Process Safety Analysis (HAZOP)
6 weeks · 0 milestones
Conduct a Hazard and Operability (HAZOP) analysis for a real or representative process section, applying the HAZOP methodology systematically to identify potential deviations, their causes, consequences, and safeguards. The analysis must cover: at least 2 process nodes (defined sections of the P&ID) with all relevant guide words applied to each parameter (flow, temperature, pressure, composition, level), a completed HAZOP worksheet for each node (deviation, cause, consequence, severity/likelihood rating, existing safeguards, and recommendations), identification of at least 3 significant hazard scenarios with unacceptable risk that require additional safeguards, and a safeguard recommendation table. The analysis must be based on a real or realistic P&ID — not a hypothetical system described in prose. Preferred proof: a HAZOP study conducted as part of a real project safety review. Accessible alternative: HAZOP of a publicly documented process (many published process engineering case studies include simplified P&IDs suitable for HAZOP exercises; IChemE publishes free guidance with example systems). The HAZOP methodology is fully documented in free HSE and CCPS guidance documents — no software license required. Proof artifacts: the HAZOP worksheet (analysis artifact) and the safeguard recommendation table (documentation artifact). Verification: a process safety engineer challenges the consequence assessment for the most severe scenario identified — 'you assessed this as a toxic release to atmosphere; have you considered the domino effect on adjacent equipment?' — requiring you to reason through your own hazard scenario.
Milestone map
Milestone map
3 milestones
Select a process engineering system suitable for a HAZOP (Hazard and Operability Study) analysis. Suitable systems include: a heat exchanger network (shell-and-tube heat exchanger with feed and product streams, cooling water circuit, and bypass); a simple chemical reactor system (continuous stirred tank reactor with feed, jacket cooling, and product streams); a distillation column with reboiler and condenser; a pump-and-pipeline system with control valves, check valves, and a receiver vessel; or a gas compression system. The system must have at least five process lines (streams) and at least two pieces of major equipment. Produce a Process Flow Diagram (PFD) showing: all major equipment (with equipment tag numbers), all process streams with flow direction, the key process parameters at each stream (temperature, pressure, flow rate, composition if relevant), and the control philosophy (which parameters are controlled and how). Free tool: draw.io with the engineering shape library.
Proof required
Submit: (1) the Process Flow Diagram (PFD) with equipment tags, stream labels, and process parameter annotations (draw.io export or equivalent); (2) a design intent statement for the system (200–300 words) covering: what the system is designed to do, the key process parameters it operates at (normal operating temperature, pressure, flow), and the key safety constraints (maximum allowable working pressure, maximum temperature, minimum flow to prevent cavitation or dry running); (3) a stream table listing all process streams with their normal operating conditions.
What gets checked
- PFD includes equipment tag numbers for all major equipment — 'HX-101 (shell-and-tube heat exchanger)' and 'P-101 (feed pump)' are valid tags; unlabelled boxes are not engineering drawings
- Stream table lists at least temperature, pressure, and flow rate for all named streams — a stream table with only stream names and no operating conditions has not captured the design intent
- Design intent statement specifies the maximum allowable working pressure (MAWP) or maximum operating temperature as a safety constraint — these are the parameters that HAZOP deviations will be assessed against