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Abstract
This thesis is intended to provide guidance to HAZQP (Hazard and Operability) review teams associated with the petroleum and chemical industries. It describes the nature, responsibilities, method and d9cumentation required in the performance of this review to ensure that it is conducted in a timely, effective and professional manner.
HAZOP technique is the most common petrochemical industry qualitative methods used to conduct process hazard analyses, the process hazard analysis guide us to identify hazard, or accident, scenarios that may be possible for a process and could result in injuries to people (employees or the public), environmental impact, etc. Other process hazard analysis methods are used such as What-If, Checklist, Fault Tree Analysis, Event Tree analysis, Failure Mode and Effects Analysis.
The typical HAZOP review is usually intended to be a formal safety audit review of an ”essentially” complete project design or modification to ensure that the probabilities or consequences of major incidents have been eliminated or reduced to acceptable levels prior to being placed in service. HAZOP review is not intended to replace or duplicate a project design review. Unusually complex or large projects may require several levels of a HAZOP review during their design phase. These may be initiated at the conceptual design stage, preliminary design, detailed design, and at the final design. Such levels are usually encountered in multi-million dollar offshore facilities, refinery, or chemical processing plant projects where major changes occurring later in the design would be severe in economic and s~hedule terms. These multi-level reviews start at a broad viewpoint and gradually narrow to specifics just as the project design proceeds. Where operating procedures are not available during the design, a supplemental HAZOP review may be considered for these documents.
The theoretical part in this thesis focus on Process hazard analysis (PHA) which is a key requirement of OSHA’s Process Safety Management (PSM) and its six methods. and the accident scenarios reasons that may be missed by PHA. Then the HAZOr technique will be discussed in details.
The practical part in this thesis discusses HAZOP through complete analysis of the Piping and Instrument Diagram (P&ID) of the process plant which is a main document used in a HAZOP study. This HAZOP study was carried out for two important petrochemical processes, one is Ethylene Dimerization to Form Butene-l while the other is Ethylene Polymerization’to form Polyethylene during operation to ensure that plant emergency and operating procedures are regularly reviewed and updated as requi’red.
The practical part in this thesis was done for Sidi Kerir Petrochemicals company (SIDPEC ),Egypt .SIDPEC is an Egyptian jpint stock company established on November 16, 1997 under Egyptian investment law. It is an adding value to local natural gas reserves in Egypt and promoting petrochemicals development. SIDPEC produce 225,000 Ton polyethylene /Year includes Linear Low Density Polyethylene (LLDPE) and High Density Polyethylene. (HDPE) under British Petroleum (BP)chemicals technology &license and Institut Fran~ais du Petrol (IFP) technology & license
On completion of this HAZOP study the likely outcomes are:
• Gives a clear view about Hazards and Consequences of the selected units of tl1 plant.
• Some improvements in operating procedures, control programs and instructiOi which may already have been implemented together with minor (low cost) hardware alterations. These will have been put in hand as parts of the study ar, completed;
•The team members will already have both a better understanding of the plant process and a better q.ppreciation of potential hazards and risks than if the stud had not been carried out .