Chemical Engineering Plant Design: Process Plant Hazards Analysis Techniques

Chemical Engineering Plant Design
Process Plant Hazards Analysis Techniques
Engr. Dr. Farhan Javed

Lecturer
Chemical Engineering Department
UET FSD Campus
1
Risk Management Process:
1-Hazard and Operability Study (HAZOP):
DEFINITION OF HAZARD & OPERABILITY
Hazard - any operation that could possibly cause a

catastrophic release of toxic, flammable or explosive
chemicals or any action that could result in injury to
personnel.
Operability - any operation inside the design
envelope that would cause a shutdown that could
possibly lead to a violation of environmental, health or
safety regulations or negatively impact profitability.
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WHAT IS A HAZOP STUDY?
A HAZOP study is an examination

procedure.
Its purpose is to identify all possible
deviation from the way in which a design
is expected to work and to identify all the
hazards associated with these deviations.
When deviation arise that results in
hazards, action are generated that
require design engineers to review and
suggest solutions to remove the hazard
or to reduce its risk to an acceptable
level.
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OBJECTIVES OF A HAZOP STUDY
Safety Issues:
 To identify scenarios that would lead to the release of hazardous or
flammable material into the atmosphere, thus exposing workers to
injury
 To check the safety of the design
 To improve the safety of an existing and or modified facility
Operability Issues:
 To decide whether and where to build
 To check operating and safety procedures
 To verify that safety instrumentation is working optimally
 To facilitate smooth, safe prompt start-up
 To minimize extensive last minute modifications
 To ensure trouble-free long-term operation
“Prevention is better than control”

13
Information Required:
HAZOP Procedure:
HAZOP Procedure:
HAZOP Procedure:
Main Terms:
HAZOP TERMINOLOGY - 4
Term Definition
Safeguard Facilities that help to reduce the occurrence frequency of the

DEVIATION or to mitigate its CONSEQUENCES. There are, in
principle, five types of SAFEGUARDS:
 Facilities that identify the DEVIATION. These comprise, among others,
alarm instrumentation and human operator detection.
 Facilities that compensate the DEVIATION, e.g., an automatic control
system that reduces the feed to a vessel in case of overfilling it (increase
of level). These usually are an integrated part of the process control.
 Facilities that prevent the DEVIATION to occur. An example is an inert
blanket gas in storages of flammable substances.
 Facilities that prevent a further escalation of the DEVIATION, e.g., by
(total) trip of the activity. These facilities are often interlocked with several
units in the process, often controlled by logical computers.
 Facilities that relieve the process from the hazardous DEVIATION.
These comprise for instance: pressure safety valves (PSV) and vent
systems.
19
HAZOP TERMINOLOGY - 4
Term Definition
Action – Where a credible cause results in a negative consequence, it
must be decided whether some action should be taken. It is at
this stage that consequences and associated safeguards are
considered. If it is deemed that the protective measures are
adequate, then no action need to be taken, and words to that
effect are recorded in the Action column.
– Actions fall into two groups:
• Actions that remove the cause.
• Actions that mitigate or eliminate the consequences.
– Whereas the former is to be preferred, it is not always possible,
especially when dealing with equipment malfunction. However,
always investigate removing the cause first, and only where
necessary mitigate the consequences.
20
HAZOP Guide Words:
HAZOP Guide Words:
HAZOP Planning and Execution
CLOSE OUT
Record/File
Completed
Actions
TRACK
ACTIONS
HAZOP
Review
Meeting
REPORT
Action List
HAZOP
Report
TEAM
System
Assessment
Team Activity
PLAN
Select Team
Examine System
Keywords
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HAZOP study team
• Independent leader (e.g., not from plant studied)

– Preferred but complete independence not essential
• Project engineer
– Provide engineering input
• Operations representative
– Plant operation
• Discipline engineers
– Process
– Instrument/ electrical
– Mechanical/ maintenance
• HAZOP minute recorder
– One of the above
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CASE STUDY 1-DAP PRODUCTION
Diammonium Phosphate (DAP) Production

 Phosphoric acid and ammonia are mixed, and a non-
hazardous product, diammonium phosphate (DAP), results if
the reaction of ammonia is complete. If too little phosphoric
acid is added, the reaction is incomplete, and ammonia is
produced. Too little ammonia available to the reactor results
in a safe but undesirable product.
Both chemicals will be used in large quantities and
in concentrated form. Due to the highly corrosive
nature of both chemicals, the project team was
assigned to investigate the hazards posed to staff
from the reaction resulting from study line 1
(phosphoric acid delivery line).
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PRODUCTION OF DAP (CONTINUOUS PROCESS)
Valve A
Line 1
Phosphoric Acid
Study line 1
Phosphoric acid delivery line
Line 2
Valve C
Valve B
Ammonia
Diammonium
Phosphate
(DAP)
Reactor
29
HAZOP STUDY REPORT ON LINE 1 OF DAP
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Chemical Engineering Plant Design

Process Plant Hazards Analysis Techniques

Engr. Dr. Farhan Javed

Hazard - any operation that could possibly cause a

A HAZOP study is an examination

“Prevention is better than control”

Safeguard Facilities that help to reduce the occurrence frequency of the

• Independent leader (e.g., not from plant studied)

Diammonium Phosphate (DAP) Production

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