HAZOP STUDY
Hazop Analysis of Hydrolysis Reactor
Project
Hazop Study on the Hydrolysis
Reactor
Node
1
Parameter
Guide Word
Deviations
Equipment
Hydrolysis Reactor(R-110)
Stream
S1010
Causes
Consequences
There may be a
failure of pump
Decrease in
reaction rates
and conversion
Flow Rate
NO
LESS
MORE
no flow rate
low flow rate
Valve may be
partially closed
Failure of system
control
Increase in
reaction rates
and conversion
low
temperature
Pre-cooler
controller is not
working properly
Desired
conversion
cannot be
achieved
high
temperature
Pre-cooler
controller is not
working properly
low pressure
Pressure controller
failed
high flow rate
Temperature
LESS
MORE
Pressure
LOW
Decrease in
reaction rates
and conversion
HIGH
high pressure
Pressure controller
failed
Reactor can be
exploded due to
overheating
Results in
different
composition of
product
Results in
different
composition of
Safeguard
Apply operating
standards and
operating
procedures for
system start-up
Check temperature
regularly
Check pressure
regularly
Hazop Analysis of Catalytic Reactor
Project
Hazop Study on the Catalytic
Reactor
Node
2
Parameters
Guide
Equipment
Stream
Deviation
Catalytic Reactor (R-200)
S-1550
Cause
Consequence
Safeguard



words
No Flow

No
No availability
Reaction will
Visual
of feed
not take
inspection of
Feed line is
place, as a
pipelines
ruptured
result

Flow
eventually
detectors to
auto thermal
be installed
operation of
in pipelines
reactor
system will
shutdown
Low Flow
Flow rate

Low

Due to line

Operational

Periodic
clogging or
conditions
maintenance
leakage(s) in
are not
of control
line
anymore
valves
Low pressure at
maintainable
delivery end

Reaction
rate also
reduces
down
High Flow

More opened
control valve
High

Reaction

Proper
temperature
maintenance
decreases
of control

down due to
valves and
less space
flow
time
indicators
Reactants

Control
conversion
switch
also gets
installation
lower
High Pressure

High
Supply at

Reactor

Relief valve
higher pressure
lining
should be
from
rupture
installed
compressing

unit
Catalyst
structure
rupturing
Pressure
Low Pressure

Low
Temperature

Results in

Carry out
decreases and
decline of
routine
causes the
process
maintenance
operating
quality

conditions to
Safeguard
are sufficient
be incorrect
High Temperature


Malfunction of

Hotspot
quench box

Thermal
temperature
runaway
and flow
Catalyst
alarm alert
deactivation
operator
Clogging of
quench nozzle
High

or pipeline

Chamber not

sufficiently
cooled
Temperature
Reduces rate
of reaction

Favours
reverse
reaction

Install high

Catalyst
structure
rupture
Low Temperature
Low

Reduce flow

Catalyst
clogging


Process

Install
stops
temperature
Reduces the
indicator
rate of
and sensors
reaction

None

No reactant

flow
or
Malfunctioning
conversion
of quenching or

inlet valve
Low rate of reaction
Reaction

Controller fails

and closes
Less
No reaction
valve


Install check
valve

Installation
Reaction
of flow
stop
meters
Reaction

Proper
incomplete
maintenance
Catalyst
and

Pipe blockage
particles
operator

Catalyst
may be
alert
distribution
damaged or

deactivated
Visual
inspection of
pipelines
Fast rate of reaction

Control valve

failure
More

Intense

Periodic
reaction
maintenance
Heat
of control
to take action
generation
valves
on alarm
resulting in
operator fails

explosion

Reactor
damage


Channelling
None

Low flow rates

Conversion

Flow rates of
of liquid and
lower than
liquid and
vapour
standard
vapour
Restricts the
should be
distribution
interaction
maintained
from distributor
between
according to
Rapid
liquid and
operating
temperature
gas resulting
conditions
variation across
in decrease
mentioned
reactor
in mass
in SOP
Uneven liquid

transfer