Professional Documents
Culture Documents
Hazard Identification
Chapter Outline
• Introduction
• Process hazards checklist
• Hazards survey
• HAZOP studies
Instructional Learning Objectives
After completing this
chapter, students should
be able to do the
following:
• Identify hazards using
process hazards
checklist
• Identify hazards using
Dow indexes
• Identify hazards using
HAZOP
What is Hazard? What is Risk?
What is Risk?
Risk = Probability of accident x Consequences
in lost of money/life
What are examples of a hazard?
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Solution - Dow F&EI Procedure
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Hazard Survey
Dow CEI Procedure
• Dow CEI is a method of rating the relative acute
health hazard potential for people in neighboring
plants or communities arising from possible chemical
release incidents.
• The following items are required for CEI
determination;
– Plot plan of plant and surrounding area
– PFD of the plant
– Physical and chemical properties of the materials
investigated
– ERPG values (Table 5-7)
– Dow CEI guide (AIChE, 1994)
– CEI from (Figure 10-6)
• The CEI procedure is given in the flowchart of Figure
10-7.
Hazard Survey
Dow CEI Procedure
• Dow CEI Procedure
– Define the possible release incidents (such as from pipes,
vessels, reactor, etc). Table 4-5 can be used as guidelines.
– Use source models to estimate release rate of material.
– Use dispersion model to determine the dispersed
concentration of materials.
– Use ERPG standard to determine CEI value and
downwind hazard distances
• Hazard surveys are suitable for identifying hazards
associated with equipment design, layout, material
storage, etc.
• They are not suitable for identifying hazards
resulting from improper operation or upset
conditions.
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A scenario…
You and your family are on a road trip by using a
car in the middle of the night. You were replying
a text message while driving at 100 km/h and it
was raining heavily. The car hits a deep hole and
one of your tire blows. You hit the brake, but due
to slippery road and your car tire thread was
thin, the car skidded and was thrown off the
road.
What is the cause of the accident?
Car speed Too fast Rushing Skidded when - Slow down -ABS brake system
Too slow emergency brake - Speed up -Safety belt
- Air bag
Select deviation
e. g more flow
GUIDE WORDS *
CONSEQUENCES
ACTION(S) REQUIRED OR
RECOMMENDEED
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Guide Words
NONE No forward flow when there should be
MORE More of any parameter than there should be,
e.g more flow, more pressure, more
temperature, etc.
LESS As above, but "less of" in each instance
PART System composition difference from what it
should be
MORE THAN More "components" present than there
should be for example, extra phase,
impurities
OTHER What needs to happen other than normal
operation, e.g. start up,shutdown,
maintenance
Guide Words
Process
fluid
Cooling water
HAZOP on Heat Exchanger – Answer
Guide Word Deviation Causes Consequences Action
Less Less flow Pipe Temperature of High
of cooling blockage process fluid Temperature
water remains Alarm
constant
More More Failure of Temperature of Low
cooling cooling process fluid Temperature
flow water valve decrease Alarm
More of More Failure of Bursting of Install high
pressure on process fluid tube pressure alarm
tube side valve
Contamination Contaminat Leakage of Contamination Proper
ion of tube and of process fluid maintenance
process cooling and operator
fluid line water goes alert
in
Corrosion Corrosion Hardness of Less cooling Proper
of tube cooling and crack of maintenance
water tube
HAZOP on Heat Exchanger – Answer
Guide Word Deviation Causes Consequences Action
NONE No cooling Failure of inlet Process fluid Install
water flow cooling water temperature is not Temperature
valve to open lowered accordingly indicator before
and after the
process fluid line
Install TAH
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