Research Article
BibTex RIS Cite

Identification and Simulation of Fire and Explosion Hazards using HAZOP and ALOHA, Case Study: The Ignition System of a Power Plant

Year 2025, Volume: 8 Issue: 3, 650 - 659, 15.05.2025

Nafiseh Farajirad , Müge Ensari Özay

https://doi.org/10.34248/bsengineering.1629732

Abstract

A power plant is widely recognized as a high-risk industrial environment due to the complex processes and potential exposure to hazardous materials, high temperatures, and powerful machinery. In the meantime, identifying fire and explosion hazards is vital to preventing catastrophic incidents, safeguarding lives and assets, and ensuring the safe, compliant operation of process plants. This study investigates fire and explosion hazards associated with the ignition system of a power plant situated in northern Iran. Hazard identification was performed using the HAZOP technique, while risk levels were assessed and prioritized through a Decision Matrix Risk Assessment (DMRA). To visualize the severity of potential hazards, the ALOHA software was employed for consequence modeling. The most important identified risk was a temperature deviation failure in the control system of the vaporizer burner. Installing a temperature indicator on the vaporizer outlet line is recommended to assist operators and supervisors in detecting and preventing such deviation and its potential consequences. The results of ALOHA indicate that the resulting explosion and radiation levels, along with potential domino effects, pose a significant threat to human life.

Keywords

ALOHA HAZOP Ignition system Powerplant

References

  • Ahmad AC, Mohzsin IN, Otman MK, Muhamad NH. 2016. A hazard identification risk assessment and risk control accidents at power plant. In: 4th International Building Control Conference (IBCC), July 13-17, Kuala Lumpur, Malaysia, pp: 54. doi: 10.1051/matecconf/20166600105.
  • Ahmadi S, Adl J, Ghalehnovi M. 2011. Relative ranking of fire and explosion in a petrochemical industry by fire and explosion index. J Qazvin Univ Med Sci, 14(4): 50-56.
  • Alaei R, Mansoori S, Moghaddam A, Mansoori M. 2014. Safety assessment approach of hazard and operability (HAZOP) for sulfur recovery unit Claus reaction furnace package; blower; heat exchanger equipment in South Pars gas processing plant. J Nat Gas Eng, 2: 271-284. doi: 10.1016/j.jngse.2014.07.007.
  • Alsaffar I, Ezzat A. 2020. Qualitative risk assessment of combined cycle power plant using hazards identification technique. J Mech Eng Res Dev, 43(2): 284-293.
  • Chang JS, Lin CC. 2006. A study of storage tank accidents. J Loss Prev Process Ind, 19(1): 51-59.
  • Crawley F, Tyler B. 2015. HAZOP: guide to best practice, guidelines to best practice for the process and chemical industries. Elsevier, Amsterdam, Netherlands, pp: 322.
  • Djapan M, Macuzic I, Tadic D, Baldissone G. 2018. An innovative prognostic risk assessment tool for manufacturing sector based on the management of the human, organizational and technical/technological factors. Saf Sci, 119: 280-291. doi: 10.1016/j.ssci.2018.02.032.
  • EPA. 2016. Environmental protection agency, ALOHA Software. URL: https: //www.epa.gov/cameo/aloha-software (accessed date: September 17, 2023).
  • Etowa CB, Amyotte PB, Pegg MJ. 2002. Quantification of inherent safety aspects of the Dow indices. J Loss Prev Process Ind, 15(6): 477-487. doi: 10.1016/S0950-4230(02)00039-6.
  • Hoorelbeke P. 2021. Process safety: an engineering discipline. De Gruyter, Berlin, Germany, pp: 240.
  • Hung MC, Lin CY, Hsiao GL. 2024. Safe firefighting distances using FDS and ALOHA for oil tank fires. Fire, 7(12): 445. doi: 10.3390/fire7120445.
  • Ilic P, Ilic S, Stojanovic LB. 2018. Hazard modelling of accidental release chlorine gas using modern tool-Aloha. Qual Life, 9(1-2): 38-45. doi: 10.7251/QOL1801038I.
  • International Labor Organization (ILO). 2023. A call for safer and healthier working environments. https: //doi.org/10.54394/HQBQ8592.2023 (accessed date: September 17, 2023).
  • Iskender H. 2020. HAZOP and ALOHA analysis of acetone. In: 4th International Symposium on Natural Hazards and Disaster Management (ISHAD), October 24-25, Bursa, Türkiye, pp: 68. doi: 10.33793/acperpro.03.02.30.
  • Khan F, Abbasi SA. 2001. Major accidents in process industries and an analysis of causes and consequence. J Loss Prev Process Ind, 12(5): 361-378. doi: 10.1016/S0950-4230(98)00062-X.
  • Kumar G, Bhattacharya R. 2015. Consequence analysis for simulation of hazardous chemicals release using ALOHA software. Int J Chemtech Res, 8(4): 2038-2046.
  • Marhavilas PK, Filippidis M, Koulinas GK, Koulouriotis DE. 2019. The integration of HAZOP study with risk-matrix and the analytical-hierarchy process for identifying critical control-points and prioritizing risks in industry - a case study. J Loss Prev Process Ind, 62: 103981. doi: 10.1016/j.jlp.2019.103981.
  • Mocellin P, De Tommaso J, Vianello C, Maschio G, Saulnier-Bellemare T, Virla L, Patience GS. 2022. Experimental methods in chemical engineering: hazard and operability analysis-HAZOP. Can J Chem Eng, 100: 3450-3469. doi: 10.1002/cjce.24520.
  • Musyafa A, Adiyagsa H. 2012. Hazard and operability study in boiler system of the steam power plant. Int J Sci Technol, 1(3): 1-10.
  • OECD. 2008. OECD Environmental outlook. OECD, Paris, France, pp: 218.
  • Penelas AJ, Pires JCM. 2021. HAZOP analysis in terms of safety operations processes for oil production units: a case study. Appl Sci, 11: 10210. doi: 10.3390/app112110210.
  • Raja AK, Srivastava AP, Dwivedi M, 2006. Power plant engineering. New Age International Pvt Ltd Publishers, New Delhi, India, pp: 712.
  • Reniers G, Dullaert W, Ale B, Soudan K. 2005. The use of current risk analysis tools evaluated towards preventing external domino accidents. J Loss Prev Process Ind, 18: 119-126. doi: 10.1016/j.jlp.2005.03.001.
  • Rodrigues AJS, da Silva MHN, de Farias DO, Teixeira MM, de Brito Rocha MF, Lins GB, D’Emery RA, Júnior JFS, Correia Neto JSC. 2017. Risk reliability analysis, resulting from explosions in petrochemical industries: a case study using Aloha software. In: 12th Iberian Conference on Information Systems and Technologies (CISTI), June 21-24, Lisbon, Portugal, pp: 48. doi: 10.23919/CISTI.2017.7975733.
  • Sánchez Colmenarejo JI, Camprubí FM, González-Gaya C, Sánchez-Lite A. 2022. Power plant construction projects risk assessment: a proposed method for temporary systems of commissioning. Buildings, 12(8): 1260. doi: 10.3390/buildings12081260.
  • Shao H, Duan G. 2012. Risk quantitative calculation and ALOHA simulation on the leakage accident of natural gas power plant. Procedia Eng, 45: 352-359. doi: 10.1016/j.proeng.2012.08.170.
  • Shin D, Gwak H, Lee D. 2015. Modeling the predictors of safety behavior in construction workers. J Occup Saf Ergon, 21: 298-311. doi: 10.1080/10803548.2015.1085164.
  • Sinpong HH. 2015. Risk assessment on combined cycle power plant mechanical maintenance. MSc Thesis, University Technical Malaysia Melaka, Malacca, Malaysia, pp: 102.

Identification and Simulation of Fire and Explosion Hazards using HAZOP and ALOHA, Case Study: The Ignition System of a Power Plant

Year 2025, Volume: 8 Issue: 3, 650 - 659, 15.05.2025

Nafiseh Farajirad , Müge Ensari Özay

https://doi.org/10.34248/bsengineering.1629732

Abstract

A power plant is widely recognized as a high-risk industrial environment due to the complex processes and potential exposure to hazardous materials, high temperatures, and powerful machinery. In the meantime, identifying fire and explosion hazards is vital to preventing catastrophic incidents, safeguarding lives and assets, and ensuring the safe, compliant operation of process plants. This study investigates fire and explosion hazards associated with the ignition system of a power plant situated in northern Iran. Hazard identification was performed using the HAZOP technique, while risk levels were assessed and prioritized through a Decision Matrix Risk Assessment (DMRA). To visualize the severity of potential hazards, the ALOHA software was employed for consequence modeling. The most important identified risk was a temperature deviation failure in the control system of the vaporizer burner. Installing a temperature indicator on the vaporizer outlet line is recommended to assist operators and supervisors in detecting and preventing such deviation and its potential consequences. The results of ALOHA indicate that the resulting explosion and radiation levels, along with potential domino effects, pose a significant threat to human life.

Keywords

ALOHA HAZOP Ignition system Powerplant

References

  • Ahmad AC, Mohzsin IN, Otman MK, Muhamad NH. 2016. A hazard identification risk assessment and risk control accidents at power plant. In: 4th International Building Control Conference (IBCC), July 13-17, Kuala Lumpur, Malaysia, pp: 54. doi: 10.1051/matecconf/20166600105.
  • Ahmadi S, Adl J, Ghalehnovi M. 2011. Relative ranking of fire and explosion in a petrochemical industry by fire and explosion index. J Qazvin Univ Med Sci, 14(4): 50-56.
  • Alaei R, Mansoori S, Moghaddam A, Mansoori M. 2014. Safety assessment approach of hazard and operability (HAZOP) for sulfur recovery unit Claus reaction furnace package; blower; heat exchanger equipment in South Pars gas processing plant. J Nat Gas Eng, 2: 271-284. doi: 10.1016/j.jngse.2014.07.007.
  • Alsaffar I, Ezzat A. 2020. Qualitative risk assessment of combined cycle power plant using hazards identification technique. J Mech Eng Res Dev, 43(2): 284-293.
  • Chang JS, Lin CC. 2006. A study of storage tank accidents. J Loss Prev Process Ind, 19(1): 51-59.
  • Crawley F, Tyler B. 2015. HAZOP: guide to best practice, guidelines to best practice for the process and chemical industries. Elsevier, Amsterdam, Netherlands, pp: 322.
  • Djapan M, Macuzic I, Tadic D, Baldissone G. 2018. An innovative prognostic risk assessment tool for manufacturing sector based on the management of the human, organizational and technical/technological factors. Saf Sci, 119: 280-291. doi: 10.1016/j.ssci.2018.02.032.
  • EPA. 2016. Environmental protection agency, ALOHA Software. URL: https: //www.epa.gov/cameo/aloha-software (accessed date: September 17, 2023).
  • Etowa CB, Amyotte PB, Pegg MJ. 2002. Quantification of inherent safety aspects of the Dow indices. J Loss Prev Process Ind, 15(6): 477-487. doi: 10.1016/S0950-4230(02)00039-6.
  • Hoorelbeke P. 2021. Process safety: an engineering discipline. De Gruyter, Berlin, Germany, pp: 240.
  • Hung MC, Lin CY, Hsiao GL. 2024. Safe firefighting distances using FDS and ALOHA for oil tank fires. Fire, 7(12): 445. doi: 10.3390/fire7120445.
  • Ilic P, Ilic S, Stojanovic LB. 2018. Hazard modelling of accidental release chlorine gas using modern tool-Aloha. Qual Life, 9(1-2): 38-45. doi: 10.7251/QOL1801038I.
  • International Labor Organization (ILO). 2023. A call for safer and healthier working environments. https: //doi.org/10.54394/HQBQ8592.2023 (accessed date: September 17, 2023).
  • Iskender H. 2020. HAZOP and ALOHA analysis of acetone. In: 4th International Symposium on Natural Hazards and Disaster Management (ISHAD), October 24-25, Bursa, Türkiye, pp: 68. doi: 10.33793/acperpro.03.02.30.
  • Khan F, Abbasi SA. 2001. Major accidents in process industries and an analysis of causes and consequence. J Loss Prev Process Ind, 12(5): 361-378. doi: 10.1016/S0950-4230(98)00062-X.
  • Kumar G, Bhattacharya R. 2015. Consequence analysis for simulation of hazardous chemicals release using ALOHA software. Int J Chemtech Res, 8(4): 2038-2046.
  • Marhavilas PK, Filippidis M, Koulinas GK, Koulouriotis DE. 2019. The integration of HAZOP study with risk-matrix and the analytical-hierarchy process for identifying critical control-points and prioritizing risks in industry - a case study. J Loss Prev Process Ind, 62: 103981. doi: 10.1016/j.jlp.2019.103981.
  • Mocellin P, De Tommaso J, Vianello C, Maschio G, Saulnier-Bellemare T, Virla L, Patience GS. 2022. Experimental methods in chemical engineering: hazard and operability analysis-HAZOP. Can J Chem Eng, 100: 3450-3469. doi: 10.1002/cjce.24520.
  • Musyafa A, Adiyagsa H. 2012. Hazard and operability study in boiler system of the steam power plant. Int J Sci Technol, 1(3): 1-10.
  • OECD. 2008. OECD Environmental outlook. OECD, Paris, France, pp: 218.
  • Penelas AJ, Pires JCM. 2021. HAZOP analysis in terms of safety operations processes for oil production units: a case study. Appl Sci, 11: 10210. doi: 10.3390/app112110210.
  • Raja AK, Srivastava AP, Dwivedi M, 2006. Power plant engineering. New Age International Pvt Ltd Publishers, New Delhi, India, pp: 712.
  • Reniers G, Dullaert W, Ale B, Soudan K. 2005. The use of current risk analysis tools evaluated towards preventing external domino accidents. J Loss Prev Process Ind, 18: 119-126. doi: 10.1016/j.jlp.2005.03.001.
  • Rodrigues AJS, da Silva MHN, de Farias DO, Teixeira MM, de Brito Rocha MF, Lins GB, D’Emery RA, Júnior JFS, Correia Neto JSC. 2017. Risk reliability analysis, resulting from explosions in petrochemical industries: a case study using Aloha software. In: 12th Iberian Conference on Information Systems and Technologies (CISTI), June 21-24, Lisbon, Portugal, pp: 48. doi: 10.23919/CISTI.2017.7975733.
  • Sánchez Colmenarejo JI, Camprubí FM, González-Gaya C, Sánchez-Lite A. 2022. Power plant construction projects risk assessment: a proposed method for temporary systems of commissioning. Buildings, 12(8): 1260. doi: 10.3390/buildings12081260.
  • Shao H, Duan G. 2012. Risk quantitative calculation and ALOHA simulation on the leakage accident of natural gas power plant. Procedia Eng, 45: 352-359. doi: 10.1016/j.proeng.2012.08.170.
  • Shin D, Gwak H, Lee D. 2015. Modeling the predictors of safety behavior in construction workers. J Occup Saf Ergon, 21: 298-311. doi: 10.1080/10803548.2015.1085164.
  • Sinpong HH. 2015. Risk assessment on combined cycle power plant mechanical maintenance. MSc Thesis, University Technical Malaysia Melaka, Malacca, Malaysia, pp: 102.
There are 28 citations in total.

Details

Primary Language English
Subjects Chemical Engineering (Other)
Journal Section Research Articles
Authors

Nafiseh Farajirad 0000-0002-1137-0600

Müge Ensari Özay 0000-0002-4785-5503

Publication Date May 15, 2025
Submission Date January 30, 2025
Acceptance Date March 15, 2025
Published in Issue Year 2025 Volume: 8 Issue: 3

Cite

APA Farajirad, N., & Ensari Özay, M. (2025). Identification and Simulation of Fire and Explosion Hazards using HAZOP and ALOHA, Case Study: The Ignition System of a Power Plant. Black Sea Journal of Engineering and Science, 8(3), 650-659. https://doi.org/10.34248/bsengineering.1629732
AMA Farajirad N, Ensari Özay M. Identification and Simulation of Fire and Explosion Hazards using HAZOP and ALOHA, Case Study: The Ignition System of a Power Plant. BSJ Eng. Sci. May 2025;8(3):650-659. doi:10.34248/bsengineering.1629732
Chicago Farajirad, Nafiseh, and Müge Ensari Özay. “Identification and Simulation of Fire and Explosion Hazards Using HAZOP and ALOHA, Case Study: The Ignition System of a Power Plant”. Black Sea Journal of Engineering and Science 8, no. 3 (May 2025): 650-59. https://doi.org/10.34248/bsengineering.1629732.
EndNote Farajirad N, Ensari Özay M (May 1, 2025) Identification and Simulation of Fire and Explosion Hazards using HAZOP and ALOHA, Case Study: The Ignition System of a Power Plant. Black Sea Journal of Engineering and Science 8 3 650–659.
IEEE N. Farajirad and M. Ensari Özay, “Identification and Simulation of Fire and Explosion Hazards using HAZOP and ALOHA, Case Study: The Ignition System of a Power Plant”, BSJ Eng. Sci., vol. 8, no. 3, pp. 650–659, 2025, doi: 10.34248/bsengineering.1629732.
ISNAD Farajirad, Nafiseh - Ensari Özay, Müge. “Identification and Simulation of Fire and Explosion Hazards Using HAZOP and ALOHA, Case Study: The Ignition System of a Power Plant”. Black Sea Journal of Engineering and Science 8/3 (May 2025), 650-659. https://doi.org/10.34248/bsengineering.1629732.
JAMA Farajirad N, Ensari Özay M. Identification and Simulation of Fire and Explosion Hazards using HAZOP and ALOHA, Case Study: The Ignition System of a Power Plant. BSJ Eng. Sci. 2025;8:650–659.
MLA Farajirad, Nafiseh and Müge Ensari Özay. “Identification and Simulation of Fire and Explosion Hazards Using HAZOP and ALOHA, Case Study: The Ignition System of a Power Plant”. Black Sea Journal of Engineering and Science, vol. 8, no. 3, 2025, pp. 650-9, doi:10.34248/bsengineering.1629732.
Vancouver Farajirad N, Ensari Özay M. Identification and Simulation of Fire and Explosion Hazards using HAZOP and ALOHA, Case Study: The Ignition System of a Power Plant. BSJ Eng. Sci. 2025;8(3):650-9.
 Download Cover Image

                                                24890