Possible
composition
e controller;
reactor;
explosion.
controller. Check
Alarm when
insulation
Destroy the
the system and
temperature
not good;
reactor.
equipments. Shut
more than
not enough
Possible
down if necessary
120 oC.
supply of
leaking of
and wait until
cooling
chemicals to
temperature is
water
environment
unstable.
Adjust the
Composition
Desired
controller, add
Controller
Heat is not product is not
heat to the7
installed
No reaction
Backflow in
or product;,
stream.
possible
Leakage in
release
the
chemicals to
pipelines
environment
R-202, HE-206 passing through HE-201 to HE202
Design Intent: Oxychlorination

Parameters: Flow, Temperature,
Pressure
Section
Intention
Parameter
Deviation
Cause
Blocking or
No
leaking in
the pipes
Consequences
Check the conditions
chemicals to
of the inlet pipes
environment, the
Sensor, alarm,
immediately. Shut
pipes might explode
flow controller
down the system
at the blocking
after 15 min if there
point.
is no flow.
3-phase separator
Increase in
malfunction; might
flowrate of
lead to explosion;
the streams
release of toxic
chemicals to
Designed for
environment
oxychlorinatio
Flow
n reaction
Release of toxic
chemicals (ethylene
Blocking or
Less
Actions
Release of toxic
Increase pressure;
More
Safe guard
and chlorine) to
leaking in
environment the
the pipes
pipes might explode
Flow controller
allows the
maximum
capacity of
95%, pressure
Adjust flow control. In

case more flow, shut
down the system.
control
Alarm at 50% of
Alarm, flow
controller
at the blocking
normal flow; Flow

controller shut down
the system if the flow
goes to 15%
point.
Less
Reverse
pressure in
No achievement of
stream,
products, pushing
blocking in
the feed back,
Alarm, flow
down the system.
outlet
possible release
controller
Check the pipes
stream,
chemicals to
failure in
environment.
controls
Immediately shut
and equipments.
Intention
Parameter
Deviation
Cause
Consequences
Safe guard
Actions
Increase in
inlet
flowrate;
More
decrease in
outlet
flowrate
Explosion, release
of chemicals to
environment.
pressure
control,level
control
Adjust the controller,

check the conditions
of the system
(outlet
Pressure
blocking)
Alarm,
Less
Backflow in
No reaction or
stream.
product, possible
Leakage in
release to
the pipelines
environment
Alarm,
pressure
Shut down system,
control, level
check the pipes and
control, install
all the
backflow
equipments.Install
preventive
pressure controller
device
Temperature
Designed for
oxychlorinatio
Too much
reaction
heat
transferred
More
into the
reactor; bad
insulated
walls
Temperature
Products'
controller. Might
composition
Temperature
consider composition
changes. Possible
sensor; Alarm
controller. Check the
explosion. Destroy
when
system and
the reactor. Possible
temperature
equipments. Shut
leaking of chemicals
goes over
down if can not find
to environment;
200 F.
the reason and
Fouling in pipes
temperature is
unstable.
Less
Heat is not
Changing in
provided for
composition of the
the reactor
products.
Composition
Adjust the
controller;
controller, add
Alarm when
heat to the
temperature
reactor. Shut down
goes under
if temperature
70oC
keeps decreasing.
10
C-502 passing to E.Cond C-502 and E.Reb C502
Design Intent: Purification of VCM

Parameters: Flow, Temperature, Pressure
11
Sectio
n
Item
VCM
Colum
n
-C502
Intention
Separate
VCM from
byproduc
ts. Reflux
Ratio =3,
87 psig,
pressure
drop
Paramet
Deviation
er
Flow
Cause
Consequen
ce
More
Outlet
stream
does not
drain, too
much
liquid
coming
back to
column,
Less
Changing in
outlet
conditions.
Failure of
valve
system.
Cannot get
expected
separation.
More heat
added to
reboiler.
Foaming
Entrainmen
t
Weeping/Du
mping;
Flooding.
Reduce
efficiency.
More
Column
malfunction
. Leaking:
VCM and
toxic
organic
compounds
. Harmful to
people.
Safe guard
Action
Flow
controller,
alarm when
output flow
rate goes
under 70%
set point
Lower select
switch. Shut
down if the
outlet stream
does not drain.
Check pipe
conditions for
blocking
Flow
controller
Check with the

controller to
see if there's
anything
wrong.
Compositio
n and flow
controller.
Balance the
heat duty of
condenser
and reboiler.
12
Section
Item
Intention
Parameter
Deviatio
n
Cause
Consequences
Safe guard
Actions
Alarm,
Adjust the
pressure
controller, check
control,level
the conditions of
control
the system
Increase in
inlet
flowrate;
More
decrease in
outlet
flowrate
Explosion, release
of chemicals to
environment.
(outlet
Pressure
blocking)
Alarm,
Backflow in
stream.
Less
VCM
Column
-C502
Separate
VCM from
byproduct
s. Reflux
Ratio =3,
87 psig,
pressure
drop
Leakage in
the
pipelines
pressure
No reaction or
control, level
product, possible
control,
release to
install
environment
backflow
preventive
Shut down system,

check the pipes
and all the
equipments.Install
pressure controller
device
Temperature
Too much
heat
transferred
More
into the
reactor;
bad
Temperatur
insulated
walls
Products'
composition
changes. Possible
explosion.
Destroy the
reactor. Possible
leaking of
chemicals to
controller. Might
Temperature
sensor;
Alarm when
temperature
goes over
200oF.
environment
consider
composition
controller. Check
the system and
equipments. Shut
down if can not
find the reason
and temperature
is unstable.
Heat is not
Less
provided
for the
reactor
Changing in
composition of
the products.
Composition
Adjust the
controller;
controller, add
Alarm when
heat to the
temperature
reactor. Shut down
goes under
if temperature
70 C
o
13
keeps decreasing.

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SAFETY AND LOSS

R-202, HE-206 passing

NODE: R-101 to HE-103

R-202, HE-206 passing through HE-201 to HE202

Design Intent: Oxychlorination

Check the conditions

of the inlet pipes

pipes might explode

down the system

after 15 min if there

pipes might explode

Adjust flow control. In

normal flow; Flow

the feed back,

down the system.

Check the pipes

Adjust the controller,

Shut down system,

check the pipes and

controller. Check the

the reactor. Possible

down if can not find

the reason and

reactor. Shut down

C-502 passing to E.Cond C-502 and E.Reb C502

Design Intent: Purification of VCM

Check with the

Shut down system,

reactor. Shut down

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