Research And Application Of HAZOP Analysis Based On HYSYS Process Simulation

Based on the traditional HAZOP analysis,this paper presents a "HAZOP-SIMU" analysis method to solve the existing problems of the traditional HAZOP analysis and improve the accuracy and objectivity of the analysis.Based on the advantages of this method,the "HAZOP-LOPA-SIMU" analysis method was further proposed to further perfect HAZOP-related safety analysis techniques.Eventually,through process simulation and HAZOP analysis data,the accident risk transmission path was discovered,and find a new way to define the risk level.The main research contents of this article are as follows:(1)Summarize the principle,method and operation flow of the traditional HAZOP analysis method,analyze its advantages and disadvantages,and use traditional methods to conduct safety analysis on the acetylene generation section of the PVC process,and find out there were 17 deviations that led to the accident and 40 causes of those deviations.(2)A HAZOP analysis method based on process simulation is proposed as "HAZOP-SIMU".This method mainly using the process simulation software HYSYS to quantify useful deviations in HAZOP analysis.The concept of “safety zone” was proposed,that is,the time when a given process parameter deviates from the normal operating value and reaches the dangerous peak time.Takeing a company's natural gas condensate de-heavy components process as an example.Based on the method proposed in this paper,the traditional HAZOP analysis is performed first;and then using the HYSYS simulation software to perform steady state simulation and dynamic simulation of the process,and select some deviations in the HAZOP analysis for gradient quantification simulation.Finally,the quantitative HAZOP analysis report ofthis process was obtained combining with the classification of the “security domain”.(3)Based on the protective layer analysis(LOPA)and HAZOP-LOPA methods,the "HAZOP-LOPA-SIMU" analysis method is proposed and applied to industrial examples.Firstly,using process simulation to quantify and analyze dangerous accident scenarios in HAZOP-LOPA analysis,and the results were combined with HAZOP-LOPA analysis results,the simulation results are found to be complementary and supportive to the HAZOP-LOPA analysis.Providing a direct basis for the assessment of the residual risk level and the adoption of relevant safety measures.In fact,the security analysis has been further improved,so that the analysis results are more accurate and objective,which is conducive to provide managers with more comprehensive security decision-making information.(4)Eventually,the dangerous transmission mechanism was discovered in the dynamic simulated data group,and verified by adding the simulation setting to expanding database,significantly improve the risk handling capacity of the accident network.On this basis,a new method of defining the risk level is proposed which further improves the relevant content of the risk level assessment in the HAZOP analysis field based on process simulation.