HAZARDS AND

OPERABILITY
STUDY
 SECTION 1
Equipment Deviations Possible Consequence Additional Process Notes and
from cause of of the implications Indications Questions
operating deviation deviation of this
conditions consequence
Storage Tank
ST - 101 Level/Weight
More Too many Excessive Increased WC-101, Check V-101
limestone limestone amount of LC 101 for repairs.
stored limestone Close V-101
crushed in case of
irregularities
Less Less Insufficient Reduced WC-101, Check V-101
limestone limestone amount of LC 101 for repairs.
stored limestone Close V-101
crushed in case of
irregularities
ST 102 More Too many Excessive Increased WC-102 Check V-102
clay limestone store amount of LC 102 for repairs.
clay crushed Close V-102
in case of
irregularities
Less Less clay Insufficient Reduced WC-102 Check V-102
limestone amount of LC 102 for repairs.
stored clay crushed Close V-102
in case of
irregularities
ST 103 More V-108 Excessive Increased WC-107 Check V-109
closing clinker stored amount of LC 107 for repairs.
failure clinker Close V-109
crushed in case of
irregularities
Less Blockage on Insufficient Reduced WC-107 Check V-109
V-108; clinker stored amount of LC 107 for repairs.
Leakage on clinker Close V-109
ST-103 crushed in case of
irregularities
Silo
BS - 101 Level/Weight
More V- 105 Excessive raw Increased LC-106, Check V-105
closing meal stored amount of WC-106 for repairs.
failure raw meal Close V-105
burned in case of
irregularities
Less Blockage on Insufficient Reduced LC-106, Check V-105
V-105. raw meal amount of WC-106 for repairs.
Leakage of stored raw meal Close V-105
BS- 101 burned in case of
irregularities
BS - 102 More V-104 Excessive Increased LC-109, Check V-110
closing cement stored amount of WC-109 for repairs.
failure cement stored Close V-110
 in case of
irregularities
Less Blockage on Insufficient Reduced LC-109, Check V-110
V-104. cement stored amount of WC-109 for repairs.
Leakage of cement stored Close V-110
BS-102 in case of
irregularities
Crusher
CR - 101 Level/Weight/Speed
More V- 101 Power surge. Additional WC-103, Check
closing energy use. LC-103, equipment,
failure. SC-101. machinery
High loading maintenance.
of clay,
Faster than
usual.
Less Blockage of Insufficient Slowed WC-103, Check
V-101. Leak power. production LC-103, equipment,
in CR-101. rate. SC-101. machinery
Slower than maintenance.
usual.
CR - 102 More V-102 Power surge. Additional WC-104, Check
closing energy use. LC-104, equipment,
failure. SC-102. machinery
maintenance.
Less Blockage of Insufficient Slowed WC-104, Check
V-102. Leak power. production LC-104, equipment,
in CR-102. rate. SC-102. machinery
maintenance.
Miller
RM - 101 Level/Weight/Speed
More V-101 and Excessive Additional WC-105, Check V-101
V-102 Limestone and energy use. LC-105, & V-102
closing Clay loaded; SP-103 /RM -101 for
failure, Power surge repairs. V-
Faster than 101 & V-102
usual. closed.
Check level
regularly
Less Blockage on Insufficient Slowed WC-105, Check V-101
V-101 and Limestone and production LC-105, & V-102
V-102 Clay loaded; rate. SP-103 /RM -101 for
Leakage of Insufficient repairs. V-
RM 101, power. 101 & V-102
Slower than closed.
usual Check level
regularly
RM - 102 More ST -103 Excessive Additional WC-108, Check V-109
oversupply clinker loaded; energy use. LC-108, /RM -102 for
V-104 Power surge SC-104 repairs. V-
109 closed.
 Check level
regularly
Less Blockage on Insufficient Slowed WC-108, Check V-109
V-101 and Clinker loaded; production LC-108, /RM -102 for
V-102 Insufficient rate. SC-104 repairs. V-
Leakage of power. 109 closed.
RM 101, Check level
Slower than regularly
usual
Conveyor Belt
CB - 101 Speed
More Uncontrolled Upset in the M-101 Speed
conveyor system; indication
speed; equipment Excess alarm.
malfunction failure. Power energy use
system. surge
Less Line Insufficient Production M-101 Speed
partially power rate is slowed indication
blocked. alarm.
CB 102 More Uncontrolled Upset in the Excess M-102 Speed
conveyor system; energy use indication
speed; equipment alarm.
malfunction failure. Power
system. surge
Less Line Insufficient Production M-102 Speed
partially power rate is slowed indication
blocked. alarm.
CB - 103 More Uncontrolled Upset in the Excess M-103 Speed
conveyor system; energy use indication
speed; equipment alarm.
malfunction failure. Power
system. surge
Less Line Insufficient Production M-103 Speed
partially power rate is slowed indication
blocked. alarm.
CB 104 More Uncontrolled Upset in the Excess M-104 Speed
conveyor system; energy use indication
speed; equipment alarm.
malfunction failure. Power
system. surge
Less Line Insufficient Production M-104 Speed
partially power rate is slowed indication
blocked. alarm.
CB - 105 More Uncontrolled Upset in the Excess M-105 Speed
conveyor system; energy use indication
speed; equipment alarm.
malfunction failure. Power
system. surge
 Less Line Insufficient Production M-105 Speed
partially power rate is slowed indication
blocked. alarm.
CB 106 More Uncontrolled Upset in the Excess M-106 Speed
conveyor system; energy use indication
speed; equipment alarm.
malfunction failure. Power
system. surge
Less Line Insufficient Production M-106 Speed
partially power rate is slowed indication
blocked. alarm.
CB - 107 More Uncontrolled Upset in the Excess M-107 Speed
conveyor system; energy use indication
speed; equipment alarm.
malfunction failure. Power
system. surge
Less Line Insufficient Production M-107 Speed
partially power rate is slowed indication
blocked. alarm.
CB - 108 More Uncontrolled Upset in the Excess M-108 Speed
conveyor system; energy use indication
speed; equipment alarm.
malfunction failure. Power
system. surge
Less Line Insufficient Production M-108 Speed
partially power rate is slowed indication
blocked. alarm.
CB - 109 More Uncontrolled Upset in the Excess M-109 Speed
conveyor system; energy use indication
speed; equipment alarm.
malfunction failure. Power
system. surge
Less Line Insufficient Production M-109 Speed
partially power rate is slowed indication
blocked. alarm.
Kiln
K101 Temperature
Less Fouled or Low Bad quality of TI-101 Check
failed conversion of the product equipment,
exchanger raw meal to machinery
tubes cement clinker maintenance

Grate Cooler
GC101 Temperature
High Minimal Crystallization Bad quality of TI-102 Check the
flow of air of Aluminates, the product, temperature
through the Ferrites and Affects the of the grate
cooler Belites will strength of the cooler prior
not happen cement to cooling of
the clinker

Speed
Less Small flow It gives less Large Check the
rate of air hydraulically- aluminate flow rate of
through the reactive crystals can air prior to
cooler silicates and lead to erratic cooling of
produces cement setting the clinker
coarse crystals characteristics
of aluminate
and ferrites