HAZARD AND OPERABILITY

STUDY
 Introduction
Tiga tujuan utama dari
SAFETY ENGINEERING
Identify hazards :
Eliminate hazards
Mitigate hazards
Safety & Layers of Protection
Safety Instrumented Function
M
Independent Protection Layers
Plant and/or
I Emergency Emergency response layer
T Response
I
G
A
Dike Passive protection layer
T
I
Relief valve,
O Rupture disk Active protection layer
N
Safety Emergency Shut
Instrumented
System Down action Isolated protection layer
Trip level alarm
P
R Operator Wild process
E Process control layer
Intervention parameter
V High level alarm
E High level
N Basic
T Process Process
Control value Process control layer
I
System
Normal behavior
O Low level
N Plant
Design
Metode analisa bahaya dan
keandalan proses untuk tujuan
‘safety’ :

• Kualitatif contohnya HAZOPS

• Kuantitatif contohnya Failure Modes Effects

 Background HAZOP

• Dikembangkan sejak th 1960-an yang lebih dikenal dgn teknik-

teknik “critical examination”.

• Perubahan dan perkembangan teknologi proses industri sangat

memungkinkan terjadinya peningkatan resiko.

• Upaya mencegah kecelakaan kerja dan kegagalan operasi pada

suatu pabrik/ perusahaan.

• Dibutuhkan metode untuk mengidentifikasi & mendokumentasikan

berbagai permasalahan “hazard” dan “operability” yang dapat
timbul dalam unit proces selama kondisi normal dan abnormal
Ada 5 type safeguards :

• Identifikasi deviation ( detector dan alarm, operator)

• Kompensasi deviation ( automatic control system)
• Pencegahan deviation (inert gas blanket di storage
tank)
• Pencegahan peningkatan deviation (interlock system)
• Relieve / mengurangi proses dari Hazardous
deviation ( Pressure Safety Valve (PSV) dan Vent
Sistem)
 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.
Cooling In the event of cooling function is lost, the
Water In
temperature of reactor would increase.
This would lead to an 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
TC
Thermocouple flow rate by a valve.

Perform HAZOP Study

Preliminary HAZOP on Reactor -
Example
Guide Word Deviation Causes Consequences Action
NO No cooling Temperature increase
in reactor

REVERSE Reverse cooling Failure of water

flow source resulting in
backward flow

MORE More cooling Instruct operators

flow on procedures

AS WELL AS Reactor product Check

in coils maintenance
procedures and
schedules

OTHER THAN Another Water source

material besides contaminated
cooling water
 Preliminary HAZOP on Reactor – Answer
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 Less cooling, possible Install check valve
flow source resulting in runaway reaction
backward flow

MORE More cooling flow Control valve failure, Too much cooling, reactor Instruct operators
operator fails to take action cool 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,
water isolate water source.
Back up water source?
Case Study – Shell & Tube Heat
Exchanger
• Using relevant guide works, perform HAZOP study on shell & tube heat
exchanger

Process
fluid

Cooling water
 HAZOP on Heat Exchanger –
Guide Word
Answer 1
Deviation Causes Consequences Action

Less Less flow of cooling Pipe blockage Temperature of process fluid High Temperature Alarm
water remains constant

More More cooling flow Failure of cooling Temperature of process fluid Low Temperature Alarm
water valve decrease

More of More pressure on Failure of process fluid Bursting of tube Install high pressure
tube side valve alarm

Contamination Contamination of Leakage of tube and Contamination of process Proper maintainance

process fluid line cooling water goes in fluid and operator alert

Corrosion Corrosion of tube Hardness of cooling Less cooling and crack of Proper maintainence
water tube
 HAZOP on Heat Exchanger –
Guide WordAnswer 2
Deviation Causes Consequences Action
Install Temperature indicator
NONE No cooling water flow Failure of inlet cooling Process fluid temperature is
water valve to open not lowered accordingly before and after the process
fluid line
Install TAH

MORE More cooling water Failure of inlet cooling Output of Process fluid Install Temperature indicator
flow water valve to close temperature too low 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 Product off set Install check valve (whether
flow inlet valve it is crucial have to check?)

CONTAMINATION Process fluid Contamination in cooling Outlet temperature too low Proper maintenance and
contamination water operator alert
TERIMA KASIH