【Equipment Reliability Improvement】HAZOP analysis (i.e., Hazard and Operability Analysis) of the storage tank system to identify potential risks
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Since July, Yangzi Petrochemical has carried out comprehensive inspections for potential hazards in its tank systems as well as HAZOP analyses. As of December 20, Yangzi Petrochemical had essentially completed the HAZOP analysis for all its storage tanks; a total of 448 tanks were analyzed, resulting in over 640 recommended measures. The safe and stable operation of tank farm systems is of utmost importance. In the second half of this year, the group company issued a special notice requiring enhanced efforts to address potential hazards in these tank areas, carry out safety risk assessments, and implement corrective measures for prevention. To this end, on the one hand, Yangzi Petrochemical carried out a thorough inspection of potential hazards in its tank systems, examining all of the company’s tanks and storage and transportation systems. A total of 717 potential hazard issues were identified, and these were addressed through corrective actions in accordance with the principles of categorized handling and hierarchical management. On the other hand, Yangzi Petrochemical has carried out comprehensive HAZOP analyses (that is, Hazard and Operability Studies) of its tank systems to identify potential risks. HAZOP analysis is a process hazard analysis method that is widely used in the global industrial sector today. It serves as an important tool and effective means for identifying potential accident risks in the field of hazardous chemicals and preventing major accidents. In collaboration with Qingdao Safety Engineering Institute, the company carried out independent HAZOP analyses on the gasoline storage tanks in the refinery and the liquefied gas storage tanks in the logistics department at the beginning of June, under the guidance of experts from the institute. The company also organized relevant technical personnel from units such as the olefin plant and the aromatic compounds plant to participate in training in order to gain experience in conducting such analyses. Starting in July, Yangzi Petrochemical carried out comprehensive HAZOP analyses on its storage tanks. As of December 20, the company had completed HAZOP analyses for 448 storage tanks, including 2 sets of cryogenic storage tanks ； A total of over 640 recommended measures were proposed. Among them, the two low-temperature storage tanks at Yangzi Petrochemical were built in 1995; although their process design met the safety standards of that time, it still falls short compared to the current latest standards. In this analysis, experts from Qingdao Safety Engineering Institute brought the latest safety standards to guide the technical staff in their work. Through these analyses, potential hazards and problems were identified and eliminated in a timely manner, which contributed to improvements in process management, equipment management, and production operation management. Through HAZOP analysis, Yangzi Petrochemical addressed the weak points in the tank system in a targeted manner, thereby improving the safe operation level of that system. (Tao Yan)
The common practice is at the initial stage of project design, after the PID is developed. Conduct a HAZOP analysis. Before driving, during the three checks and four verifications, review the HAZOP to ensure that the identified risks have been addressed through design, construction and installation, DCS interlock protection, operating procedures, etc. After starting up the operation, in light of the actual equipment conditions, processes, and DCS interlock changes, change management must be carried out to ensure proper risk identification and control. A comprehensive HAZOP review should be conducted every 5 years.
This is **Document 2014 116**, which stipulates that priority should be given to addressing two key aspects and one major issue. It also sets certain requirements regarding the safety functions of systems related to safety; analyses are required both for newly installed devices and those that are already in use
It is best to have a third party conduct a HAZOP, with the participation of competent designers and operational engineers. Ensure independence. Prevent project teams from subjectively lowering risk assessments in order to save money. It also avoids excessive design redundancy required by the operating department. Once the final report is finalized, all requirements must be implemented. If something goes wrong, there is a suspicion of dereliction of duty.
It would be great to have a complete HAZOP analysis report for a certain storage tank available, so that everyone can learn from it, draw inspiration from it, and even conduct an analysis of it
Yes, that’s better. You can search for it online; for now this is just a piece of information
Here is a sample you can take a look at: https://wenku.baidu.com/view/39ef7025e518964bcf847c70.html. And also this one: http://www.docin.com/p-1427448293.html
It’s funny to look at such formulaic HAZOP analysis texts – a bunch of people sitting there seriously, with loads of fancy wording related to HAZOP, but little evidence of them actually applying the requirements of HAZOP analysis to the review of corporate regulations, management processes, operational procedures and techniques, or emergency response plans... So I think it’s really pointless for Chinese companies to engage in activities like HAZOP, ISO9000, ERP, TPM, and the like; it’s just a form of unnecessary trouble-making!
Inventing tricks is a process; of course, it’s not good if one keeps coming up with tricks