HAZOP

RISK & SAFETY ANALYSIS

METHODOLOGY

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 INTRODUCTION
METHODOLOGY
GUIDE WORDS
PROCEDURE
RISK MATRIX
HAZOP TEAM
REPORTING
PREPARATORY WORK
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INTRODUCTION
HAZOP (HAZard & OPerability study) 'invented' by ICI-UK in 1964.
Used widely in chemical industry after the Flixborough disaster in 1974 (28 killed).

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 METHODOLOGY
HAZOP methodology is the most widely used aid to loss prevention:
• It is easy to learn
• It can be easily adapted to almost all the process operations
• No special level of academic qualification is required

HAZOP applies in a systematic way keywords or guidewords to the plant to uncover

potential problems.
Primary keywords Secundary keywords
FLOW NO
TEMPERATURE MORE
LEVEL LESS …
PRESSURE …

The results are recorded in columnar format under the following headings:

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 METHODOLOGY - exemple

Deviation : NO FLOW
Cause : Strainer S1 blockage due to impurities
Consequences : 1. Incomplete reaction in tank V1
2. Pump P1 damage by cavitation
Safeguards : Pressure indicator PI at pump outlet
Actions that remove the cause :
Install duplex strainer with differential pressure
Actions that mitigate / eliminate the consequences :
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 GUIDE WORDS

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 PROCEDURE
Describe the design, intention, operating conditions, … of the plant section

Select Consider Identify Identify Identify Quantify Agree on

first/next first/next causes conse- safe- the risk actions
node guide- and quences guards (safety, and
(tank, word or record and and environ- record
pump, deviation them record record ment, them
valve,…) them them financial)

No Last
guide-
word?

Yes

No Last
node?

Consider next
plant section
Yes
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 RISK MATRIX
3 categories of risk:
 People Safety
 Environment
 Financial consequences

Action to be taken when

« Severity » x « Likelihood »
superior to 8 (red zones)
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 HAZOP TEAM
HAZOP requires a multidisciplinary team (maximum 6-10 members):
MEMBER TASK - EXPERTISE
HAZOP leader (1) experienced in Hazop but not directly involved in
the design, to ensure that the method is followed
carefully
HAZOP secretary (1) to ensure that problems are documented and
recommendations passed on
Process Engineer to explain any process details
Design Engineer to explain any design details
Operation supervisor to consider the plant in use and question its
operability, and the effect of deviations
Maintenance someone concerned with maintenance of the
supervisor process
Specialist(s) with relevant technical knowledge
(main equipment, plant control …)
EHS responsible ensure the EHS standards
(1) From external office expert in HAZOP organization.
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 REPORTING
Exemple extracted from final report
Severity (S)
Likelihood (L)
Node name Rate Ranking (RR = SxL)
Guide word Risk category
Drawing reference PR – People Risk
AR – Assets Risk
ER – Environment Risk

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 PREPARATORY WORK
From the team:
 Block flow diagram
 Process Flow Diagrams (PFD)
 Process Description containing operating parameters, flow rates, volumes,
as well as a brief summary of how each plant item functions
 Process and Instrumentation Diagrams (PID)
 Cause & Effect Charts setting out how control and trip systems operate
 Details of vendor packages if available
 Plant layout drawings

From the HAZOP leader:

 Assemble the data
 Understand the subject
 Subdivide the plant and plan the sequence
 Mark-up the drawings
 Devise a list of appropriate Keywords
 Prepare Node Headings and an Agenda
 Prepare a timetable
 Select the team

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