A heat exchanger is used to heat flammable, volatile solvent, as shown in FIGURE Q1.

The temperature of the outlet stream is measured by a thermocouple, and a controller

valve manipulates the amount of steam to the heat exchanger to achieve the desired set
point temperature. Construct a HAZOP study on the intention of flow of hot solvent from
heat exchanger using guidewords NO, LESS, MORE, AS WELL AS and REVERSE.
Propose only TWO (2) possible causes, consequences and actions for each of the
guidewords.
[15 marks]

Steam

Control
Valve
TRC

Volatile
Solvent
Heat Exchanger

Condensate

FIGURE Q1: Volatile solvent heating system

Internal
 HAZARD AND OPERABILITY STUDY REPORT
PROJECT TITLE FLOW OF HOT SOLVENT IN HEAT EXCHANGER DATE 26/11/2016
STUDY NODE 1 PROCESS HEATING OF FLAMMABLE, VOLATILE SOLVENT
No STUDY NODE PARAMETER GUIDE DEVIATION CAUSES CONSEQUENCES ACTIONS
WORD
1 Thermocouple Temperature LESS LOWER 1. Malfunction 1)Flow of 1) Install low
at Outlet TEMPERATURE of solvent from temperature
Stream thermocouple heat exchanger alarm
2. Lower than below desired 2)Regular
the temperature maintenance
acceptable 2)Loss of and
thermocouple material as inspection of
temperature desired product the
range are not achived. temperature
controller
MORE HIGHER 1. Malfunction 1)Flow of 1) Install
TEMPERATURE of solvent from relief valve
thermocouple heat exchanger 2) Install
2. Too high to above desired high
be detected temperature temperature
by 2) Overpressure alarm
thermocouple occur as more
temperature solvent change
range to vapor.
2 Heat Flow NO NO FLOW 1. The inlet 1) no flow of 1) Install
Exchanger valve failed to hot solvent flow alarm
System open from heat system and
(malfunction) exchanger indicator
2. The inlet 2) Damage the 2) Regular
solvent is heat exchanger. inspection
insufficient and
maintenance
of the piping
system and
control valve
REVERSE REVERSE 1. The inlet 1) No flow of 1) Install
FLOW solvent has hot solvent pressure
low pressure from heat indicator
2. Failure of exchanger 2) Install
inlet solvent 2) Heat check valve
source exchanger
resulting overheated
backward
flow
Pressure LESS LOW 1. Control valve 1)Reverse Flow 1) Install
PRESSURE failure. 2)Loss of solvent pressure
2. Leakage in indicator

Internal
 pipe 2) Install
check valve

MORE HIGH 1. Excessive 1) Explosion 1) Install

PRESSURE flow from 2)Solvent from pressure
inlet streams.heat exchanger indicator
2. Control valve does not reach 2) Install
failure. desired relief valve
temperature
3 Controller Flow LESS LOW FLOW 1. Failure of 1)Solvent from 1) Install
Valve of receiving heat exchanger flow alarm
Steam Line signal from below desired with
thermocouple temperature minimum
2. Control valve 2) Pressure drop flowrate
failure in heat 2. Regular
exchanger. inspection
and
maintenance
of piping
system and
control valve
MORE HIGH FLOW 1. Control valve 1) Explosion 1) Install
failure 2) Rupture of flow alarm
2. Inlet steam heat exchanger with
overheated due to maximum
causes high overpressure flowrate
pressure and 2. Regular
overflow inspection
and
maintenance
of piping
system and
control valve

Internal