صفحه 1:
Hazards And
Operability Analysis
(HAZOP)
صفحه 2:
When to Use HAZOP
+ HAZOP is a hazards identification tool.
+ It is best used as late as possible with a new
design, in order to be as complete as
possible.
* With an existing facility it can be used at any
time.
* HAZOP can also be used for analyzing
operating instructions and procedures so that
sources of human error can be identified (and
corrected).
صفحه 3:
Advantage
* HAZOP is very thorough, because
you force yourself to painstakingly
examine most aspects.
* HAZOP is the most widely used
methodology used in the world
today as a tool for hazards
identification.
صفحه 4:
Disadvantage
* HAZOP is very time consuming and
costly
۰ ۱۲ not set up correctly and managed
properly,
it can be ineffective
* Needs Leadership by an Expert in
the field of HAZOP.
صفحه 5:
مطالعه عملیات وخطر ۲۱۵2۵۳
* مطالعه ۳۱۸20۳ معمولا در مراحل زیر از
چرخه عمر سیستم انجام می شود:
”مرحله ايده وتفکر
”مرحله طراحى جزئيات
”مرحله عمليات
صفحه 6:
Basis
* Simulates abnormal situations by
using Guidewords applied to
Parameters and Operations to
create Deviations.
صفحه 7:
Methodology
1. Collect applicable documents and drawings, e.g., process
flow diagrams, piping and
instrument diagrams, plot plans, etc.
2. Break facility down into manageable sections ("Nodes").
Break P&IDs down into Nodes.
Nodes are equipment items (or numbers of items).
If nodes are too small you can loose sense of analysis and
incur excessive repetition.
If nodes are too large, hard to handle, becomes confusing.
صفحه 8:
Methodology
3. Prepare list of Parameters and
Operations to be examined,
composition, pressure,
temperature, flow, etc.
4. Apply Guidewords to Parameters
and Operations.
صفحه 9:
Main Guidewords
* More or High or Higher or Greater than
the
design intent.
٠ No, None, Le ss or Low or Lower or
Reduced than the design intent.
* Part of or Not all of or Partially than the
* design intent.
* As well as or In addition to the
* design intent.
صفحه 10:
Main Guidewords
* Reverse or Opposite to or
Instead of the design intent.
* Other than or What else the
design intent.
صفحه 11:
Guidewords Applied to Time
(Used for BATCH and Periodic Type transfer
Operations)
Sooner than intended
Later than intended
Before what is intended
After what is intended
While what is intended is occurring
صفحه 12:
Applicable parameters typically
include:
Pressure
Temperature
Flow
Composition
Level
Reaction Rate
Viscosity
pH
صفحه 13:
Applicable operations typically
include:
Filling
Transferring
Purging
Emptying
Draining
Venting
Maintenance
Start-up
Shut-down
صفحه 14:
Methodology
5. For each Node create Deviations,
e.g., High pressure, High
temperature, High flow,
Low pressure, Low temperature, Low
flow, Reverse flow, etc.
6. List and record Causes for each
Deviation.
7. List and record Consequences
associated with each Cause.
صفحه 15:
Methodology
8. List and record Safeguards or
Controls that may prevent the
Cause and for the
Consequences.
9. List any future Actions or
Recommendations you think
should be implemented.
صفحه 16:
WOLOP Cxavple
, Oowrpressor ‘let
Low
3 y وه وت to quickly tea) vlorwe, skut-dowas
0 |
۲
‘abet Dive | to و
@uscuce vlorws ore equestly bypassed wad are
موجه ماه ام
|
@stowalie peat voutloey are oftea set fa crawl أمجدف وز صا
weds:
صفحه 17:
چم سه 0 سس xin a
foe EG م د ۱۳ مس وس
fase — ae 8 Op
frie am ow a Sr
iis eo 3 oo
es Raw Goes CUO 1 لسلسم ا
|1۳ 7۳۱۳۳۱۲۱۳۵13۲۳۳۲ ۲۳۳۳۳ 72۲ od wt ID" Wier the startup period
Oude Oni) ee ee يرنه ا صصص Sd
52
GPG Dike open
bie break.
۳۳
میاه لوا امسا وات وا مرول هار موی موه انوا اس امم 0 ود ها ۰ 0
release مسا ۳ ۵
۳۳۳۳
0
Athen level char WELD ston, ۵
اسر سس اسر
۳ اس
Cetera Houronfice, st (8D po Thigh level, ont check he q 0 0
a oo ماس hydrocarbon وتان سس سس 8
1 wo
صفحه 18:
۳
کارگاه
عنوان:شناسایی خطر از روش ۲۱۸20۴
دستور کار:با استفاده از تکنیک HAZOP خطرات مثال پیوست را
تجزیه و تحلیل نمائید.
ملاحظات:انحرافات را بر اساس کلمات راهنما استخراج نمائید.
ورودیزسناریو پیوست
خروجیزیرگه تکمیل شده ثبت آنالیز ۲۱3۵200
صفحه 19:
DAP Process
موی
LOADING,
صفحه 20:
+ Diammonium phosphate (DAP)
is made by reacting ammonia
and phosphoric acid.
+ DAP is non-hazardous.
+ Ammonia is the most hazardous
chemical present.
4+ Reaction is exothermic.
صفحه 21:
Phosphoric Acid Feed Line to DAP Reactor
: :
“Consider using
a
closed tank for
DAP
storage or
ventilation.
*Consider
adding an
alarm/shutdown
of
the system for
low
flow to the
reactor.
‘Ensure that
periodic = 21
maintenance
1-1-
Ammonia
detector
and Alarm.
1-1. Unreacted
Ammonia
in storage tank
that
release to
enclosed
work area.
1-2. Loss of
DAP
production.
2-1. Same as1-
11-2.
3-1. Same as1-
11-2.
4-1-1
Periodic
maintenanc
4-1. Same as1-
11-2.
1. No feed
material in
storage tank.
No Flow
2. FIC fails high.
3. Leak or rupture
of
the line.
4. Control valve B
fail
le
صفحه 22:
Ammonia Solution Storage Tank
“von
‘High Level | 7. Unloading ‘7-1. Potential | 7-1-1. Level_| “Review
ammonia release of indicator on | ammonia
from the ammonia to the | the storage | unloading
unloading Atmosphere. tank. procedures to
station without 7-12 ensure
adequate space in Ammonia __| adequate space
the storage tank | in the storage
8 relief valve | tank before
ammonia storage tn the ست
ا atmosphere.
8. Ammonia 8-1. Same as7- ‘Consider
storage tank level | 1. sending the
indicator fails low. relief valve
discharge to a
scrubber.
‘Consider
adding
independent
high level
alarm for the
ammonia
storage tank.
صفحه 23:
Ammonia Feed Line to the DAP Reactor
“one
High Flow |9.Ammonia feed | 9-1. Unreacted | 9-1- “Consider
line control valve | ammonia carry | Periodic adding an
A fails open. over to the DAP | maintenance | alarm/
storage tank | of valve A. | shutdown of
and release to the system for
the work area. high
Ammonia flow
to the reactor.
10. Flow indicator | 10-1. Same 10-1-
fails low. as9-1. 1.Ammonia
detector and
Alarm.
11. Operator sets | 11-1. Same “Ensure
ammonia flow rate | as9-1. periodic
too high. maintenance
and inspection
for valve A is
adequate.
+Ensure
adequate
ventilation
exist for
enclosed work
area and/or?
consider using
صفحه 24:
Ammonia Feed Line to the DAP Reactor
wee’
14. External
impact.
inspection
tours by
operator in
the DAP
process
area.
15. Maintenance
errors.
صفحه 25:
Phosphoric Acid Solution Storage Tank
“one
16. Low 16-1. 10-1 “Ensure
۱۳ Phosphoric Acid | Unreacted 1.Ammonia_| existence of
ion of _ | concentration ammonia in the | detector end | adequate
ic | supplied by the —_| reactor carried | Alarm. material
Phosphoric | vendor. over to the DAP handling and
Acid storage tank receiving
and release to procedures and
the work area. labeling.
17. Error in 17-1. Same “Consider
charging as16-1. verifying the
Phosphoric Acid to Phosphoric
the supply tank Acid
concentration
in the storage
tank before
operation.
+ Ensure
adequate
ventilation
exist for
enclosed work
area and/or
consider using
an enclosed
DAP storage.
tank.
صفحه 26:
DAP Reactor
“oe
7
(Other 18. Agitator motor | 18-1. 18-1-1. *Consider
Than) _| fails. Unreacted Ammonia adding an
ة ammonia in | detector and | alarm/
وده the reactor Alarm. shutdown of
91 carried over to the system for
the DAP loss of
storage tank agitation in the
and release to
reactor.
the work area.
+Ensure
adequate
ventilation
exist for
enclosed work
area and/or
consider using
an enclosed
DAP storage
tank.
19. Agitator 19-1. Same 19-1-1. Same
Mechanical as18-1. as18-1-1,
linkage fails.
20. Operator fails | 19-1. Same 19-1-1. Same
to activate the as18-1. as18-1-1.
agitator. 2
صفحه 27:
DAP Reactor Outlet line to the DAP Storage tank.
_ “oe
e tion
‘Reverse/ | 21. No credible No significant
misdirecte | causes. effects.
d flow
