m09 Batch Hazop

HAZOP Study of Batch Plants and Operations
Data Requirements
Definition of steps, including process conditions, agitation / mixing, charging,
reacting, discharging etc.
Interlocks in operation during step (e.g. valves held closed)
Necessary conditions to move to next step
Details of alarms, including watchdog timers
Det Norske Veritas AS. All rights reserved.
Preparations
Leader and some members should prepare before study to understand:
Hazards of the process
Control scheme, including sequence control
Cycle of operations and main process steps
Study sections to be used
Preparations
Leader must decide how to carry out the study, after preparing the following:
A matrix showing the process steps and the study sections, and showing which
section is active in which step
A chart showing which valves, drives, pumps and instruments are active in each
step of the process
Guidewords
The standard guidewords from Process HAZOP are used
Additionally, guidewords related to the following parameters are used:
- Time
- Step
- Action
Additional Guidewords: Time

NO TIME
Event or action missed altogether
MORE TIME
Event occurs after it should or takes longer time
LESS TIME
Event occurs before it should or takes shorter time
WRONG TIME
Event or action occurs when it should not
Additional Guidewords: Step

STEP TOO LATE
An input fault prevents step on
STEP TOO EARLY
Step on conditions met early
STEP LEFT OUT
Operator forgets a step
STEP BACKWARDS
Fault causes incorrect transfer to another step
Additional Guidewords: Step

STEP TOO LATE
An input fault prevents step on (= MORE TIME)
STEP TOO EARLY
Step on conditions met early (= LESS TIME)
STEP LEFT OUT
Operator forgets a step (= NO TIME)
STEP BACKWARDS
Fault causes incorrect transfer to another step

(= WRONG TIME)
Thus, guidewords associated with the parameter STEP can be addressed by TIME
Additional Guidewords: Action

PART ACTION
One sub-action in a step is missed
EXTRA ACTION
Operator includes an action from another step
WRONG ACTION
An aberration - needs serious brain storming
Procedure: Option 1 Step by Step

Consider 1st step, for all active sections, then all inactive sections
Use all guidewords for active sections, not for inactive sections, where becomes
active is the deviation
Take each step in turn and repeat this process
Identify and study other sections not in normal operation
10
Step by Step Method

1st Step
Take 1st Active Section
Complete Logsheet
No
Take next active
section
Last Active Section ?
Yes
Take other inactive sections
Complete Logsheet
Last Step ?
Yes
Finshed
11
Next
Step
Procedure: Option 2 Section by Section

Consider 1st section, for all steps:
- First for steps when it is active
- Then for others
Use all guidewords for active steps, not for inactive steps, where becomes active
is the deviation
Take each section in turn, and repeat this process
Identify and study other sections not in normal operation
12
Section by Section Method

1st Section
Take 1st Step in which

this section is active
Complete Logsheet
No
Take next step in
which
this section is
active
Last Step in which this

section is active ?
Yes
Take steps in which this
Section is not active
Complete Logsheet
Last Section ?
Yes
Finshed
13
Next
Section
Procedure: Which Option?

Consider matrix showing steps and sections:
If there are fewer steps, use step-by-step
If there are fewer sections, use section-by-section
If there are equal numbers of each, it does not matter which option you choose
14
Refrigerated Ship Loading: Batch HAZOP Example

XCV4
V281
T1
P1
Q.R.C.
10
150#
T1
V284
V282
1.5
10 Export Line
1.5
XCV3
V78
1
V280
V283
V80
V77
To Sea
e.g. Ammonia or LNG
8 Vapour Return Line
15
Analysis Matrix for Refrigerated Ship Loading

Steps
(1)
Cool Line
(2)
Connect
Arm
(3)
Cool Arm
Delivery Line
Recirculation
Line
Loading Arm
Sections
(4)
(5)
(6)
Load Ship Purge and Disconnect
Drain Arm
Arm
Which approach is recommended: section-by-section or step-by-step?

In what order should the steps be considered for each section?
16
Open/Closed Valves etc. for Refrigerated Ship Loading

Steps
(1)
Cool Line
(2)
Connect
Arm
(3)
Cool Arm
V77
V80
V78
V284
XCV3
V280
XCV4
V281
QRC
Conn
Conn
Conn
Conn
V282
V283
Valves etc.
(4)
(5)
(6)
Load Ship Purge and Disconnect
Drain Arm
Arm
O = Open; C = Closed; D = Disconnected; Conn = Connected
17
Batch Reactor HAZOP Example

Distillation
Column
Nitrogen Purge
Solvent A
Condenser
HV-1
Reactant B
PCV-1
HV-2
Reactant C
HV-5
Coolant in
TCV-2
Catalyst D
HV-3
AV-1
HV-7
Stirrer
AG-1
HV-4
Vacuum
Vent
Receiver
R2
Heating/cooling fluid
TCV-1
Distillate
Transfer
Batch
Reactor R1
P-3
HV-6
Product discharge to storage
P-1
P-2
PCV-2
Excess heating/cooling fluid discharge
Slide 18
HAZOP Procedure For Batch Units

VALVE/EQUIPMENT ITEM
PROCESS STEP
HV-1
HV-2
HV-3
HV-4
HV-5
HV-6
HV-7
PCV1
PCV2
AV-1
TCV1
TCV2
AG-1
P-1
P-2
P-3
Before start of batch
Off
Off
Off
Off
1. Nitrogen Purge
Off
Off
Off
Off
2. Charging Solvent A
Off
Off
Off
Off
3. Charging Reactant B
On
Off
Off
Off
4. Charging Reactant C
On
Off
Off
Off
5. Charging Catalyst D
On
Off
Off
Off
6. Heating
On
On
Off
Off
7. Pull Vac on Reactor
On
On
Off
Off
8. Distillation
On
On
Off
Off
9. Break vacuum
On
On
Off
Off
10. Cooling
On
On
Off
Off
11. Discharge Distillate
On
On
Off
On
12. Discharge Product
Off
Off
On
Off
Symbols used:
C = closed
O = open
M = modulating
Slide 19
HAZOP Procedure For Batch Units

PROCESS STEPS
STUDY SECTIONS
10
11
12
1. Nitrogen purge
2. Reactor
3. Jacket heating/cooling
4. Heating/cooling supply
5. Heating/cooling discharge
4. Solvent A
5. Reactant B
6. Reactant C
7. Vacuum system
8. Vent system
9. Catalyst D
10. Distillation Column & Condenser
11. Condenser coolant
12. Receiver
13. Distillate transfer system
14. Product Discharge system
circulation system
Det
Norske
Veritas
AS. All
rights
22 May
2013
Slide 20
Batch HAZOP Logsheet

Project:
Batch Reactor HAZOP
Node Description:
Step 1
Nitrogen Purge to reactor
Section
Nitrogen purging line to reactor (active for this step)
GUIDEWORD/
DEVIATION
No Flow
More
Pressure
Less Time
CAUSES
Node: 001
Page: 1
CONSEQUENCES
SAFEGUARDS
REC
#
RECOMMENDATION
R1
Provide a flowmeter in
the nitrogen supply line
to indicate nitrogen flow
to the reactor during
purging.
Bursting disc system on R2

reactor set at 3 Barg.
(not shown on
drawing).
Ensure that the nitrogen

supply pressure is below
1 Barg to prevent failure
of the reactor bursting
disc should the reactor
become
pressurised
with nitrogen.
Include in operating
procedures for Step 1
the time the reactor
must be purged with
nitrogen
for
before
proceeding to Step 2.
Manual valve closed No nitrogen supply to reactor.

or line blockage.
There no purging and potential
No nitrogen supply. flammable atmosphere in the
reactor when solvent is charged
(Step 2). Potential fire or
explosion if there is a source of
ignition.
Nitrogen supply
Possible overpressure of reactor,
pressure too high
distillation system and receiver
which could cause failure.
Operator knowledge
and training. Reliable
nitrogen supply.
Operator does not

purge reactor for
long enough.
As for No Flow
(above).
As for No Flow (above).
Det
Norske
Veritas
AS. All
rights
22 May
2013
R3
Slide 21

Project:
Node Description: Step 1

Section
GUIDEWORD/
DEVIATION
CAUSES
Reverse low Reacor manway

(Reactor)
open
Less Flow
(Vent Line)
Node: 002
Batch Reactor HAZOP
Page: 1

Reactor, Distillation line, condenser, receiver and vent line (all active for this step)
CONSEQUENCES
SAFEGUARDS
Discharge of nitrogen around

reactor area. Possible hazard to
operators if they are close to the
reactor
Standard pre-checks
for this process are that
reactor manway should
be bolted closed before
starting the nitrogen
purge.
Standard pre-checks
for this process are that
catalyst charge valve
should be closed
before starting the
nitrogen purge.
As before.
Operating procedures.
Catalyst charge
valve open.
As above.
Vent valve closed

during nitrogen
purging.
Inadequate purging with same

consequences as for No Flow
and More Pressure in Node 1
(i.e. inadequate purging and
increase in pressure in reactor
system).
Det
Norske
Veritas
AS. All
rights
22 May
2013
REC
#
RECOMMENDATION
Slide 22

Project:
Node: 003

Section
GUIDEWORD/
DEVIATION
More flow
(vacuum
line)

Other non-active sections in this step.
CAUSES
Vacuum valve PCV1 open when

purging reactor with
nitrogen.
Page: 1
CONSEQUENCES
SAFEGUARDS
Vacuum created in reactor and

increased purging flow. No
hazard.
Det
Norske
Veritas
AS. All
rights
22 May
2013
REC
#
RECOMMENDATION
Pressure gauge on
reactor.
Slide 23

Project:
Node: 001

Section
GUIDEWORD/
DEVIATION
CAUSES
No flow
Operator forgets to
charge solvent.
Valve blocked.
More time.
Operator error.
Batch meter set
incorrectly.
Wrong
Action
Operator error.
Wrong solvent
supply routed to
reactor.
Page: 2
Charging Solvent A to reactor

Solvent A feed line to reactor
CONSEQUENCES
SAFEGUARDS
No solvent transfer to reactor.

Potential exothermic reaction
when other eactants are heated
during the process. This would
cause loss of product (failed
batch).
Too much solvent added to
reactor. Reactor may be
overfilled when reactants are
added. Possible discharge of
reactants and solvent from the
catalyst charging connection
during Step 5.
Wrong solvent transferred to
reactor. Loss of product (failed
batch). Potential hazard of using
incorrect solvents not known.
Det
Norske
Veritas
AS. All
rights
22 May
2013
REC
#
RECOMMENDATION
R4
Provide
software
interlock on batch meter
for Solvent A to ensure
that
batch
quantity
cannot be exceeded.
Operator checks
solvent quantity added
on meter upsteam.
This is entered on the
batch record sheet.
Check
what
other
solvent
could
be
mistakenly added to the
reactor
and
check
whether these could
create a hazard if they
were used instead of
Solvent A.
Slide 24

Project:
Node: 005

Section
GUIDEWORD/
DEVIATION
Less flow
CAUSES
Reactor drain valve

open
Page: 1

Reactor (active during this step)
CONSEQUENCES
SAFEGUARDS
Solvent discharged from reactor

drain line. Inadequate solvent in
reactor. Possible effect on
reaction/product quality.
Operating procedues
and pre-start checks
that run out valve is
closed before adding
solvent. Solvent loss
would be small since P2 must be used to
remove material from
the reactor
Det
Norske
Veritas
AS. All
rights
22 May
2013
REC
#
RECOMMENDATION
Slide 25

Project:
Node: 005

GUIDEWORD/
DEVIATION
Section
CAUSES
Page: 1

Other non active sections
CONSEQUENCES
SAFEGUARDS
REC
#
RECOMMENDATION
No hazards identified.
Det
Norske
Veritas
AS. All
rights
22 May
2013
Slide 26
Safeguarding life, property

and the environment
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m09 Batch Hazop

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HAZOP Study of Batch Plants and Operations

Det Norske Veritas AS. All rights reserved.

Det Norske Veritas AS. All rights reserved.

Det Norske Veritas AS. All rights reserved.

Det Norske Veritas AS. All rights reserved.

Additional Guidewords: Time

Event or action missed altogether

Event occurs after it should or takes longer time

Event occurs before it should or takes shorter time

Event or action occurs when it should not

Det Norske Veritas AS. All rights reserved.

Additional Guidewords: Step

An input fault prevents step on

STEP TOO EARLY

Step on conditions met early

STEP LEFT OUT

Operator forgets a step

Fault causes incorrect transfer to another step

Det Norske Veritas AS. All rights reserved.

Additional Guidewords: Step

An input fault prevents step on (= MORE TIME)

STEP TOO EARLY

Step on conditions met early (= LESS TIME)

STEP LEFT OUT

Operator forgets a step (= NO TIME)

Fault causes incorrect transfer to another step

Det Norske Veritas AS. All rights reserved.

Additional Guidewords: Action

One sub-action in a step is missed

Operator includes an action from another step

An aberration - needs serious brain storming

Det Norske Veritas AS. All rights reserved.

Procedure: Option 1 Step by Step

Det Norske Veritas AS. All rights reserved.

Step by Step Method

Take 1st Active Section

Last Active Section ?

Det Norske Veritas AS. All rights reserved.

Procedure: Option 2 Section by Section

Det Norske Veritas AS. All rights reserved.

Section by Section Method

Take 1st Step in which

Last Step in which this

Det Norske Veritas AS. All rights reserved.

Procedure: Which Option?

Det Norske Veritas AS. All rights reserved.

Refrigerated Ship Loading: Batch HAZOP Example

e.g. Ammonia or LNG

Det Norske Veritas AS. All rights reserved.

8 Vapour Return Line

Analysis Matrix for Refrigerated Ship Loading

Which approach is recommended: section-by-section or step-by-step?

Det Norske Veritas AS. All rights reserved.

Open/Closed Valves etc. for Refrigerated Ship Loading

O = Open; C = Closed; D = Disconnected; Conn = Connected

Det Norske Veritas AS. All rights reserved.

Batch Reactor HAZOP Example

Det Norske Veritas AS. All rights reserved.

Excess heating/cooling fluid discharge

HAZOP Procedure For Batch Units

Before start of batch

7. Pull Vac on Reactor

11. Discharge Distillate

12. Discharge Product