1. History of Hazop and Introduction
Hazop is hazard identification technique widely used in Chemical Plant, Initially Hazop Technique developed by UK based company, Imperial chemical Industries. this is very good tools to identify the hazard pertinent to Plant Operation and process Equipment. Later on this Technique widely use in chemical Reaction Process, batch Process and operations. Today Hazop Play a very vital role as hazard identification tools in Chemical plant, pharmaceutical plant as well as engineering plant.
2. Imortance of Hazop In process industries
Process industries menas generally Chemical, Pharma, Oil and gas where highly hazardous chemical are stored, handled or manufactured . becuase , chemicals are very vulnerable to Heat , temperature , flow and Pressure. A very minute changes in these factor could cause a disaster accident. That’s why , in process industries , all the hazard related to design, Layout ,siting , equipment and instrument design , operation of process are identified at design stage and thorough discussion of hazard and required control measure initially discussed . To identify all hazard and associated risk , Hazop tools used as wide spread . Because Safety is a matter of human life , so prevention is better then cure principal applied and it is moral duty of employer to provide the risk free workplace to ensure safety of life and Plant .
3. Where Hazop study could be used to identify Hazard and Risk ?
The following are subject where hazop study widely use to identify the hazard and associated risk and decide the control measures to mittiagte the risk :-
- Chemical manufacturing Process
- Chemical Transporation and transferring prcocess through pipeline, Tanker etc.
- Reactor and pressure vessel Design
- Design of piping Layout
- Chemical or product change Process.
- Introduction of New product
- Introduction of New equipment in existing system
- Any changes in existing design of system.
- Modification and expansion of existing system.
4. What Parameters to be analyzed to identify the hazard and risk in Hazop ?
As We know , Hazop study is realted to Process and operation related hazard and risk . So all the Parameters related to Process and Operation are analyzed to identify the loope holes, operational error, fails , exceedance of parameters etc. generally following parameters are take in cosideration for Hazop study:
- Process Temperature
- Process Pressure
- Flow of Material
- Cooling
- Heating
- Addition rate of chemical in Semi Batch process
- Cahrging of Material (Raw and catalyst)
- Rate of Reaction
- Agitation Speed in Reactor
- Speed of Rotational Part of Equipment
- Mixing
- Blending
5. What Technical word being used in HAZOP study and What does it mean ?
While we conducting Hazop study for a process , we usually use some key word . these keyword are heart of Hazop study and without these word there is no meaning of the same. Most Common words are as follwing with deatailed description:
5.1. Guide word :– These are main core element of Hazop study. as name itself explainatory , these are guide for Hazop study amd Propell and lead to study forward. Guide word are use as prefix with parameter of Process or Operation. Some Common Guide words are as Following:-
- No : means there is no as per intention of process or operation
- Less :- Means less than intended .
- More : means more than intention
- Other Than:- Output is some different than intention or required output
- Reverse :- jsut Opposite of intended Output or Result.
5.2. Node: – Node is a location on P & ID or a section of drawing or a part of process under consideration. Node contain the Section or Part of Actual Process Equipment, Piping, Instrument etc. Other Word, we can say that Node is a part of system or design where we brainstorm to identify the hazard and associated risk.
5.3. Parameters: Parameters are Process or Operation variables e.g. Temperature, pressure, flow, Heating, cooling etc.
5.4. Deviation: – Deviation name itself explains the meaning; deviation means diversions from standard Procedure or diversion from standard process step or Operation or not performance as per out intention. Deviation is cause by some causes. In Hazop study, deviation is simulated or assume through brainstorming. in Hazop deviation are defined as = Guide word + Process parameters, e.g. if a Parameters is “pressure” then deviation could be as Following with Various guide word, as, “No Pressure” “Low Pressure” “high pressure” etc.
5.5. Consequences: The Consequences are result of Deviation , Imapct or effect of the deviation on system or process or operations.
6. Who can participate in HAZOP or Who is elligible for HAZOP study?
The Following are competenet to conduct or to particiapte hazop study :
- Mechanical engineer ( Maintenance Manager)
- Project Engineer (Civil )
- Process Engineer ( Chemical )
- Instrument engineer
- EHS Professional
- Process Expert
- Operational Senior Person having Practical knowledge
7. Which Document or evidences required to condcut a Hazop study?
To conduct a effective Hazop study and make it productive and result oriented , following are required for references :
- A detailed , Comprehensive P & ID
- Cause and effect diagrame of Instrument
- Standard Operating Procedure of Process or Operation under review
- Mechanical details of Instrument and Equipment with reference to Design
- Reciepie of process
- MSDS of Chemical use in Process
- Functional Parameters of process
- Utility Services related to operation and Process
- Safety instrument or equipment already installed
- Past Accident history record
- Past Process Incident Record
- Past process and operation deviations
- Functional and operational design of proces and operation.