UNIVERSITAS INDONESIA
HEAT REFLECTIVE PAINT “NurCoolant”
GROUP 5 LIST OF MEMBERS: ARIZ KIANSYAHNUR H. (1006679453) (1006679453) FEBRIAN TRI ADHI W.(1006679586) FIRDHAUZI KUSUMA R. (1006679592) NATHANAEL SANDY (1006773300) (1006773300)
FACULTY OF ENGINEERING DEPARTMENT OF CHEMICAL ENGINEERING DEPOK MAY 2013
Definition
The HAZOP (Hazard and Operability Study) method is technique used to identify the hazards on process facilities and prepare the system safety of potential hazards occurring in the operation. Even those who are not familiar with the hazards analysis process will often have heard of the term HAZOP, even if they are not really sure what it means. It has happened when the Process Safety Management (PSM) regulations in the United States were being promulgated in the early 1990s it was not unknown for a plant manager to say, "I know what PSM is, it's HAZOPs!" In fact the HAZOP method is just one of the many types of Process Hazards Analysis (PHA) techniques that are available, and PHAs are just one element of a PSM program. Nevertheless, these managers were somewhat justified in what they said because they knew that, unless they could identify the hazards on their facilities, they could not reduce risk. The goals of HAZOP are to figure out:
The potential hazards, especially the most dangerous ones for human being and environment
Some various operability problems in each process because of some deviations toward the design intent in plant, both active one or about to begin one. Furthermore, both regulators and legal advisors generally support the use of the
HAZOP technique because of its reputation and because it is so thorough. The use of the HAZOP technique is very defensible if a company is challenged regarding its safety performance, particularly in a legal dispute. As a result of its widespread use and acceptance, large numbers of process safety practitioners are now trained in the use of the HAZOP method, and many of those are also trained as leaders/facilitators. Furthermore, a substantial HAZOP infrastructure has developed. Many consulting companies offer HAZOP facilitation services special-purpose software.
Technique
A HAZOP is organized by dividing the unit to be analyzed into nodes. A node represents a section of the process where a significant process change takes place. For example, a node might cover the transfer of material from one vessel to another through a pump. In this case the process change is the increase in pressure and flow that occurs across the node. Another node might include an overhead air-cooler on a distillation column. Here
temperature and phase are the process variables that change. The HAZOP team would systematically examine a proposed process design by asking questions using guidewords representing deviations from the intended parameters of the process which can be seen in table below:
Table . Guide Words and the Meaning
Guide Words
Meaning
No or None
The negation of the intention (e.g.: no flow)
More
A quantitative increase (e.g.: high pressure)
Less
A quantitative decrease (e.g.: low pressure)
As Well As
In addition to (e.g.: impurity)
Part Of
A qualitative decrease (e.g.: only one of two components present)
Reverse
The opposite of the intention (e.g.: back flow)
Other Than
Complete substitution (e.g.: wrong material)
Table . Type of Problems Indication
Deviation
Typical Problems
No Flow
Blockage, pump failure, suction vessel empty, vapor lock, control failure, etc.
Reverse Flow
Pump failure, pump reversed, over pressurization, etc.
More Temp
Blockage, loss of control, reaction, explosion, valve closed, etc.
More Press Less Flow
Pump failure, leak, partial blockage, sediment, cavitation, etc.
Less Temp
Heat loss, vaporization, leak, imbalance of input and output, etc.
Less Press As Well As
Presence of contaminants, e.g.: water, air, lubrication oil, etc.
Although the strength of the HAZOP method lies in its clear organization, it is important not to allow the analysis to become too rigid. If the team finds that it is talking about "Reverse Flow" even though the current guideword is "High Flow", the leader should probably let the discussion continue. If he or she were to postpone the discussion until the "right" guideword, the current thinking and creativity may be lost. On the other hand, the leader must also keep the discussion focused on the issue at hand, and should prevent too many digressions.
1.
Select a node, define its purpose and determine the process safe limits.
2.
Select a process guideword.
3.
Identify the hazards and their causes using the deviation guidewords.
4.
Determine how the hazard is "announced", i.e., how the operator knows a safe limit has been exceeded.
5.
Estimate the consequences (safety, environmental, economic) of each identified hazard.
6.
Identify the safeguards.
7.
Estimate the frequency of occurrence of the hazard.
8.
Risk rank the hazard, with and without safeguards.
9.
Develop findings and potential recommendations.
10. Move on to the next process guideword, or to the next node if the guideword discussion is complete.
Some mistakes might happen in assessing HAZOP are: 1. Failing to establish a "safe" environment for team members. 2. Consequences of events not carried to conclusion. 3. Taking unwarranted credit for 4. Too little credit given for safeguards 5. Making recommendations as specific as possible 6. Poor recording of HAZOPS 7. Failure to HAZOP start-up and shut-down procedures 8. Poorly up-dated P&IDs 9. A HAZOP is performed in lieu of properly executed design reviews 10. Wrong technique for system being.
Table . HAZOP Sheet for Weigh Tank
Weigh Tank
Deviation No.
Cause
Consequences The ingredients will run out earlier before they come into mixer
Guide Word
Parameter
1.
Less
Level
The amount of ingredients put into the weigh tank is too few
2.
More
Level
The amount of ingredients put into the weigh tank is too many
3.
Other Than Specification
Feed Ingredients
Wrong substance delivered and human error
Safeguards
Rechecking inspection/maintenance regime done by engineers to prevent any problems The ingredients will Rechecking be over capacity inspection/maintenance regime done by engineers to prevent any problems Possible reaction Reviewing Question will occur since it and Answer procedures will affect the work done by engineers to system of any solve the problems equipment
Action Required By designing the weigh tank with alarm for low level occurring
Action Assigned to Engineer
By designing the weigh tank with alarm for high level occurring
Engineer
By ensuring the engineers to distinguish each ingredients used
Engineer
Table . HAZOP Sheet for Energy Efficient Mixer 1
Energy Efficient Mixer 1
Deviation No. 1.
Guide Word
Parameter
Other Than Specification
Flow in (Feed)
Cause
Consequences
Safeguards
Action Required
The flow inlet has obstacle to go through mixer or even no flow coming in
The composition to mix the materials needed will be imperfect, not suitable toward the
Checking the materials coming to the mixer for batch system done by engineers
By designing the center flow control as well
2.
Other Than Specification
Flow out (Feed)
Wrong substance delivered and pollutant coming through the flow
3.
Less
Level
Mixture of ingredients needed is lower than the capacity of mixture tank
4.
More
Level
Mixture of ingredients needed is higher than the capacity of mixture tank
safety standard, and not fulfill the specification of market The composition to Checking the materials mix the materials coming to the mixer needed will be for batch system and imperfect, not the filter used suitable toward the safety standard, and not fulfill the specification of market Impeller in mixer Rechecking will run faster then inspection/maintenance there will be regime done by friction between engineers to prevent impeller and mixer any problems and economic loss The overcapacity of Rechecking tank will be hard to inspection/maintenance make impeller run regime done by and economic loss engineers to prevent any problems
Action Assigned to Engineer
By designing the optimal performance of the filter
Engineer
By ensuring the capacity and composition of the mixture is suitable with the procedure
Engineer
By installing safety control where
Engineer
machine won’t be on
if overcapacity happens like alarm
Table . HAZOP Sheet for Grinding Machine
Grinding Machine
Deviation No. 1.
Guide Word
Parameter
Other Than
Flow in (Feed)
Cause
Consequences
Safeguards
Action Required
The mixture coming
The cutter in
Rechecking the
By ensuring the
Action Assigned to Engineer
2.
Other Than Specification
Flow out (Feed)
Wrong substance delivered and pollutant coming through the flow
3.
Less
Level
Mixture of ingredients needed is lower than the capacity of mixture tank
4.
More
Level
Mixture of ingredients needed is higher than the capacity of mixture tank
safety standard, and not fulfill the specification of market The composition to Checking the materials mix the materials coming to the mixer needed will be for batch system and imperfect, not the filter used suitable toward the safety standard, and not fulfill the specification of market Impeller in mixer Rechecking will run faster then inspection/maintenance there will be regime done by friction between engineers to prevent impeller and mixer any problems and economic loss The overcapacity of Rechecking tank will be hard to inspection/maintenance make impeller run regime done by and economic loss engineers to prevent any problems
By designing the optimal performance of the filter
Engineer
By ensuring the capacity and composition of the mixture is suitable with the procedure
Engineer
By installing safety control where
Engineer
machine won’t be on
if overcapacity happens like alarm
Table . HAZOP Sheet for Grinding Machine
Grinding Machine
Deviation No. 1.
Guide Word
Parameter
Other Than
Flow in (Feed)
Specification
Cause
Consequences
Safeguards
Action Required
The mixture coming
The cutter in
Rechecking the
By ensuring the
from previous mixer tank is too hard to be cut and crushed to get paste form of paint or can
grinding machine is hard to run and motor of transfer will be broken fast
performance of equipment, standard operating system, and viscosity of the mixture coming from previous mixer tank
cutter in grinding machine is sharp and the mixture of ingredients has the best quality
be said it’s not
Action Assigned to Engineer
perfectly mixed Table . HAZOP Sheet for Energy Efficient Mixer 2
Energy Efficient Mixer 2
Deviation No.
Cause
Consequences
Safeguards
Action Required
The composition to mix the materials needed will be imperfect, not suitable toward the safety standard, and not fulfill the specification of market The composition to mix the materials needed will be imperfect, not suitable toward the safety standard, and not fulfill the specification of market
Checking the materials coming to the mixer for batch system done by engineers
By designing the center flow control as well
Checking the materials coming to the mixer for batch system and the filter used
By designing the optimal performance of the filter
Guide Word
Parameter
1.
Other Than Specification
Flow in (Feed)
The flow inlet has obstacle to go through mixer or even no flow coming in
2.
Other Than Specification
Flow out (Feed)
Wrong substance delivered and pollutant coming through the flow
Action Assigned to Engineer
Engineer
Specification
from previous mixer tank is too hard to be cut and crushed to get paste form of paint or can
grinding machine is hard to run and motor of transfer will be broken fast
performance of equipment, standard operating system, and viscosity of the mixture coming from previous mixer tank
be said it’s not
cutter in grinding machine is sharp and the mixture of ingredients has the best quality
perfectly mixed Table . HAZOP Sheet for Energy Efficient Mixer 2
Energy Efficient Mixer 2
Deviation No.
Action Assigned to Engineer
Cause
Consequences
Safeguards
Action Required
The composition to mix the materials needed will be imperfect, not suitable toward the safety standard, and not fulfill the specification of market The composition to mix the materials needed will be imperfect, not suitable toward the safety standard, and not fulfill the specification of market
Checking the materials coming to the mixer for batch system done by engineers
By designing the center flow control as well
Checking the materials coming to the mixer for batch system and the filter used
By designing the optimal performance of the filter
Engineer
By ensuring the capacity and composition of the mixture is suitable with the procedure
Engineer
By installing safety control where
Engineer
Guide Word
Parameter
1.
Other Than Specification
Flow in (Feed)
The flow inlet has obstacle to go through mixer or even no flow coming in
2.
Other Than Specification
Flow out (Feed)
Wrong substance delivered and pollutant coming through the flow
3.
Less
Level
4.
More
Level
Mixture of ingredients needed is lower than the capacity of mixture tank and operator error Mixture of ingredients needed is higher than the capacity of mixture tank and operator error
Impeller in mixer Rechecking will run faster then inspection/maintenance there will be regime done by friction between engineers to prevent impeller and mixer any problems and economic loss The overcapacity of Rechecking tank will be hard to inspection/maintenance make impeller run regime done by and economic loss engineers to prevent any problems
machine won’t be on
if overcapacity happens like alarm and drain valve to purge the higher mixture of solvent and previous mixture
Table . HAZOP Sheet for Pump
Pump
Deviation No. 1.
Guide Word
Parameter
Less
Level
Cause
Consequences
Safeguards
Action Required
The flow inlet is too low then there will also be air coming in to the pump and operator error
Pump failure and cavitation occurs
Rechecking inspection/maintenance regime done by engineers to prevent any problems
By designing the level alarm system and installing gas detector
Action Assigned to Engineer
3.
Less
Level
4.
More
Level
Mixture of ingredients needed is lower than the capacity of mixture tank and operator error Mixture of ingredients needed is higher than the capacity of mixture tank and operator error
Impeller in mixer Rechecking will run faster then inspection/maintenance there will be regime done by friction between engineers to prevent impeller and mixer any problems and economic loss The overcapacity of Rechecking tank will be hard to inspection/maintenance make impeller run regime done by and economic loss engineers to prevent any problems
By ensuring the capacity and composition of the mixture is suitable with the procedure
Engineer
By installing safety control where
Engineer
machine won’t be on
if overcapacity happens like alarm and drain valve to purge the higher mixture of solvent and previous mixture
Table . HAZOP Sheet for Pump
Pump
Deviation No. 1.
Guide Word
Parameter
Less
Level
Cause
Consequences
Safeguards
Action Required
The flow inlet is too low then there will also be air coming in to the pump and operator error
Pump failure and cavitation occurs
Rechecking inspection/maintenance regime done by engineers to prevent any problems
By designing the level alarm system and installing gas detector
Action Assigned to Engineer
Table . HAZOP Sheet for Paint Filling Machine
Paint Filling Machine
Deviation No.
Guide Word
Parameter
1.
Less
Level
2.
No
Level
Cause
Consequences
The flow inlet has The product is not obstacle to go complete and can through mixer from danger the safety previous mixer tank also can distract the and operator error next process and even economic loss since the target of production is not achieved Distraction of Economic loss as stream in belt the production conveyor because stops from this spot the pollutant stuck to the downstream in wheel of production conveyor
Safeguards
Action Required
Rechecking By ensuring the final inspection/maintenance capacity of products, regime and feed automatically flowing has been processing the completed previous stream, and reviewing the upstream equipment done by supervisor Checking the belt conveyor in a good condition to use
By doing daily inspection to all belt conveyors after production has finished
Action Assigned to Engineer, Technician
Technician
Table . HAZOP Sheet for Automatic Packaging Machine
Automatic Packaging Machine
Deviation No. 1.
Guide Word
Parameter
Other Than Specification
Tin Feed
Cause
Consequences
The tin can be broken or not qualify the standard from the vendor as long as the delivery
The product will be off spec, not qualify the standard operating system, and can affect the
Safeguards
Action Required
Rechecking By ensuring the inspection/maintenance product coming out regime of tin will be of the machine and suitable toward the mapping the off spec specification product (separation)
Action Assigned to Engineer, Technician
Table . HAZOP Sheet for Paint Filling Machine
Paint Filling Machine
Deviation No.
Guide Word
Parameter
1.
Less
Level
2.
No
Level
Cause
Consequences
The flow inlet has The product is not obstacle to go complete and can through mixer from danger the safety previous mixer tank also can distract the and operator error next process and even economic loss since the target of production is not achieved Distraction of Economic loss as stream in belt the production conveyor because stops from this spot the pollutant stuck to the downstream in wheel of production conveyor
Safeguards
Action Required
Rechecking By ensuring the final inspection/maintenance capacity of products, regime and feed automatically flowing has been processing the completed previous stream, and reviewing the upstream equipment done by supervisor Checking the belt conveyor in a good condition to use
By doing daily inspection to all belt conveyors after production has finished
Action Assigned to Engineer, Technician
Technician
Table . HAZOP Sheet for Automatic Packaging Machine
Automatic Packaging Machine
Deviation No. 1.
Guide Word
Parameter
Other Than Specification
Tin Feed
Cause
Consequences
The tin can be broken or not qualify the standard from the vendor as long as the delivery
The product will be off spec, not qualify the standard operating system, and can affect the
or loading process
safety of loading and inventory process The product will be off spec, not qualify the standard operating system, and can affect the safety of loading and inventory process Economic loss as the production stops from this spot to the downstream production
2.
Other Than Specification
Carton Feed
The carton can be broken or not qualify the standard from the vendor as long as the delivery or loading process
3.
No
Level
Distraction of stream in belt conveyor because the pollutant stuck in wheel of conveyor
Safeguards
Action Required
Rechecking By ensuring the inspection/maintenance product coming out regime of tin will be of the machine and suitable toward the mapping the off spec specification product (separation)
Rechecking By ensuring the inspection/maintenance product coming out regime of tin will be of the machine and suitable toward the mapping the off spec specification product (separation)
Checking the belt conveyor in a good condition to use
By doing daily inspection to all belt conveyors after production has finished
Action Assigned to Engineer, Technician
Engineer, Technician
Technician
or loading process
2.
Other Than Specification
Carton Feed
The carton can be broken or not qualify the standard from the vendor as long as the delivery or loading process
3.
No
Level
Distraction of stream in belt conveyor because the pollutant stuck in wheel of conveyor
safety of loading and inventory process The product will be off spec, not qualify the standard operating system, and can affect the safety of loading and inventory process Economic loss as the production stops from this spot to the downstream production
Rechecking By ensuring the inspection/maintenance product coming out regime of tin will be of the machine and suitable toward the mapping the off spec specification product (separation)
Checking the belt conveyor in a good condition to use
By doing daily inspection to all belt conveyors after production has finished
Engineer, Technician
Technician
References
Chemical Industries Health and Safety Council. 1977. Hazard and Operability Studies. London: Chemical Industries Association. Lees, F. P. 1981. Some Features of and Activities in HAZOP Studies. The Chemical Engineer. Kletz, T. A. 1986. Notes on the Identification and Assessment of Hazard . London: The Institution of Chemical Engineers.
References
Chemical Industries Health and Safety Council. 1977. Hazard and Operability Studies. London: Chemical Industries Association. Lees, F. P. 1981. Some Features of and Activities in HAZOP Studies. The Chemical Engineer. Kletz, T. A. 1986. Notes on the Identification and Assessment of Hazard . London: The Institution of Chemical Engineers.