M03 HAZOP Study Methodology

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DNV GL © 2013

Overview

Learning goals – Develop an in-depth understanding of

the key principles and methodologiesassociated with executing a HAZOP

study

Topics – Deviations / uidewords

– HAZOP process

– Preparations

– !election of study sections

Slide2



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How do we perform a HAZOP?

"y considering the plant section #y section$ line #y line$ item #y item

"y defining %normal operation&

"y considering deviations from normal operation

"y using guidewords to identify these deviations and to initiate the discussion

Slide3



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Selecting a HAZOP Study Section/Nodes

'his is the HAZOP (eader&s responsi#ility

)hoice depends on the system and the team

olden rule is *+eep it simple,

(arge$ complex systems increase the chance of missing something

ormally follow the process flow

!tart where the line enters the P.D

)ontinue

– to next change of design intent or

– to significant change of process conditions or

– to next e0uipment item

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Selecting a HAZOP Study Section

Aim for sections which will take no more than 1 hour to study

Aim for not more than 2 causes for the first guideword

f the team needs to address the section in parts$ it is more than 1 section

HAZOP (eader and 3ecorder should study sections #efore the workshop

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Original Guideword ParametersFlow Pressure Temp Composition

No

Reverse (Wrong)

More

Less

Part of

As well as

Other than

uidewords / !eviations

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HAZOP process

Slide7

Describe design intention, operating conditions etc.

Consider first or next guide word

Identify all causes and record

Identify all consequences and record

List existing safeguards and record

Take next section

Agree any actions necessary and responsible person /org. and record

Last guide word?

Yes

No



DNV GL © 2013

HAZOP / HAZ"! logsheet

Step Guideword

/ Deviation

Cause Consequence Existing

Safeguards

Finding /

Recommendation

R: Remark / A:

Action

Action

responsible

Time

1.

1.1

1.2

2.



DNV GL © 2013

HAZOP / HAZ"! logsheet with ris# ran#ing

Step Guideword

/ Deviation

Cause Conseq

uence

Existing

Safeguards

P C R Finding /

Recommendati

on

R: Remark /

A: Action

Action

responsible

Time

1.

1.1

1.2

2.



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$ideo% HAZOP team in action

42 minutes

Demonstrates use of guidewords

'eam selection

5acilitator skills

)ooperation #etween facilitator and scri#e

After the video6

17 minutes with reflection / discussion6 8hat did the group do9

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HAZOP uidewords & No 'low

8rong routing

"lockage

ncorrect slip plate

ncorrectly fitted check valve

"urst pipe$ large leak

:0uipment failure ;valve$ pump$ vessel$ control system$ etc<=

ncorrect pressure differential$ isolation in error$ etc<

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HAZOP uidewords & (ess 'low

(ine restrictions

5ilter #lockage

Defective pumps

5ouling of vessels$ valves$ orifice plates

Density or viscosity changes - etc<

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HAZOP uidewords & )everse 'low

Defective check valve

ncorrect pressure differential

'wo-way flow

:mergency venting - incorrect operation

n-line spare e0uipment etc<

(eak upstream

Slide13



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HAZOP uidewords & More (evel

Outlet isolated or #locked

nflow greater than outflow

)ontrol failure

5aulty level measurement

ravity li0uid #alancing etc<

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HAZOP uidewords & More Pressure

!urge pro#lems

)onnection to high pressure system

as #reakthrough ;inade0uate venting=

Defective isolation procedures for relief valves

'hermal overpressure

Positive displacement pumps

5ailed open P<)<><?s

@

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HAZOP uidewords & (ess Pressure

eneration of vacuum condition

)ondensation

as dissolving in li0uid

3estricted pump/compressor suction line

ndetected leakage

>essel drainage

"lockage of #lanket gas reducing valve

etc<

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HAZOP uidewords & More *emperature

Am#ient conditions

5ouled or failed exchanger tu#es

5ire situation

)ooling water failure

Defective control

Heater control failure

nternal fires

3eaction control failures

Heating medium leak into process

etc<

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DNV GL © 2013

HAZOP uidewords & (ess *emperature

Am#ient conditions

3educing pressure

5ouled or failed exchanger tu#es

(oss of heating

DepressuriBation of li0uefied gas

Coule/'hompson effect

etc<

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HAZOP uidewords & +omposition +hange

Phase change

!ettling of slurries

(eaking isolation valves$ exchanger tu#es etc<

ncorrect feedstock specification

Process control upsets

3eaction intermediates or #yproducts

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HAZOP uidewords & A,normal Operations

Purging

5lushing

!tart-up

ormal !hutdown

:mergency !hutdown

:mergency Operations

nspection of operating machines

uarding of machines

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HAZOP uidewords & Maintenance -typically covered separately.

solation Philosophy

Drainage

Purging

)leaning

Drying

!lip plates

Access

3escue plan

'raining

Pressure testing

8ork permit system

)ondition monitoring

(ifting and manual handling

etc<

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Safeguards

!afety valves

Detectors

'raining

Procedures

onitoring of critical parameters

aintenance / nspections

Heat tracing

P!D$ :!>

PP: ;last #arrier=

Slide23



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01ample HAZOP Study Section -Node. !escription Sheet

Slide25

Project: Fuel Transfer System Revision: 0 Node: Page: 1

001

Date: 31/10/95 Time: 12:18:49

Session: 0 Team: (see below)

Node Description:

The hose connection from the road tanker to the tank including the pump and manual valves onthe pump inlet and outlet.

Leader: Recorder:

Organisation: XYZ

Location: Various

Design Intention:

To transfer petrol from the road tanker to the tank via the installed pump.

P&ID’s Rev #’s:

Normal Process Conditions (Range):

Temperature:

Pressure:Flow Rate:

Ambient

Static head from tanker, 3 Bar g maximum at pump discharge500 litres per minute

Team Members:L D RedE X Pert

R E CordO P Erator

N O FlowS I Tinn

Mal Function R N Awae



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01ample HAZOP Study (ogsheet

Slide26

Project: Mode: 001 Fuel Transfer System

Page: 2

Node Description:The hose connection from the road tanker to the tank including the pump and manual valves on the pump inlet and outlet.

GUIDEWORD/

DEVIATION

CAUSES CONSEQUENCES SAFEGUARDS REC# RECOMMENDATIONS

No Flow Manual valve on pump

inlet closed

Manual valve on pump

outlet closed

Line blocked

No transfer of fuel. Pump

starved of liquid which

could cause mechanicaldamage and possible

leakage from the pump on

to the road way.

No transfer of fuel. Pump

runs against a closed

discharge which could causeoverheating, mechanical

damage and leakage of left

for too long.

As above

Operators knowledge and

training.

Local stop which will beused by operator if pump

leaks or is noisy.

As before. Also this valve is

normally kept open.

As above. Line blockage is

unlikely since fuel deliveredis clean.

R1

R2

Provide low level/dry running

cut out for the pump to

prevent pump damage on lossof suction.

Develop a checklist for use by

the operator when carrying

out transfers. Ensure checks ofmanual valve positions are

included in this checklist for

all stages of fuel delivery.



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01ample HAZOP Study (ogsheet -+ontinued.

Slide27

Project: Mode: 001 Fuel Transfer System

Page: 3

Node Description:The hose connection from the road tanker to the tank including the pump and manual valves on the pump inlet and outlet.

GUIDEWORD/

DEVIATION

CAUSES CONSEQUENCES SAFEGUARDS REC# RECOMMENDATIONS

Reverse Flow

More Flow

Backflow of fuel whendisconnecting tanker

hose

Tanker hose or transfer

pipe rupture.

Spillage of fuel in area withpossible discharge on the

road way to the surface

water system.

Driver or operator could be

splashed with fuel when

disconnecting hose.

Discharge of fuel from hose

or pipe. Spillage locally

with potential for fire.

Discharge of fuel on the

road way and potentially to

the surface water system.

Driver would physically lifthose to check whether liquid

remains before

disconnecting.

Driver wears goggles and

gloves.

Hoses and pipework are

rated for 7 Barg pressure.

Maximum pump pressure is

3 Barg.

As above.

R3

R4

R5

R6

Install a non-return valve inthe line between the manual

valve and pump.

Ensure operator wears suitable

eye protection and gloves

Review adequacy of the fire

fighting equipment at the road

tanker unloading area.

The road tanker unloading

area should be bunded and

provided with an interceptorto prevent discharge of fuel to

the surface water system.

M03 HAZOP Study Methodology

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