hazop

7/21/2019 Hazop

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7/21/2019 Hazop


Cadila Pharmaceuticals

Limited 2

HAZOP STUDY

• Hazard and Operability study

• Look for potential hazards

• Discover operational problems

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BEFORE A HAZOP: THE QUESTIONS

• When should the HAZOP be carried out

• What should be HAZOPed

• Who is re!uired

• What information is re!uired

• What preparation is re!uired to help the HAZOP "o

smoothly

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WHEN?

NEW PROCESS/PLANT

Once ne# process$plant desi"n is %frozen&'

Pipin" ( )nstrumentation Dia"rams *P()Ds+ are fi,ed

Process route has been chosen

Operatin" instructions are prepared

-asis of safety in place.

• /ot too late'

0 easier to chan"e paper#ork than metal#ork

0 costs of re1schedulin" a pro2ect.

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WHEN?

EXISTING PROCESS/PLANT

3o prescribed schedule

Once follo#in" up to date'

Pipin" ( )nstrumentation Dia"rams *P()Ds+

Operatin" procedures

Pre1meetin" may be re!uired to ensure everythin" is

up to date beforehand.

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MANAGING A HAZOP STUDY

1. Def!e "#e $%&'e (!)&*+e%",e$ &f "#e $"-)

4. Appoint a team leaderand select the team

5. 6onduct HAZOP

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WHAT TO HAZOP?

SCOPE OF HAZOP STUDY

What is ne# and #hat is e,istin"7ay only #ant to cover the ne# parts

Are parts of the process repeats of previous

processes6ould use a checklist or other techni!ue on repeat plant

What are the natural boundary limits of the

plant

6han"e of responsibility-ulk stora"e or container char"in"$dischar"in"

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WHAT TO HAZOP?

Do #e cover utilities $ services $ vent systems

All can be affected by a process8 even if plant is e,istin". )s it a ne# or revised process in e,istin"

plant$e!uipmentHAZOP is re!uired but look at effects of chan"es only.

Are additional revie#s re!uiredPressure relief.

Plant layout.

6omputer control system.

9eneral safety$adherence to re"ulation etc.

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:. Define the scope andob2ectives of the study

. A''&!" ( "e(0 e()e2(!) $ee%" "#e "e(0

5. 6onduct HAZOP

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WHO IS REQUIRED?

MA3E UP OF HAZOP TEAMS

NEW PROCESS/PLANT DESIGN

)ndependent chairman$secretary Pro2ect en"ineer Process en"ineer ;H< e,pert )nstrumentation en"ineer *if hi"hly

instrumented plant+ 6ommissionin" or plant mana"er =esearch chemist

;,perience important

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WHO IS REQUIRED?

MA3E UP OF HAZOP TEAMSEXISTING PLANT 4REPEAT HAZOP5 NEW PROCESS OR

MODIFICATION6

•)ndependent chairman$secretary•Plant mana"er *production back"round+•Process foreman or operator *practical e,perience+•Plant maintenance en"ineer *mechanical back"round+

•)nstrument en"ineer *if hi"hly instrumented process+•Process en"ineer•<H; e,pert•Process chemist•E7'e2e!%e 0'&2"(!"

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WHAT INFORMATION?

3EY DOCUMENTS

Process ( )nstrumentation Dia"rams *P()Ds+1 )mportant for all studies

-asis of study on continuous plant

Operatin" )nstructions *batch sheets8 recipes etc.+ -asis for batch process HAZOPs

Also for batch operations in continuous plants e.". chan"in" filters

Also for start1up$shutdo#n8 maintenance operations etc.

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WHAT INFORMATION?

OTHER IMPORTANT DOCUMENTS

<e!uence and )nterlock )nformation *computer controlled plants+

>unctional Desi"n <pecifications

6ause and effect charts

Process >lo#charts

7ass and heat balances

9eneral Arran"ement ( ;levation Dra#in"s

Plant layouts

=esearch and Development reports

?essel specifications ( mechanical dra#in"s

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WHAT INFORMATION?

HAZARD DATA

• Process Hazard Data 0 7aterial hazard data

0 =esults of flammability and thermochemical testin"

Previous hazard study reports

-asis of safety and risk assessment studies

Operation8 i.e. fire and e,plosion

=eaction

)ncident reports

<ame or similar plants and$or processes

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WHAT OTHER PREPARATION?

• Process should be divided into steps8 each #ith a)ef!e) )e$8! !"e!"'

0 ;,amples

• 3ransfer A from vessel @ to vessel

• Heat up vessel to BC6 over 5C minutes• ;,amine the P()D for continuous process

• 3hese distinct steps are called N&)e$

• T#$ $ )&!e * S"-) Le()e2.

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DEFINITION OF NODES

• )mpossible to simultaneously analyse all possible deviations

of a process8 so it is subdivided into nodes *mana"eable

units+

• /o clear and uni!ue methodolo"y to define the nodes that

subdivide the system under study

• =ules for /odes' 0 <hould cover the entire facility.

0 7ust have continuity bet#een plant sections and

operations

0 S#&-) #(,e ( $'e%f% )e$8! !"e!"&!

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WHAT PREPARATION?

TYPICAL NODES

/odes can be'

Lines ?essels Plant sections Process steps

if doin" start1up$shutdo#n or batch process

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NODES

B("%# ,$. C&!"!-&-$

C&!"!-&-$ '2&%e$$'

•Plant element

0 Pump

0 =eactor

0 ;,chan"er

0 6olumn

•Line *pipin"

• B("%# '2&%e$$:

0 <tep of operatin" procedure

0 3ransitory operation *start8

stop8 samplin"+

0 <pecial operation

*maintenance8 cleanin"8 ...

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NODES AND BATCH OPERATING

INSTRUCTIONS

Operatin" steps sometimes need to be sub1divided

<tep : can be sub1divided into 5 nodes

<3;P/o

OP;=A3)O/ P=;6AE3)O/< <)9/

:B)nstall drum of reactant -

in char"in" bay;nsure drum is

earthed

:D3ransfer BB l of - to

char"in" vessel ?:C:usin" vacuum

Wear full protectiveclothin" and

"o""les

:F6har"e reactor =:C: #ithBB l of - over :B minutes

7anually controlvalve :C:

STEPNo

OPERATION

16a Establish nitrogn blan!t on "r#$ %nt

16b Establish %a&##$ on '101 &harging %ssl

16& Trans(r 55 l o( ) to &harging %ssl '101

9MIXED NODES

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9MIXED NODES

• 6an have P()D and operatin" procedures based

nodes to"ether

• 7anual operations on continuous plant

0 >ilter chan"es

• -atch operations involvin" comple, plant 0 -atch distillations can be split into'

• Heatin" system

• ?apour line throu"h condenser

• 6ondensate line

NODES EXAMPLE

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NODES EXAMPLE

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SIMPLE EXERCISE

MA3ING INSTANT COFFEE

• /odes' 0 -rin" out cup$mu"

0 >ill kettle

0 -oil kettle

0 6har"e 6offee to cup

0 >ill #ith cup #ith boilin" #ater

0 Add milk and su"ar *optional+

0 <tir

0 3ransfer to place of use.

OTHER STATUS GRIDS

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OTHER STATUS GRIDS

3akes considerable advance preparation time

/eed to "et a balance a"ainst level of detail re!uired

S"e'N&.

P2&%e$$S"e'

A8"("&2 B&""&0;(1,e

;e!";(1,e

<(%=e"H&" W("e2

: ?erify=eactor6lean and;mpty

Off 6losed Open Off

4 6har"e A Off 6losed Open Off

5 6har"e - Off 6losed Open Off

G <tart A"itator

On 6losed 6losed Off

B Heat1up toCI6

On 6losed 6losed On 16ontrolledby D6<

DRAINS ;ENTS AND

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DRAINS5 ;ENTS AND

INTERCONNECTED PLANT

• 7ay need to look at interactions in drains8 vents

and relief systems'

0 Often connected to various plants.

0 )nterface bet#een a number of P()Ds 0 >luid incompatibilities

0 <imultaneous releases

0 Possible chokes8 causin" backflo#


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:. Define the scope andob2ectives of the study

. A''&!" ( "e(0 e()e2(!) $ee%" "#e "e(0

5. 6onduct HAZOP

HAZOP APPROACH

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HAZOP APPROACH

Define )ntended Process

=epeat

Action6ause 6onse!uence <afe"uard

P(2(0e"e2

G-)e W&2)>

De,("&!

J

EXAMPLE

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EXAMPLE

DE;IATIONS

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DE;IATIONS

• Deviation from D;<)9/ )/3;/3 0 )f variation is e,pected *e.". operatin" process #ithin

temperature ran"e+8 then deviations outside this %envelope&

should be considered

• Deviations are often from measurable parameter

that can be controlled' 0 >lo# 0 3emperature 0 Pressure

• Deviation J "uide#ord K parameter

GUIDE WORDS

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GUIDE WORDS

O"#e2 "#(!

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O"#e2 "#(!

• <tart up$ <hut do#n

• <pilla"e

• <amplin"8 <tora"e etc..

• Waste Disposal

• >ire >i"htin"

• >irst Aid

• 7aterials of construction

• /oise• Labellin" 1 Pipe#ork etc..

• 7aintenance

• <tatic

• Liftin" and Handlin"

• Dischar"es to Atmosphere• ?acuum =elief

• ;,plosion =elief

• ;ffluent <treams 1 7i,in"

• <pares• 3rainin"

• <pecial 3ools

• 6leanin"

• >oamin"

COMMON PARAMETERS

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COMMON PARAMETERS

*lo+,#antit-T$.rat#rPrss#r

/%lon&ntrationo$.ositionnsit-'is&osit-

Ra&tion Agitation at Trans(r S.aration

Ti$ S#n& Or"r onta$ination orrosion

HAZOP GUIDEWORDS FOR PIPE FLOW

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HAZOP GUIDEWORDS FOR PIPE FLOW

G-)e ?&2) De,("&!

/one /o flo#

7ore of Hi"h flo#

Less of Lo# flo#

=everse -ack flo#

Part of Wron"concentration

As #ell as 6ontamination

Other than Wron" material7isdirected

IN;ALID GUIDE WORDS /PARAMETER

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IN;ALID GUIDE WORDS /PARAMETER

COMBINATIONS

• Other than K temperature

• /o K temperature *unless at 14F5.:BI6+

• =everse K time• Part of K pressure

DE;IATION EXAMPLE

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O.rating&on"itions

L

/%l

O.ti$al st.oint

O.rating&on"itions

Ti$

Deviation+ith rs.&tto th intnt

SIMPLE EXERCISE

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SIMPLE EXERCISE

MA3ING INSTANT TEA

• >)LL)/9 6EP W)3H WA3;=

• Appropriate deviations 0 /o flo# 0 7ore flo# 0 As #ell as flo# 0 Other than flo# 0 7ore level

0 Less temperature 0 Other than composition 0 6ontamination

Other deviations are unlikely orinappropriate e.". morepressure.

HAZOP APPROACH

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HAZOP APPROACH


=epeat

ActionC(-$e 6onse!uence <afe"uard

Parameter

9uide Word>

Deviation

J

CAUSES

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• 3he reasons for the deviation 0 e.". 6auses for no flo# of solvent to vessel

• Pump failed

• ?alve*s+ closed

• -locka"e

• /o material char"ed.

• 6an be associated #ith the node in !uestion8 but

also can be before or after it.

CAUSES

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GUIDELINES

• -e as clear as possible e.". used 3A9 numbers

• 7ay need to */ot necessary+ 0 split do#n further8 if conse!uences are different 0 "roup to"ether e.". if conse!uences are trivial.

• /ot normally considered as causes' 0 3#o independent faults *e,cept t#o human error or t#o

failures #ith severe conse!uences+. 0 >ailures of safety devices *relief valves8 rupture disks8 safety

shutdo#n systems+.

OTHER TYPICAL CAUSES

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0 Human error

0 ;!uipment failure

0 Obstruction

0 6orrosion 0 >ailure8 leak

0 <torm8 frost8 sun8 fire

SIMPLE EXERCISE

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SIMPLE EXERCISE

MA3ING INSTANT TEA

• >)LL)/9 6EP W)3H WA3;=

• Appropriate causes for 7ore

Level

0 Human error

0 Hi"h flo#

0 6ontrol failure *6offee

machine+

HAZOP APPROACH

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=epeat

Action6ause C&!$e@-e!%e <afe"uard

Parameter

9uide Word>

Deviation

J

CONSEQUENCES

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• 6onse!uence of deviation 0 ;.". Possible conse!uences of no flo# of solvent to vessel

• Pump cavitation

• Line failure due to over1pressurisation1 spilla"e of solvent leadin" to possiblefire

• =una#ay reaction *if solvent is diluents+

• <hould state ultimate hazard e.". fire8 to,ic e,posure etc.

• <hould NOT take into account active safe"uards 0 =e!uirin" action

• <hould be listed for each cause.

CONSEQUENCES

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GUIDELINES

• One cause may have multiple conse!uences. >or e,ample8 a

an open drain on a methanol pump could lead to' 0 Pool fire 0 3o,ic cloud dispersion. 0 >lammable cloud e,plosion. 0 Dischar"e into public #ater#ays. 0 Loss of production

• Once a"ain8 be precise

• List EL3)7A3; conse!uences re"ardless of safe"uards. 0 6an take account of passive safe"uards such as #alls

• <hould be listed a"ainst each cause

CONSEQUENCES

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GUIDELINES

• >ollo# the !uestion M<o WhatM

• 6onsider the plant layout and the distribution of staff in it.

• 6onsider the conse!uences on the node in !uestion8 but also

before and after it.• Discard those conse!uences #hose probability of

occurrence is very lo# e.". #here there are passive

safe"uards.

CONSEQUENCES

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• ;ffects intensity' physical out#ard si"n of the event ' – Overpressure – 3hermal flu, – Atmospheric spreadin" of to,ic or flammable "as – Described "(=!8 !"& (%%&-!" '($$,e $(fe8-(2)$ *6ertain

functionin" ' pressure resistance8 retention pit *e.". #aterproof +8

fire#all8 ...+

• Dama"es impacts on tar"ets *7an8 environment8 facilities+• -urn• Lethal effects• Pollution *land8 #ater8 air+• >acility destruction

CONSEQUENCES

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EXAMPLE

• Possible conse!uences of no flo# of flammable solventto vessel

• Pump cavitations8 causin" pump dama"e and possible fire

• Line failure due to over1pressurisation8 leadin" to spilla"e of

solvent leadin" to possible fire• As above for pipe rupture

• =una#ay reaction *if solvent is diluents+

SIMPLE EXERCISE

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MA3ING INSTANT TEA

>)LL)/9 6EP W)3H WA3;=

• Appropriate conse!uences for

7ore Level 0 <pilla"e of boilin" #ater$3;A 0 Possible scaldin" of

6offeemaker.

HAZOP APPROACH

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(in Intn"" Pro&ss

R.at

A&tiona#s ons#n& SafeguardPara$tr

#i" or"

+

%iation

SAFEGUARDS

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• Any measure that prevents the occurrence of

an accident or limit the escalation of events

that arise as a result of it.

• >or each deviation8 safe"uards can either' 0 Prevent or control causes 0 7iti"ate conse!uences

• 6an be several or even none

• 6an be either hard#are or soft#are

0 Procedures can be a safe"uard

SAFEGUARDS

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6an be'•Passive

0 static devices

0 ;.". a bund or fire la""in"

• Active 0 dynamic devices re!uire an e,ternal input

0 ;.". <afety trip

SAFEGUARDS

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• -y takin" into account preventive and protective independent safe"uards8 the

risk is reduced

•

3he fre!uency of an undesirable event is lo#ered

– Accordin" to the number of '2e,e!",e $(fe8-(2)$ and their

effectiveness

• 3he severity of the conse!uences is lo#ered

– Accordin" to the number of '2&"e%",e $(fe8-(2)$8 their action

and their effectiveness

PRE;ENTATI;E SAFEGUARDS

EXAMPLES

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EXAMPLES

• Procedural safe"uards ' 0 Written procedures aimed at verifyin" the implementation of certain

actions8 N 0 ;,ample ' vacuum ti"htness test before each operation

• Human safe"uards' 0 An operator action is needed

• 7aterial safe"uards' 0 )ndependent from the operator 0 6ontrol system 0 )nstrumental safety chains 0 ?ent device

PROTECTI;E SAFEGUARDS

EXAMPLES

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EXAMPLES

• ;ye <ho#er1<pray and safety sho#ers

• Leak detection and #ater curtains

• Alarm and buildin" evacuation

• >ire fi"htin" response• uick closin" valve in case of leak

• ;,tin"uisher systems

• Personal protective e!uipment

SIMPLE EXERCISE

MA3ING INSTANT TEA

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MA3ING INSTANT TEA

• >)LL)/9 6EP W)3H WA3;=

• Appropriate safe"uards for 7ore

Level

0 3rainin"

0 <mall !uantity char"ed

*inherent safety+

0 Ese of saucer.

HAZOP APPROACH

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(in Intn"" Pro&ss

R.at

Actiona#s ons#n& Sa(g#ar"

Para$tr

#i" or"

+

%iation

ACTIONS AND RECOMMENDATIONS

HAZOP OB<ECTI;E

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HAZOP OB<ECTI;E

3he ob2ective of the HAZOP is the

)dentification

of Potential Hazards and

Operability Problems

)t isnot

the solution of those problems

Actions #ill be "enerated for subse!uent desi"n consideration

ACTIONS OR RECOMMENDATIONS

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• <hould only be re!uired if a"reed safety or operability ob2ectives are not met

• 7ay call for hard#are or soft#are solutions

• 6an often state an ob2ective and not a specific re!uirement'

0 ;.". %Provide system to prevent vessel hi"h pressure&8

rather than %install vessel pressure trip that shuts inlet

valve&.

• 7ay ask for further consideration or investi"ation

0 Actions may therefore "enerate further actions or

recommendations 0 Hence revie#s may be re!uired.

ACTIONS OR RECOMMENDATIONS

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• 6arefully consider #ordin"

A MrecommendationM may commit the company to a

*potentially costly+ course of action 3he team must be sure that this #as the intention

• )f necessary8 actions should be prioritised by the severity of the risk

0Priority to be assi"ned durin" the HAZOP meetin"8

and confirmed by the team leader after#ard

• Actions should be assi"ned #ith a timescale for implementation appropriate to the

priority.

SIMPLE EXERCISE

MA3ING INSTANT TEA

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MA3ING INSTANT TEA

• >)LL)/9 6EP W)3H WA3;=

• Appropriate recommendationsfor 7ore Level

0 3rainin" for 6offeemaker

0 )ncreased supervision

0 <pilla"e containment

HAZOP RECORDING

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T-.i&al +or!sht as (ollo+s

9PARAMETER FIRST APPROACH

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=epeat

Action6ause 6onse!uence <afe"uard

Parameter

9uide Word

>

Deviation

J

• Often used in HAZOPs.• ;ach parameter considered in

turn

• Deviations8 #ith associated

causes8 conse!uences etc. listed

for each parameter

• Once all credible deviations

e,hausted for the parameter8

start on ne,t one.

NODE IS FINISHED

ADDITIONAL ISSUES TO CONSIDER

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ADDITIONAL ISSUES TO CONSIDER

• >ailure of utilities *po#er8 air8 steam coolin" #ater etc.+

• >ailures and deviations associated #ith process control systems8 e.".PL6s. /.-. 7ore detailed study such as a 6HAZOP may be re!uired.

• Plant maintenance.• Pressure relief systems• 3estin" of alarms and trips• 9eneral #orkplace hazards such as hot surfaces8 machinery8 liftin" etc.

3#o points'• 6hecklists can be used to prompt discussion of additional issues• )ssues may be covered by separate assessments.

R$= ($$e$$0e!" ! HAZOP

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RIS3 ASSESSMENT

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HAZA=D )D;/3)>)6A3)O/

6an Hazard -e ;liminated6ost ;ffectively

6O/<;E;/6; A/AL<)<

6an 6onse!uences -e;liminated Or =educed

3o Acceptable Limits6ost ;ffectively

EA/3)>)6A3)O/ O> ;?;/3P=O-A-)L)3 A/D =)<

Does =isk 7eet A"reed 6riteria

;liminate Hazard

)mplement and=e1assess

7ake )mprovementsand =e1assess

3OL;=A-L; $ A66;P3A-L; A63)?)3

es /o

es/o

es/o

A:OP

HAZOP (!) 2$= ($$e$$0e!"

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• HAZOP primarily a #((2) )e!"f%("&! tool

• 7ay need risk assessment to' 0 Define need for action$recommendation

0 Qustify need for action$recommendation

0 Qustify cost of action$recommendation

0 Assi"n priority action$recommendation

• R$= R(!=!8 4RR6 therefore increasin"ly used in HAZOP• == normally made A>3;= safe"uards taken into account

N&"&! &f R$=

=i k > f t it f

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• =isk J >re!uency of event , severity of conse!uence

• >armer curve

N&"&! &f R$=

f f

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• A level of risk can be reduced by lo#erin" the fre!uency

of an undesirable event and$or by miti"atin" the severity

R$= "&e2(*"/(%%e'"(*"

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/eed to have criteria for #hether a risk is acceptable$tolerable or

not.

EFFECT OF SAFEGUARDS

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• Preventative safe"uards reduce the fre!uency• Protective safe"uards miti"ate *reduce+ the conse!uences.

• 3#o cases have to be considered '

0 :+ 3he safe"uard #orks' Dama"es severity is lo#ered8

occurrence fre!uency remains unchan"ed

0 4+ 3he safe"uard does not #ork' <everity remains unchan"edbut this event fre!uency is lo#er than the startin" fre!uency

• Have a failure probability per demand

HAZOP RIS3 TOLERABILITY MATRICES

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F&2 HAZOP !ee) ( $0'e2 ($ &f )ef!!8 "&e2(*"/(%%e'"(*"5 .e. 2$=

"&e2(*" 0("2%e$

A$& =!&! ($ 9R$= R(!=!8

• A McrudeM risk !uantification

• Eses !ualitative rather than !uantitative terms

• 6an be carried out before and$or after the preventative and protective

safe"uards are taken into account.

0 /.-. ) tend to prefer after only8 as the rankin" is often used to 2ustify

recommendations.

HAZOP RIS3 RAN3ING

A McrudeM risk !uantification

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!

A 'Acceptable as desi"ned

6 'AcceptableR risk control measures alreadyspecified

/ '/ot DesirableR risk control measures to be

installed #ithin specified period

E 'EnacceptableR only acceptable if risk control

measures installed before operation

= '=e1desi"n re!uired

: 4 5 G B

: A A A 6 /

4 A A 6 6 /

5 A 6 6 / E

G 6 6 / E =

B 6 / E = =

6onse!uence

HAZOP RIS3 RAN3ING

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Limited 7272

6onse!uence 6ate"ories >ire ;,plosion 3o,ic =elease ;nvironmental =elease Personnel =isk Production Loss

6apital Loss

Eseful for hazards rankin"8 buttime consumin"

>or operability8 cost $ benefit

principles may be used

<ites often develop their o#n

system

>re!uency 6onse!uence

: /ot e,pected durin" plantlifetime

/o $ 7inor effect

4

5

G

B 6ould occur on a re"ularbasis

7a2or catastrophe

RIS3 RAN3ING IN PHA PRO

7/21/2019 Hazop



Limited 73

• Se,e2"

0 : /o in2ury or health impacts 0 4 7inor in2ury or minor health impacts

0 5 )n2ury or moderate health impacts

0 G Death or severe in2ury

• L=e#&&)

0 : /ot e,pected to occur durin" facility life

0 4 6ould occur once durin" facility life

0 5 6ould occur several times durin" facility life

0 G 6ould occur on an annual basis *or more often+

• L=e#&&) $e,e2" 0-"'e) "&8e"#e2

RIS3 RAN3ING IN PHA PRO

7/21/2019 Hazop



Limited 74

7/21/2019 Hazop



Limited 75

THAN3S

hazop

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