A Hazard and Operability Study (HAZOP) on Continuous Stirring Tank with

Recycling in Fermenter
Company: University of San Agustin

Facility: Continuous Stirring Tank with Recycling in Fermenter

Parameter: Water Flow

Deviation Causes Consequences Safeguards Recommendations
No Pump Failure. Potential pipe Valves are visible Consider modifying the Standard
failure from the control room Operating Procedure to
Manual valve keep the containment isolation
closed Potential slip Standard Operating valve closed
hazard Procedure
Closed block Install flow meters
valve anywhere Flowing water from tan
in water piping ker makes audible
sound
Low Line Blockage Prolonged Clear blockage Install flow meters
treatment
process
Failure of a Increase pump pressure Consider relocating tank isolation
flexible coupling valves from the piping to directly
at one of the on the tank, upstream of
tank connections the flexible coupling
Backflow Check valve Loss of Cooling Install Check Bulb Consider modifying the Standard
failure Operating Procedure to
Possible
Tank Capacity Runaway
Exceeded reaction

Backflow due to Contamination

high back
pressure
Parameter: pH Level
Deviation Causes Consequences Safeguards Recommendations
Low Low H2SO4 Yeast Growth Install pH indicator Install a heat exchanger in juice
tank
Low Alcohol
Yield Install pH meter

Sterilization of Reactor Tank

High Too much Lime Bacterial Install pH indicator Install a heat exchanger in juice
Contamination tank

Low Alcohol Install pH meter

Yield
Sterilization of Reactor Tank

Rj Junsay ChE 532: Equipment Design

BS ChE 5 July 30, 2018
Parameter: Foaming
Deviation Causes Consequences Safeguards Recommendations
Low Low pressure in Install floater Install floater
the reactor
High More Flow rate Overflow in the Install floater Install floater
reactor tank
Add antifoam such as silicon oil
Runaway
Reaction
Parameter: Pump Maintenance
Deviation Causes Consequences Safeguards Recommendations
Pump Ma Pipe is not Potential Standard Operating Consider adding bleeder valves to
intenance depressurized personnel Procedure the piping on the suction and
exposure discharge side of the pump
Safety shower in the
area
Parameter: Temperature
Deviation Causes Consequences Safeguards Recommendations
Low Cold Weather/ Reactor Cools Temperature indication Install Heat Exchanger
Low Ambient
Temperature Reactants Local temperature and
Concentration pressure indicators
Low water Builds up
Supply Pump failure alarm in th
Temperature Possible e DC
runaway on
Heat exchanger f heating
ouling

Partial Plugged
Cooling Line
High How Weather/ Potential overh Temperature indication Injection of cooling water
High Ambient eating of sludg
Temperature e with potential Local temperature indic Install Heat Exchanger
to kill microor ators
High water ganisms
Supply
Temperature Potential decre
ase in digester
Hot water tempe efficiency
rature transmitt
er fails LOW Potential perso
nnel exposure
to hot fluids (>1
40F

Rj Junsay ChE 532: Equipment Design

BS ChE 5 July 30, 2018
Parameter: Maintenance
Deviation Causes Consequences Safeguards Recommendations

Tank Accessing Potential Tanks supposed to be Consider verifying ladder and

Maintena instruments on t personnel fall equipped with guardrails are included on the tank
nce op of the tank hazard guardrails and caged ve specification
rtical ladder

Standard Operating
Procedure

Safeguards: Existing or proposed (for new projects) measures that detect or warn of a deviation or
consequence, prevent a deviation or consequence or mitigate the effects of a consequence.

Recommendations: Design, operating or maintenance changes that reduce or eliminate deviations, causes
and/or consequences.

Rj Junsay ChE 532: Equipment Design

BS ChE 5 July 30, 2018