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Hazop Sample.pdf
- 1. Reactor Table 6 ReactorHAZOP Sheet HAZOP STUDY RECORD SHEET PROJECT: TEREPHTHALIC ACID MAJOR UNIT: REACTOR Stream System : TPA Production Study node: Inlet to Reactor (Air + Acetic Acid + p- Xylene) Deviation Parameter Guide Word Possible consequences Possible causes Safeguard/ Action required Flow More 1. Upsetting process 2. Uncontrolled reaction 3. Excessive heat • Excess air • Excess Air Valve fully open • Install high flow alarm • Install dry air control valve after compressor. • Operator to continuously monitor pipe/valve condition and manually change valve position no • No reaction • No product • Pipe rupture • Valve fully closed • Blockage • Install feed flow meter • To be included in biweekly routine checkup procedure by Inspection Team Less • Less pressure • Less favorable product • Pipe leakage • Valve partially closed • Install low flow alarm • Operator to continuously monitor pipe/valve condition and manually change valve position Pressure More • High velocity of reactant • Overpressure • High temperature • Valve failure • Overheat • High pressure alarm • Install pressure safety valve (PSV) • Install high temperature alarm Less • Less reaction • Less favorable product • Leakage • Compressor failure • Insert safety valve • Install low pressure alarm Temperature More • Uncontrolled reaction • Mechanical failure • May cause explosion • Pressure increase Install temperature sensor
- 2. Crystallizer Table 7 CrystallizerHAZOP Sheet Less • Less pressure, less favorable product. • Low pressure • Install temperature sensor HAZOP STUDY RECORD SHEET PROJECT: TEREPHTHALIC ACID MAJOR UNIT : CRYSTALLIZER Stream System : TPA Production Study node: Outlet of Reactor TPA mixture Guide Word Deviation Possible Consequences Possible Causes Safeguard/Action required Flow More • Upsetting process • Increase demand for solvent • Increase in temperature • Uncontrolled reaction • Install high flow alarm • Regular monitoring by Control Team. No No product • Pipe rupture, valve fully closed, blockage • No reaction • To be included in biweekly routine checkup procedure by Inspection Team • Regular monitoring by Control Team • Operator to continuously monitor pipe/valve condition and manually change valve position Less • Less product form • Decrease in temperature • Low reaction rate • Pipe leakage • Valve partially closed • Install low flow alarm • To be included in biweekly routine checkup procedure by Inspection Team • Regular monitoring by Control Team
- 3. Scrubber Table 8 ScrubberHAZOP Sheet Dryer Table 9 Dryer HAZOP Sheet Item Guide word Deviation Possible consequences Possible causes Safeguard/ Action required S C R U B B E R Pressure More Low absorption rate Uncontrolled reaction Install pressure safety valve (PSV) Install high pressure alarm Less Less flow rate to the absorber Agitate absorption process Take longer time Low reaction rate Pipe leakage Install low flow alarm Operator to monitor pipe/valve condition Regular monitoring by Control Team Temperature More Increase in utility Uncontrolled process conditions Install temperature sensor Install auto-control valve for utility less Less pressure Take longer time for absorption process Low absorption rate Install temperature sensor Item Guide Word Deviation Possible Consequences Possible Causes Safeguard/ Action required D R Y E R Pressure More Low drying rate Uncontrolled air flowrate Install pressure safety valve (PSV) Install high pressure alarm Less Less flow rate to the dryer Improve steam flowrate to the process Take longer time Low drying rate Pipe leakage Install low flow alarm Operator to monitor pipe/valve condition Regular monitoring by Control Team More Increase in utility Uncontrolled drying process Install temperature sensor
- 4. Temperature Install auto-control valvefor utility less Less pressure Longer time for drying process Low flowrate Install temperature sensor