In this presentation are shown the basic concepts related to Hazard and Operability Studies for chemical processes and Material Safety Data Sheets

1. HAZARD & OPERABILITY STUDY (HAZOP) &
MATERIAL SAFETY DATA SHEET (MSDS)
1
PROCESS ENGINEERING

2. HAZOP & MSDS
IRIS BUSTAMANTE PÁJARO*
ANGIE CASTILLO GUEVARA*
ALVARO JOSE GARCÍA PADILLA *
KARIANA ANDREA MORENO SADDER*
LUIS ALBERTO PATERNINA NUÑEZ*
9th SEMESTER
CHEMICAL ENGINEERING PROGRAM
UNIVERSITY OF CARTAGENA
2
PROCESS ENGINEERING

3. 3
HAZOP&MSDS
OUTLINE
1. Introduction
2. HAZOP
2.1. Definition
2.2. HAZOP procedure
2.3. Factors
2.4. Advantages
2.5. Disadvantages
3. MSDS
3.1. Definition
3.2. Sources
3.3. Typical sections
3.4. Pictograms
3.5. Example
Conclusion
Acknowledgements
HAZARD & OPERABILITY STUDY & MATERIAL SAFETY DATA
SHEET
"Good, better, best. Never let it rest. 'Til your good is better and your better is best." - St. Jerome

4. 4
HAZOP&MSDS
INTRODUCTION
HAZOP
Most widely used process
hazards analysis technique in the
chemical process industries.
Importance:
May help avoid problems and save lives and/or business expenses
Provide analysis and details about hazards or errors in a system design
Chemical engineer, job duties:
Evaluate equipment and processes to ensure compliance with safety and
environmental regulations
Turton et al., 2009

5. 5
HAZOP&MSDS
INTRODUCTION
Important resource for workers to learn more
about the product(s) used
Chemical engineer, job duties:
Manufacturing processes involve the manipulation of chemical with which
physical and chemical transformations are carried out.
MATERIAL SAFETY DATA SHEET
Essential for the development of a complete
health and safety program

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HAZOP&MSDS
DEFINITION
HAZARD & OPERABILITY STUDY (HAZOP)
Definition Reference
Systematic technique for identifying all plant or
equipment hazards and operability problems
Peters &
Timmerhaus,
1991
Formal procedure to identify hazards in a chemical
process facility
Daniel et al.,
2002
Modified brainstorming technique for identifying and
resolving process hazards by considering seemingly
unusual occurrences.
Turton et al.,
2009
Table 1. HAZOP concepts for different authors

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HAZOP&MSDS
DEFINITION
HAZARD & OPERABILITY STUDY (HAZOP)
Outside-the-box technique Focuses early on the more
probable failure scenarios
Useful in identifying human
factors that can contribute to
system failures
Let the mind go free
When to use it?
The best time is when the design is fairly firm

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HAZOP&MSDS
INFORMATION REQUIRED
PFDs P&IDs
Equipment specifications Mass & energy balance

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HAZOP&MSDS
HAZOP PROCEDURE
Select unit of
process
Choose a study
node
Describe design
intent
Vessel
Pipeline
Operating instructions
Vessel V-1 is
designed to store the
benzene feedstock
and provide it on
demand to the reactor
Reactor
Storage tank

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HAZOP&MSDS
HAZOP PROCEDURE
Pick up process
parameter
Apply a guide word
to parameter
Possible causes &
protective systems
Flow
Level
Temperature
Pressure
Concentration
pH
Viscosity
State
Agitation
Volume
Reaction
Sample
Component
Stability
Power
Inert
No, not, none
More, greater
Less, lower
As well as
Part of
Reverse
Other than
Sooner than
Later than
Where else
Hardware failures
Human errors
Unanticipated
process state
Example: Change of
composition
External disruptions
Example: Loss of
power
Example: Higher
temperature, backflow

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HAZOP&MSDS
HAZOP PROCEDURE
Guide Words used for the HAZOP Procedure
Guide words Meaning Comments
No, Not, None The complete
negation of the
intention
No part of the design intention is
achieved, but nothing else
happens.
More, Greater Quantitative increase Applies to quantitates such as
flow rate and temperature and to
activities such as heating and
reaction.
Less, Lower Quantitative
decrease
As well as Qualitative increase
All the design and operating
intentions are achieved along
with some additional activity,
such as contamination of
process streams.
Table 2. HAZOP guide words and meanings
Daniel et al., 2002

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HAZOP&MSDS
HAZOP PROCEDURE
Guide words Meaning Comments
Part of Qualitative decrease Only some of the design intentions
are achieved, some are not.
Sooner than Too early or in the
wrong order Applies to process steps or actions
Later than Too late or in the
wrong order
Reverse The logical opposite
of
Most applicable to activities such
as flow or chemical reaction
Other than Complete
substitution
No part of the original intention is
achieved
Where else In additional
locations
Applies to process locations in
operating procedures
Table 2. HAZOP guide words and meanings (continuation)
Daniel et al., 2002

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HAZOP&MSDS
HAZOP PROCEDURE
Table 3. Process parameters and valid guide words
Daniel et al., 2002
Valid guide word for Process Lines and vessels
Lines
Vessels

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HAZOP&MSDS
HAZOP PROCEDURE
Evaluate the
consequences
Recommend an
action
Record all
information
These are the results
of the deviations
should they occur
Example: release of
toxic materials
Trivial consequences,
relative to the study
objective, are dropped
The action to be taken
is assigned by the
HAZOP team.

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HAZOP&MSDS
HAZOP PROCEDURE
HAZOP form for recording all information
Daniel et al., 2002
Project name: Date: Page of
Completed:
No actions:
Replay date:Reference drawing:Section:
Process:
Item
Study
node
Process
parameters
Deviations
(guide words)
Possible
causes
Possible
consequences
Action
required
Assigned
to:

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HAZOP&MSDS
HAZOP PROCEDURE
Daniel et al., 2002
Case of study
Cooling coils
Reactor
TC
Thermocouple
Monomer
feed
Cooling
water out
Cooling
water in
The reaction is
exothermic, so a cooling
system is provided to
remove the excess
energy of reaction.
Perform a HAZOP study
on this unit to improve
the safety of the
process.
Use as study nodes the
cooling coil (process
parameters: flow and
temperature) and the
stirrer (process
parameter: agitation).

17. HAZOP&MSDS
HAZOP PROCEDURE
Case of study

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HAZOP&MSDS
FACTORS
The success or failure of the HAZOP depends on:
The completeness and accuracy of drawings and other
data used as a basis for the study
The technical skills and insights of the team
The ability of the team to use the approach as an aid to
their imagination in visualizing deviations, causes, and
consequences
The ability of the team to concentrate on the more
serious hazards which are identified

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HAZOP&MSDS
ADVANTAGES
The HAZOP team utilizes operational experience
The process covers safety as well as operational aspects
As a systematic process it provides rigor for focusing on
system elements and hazards
HAZOP covers human errors
For team members the process is easily learned and
performed

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HAZOP&MSDS
DISADVANTAGES
A HAZOP focuses on single events rather than
combinations of possible events
The HAZOP focus on guide-words allows it to overlook
some hazards not related to a guide-word
Training is essential for optimum results, especially for
the facilitator
HAZOPs are typically very time consuming and thus
expensive

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HAZOP&MSDS
DEFINITION
MATERIAL SAFETY DATA SHEET
One of the most important references used during an industrial hygiene
study involving toxic chemicals
What is a MSDS?
MSDS is a document that contains
information on the potential hazards
(health, fire, reactivity and environmental)
and how to work safely with the chemical
product.
The industrial hygienist or safety professional must interpret the
physical and toxicological properties to determine the hazards
associated with a chemical.
Daniel et al., 2002

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HAZOP&MSDS
SOURCES
WHERE TO FIND A MSDS?
Chemical
manufacturer
Daniel et al., 2002
Commercial
source
Private library developed
by the chemical plant

23. HAZOP&MSDS
SOURCES
MATERIAL SAFETY DATA SHEET ON INTERNET

24. HAZOP&MSDS
SOURCES
MATERIAL SAFETY DATA SHEET ON INTERNET

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HAZOP&MSDS
TYPICAL SECTIONS
MATERIAL SAFETY DATA SHEET SECTIONS
Turton et al., 2009
Material and manufacturer identification
Hazardous ingredients/identity information
Physical/Chemical characteristics
Fire and explosion hazard data
Reactivity data
Health hazard data
Precautions for safe handling and use
Control measures

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HAZOP&MSDS
PICTOGRAMS
HAZARD COMUNICATION STANDARD PICTOGRAMS
Source: www.osha.gov/Publications/HazComm_QuickCard_Pictogram.html

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HAZOP&MSDS
PICTOGRAMS
NFPA DIAMOND
Source: www.osha.gov/Publications/HazComm_QuickCard_Pictogram.html

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HAZOP&MSDS
EXAMPLE

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HAZOP&MSDS
EXAMPLE

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HAZOP&MSDS
EXAMPLE

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HAZOP&MSDS
EXAMPLE

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HAZOP&MSDS
EXAMPLE

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HAZOP&MSDS
EXAMPLE

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HAZOP&MSDS
EXAMPLE

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HAZOP&MSDS
EXAMPLE

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HAZOP&MSDS
EXAMPLE

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HAZOP&MSDS
EXAMPLE
MSDS available on: www.sciencelab.com

38. HAZOP&MSDS
CONCLUSION
38
HAZOP study offers at the end of
the activity, knowledge, obtained by
identifying potential hazards and
operability problems in a structured
and systematic manner, is of great
assistance in determining
appropriate remedial measures.
MSDS informs about the hazards of
the product, how to use the product
safely, what to expect if the
recommendations are not followed,
what to do if accidents occur, how
to recognize symptoms of
overexposure, and what to do if
such incidents occur
Source: www.wiseweek.com

39. THANKS !
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