hazop group 7
TRANSCRIPT
KESELAMATAN DAN KESIHATAN PEKERJAAN (KAS3501)
Semester II 2014/2015
Group 7
Presentation date : 1 april 2015
NO.MATRI
C
NAME
UK29510 MASITAH BINTI RANI
UK29551 LIM XIN YI
UK29512 ILANI BINTI ZAMRI
UK29526 ZULFUAZ BINTI RAMSAH
UK29514 NUR SAADIAH BINTI ZAINI
Hazard and Operability Studies (HAZOP)
What is HAZOP??
A formal procedure to identify hazards
in a chemical process facility.
Systematic, comprehensive, effective,
flexible and well accepted.
Identify all the possibilities where
processes and operation can go
wrong.
For large process, the studies could
take months of biweekly meetings to
complete.
Purpose and objective of HAZOP
• HAZOP identifies potential hazards , failures and operability problems.
• Its use is recommended as a principal method by professional institutions and legislators on the basis of proven capabilities for over 40 years.
• It is most effective as a team effort consists of plant and prices designers, operating personnel, control and instrumentation engineer etc.
• It encourages creativity in design concept evaluation.
• Its use results in fewer commissioning and operational problems and better informed personnel, thus confirming overall cost effectiveness improvement.
• HAZOP reports are an integral part of plant and safety records and are also applicable to design changes and plant modifications, thereby containing accountability for equipment and its associated human interface throughout the operating lifetime
• Necessary changes to a system for
eliminating or reducing the probability of
operating deviations are suggested by the
analytical procedure.
• HAZOP provides a necessary
management tool and bonus in so far that
it demonstrates to insurers and inspectors
evidence of comprehensive thoroughness.
HAZOP MethodologyThe HAZOP analysis process is executed in four phases as illustrated
below:
Definition Phase
Begins with preliminary identification of risk assessment team
members.
HAZOP is intended to be a cross-functional team effort and
relies on specialists (SMEs) from various disciplines with
appropriate skills and
experience who display intuition and good judgment.
HAZOP should always be carried out in a climate of positive
thinking and frank discussion.
The risk assessment team must identify the assessment
scope carefully in order to focus effort.
HAZOP Team Composition
A Leader (Chairman) - the person who leads and
facilitates the HAZOP study by asking questions of the
team and encourage team to draw conclusion.
Secretary (Recorder) - the person who records the
discussions (worksheet) and produce final report.
• Team members - who represent of each of the key
disciplines involved in the facility such as Process
design, Operations, Control & Instrument, Safety, etc.
Team members provide essential inputs and discussions
to HAZOP study as per their knowledge and experience
of the process under study
HAZOP Team
HAZOP Team
Process/ Chem Eng.
Mechanical/Electrical/
Civil Eng.
Control & Instrument
Eng.
Plant Manager
Plant Superinten
dent
Safety Eng.
Supervisor
Senior technician
Lab Chemist
Preparation Phase
The Preparation Phase typically includes the following activities:
Identifying and locating supporting data and information
Identification of the audience and users of the study outputs
Project management preparations
(ex: scheduling meetings, transcribing proceedings, etc.)
Consensus on template format for recording study outputs
Consensus on HAZOP guide words to be used during the study
Once the HAZOP guide words are selected, the Examination Phase may begin.
Documents Needed for HAZOP
Study For Preliminary HAZOP
Process Flow Sheet ( PFS or PFD )
Description of the Process
For Detailed HAZOP
Piping and Instrumentation Diagram ( P & ID )
Process Calculations
Process Data Sheets
Instrument Data Sheets
Interlock Schedules (Cause and Effect Chart)
Layout Requirements
Hazardous Area Classification
Description of the Process
Incident Records (for existing plant HAZOP)
Modification Records (for existing plant HAZOP)
Process information required for
HAZOP study
Process flow diagram (PFD) Piping and Instrumentation
Diagram (P&ID’s)
MSDS
Mass and energy balances Report
Process
simulation
data
Examination Phase
The Examination Phase begins with identification of all elements (parts or steps) of the system or process to be examined.
For example:
Physical systems may be broken down into smaller parts as necessary
Processes may be broken down into discrete steps or phases
Similar parts or steps may be grouped together to facilitate assessment
The HAZOP guide words are then applied to each of the elements. (not all combinations of guide words and elements are expected to yield sensible or credible deviation possibilities)
Documentation & Follow-up
Phase The documentation of HAZOP analyses is often facilitated by
utilizing a template recording form as detailed in IEC Standard
61882.
Risk assessment teams may modify the template as necessary
based on factors such as:
Regulatory requirements
Need for more explicit risk rating or prioritization
Company documentation policies
Needs for traceability or audit readiness
Other factors
A typical HAZOP recording template is shown on the following slide
HAZOP Recording Template
Example
HAZOP
PROCEDURE
Start
Divide the plant
into various study
nodes or units
Take one
unit or study
node at a
moment
Compare the study
node with the unit
of Information
Base
Expert
INFORMATION
BASE
Is unit
matching
?
Yes
Apply guide
words
Analyze the causes
and consequences
of the deviation
drawn from the
INFORMATION
BASE
Add or remove
causes and
consequences due
to special behavior
of unit
Are all
deviation
s over?
No
No
YesAre all
study
nodes
over?
No
Yes
Prepare HAZOP
report
Stop
HAZOP PROCEDURE
1. Begin with detailed and up to date process
info.
2. Divide into separate units
and perform the HAZOP study for each unit.
3. Choose a study node for
the selected unit.
4. Provide brief description of
the function/design intention of the
study node.
5. Pick a process
parameter.
HAZOP Procedure
cont’..
6. Apply guide words/deviations
to the process parameter to
suggest possible deviations.
7. For each deviations, determine
possible causes and note any
protective systems.
8. Evaluate the consequences of the deviations (if
any).
9. Recommend action.
10. Record all information (in HAZOP form).
HAZOP Procedure cont’..
11. Repeat step 5 through 9 until
all applicable guide words have been
applied on the chosen process
parameter.
12. Repeat step 4 through 11
until all applicable process
parameters have been
considered for the given study
node
13. Repeat steps 2 through 12 until all study nodes have
been considered for
the given section
14. Process to the next section
and repeat steps 2 through
13 until all sections have
been considered for
the process plant.
15. HAZOP study complete.
A P&ID for Phosgene
reactor
A reactor
as the unit
What is unit?
What is node?
NODE: Concentrate on one location in
the process
Coolin
g coils
as
node 1Stirrer
as
node 2
Function of the study node
Study node
• Cooling coils
• stirrer
Function/design intention
• To remove excessive energy of reaction
• To promote mixing of reactants
Process parameter
• Flow
• Temperature
• Agitation
Common HAZOP Analysis
Process Parameters
Process Parameters
Flow
Pressure
Temperature
Level
Reaction
Speed
Time
pH
Toxicity
Mixing
HAZOP Guide WordsGuide Words
• NO or NOT
• MORE
• LESS
• AS WELL AS
Meanings
• The complete negation of intention
• Quantitative increase
• Quantitative decrease
• Qualitative increase
Comments
• No part of the designintention is achieved, but nothing else happen
• Applies to quantities such as flow rate and temperature and to activities such as heating and reaction.
• Applies to quantities such as flow rate and temperature and to activities such as heating and reaction.
• All the design and operating intentions are achieved along with some additional activity, such as contamination of process stream.
HAZOP Guide Words cont’
Guide Words
• PART OF
• REVERSE
• OTHER THAN
• SOONER THAN
Meanings
• Qualitative decrease
• Logical opposite of intention
• Complete substitution
• Too early or in the wrong order
Comments
• Only some of the design intentions are achieved, some are not.
• Most applicable to activities such as flow or chemical reaction. Also applicable to substances, for example, poison instead of antidote.
• No part of the original intention is achieved- the original intention is replaced by something else.
• Applies to process steps or actions.
HAZOP Guide Words cont’
Guide Words
• LATER THAN
• WHERE ELSE
Meanings
• Too late or in the wrong order
• In additional locations
Comments
• Applies to process steps or actions.
• Applies to process locations, or locations in operating procedures.
Advantages Disadvantages
Provide complete identification of
hazards from operational upsets,
operational procedures (SOPs) and
equipment failures
Potentially identify hazards
independent of the risk (as HAZOP is
not a risk assessment process)
Fewer commissioning and operational
problems
Need a team with experience
judgment
Less down time Time consuming and expensive
Improved product quality and less
waste is produced
Requires detailed design drawing to
perform the full study
Employees’ confident in the safety of
the process
Focuses on one-event causes of
deviation only
Better informed personnel
Could be used as evidence of
comprehensive thoroughness to
insurers and inspectors
Adv & dis-adv HAZOP
References
1. Guides, R. M. (n.d.). Manufacturing Technology Committee – Risk Management Working Group. Retrieved March 26, 2015, from Risk Management Training Guides:http://images.alfresco.advanstar.com/alfresco_images/pharma/2014/08/21/347197a7-b965-45fe-ac72-daeeb77baa21/article-727769.pdf
2. LABORATORY, H. A. (2000). REVIEW OF HAZARD IDENTIFICATION. Retrieved March 26, 2015 , from HEALTH AND SAFETY LABORATORY:http://www.hse.gov.uk/research/hsl_pdf/2005/hsl0558.pdf
3. Planning, N. G. (2008, July). Hazardous Industry Planning.Retrieved March 26, 2015, from http://www.planning.nsw.gov.au/plansforaction/pdf/hazards/haz_hipap8_rev2008.pdf