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Study Node: Oxidation Reactor Process : Oxidation of p-xylene to Terephthalic Acid
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Hazard and Operability Analysis example.Full description
HAZOP STUDY FOR UNLOADING OF 98% SULPHURIC ACID FROM ROAD TANKER TO S TORAGE TANK SYSTEM NODE A ROAD TANKER TO TRANSFER PUMP Sr No
Guide W ord
Deviation
DATE
24-Jun-10
Probable Causes
Possible Consequences
PLACE: ETP CONTROL ROOM Safeguard Provided
Recommendation
Valve not opened on road tanker
No Hazard. The pump shall cavitate.
Visual monitoring by operator
SOP controlled. Point to be checked in checklist
PRESSURE ( Vaccum) Less
Vent valve choked or closed
Implosion of the tank
SOP/Checklist provided
SOP to contain vent checking- ensure vent is opened and there is no choking of vent. If vent is choked it has to be cleared first.
3
TEMPERATURE
More/Less
--N/A--
No hazard
--N/A--
--N/A--
4
LEVEL
More/Less
--N/A--
No hazard
--N/A--
--N/A--
5
MATERIAL Occurrence of Exothermic INCOMPATIBILITY/ Reaction CHEMICAL REACTION
SOP/ SOP/LA LAB B Res Resul ultt ver verif ific ica atio tion
This This point oint to be cove covere red d in chec checkl klis istt
Eyeshower provided, emergency stop of the pump provided, secondary containment with acid proof dyke constructed.
SOP to include shutdown of transfer of pump from remote breaker during emergency as the START/STOP in the field is cl ose to the pump and the operating personnel may get exposed to acid during accidental release. A leak test with N 2 is recommended on the suction side prior to each transfer and corresponding piping provision be constructed.
1
FLOW
2
6
LEAKAGES
SYSTEM
7
No
Occurrence of leakages
Flanges not suitably bolted, gaskets missing, Spillage of Acid. incompatible transfer hose material, faulty hose
TRANSFER PUMP TO STORAGE TANK
NODE B
FLOW
Heat generations, exothermic Wrong material offloading chemical reaction, from tanker contamination
More
Leakage of discharge line Spillage of Acid.
Pump shutdown from MCC
SOP to cover in Emergency Handling
PAGE 1 OF 2
Sr No
Guide Word
Deviation
Probable Causes
Possible Consequences
Safeguard Provided
8
FLOW
Reverse
Back Pressure/Over Pressure from storage tank
Flow back into road tanker
9
PRESSURE
High
Inlet solenoid valve to tank closed. Discharge Manual Valve at pump discharge closed
Pipe work and its accessories to be subjected to s hutoff head SOP/Checkllist controlled off the centrifugal transfer pump. No hazard
FIRE
--N/A--
No hazard
10
11
EMERGENCY
Overflow, Spillages & Leakages
Kailash Prakash Pandey
Unmesh Biswas
Voduri Rama Rao
Neeraj Gupta
Personnel Injury from acid fumes and direct contact. Loss of material.
Non return valve present at pump discharge
Recommendation
--N/A--
Operator to monitor the discharge pressure of the pump for preventing the pump running at shutoff head during transfer.
Fire hydrant present in the vicinity
--N/A--
Usage of appropriate PPE for the personnel, Acid Proofed Dykes, Eye shower.
Road barricading to be done during transfer to prevent vehicle movement, Man movement to be controlled to only authorised trained personnel.