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1.13 Process Safety Management 2/2 (benefits of HAZOP (Early…
1.13 Process Safety Management 2/2
HAZOP
Identifies possible deviations from design intent or from normal operating conditions and causes & consequences of those deviations
HAZOP operates on the basic premise that problems only arise when there is a deviation from normal / design operating conditions
Assumes that the facility will be built, operated and maintained by competent personnel
Identifies potential hazards and operability problems
HAZOP is not a problem solving technique
While HAZOP may help improve project designs, it should not be confused with a project design review
Thorough, logical & systematic process within a set framework
Uses a multi-disciplinary team to review
Assessment of adequacy of process design
Assessment of adequacy of installed facility or process
Assessment of problem areas in procedures
Assessment of design modifications
Identification of hazards for HSE Case / CIMAH Case (new or existing facility)
when to do
During projects
--Preliminary design (PFD’s)
--Final design (detailed P&ID’s)
During operation (existing facility or proposed modifications)
Whenever a new onshore or offshore facility is to be built.
Detailed systematic risk evaluations should be undertaken at specific stages of a project such as:
--concept,
--detailed design,
--manufacturing,
--installation &commissioning
--during operations
During operations
Risk evaluations should be undertaken for ALL changes that occur to the facility
This includes: equipment /technical, procedural and training, including organisational changes.
To enable problems to be identified early in the CAPEX phase of a project.
process
Appoint a HAZOP Leader and Scribe
Define objectives and scope
Select the HAZOP team
Arrange schedule & venue for HAZOP meetings
Obtain suitable data
Plan the sequence for the study
Carry out the HAZOP study
Produce a HAZOP Report
Action Tracking
The HAZOP process is based on PFDs /P&IDs
Divide P&IDs in Nodes for review
Property Word
Guide Word
Deviation from Design Intent
Causes
Consequences
Controls
Actions
benefits of HAZOP
Early identification of problem areas
Encourages creativity in conceptual design process
Remedial measures identified prior to equipment procurement, construction and commissioning
Problem-free startup
Significant cost savings
Understanding of plant operation –transfer of technology from vendor to client and Process people to Operations personnel
Improved commissioning, operating, maintenance and emergency procedures
Provides essential information for the HSE Case / CIMAH Case
Meets legislative requirements
Consensus avoids minority reports
Consensus on actions saves time outside meetings
Consensus on needs for further study allows any diverging views to be communicated to the study team
Consensus that no action necessary ends the issue in the meeting
This is why we project the information being recorded on a screen so as people can agree on the words. Can record areas of opinion –further review.
Generic &flexible
Core strength is competent multi-disciplined team
Systematic &exhaustive
Cross-fertilisation of knowledge
'Design against failure'
Comprehensive record
Accountability
Key “Parameters” usually considered:
Flow
Pressure
Temperature
Level
Composition
Other
Equipment failure
Control system failure
Unstable reaction conditions
Chemical reactivity hazards
Human error
Influence from other systems
External events such as fire or explosion or impact
Extreme environmental events
Control
The emphasis is that controls should be independent
Prevention:
Design standards (mechanical, instruments, controls,process)
Operating procedures
Reaction control
Alarm /Trip Systems
Pressure relief valves
Human factors
Mitigation:
Gas and fire detection
Fire protection, e.g. water spray system
Emergency Shutdown System
Alarm system
SIS
Evacuation / emergency plans
Reporting
Scope of study
Description of study method
Description of unit or process
Team members and dates
P&IDs studied
Summary of recommendations
Complete list of HAZOP recommendations
Complete list of operability recommendations
Reject safety recommendations
Reject operability recommendations
HAZOP study worksheets
HAZOP study team members
List of Drawings