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Examples for Process Risk and Reliability Management
In order to illustrate many of the concepts and ideas discussed in this series of ebooks, five simple worked examples are provided in the book Process Risk and Reliability Management . A full download of the examples is available here at no cost.

Example 1: Process Flow

The first example shows a simple process involving the flow of liquid from a tank into a pressure vessel. This example is used to illustrate the principles and techniques of process hazards analysis.

Figure 1
Process Flow Example

Process Flow Example used to illustrate concepts such as HAZOP guidewords and the development of P&IDs.

Example 2: Equipment

The second example is to do with an equipment item that is widely used throughout the process industries: a shell and tube heat exchanger. The example is used to illustrate equipment failure analysis techniques, particularly Failure Modes and Effects Analysis (FMEA).

Figure 2
Heat Exchanger Example

Heat Exchanger Example used to illustrate FMEA (Failure Modes & Effects Analysis) and Mechnical Integrity issues.

Example 3: Operations

Figure 3 shows a forced draft cooling tower. Warm water from the users enters at the top of the tower then flows down the packing into the basin. Air is pulled into the base of the tower by the fans at the top of the tower. The air flows counter-currently against the warm water. Some of the air evaporates, thus cooling the water. The cooled water is pumped to the users. Make up water and treatment chemicals are added as shown.

This example is used to illustrate the development of operating and maintenance procedures.

Figure 3
Cooling Tower Example

Cooling Tower Example used to illustrate the development of operating procedures and the use of fault trees.

Example 4: Management Workflow

The fourth example illustrates the development and use of risk management systems.

Figure 4
Work Flow Example

Workflow Example used to illustrate audits and management of change (MOC).

Example 5: Significant Potential Incident

The fifth example is loosely based on an actual incident.

The cone-roof, atmospheric storage tank shown in Figure 5 stores a non-flammable, low vapor pressure inorganic liquid. The vapor space above the chemical is air; the tank breathes in and out through a simple vent line. Also shown is a vehicle; one of the facility roads runs close to the tank. A fairly steady stream of vehicles uses the road. The fifth and final example illustrates the development and use of risk management systems.

The pump stopped operating, the check valve failed to hold and light hydrocarbons flowed backward into the tank. A layer of hydrocarbons formed on top of the inorganic liquid, as shown.

Figure 5
Reverse Flow Scenario

High potential incident - backflow from tank.

The hydrocarbons in the tank vaporized, then vented to atmosphere as shown. A hydrocarbon detector located about 100 meters from the tank detected the presence of flammable vapors.

The vapors did not light off. However the potential for a serious event is high — the vapors could have ignited at a vehicle engine. The flame front could have entered the tank and caused the vapors in the tank to explode.

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