ASSIGNMENT
Group Members:
5 Junaid Ur Rahman 2016-Ch-734
Muhammad Usman 2016-Ch-739
Muhammad Sufyan 2016-Ch-730
Muhammad Sajid 2016-Ch-738
10 Submitted To:
Dr. Waqas Aleem
Subject:
Engineering Maintenance
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“APPLICATION OF HAZOP & FMEA ON GASIFIER”
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MUHAMMAD NAWAZ SHARIF UNIVERSITY OF ENGINEERING
AND TECHNOLOGY, MULTAN.
Hazard & Operability Analysis (HAZOP)
Overview To HAZOP:
Hazard and Operability Analysis (HAZOP) is a structured and systematic technique for
5 system examination and risk management. In particular, HAZOP is often used as a
technique for identifying potential hazards in a system and identifying operability
problems likely to lead to nonconforming products. HAZOP is based on a theory that
assumes risk events are caused by deviations from design or operating intentions.
Identification of such deviations is facilitated by using sets of “guide words” as a
10 systematic list of deviation perspectives. This approach is a unique feature of the HAZOP
methodology that helps stimulate the imagination of team members when exploring
potential deviations.
As a risk assessment tool, HAZOP is often described as:
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A brainstorming technique
A qualitative risk assessment tool
An inductive risk assessment tool, meaning that it is a “bottom-up” risk
identification
20 approach, where success relies on the ability of subject matter experts (SMEs) to
predict deviations based on past experiences and general subject matter expertise.
When describing the HAZOP methodology, the following definitions 1 are useful:
25 Hazard: Potential source of harm. Deviations from design or operational intent may
constitute or produce a hazard. Hazards are the focus of HAZOP studies, and it should be
noted that a single hazard could potentially lead to multiple forms of harm.
Harm: Physical injury or damage to the health of people or damage to property or the
30 environment. Harm is the consequence of a hazard occurring and may take many forms:
patient or user safety, employee safety, business risks, regulatory risks, environmental
risks, etc.
Risk: Combination of probability of occurrence of harm and the severity of that harm. In
35 a strict sense, “risk” is not always explicitly identified in HAZOP studies since the core
methodology does not require identification (also referred to as rating) of the probability
or severity of harm. However, risk assessment teams may choose to rate
Usage
40 HAZOP is best suited for assessing hazards in facilities, equipment, and processes
and is capable of assessing systems from multiple perspectives:
Design:
1. Assessing system design capability to meet user specifications and safety standards
2. Identifying weaknesses in systems
5 Physical and operational environments:
o Assessing environment to ensure system is appropriately situated, supported,
serviced, contained, etc.
Operational and procedural controls:
10 Assessing engineered controls (ex: automation), sequences of operations,
procedural controls (ex: human interactions) etc.
Assessing different operational modes – start-up, standby, normal
operation, steady & unsteady states, normal shutdown, emergency shutdown,etc
HAZOP guide words are key supporting elements in the execution of a HAZOP analysis.
According to IEC Standard 61882:
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“The identification of deviations from the design intent is achieved by a questioning
process using predetermined “guide words”. The role of the guide word is to stimulate
imaginative thinking, to focus the study and elicit ideas and discussion.”
25 Risk assessment teams are responsible for identifying the guide words that will best
suit the scope and problem statement for their analysis. Some common HAZOP
guide words include:
HAZOP Methodology:
5
The HAZOP analysis process is executed in four phases as illustrated below:
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HAZOP Application on Gasifier
Following HAZOP technique is applied to a biomass gasifier where gasification is
5 done to create a Syn-gas mainly containing CO and H2 & small amounts of CO2 .
Biomass gasifier contains 3 inlet streams, 1 st of biomass conveyed through a screw
conveyor, 2nd of Air conveyed through a heavy duty compressor, 3 rd of steam (main
heat source of gasifier) & 2 outlet streams, 1st of Ash content & 2nd of Syn-gas.
Main reactions include combustion reaction & water gas reaction
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HAZOP study mainly covers:
Parameters
Guide Words
15 Possible Cause
Possible Consequences
Additional Implications
Actions Requires
Safe Guard
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Following parameters are discussed under HAZOP study:
Temperature
Pressure
25 Flow Rate
Level
Composition
Residence Time
30 Parameter: Temperature
Parameter: Pressure
Parameter: Flow Rate
Parameter: Level
Parameter: Composition
5 Parameter: Residence Time
