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WORK INSTRUCTION

HAZOP PROCEDURE

WI-SSA-ENGDGN-016-E

B.LANDREAU J. MEDINA LUNA C. SEGUIN B. CHAUVIN

14/08/08 2 Updating
ENG QUAL ORGA ENG

Date Revision Description of Revision Prepared by Checked by Approved by

Only the electronic version is updated, before any use the current version of this document shall be verified on the INTRANET network

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REVISION RECORDING

Date Revision Description of Revision Prepared by Checked by Approved by

Updating:
B.LANDREAU J. MEDINA LUNA C. SEGUIN B. CHAUVIN
14/08/08 2 direct revision 2 to be compliant with
ENG QUAL ORGA ENG
French version
E. TAMANJI J. MEDINA LUNA L. STEFANI E. ZIELINSKI
06/10/05 0 First issue
SAF QUAL ORGA ENG

This document is in accordance with relevant conclusions of the "Engineering Integration Project".

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INDEX

1. SCOPE AND PURPOSE ............................................................................................................................4

1.1 PURPOSE ...........................................................................................................................................4
1.2 APPLICABILITY ....................................................................................................................................4

2. REFERENCE DOCUMENTS......................................................................................................................4

3. DEFINITIONS .............................................................................................................................................5

4. ACTIVITIES DESCRIPTION.......................................................................................................................6
4.1 RESPONSIBILITIES ...............................................................................................................................6
4.1.1 Technical Manager (TM)......................................................................................................6
4.1.2 PSL Safety ...........................................................................................................................6
4.1.3 Discipline Engineers ............................................................................................................6
4.2 HAZOP STUDY OBJECTIVES ...............................................................................................................7
4.2.1 Goals....................................................................................................................................7
4.2.2 Planning Requirements........................................................................................................7
4.3 EXECUTING A HAZOP STUDY..............................................................................................................8
4.3.1 General ................................................................................................................................8
4.3.2 HAZOP Study Methodology.................................................................................................8
4.3.3 HAZOP Brainstorming Process ...........................................................................................9
4.3.4 HAZOP Action Follow-Up, Tracking and Close-out...........................................................10
4.4 HAZOP STUDY ORGANIZATION WITHIN PROJECTS .............................................................................11
4.4.1 Scope of Work ...................................................................................................................11
4.4.2 HAZOP Documentation Package ......................................................................................11
4.4.3 Schedule of HAZOP Sessions ...........................................................................................12
4.4.4 Software .............................................................................................................................12
4.4.5 HAZOP Team Members ....................................................................................................12
4.5 HAZOP STUDY DELIVERABLES .........................................................................................................13
4.6 TERMS OF REFERENCE .....................................................................................................................14

5. FLOWCHART ...........................................................................................................................................17

ATTACHMENT A – TYPICAL GUIDE WORDS, COMMON DEVIATIONS AND CAUSES...................1/1

ATTACHMENT B - OVERVIEW OTHER GUIDE WORDS TO BE CONSIDERED ...............................1/1

ATTACHMENT C – EXAMPLE OF HAZOP TABLE AND HAZOP ACTION SHEET............................1/2

ATTACHMENT D - GUIDELINES ON PLANNING AND SCHEDULING REQUIREMENTS.................1/1

ATTACHMENT E - HAZOP FOLLOW-UP..............................................................................................1/3

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1. SCOPE AND PURPOSE

1.1 PURPOSE
The purpose of this instruction is to provide a reference guideline and terms of reference for the
execution of Hazard and Operability (HAZOP) Studies within the Saipem s.a. organization.
The objective of the present instruction is to outline processes and minimum requirements for
execution of HAZOP studies on all Saipem s.a projects. The procedure provides guidance on
definition of:
• Framework on organizing HAZOP studies
• Technical content of HAZOP study
• Study objectives during project execution
• Minimum requirements for execution of HAZOP study
Excluded from this instruction is description on how to chair or participate in HAZOP studies.
Reference should be made to specialist training programmes and literature available on topic.

1.2 APPLICABILITY
Design reviews are carried out during project execution to demonstrate that Client Statement of
requirements and technical integrity of installations designed and constructed by Saipem s.a are
upheld. HAZOP reviews form an integral part of design review process.
This instruction is applicable for basic or FEED, detailed engineering, EPCI and combinations
thereof.
It is the intent that HAZOP execution within Saipem s.a shall follow processes described in this
procedure. For each Saipem s.a project, a project specific HAZOP procedure shall be developed,
the terms of reference and contents taken from the present instruction and customized to
requirements of the project.
For contracts where HAZOP procedures are provided by Client, this instruction shall be
superseded by Client procedure.
Any deviations from the present instruction should be submitted to the Safety & Environment
HOD for approval.

2. REFERENCE DOCUMENTS

• A Guide to Hazard and Operability Studies”, Knowtlon R.E. & Shipley D.K., Chemical Industries
Association, 1977
• “HAZOP & HAZAN: Notes on the identification and assessment of hazards”, Kletz T.A., Institution of
Chemical Engineers, Rugby. 3rd edition, 1992
• “HAZOP: Guide to best practice”, ICHEME, 2000

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3. DEFINITIONS

FEED Front End Engineering Design

Hazard & Operability Technical identification for hazards and problems of operability
(HAZOP) Study connected with the process and the auxiliary installations.

Hazard Source or situation with a potential for harm in terms of injury or ill
health, damage to property, damage to the workplace environment, or
a combination of these.

HAZOP Chairman or A person, independent of the process and engineering intentions

facilitator being examined, with proven competence in the methodology of
HAZOP studies who will lead, advice and assist the study. The
Chairman’s duties will include the use of applicable guide words to
stimulate the team discussion and ensure comprehensive coverage
during examination sessions.

HAZOP coordinator The HAZOP coordinator is appointed by the project team to coordinate
all activities associated with review meeting notes, follow-up and
close-out reports.

HAZOP Team A small group of people who carry out the HAZOP Study. The
composition of the team is to include the expertise appropriate to the
facilities or systems being covered by the HAZOP and must include
engineering and operational expertise.

HIPPS High Integrity Pressure Protection System

HOD Head Of Department (Technical Engineering Department)

HSE Health Safety Environment

HVAC Heating, Ventilation and Air Conditioning System

P&ID Piping & Instrumentation Diagram

PFD Process Flow Diagram

PPL Project Process Leader

PSL Project Specialist Leader

PSV Pressure Safety Valve

SIL Safety Integrity Level

TM Technical Manager (for Offshore non Plant projects, reference is made

to PEM, Project Engineering Manager)

U&ID Utility and Instrumentation Diagram

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4. ACTIVITIES DESCRIPTION

4.1 RESPONSIBILITIES

4.1.1 Technical Manager (TM)

The TM is overall responsible for the execution and quality of the HAZOP study.
He is responsible, in particular, for:
• Including HAZOP study as key milestone on project planning,
• Ensuring sufficient specialists are available to participate to the HAZOP study,
• Ensuring all required participants are available to attend HAZOP review sessions and
HAZOP close-out sessions,
• Chairing the HAZOP action close-out meeting. HAZOP action follow-up is performed
by HAZOP coordinator under the overall responsibility of the TM.

4.1.2 PSL Safety

The PSL Safety is responsible for:
• Ensuring HAZOP milestone is flagged in overall project planning (level 1),
• Developing project HAZOP procedure,
• Defining scope and interfaces for HAZOP study,
• Conferring with TM in appropriate timing for HAZOP sessions (including number),
• Appointing HAZOP facilitator and scribe,
• Establishing list of documentation and amenities required for execution of HAZOP,
• Providing software for HAZOP meeting notes,
• Assigning a Safety engineer to participate to the HAZOP session,
• Ensuring response to actions assigned to Safety & Environment Department.

4.1.3 Discipline Engineers

The success and quality of HAZOP study is highly dependent on the HAZOP team
composition and experience. Team members should have a wide experience on process,
operational and maintenance issues on installation facilities under investigation.
Each discipline is responsible for providing experienced engineers, conversant with the
project processes and design for the HAZOP brainstorming sessions. Each discipline is
responsible for providing appropriate responses to action or recommendations assigned
to the discipline.

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4.2 HAZOP STUDY OBJECTIVES

4.2.1 Goals
The purpose of a HAZOP is to identify possible deviations from the intent of a design or
operation (including maintenance) which could lead to process and operating problems or
hazardous situations.
The goals of a HAZOP study can be summarized as follows:
• Review, in a Safety point of view, the design and operation of the facility and evaluate
whether any of the deviations which may occur, either from a malfunction,
misoperation or in the normal process of operation:
− Can cause a hazard to people working on the facility or installation, to the general
public, to plant and equipment, or to the environment,
− Or result in operating characteristics which are outside the normal operating
envelope.
• Review whether the precautions incorporated in the design are sufficient to either
prevent the hazard occurring or reduce any consequence to an acceptable level
• Review whether the incorporated precautions ensure that problems related to
operability and maintainability are acceptable.
• Ensure the plant can be started up, operated, maintained and shutdown safely.

4.2.2 Planning Requirements

HAZOP study execution is a key milestone on any project planning. This section provides
guidelines on appropriate execution periods on a typical engineering project without
predefined contractual obligations.
HAZOP studies intend to analyze the scope of what can go wrong on process facilities
and how the system can accommodate the process excursions without leading to
occurrence of a hazardous event. Implicitly the process facility design shall be sufficiently
matured incorporating process mitigation and control measures as identified during the
project execution prior to HAZOP.
Timing is of absolute importance. Executed too early in a project, the HAZOP review is
limited to process aspects, with actions and recommendations oriented towards detailed
process options rather than hazards and operability items. More often, complementary
HAZOPs are required by Client.
Executed too late, the design is too far advanced and implementation of HAZOP actions
or recommendations has then more impact on project cost, quality and overall schedule.
HAZOP sessions shall be scheduled to take place when the following activities are
completed as a minimum:
• P&IDs are completed and issued to Client for review.
• P&ID reviews by Client have been undertaken and main pending process issues on
P&IDs resolved.
• Line size checks have been completed
• Client comments have been included in a new set of P&IDs, issued for HAZOP
purposes.
• Process and control philosophies, as well as Safety Concept or philosophy are
issued.

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For details refer to Attachment D on guidelines for planning HAZOP studies.

4.3 EXECUTING A HAZOP STUDY

4.3.1 General
HAZOP is particularly dedicated to the identification of the hazardous situations that may
result from process deviations from the normal operating conditions. Normal operating
conditions include start-up, shutdown and routine maintenance activities. Hence, it
focuses on probable consequences which may cause loss of production, damage to
environment, loss of assets, operation upsets or potential production losses, to cause
injury or a fatality.
The HAZOP technique is a highly disciplined procedure using the ‘Method Study Critical
Examination’ technique. It concentrates on the adequacy and integrity of the proposed
design and not the reasons for selecting that particular design. It is essentially a problem
identifying technique, rather than a problem solving one. It proceeds by stimulating the
consideration of all possible deviations from the expected operating conditions.

4.3.2 HAZOP Study Methodology

The study sequence is as follows:
• Definition of battery limits of facilities.
• Split of facilities into HAZOP discrete systems for analysis and further into nodes.
• Execution of HAZOP review sessions using brainstorming techniques
• Listing of remedial actions and/or recommendations and assigning responsible party
for resolutions
• Close-out of remedial actions/recommendations with approval visa by Project
(Saipem s.a. and Client).
Steps 1 & 2 are carried out by the HAZOP facilitator/chairman and project representative,
HAZOP coordinator.
Step 3 is carried out by a multidisciplinary team in work sessions, led by the facilitator. A
series of guide words shall be applied to each line or piece of equipment in turn. A list of
suggested used guide words and deviations is provided in Attachment A and B.
Step 4 is carried out by the HAZOP facilitator and Coordinator, after the HAZOP
sessions.
Step 5 concerns HAZOP follow-up and action (see section 4.3.4. and Attachment E).
The HAZOP team will have the authority to recommend design changes where
necessary.
HAZOP session notes are taken online by HAZOP scribe. HAZOP study sessions are
documented in a HAZOP study report which contains discussions, findings and actions
raised during the HAZOP. Typical list of contents is provided in section 4.5. Typical
HAZOP findings table and action sheet are shown in Attachment C.
Particular attention shall be paid to minute-taking of HAZOP meeting notes. Meeting
notes shall be clearly written and self explanatory such that persons not present in the
meeting can fully comprehend findings.

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4.3.3 HAZOP Brainstorming Process

The general process is described below and in figure attached:
• Step 1 : Identification of systems and battery limits
• Step 2 : System functional description
• Step 3 : Breakdown of the system into nodes
• Step 4 : Select the node and define the node's operating and design conditions
• Step 5 : Application of a parameter
• Step 6 : Application of a guide word which, when combined with the selected
parameter, will give the deviation from the normal operating conditions considered
• Step 7 : Determination of all potential causes of the deviation
• Step 8 : Evaluate the consequences of each deviation
• Step 9 : Identify the existing preventive and protective measures against the causes
and consequences previously determined
• Step 10 : Evaluate if a supplementary measure or further consideration of the
problem is required and agree the eventual recommendation
Go back to step 6 to apply the next guide word to the selected parameter until all guide
word have been applied to the selected parameter.
Go back to step 5 to apply the next parameter to the selected node until all relevant
parameters for this node have been investigated.
Go back to step 4 to move onto the next node of the system until the whole system has
been reviewed.
Go back to step 2 to handle another system.
The brainstorming process is reflected in the scheme below.

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4.3.4 HAZOP Action Follow-Up, Tracking and Close-out

Actions raised during the HAZOP shall be recorded, with the date of HAZOP, a
description of the action, the name of the entity/person responsible for addressing the
action and an agreed completion date.
Each action responsible party is responsible for ensuring resolution of the HAZOP
actions; checking that recommendations are implemented or satisfactorily resolved; and
for signing off the actions as implemented or resolved. The action parties identified shall
be responsible for implementing all necessary design changes and answering any
outstanding queries raised.
All actions shall be tracked until they are implemented or satisfactorily resolved and
closed out. Completed action sheets shall be collated by the TM or HAZOP Coordinator
and documented in HAZOP Action Close-out Report. All closed out actions shall be
signed off by the PSL in charge.

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A system for tracking progress on follow-up actions will be implemented. Completion of

the change or a positive date for completion shall be recorded, and a formal status report
issued, for project management review, periodically (typically every month) or until all
actions have been closed out. The status report shall identify action completion dates and
the responsible party. The status report shall also identify completed items and
agreement of the Client Project Representative.
All completed HAZOP actions shall be submitted to Client for approval. These shall
include all HAZOP actions including rejected and non-implemented ones accompanied by
justification.
If a recommendation is not implemented, a record shall be made of the reasons why. The
person assigned to track progress is responsible for ensuring that this is done. If
agreement is not achieved on an action, the SAIPEM s.a. Project Representative shall
resolve it by referring the matter to the Client Project Representative.
Some actions may be outside the SAIPEM s.a. scope. These shall be assigned to Client.
Typically these would be:
• Operational tasks
• Procedural Issues

4.4 HAZOP STUDY ORGANIZATION WITHIN PROJECTS

4.4.1 Scope of Work

HAZOP studies shall be executed during all engineering phases of the works. Studies
shall consider normal operation periods, including periods associated with routine
maintenance, start-up and shutdown. Simultaneous production and other high risk
activities, such as construction shall not be considered during the engineering HAZOP
sessions.
The HAZOP coordinator shall identify the facilities subject to a HAZOP review in this
section.

4.4.2 HAZOP Documentation Package

The following project documentation shall be available during the HAZOP sessions:
• PFD
• P&IDs, U&IDs, Vendor package P&IDs
• Process Basis of Design
• Process description
• Operation Philosophy
• Flare and depressurisation system design basis
• Cause and Effect Description/Charts
• Equipment List

Other support documentation for the HAZOP sessions:

• Instrument & Control Philosophy
• SIL assessment rating (if applicable)

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• Maintenance Philosophy
• Overall plot plan
• API14C (or Safe charts), if applicable
• Piping Classes
• Hazardous Area Classification Drawings
• Emission philosophy
• Isolation philosophy
• Drainage philosophy
• Safety Concept or Philosophy

4.4.3 Schedule of HAZOP Sessions

In this section the number of HAZOP sessions to be carried out on the project should be
listed, with expected start and completion dates.
Interfaces shall be reviewed in each session as indicated on P&ID reviewed. Subsequent
HAZOP sessions, in event of multiple sessions shall be used to review in detail interfaces
of systems for which detailed information is available from upstream and downstream
facilities.
The duration of HAZOP sessions shall generally be limited to partial days to prevent team
member burnout and to permit efficient recording of each session by the HAZOP scribe.
Meeting session duration shall be limited to a maximum of six hours per day.

4.4.4 Software
HAZOP meeting notes shall be taken using HAZOP software, Lihou Technology Ltd,
latest revision.
All notes shall be taken online. A projector shall be provided in the meeting room. Meeting
notes shall be made available at the end of each session, and reviewed by the HAZOP
team prior to start a new HAZOP session (next day).
A flipchart shall also be available in meeting room.

4.4.5 HAZOP Team Members

4.4.5.1 Main attendees

The HAZOP study shall be carried out by a multi-disciplinary team with preferentially
facility end users Client representative.
Minimum team member composition shall comprise the following:
• HAZOP chairman or facilitator
• HAZOP scribe/secretary
• Process Engineer or Project Process Leader : Saipem s.a.
• Process Engineer : Client Representative
• Operations representative : Client

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• Technical Manager (part-time) : Saipem s.a.

• Safety Representative : Saipem s.a. or Client
• PSL Instrument (on call): Saipem s.a.
• Package design engineer(part-time) : Saipem s.a. and Vendors
• PSL Layout (on call): Saipem s.a.
• Materials Engineering specialist (on call): Saipem s.a.
• Interface Representative (on call): Client or Project Representative
Package Vendors’ presence shall be required for complicated systems e.g. rotating
machinery such as turbo-generators, turbo-compressors, process packages, furnaces,
and any other systems as identified by relevant discipline engineers.
Continuity is vital. Each member of the team should preferably attend each session,
although additional specialists may be added when required.

4.4.5.2 HAZOP Chairman

A prime role within the team is the HAZOP Chairman. The person chosen to be the
team leader should be sufficiently experienced in leading a HAZOP and appropriately
qualified. The chairman shall preferentially be an independent person, who is not part
of the Client or Saipem s.a. engineering design team.
The Chairman’s role is to guide the study through all the steps necessary for
completeness without too many diversions, and ensure that all aspects of every part of
the process or plant are covered, and that each item is given due attention in relation to
its importance.
The Chairman will agree the scope of the study with the engineering team or HAZOP
coordinator. This includes defining the battery limits of the HAZOP. The Chairman is
responsible for final editing and issuing the HAZOP Study Report.
The HAZOP Chairman shall also:
• Decide the study meeting plan
• Determine the HAZOP nodes
• Select items for discussion
• Consider deviations and consequences
• Capture ideas and filtering out real concerns
• Consolidate discussion conclusions, getting agreement and recording the
necessary action
• Exercise time management

4.5 HAZOP STUDY DELIVERABLES

For each HAZOP review, a separate HAZOP study report shall be established. Action sheets and
action close-outs shall be documented in a separate document, HAZOP Action close-out report.
All HAZOP study Reports and Close-out Reports shall be registered as controlled documents.
The custodian for these reports shall be the HAZOP coordinator.
The HAZOP study report, with meeting findings shall be issued within one week of completion of
the HAZOP study sessions.

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Typical HAZOP Study Report Contents is provided below:

• A contents list and executive summary.
• An introduction giving the background to the study, its purpose and timing.
• The names, roles and responsibilities of the HAZOP Team.
• The study definition, detailing the scope of the study, the method employed and the items
(PFDs, P&IDs etc) reviewed (or nor reviewed).
• A summary of the design and operating conditions.
• A description of the plant studied, and the nodes.
• Compiled HAZOP worksheets
• Recommendations for additional action or changes to the design/operations, generated by
the study
• Allocated responsible party to address recommendations and close-out actions
• The relevant mark-up P&IDs, Cause and Effect Diagrams and any other data or documents
studied.
HAZOP action close-out and records showing the implementation of all actions and the resolution
of any recommendations shall be incorporated in the HAZOP Action Closeout Report. This shall
also include the minutes of the HAZOP close-out meeting.
The HAZOP report and all associated records shall be archived. Copies shall be formally handed
over to the Project Development Team and Operations Team of the facility.

4.6 TERMS OF REFERENCE

Node:
It is the division of a facility or a system into subsystems that will be a basic element on which
deviations will be applied. It is usually driven by the normal process flow and is mostly associated
with only one process operation (transfer, heat exchange, physical separation, distillation…).
Before beginning the HAZOP brainstorming process on the node, the design intent and the
operating conditions (along with sizing criteria) are described by process design engineer. It is
recommended to record this information in the HAZOP minutes for studied operating modes.

Design & Operating Intentions:

The way the process and equipment is intended to work under both normal and anticipated
abnormal conditions.

Deviation from Operating Envelope:

A modification from the intent of the design and the normal operating envelope.

Parameter:
It is typically physical and chemical properties of the fluid considered in the node: the usual
parameters are flow, pressure, temperature, level; additional ones include phase, composition,
operation, maintenance.
Not all parameters are applicable to each node.

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Guidance notes:
Pressure: Areas of particular concern are the LP/HP system interfaces (through pressure control
devices), isolation philosophy (for maintenance), vessel and piping overpressure protection
(PSVs, HIPPS) and compressor/pump maximum outputs.
Temperature is meaningful when high and low temperatures may be found on certain equipment
(heater, pressure reducing valve) or during certain operations (e.g. blow-down). Phase changes
may occur due to freezing (e.g. minimum temperature in the blow-down vessel lower than water
dew point), boiling and Gas to Oil Ratio changes. Low temperatures may lead to waxing or
hydration, causing blockages at fitting connections, valve seats, restricted orifices, piping
pockets…
Level is usually only relevant for vessels and storage tanks. Consider elevation issues (multi-deck
offshore installations, different elevation levels in onshore sites).
Phase issues are usually of relevance for flow lines and transport pipelines where external
conditions may lead to fluid physical transformations (hydrates, slugging…). Sand may also be a
concern.
Composition is relevant for a stream where there can be changed into components ratio, more or
less than expected (more water, more crude oil, more H2S…). Possible contamination (due to a
heat exchanger leak, valve failure or misoperation…) or for cases of injection system failure
(methanol, corrosion inhibitor…) should also be considered.

Guide words:
Guide words are simple words used to qualify any departure from the design intent and are to be
combined with a parameter to determine a process deviation. When used in association with a
design and operating intention they guide or prompt discussion of the possible consequences of a
deviation.
A full list of guide words and deviations that shall be applied during the HAZOP is shown in
Attachments A and B.
Not all guide-words are applicable to each parameter, e.g. "part of" to "temperature".

Deviation:
This is the combination of a guide word with a parameter.

Causes:
Any incident or condition whose occurrence during normal operation has the potential to initiate
an undesired situation, such as operating outside the normal operating envelop or catastrophe.
Emphasis shall be placed on causes initiated in the node under review. Consequences on
upstream and downstream nodes shall be evaluated.
The main categories of causes are: human error, equipment or instrument failure, external
events. External events to be considered include fire and seismicity.
Double jeopardy, defined as being the combination of two simultaneous and independent failures,
shall not be considered in HAZOP studies.

Consequences:
As accurate are the description of the consequences associated with identified causes, as
efficient is the brainstorming of the HAZOP team for detecting omission in the design.
Sometimes, developing the potential escalating scenarios associated with one cause may be

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beneficial: it may be the case for more pressure on a section equipped with a pressure relieving
device connected to a certain drain system.
Through this exercise, it allows to review thoroughly the design intents on the node and the
system and to draw a picture of what could happen in the mind of team members and,
particularly, of operations representative. Operations and Maintenance representatives may in
certain cases associate these developing scenarios with former design cases, experienced
operational situations or past mishaps. Here is typically the benefit of inductive brainstorming
process of the HAZOP.
The consequences must be defined in terms of potential hazards or operability problems. If
appropriate, a chronological sequence of events following the initial causes may be recorded. At
this stage of the brainstorming process, neither preventive nor protective measures shall be taken
into consideration for qualifying the extent of the consequences.
The consequences may be multiple for one cause. In this case, mitigation measures should be
identified respectively.

Safeguards:
These typically describe the safeguards that are already in place. It shall embrace preventive
measures that act upon the occurrence of the cause and protective measures that act on the
detection of the deviation, its control and eventually the mitigation of the potential consequences.
Detection and control measures of the deviation shall be carefully identified with relevant design
criteria when available (design pressure / design temperature for an equipment, set pressure for
PSVs).
Typical protective measures are listed below:
• Process control responding to the deviation
• Alarms to alert operators of a process parameter excursion
• Safety loops or Instrumented Protective Functions that partially or totally initiate a shutdown
of the plant
• Mechanical strength of the system
• Relieving Systems

HAZOP Study Report:

A report documenting the discussions, findings and actions raised during the HAZOP. It shall also
include details of the persons undertaking the HAZOP; copies of the reference drawings and
documents used during the HAZOP; the key conclusions of the HAZOP; and the actions raised
for follow-up.

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5. FLOWCHART

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Attachment A – Page: 1/1

ATTACHMENT A – TYPICAL GUIDE WORDS, COMMON DEVIATIONS AND CAUSES

GUIDE WORD PARAMETER EXPLANATION

NO Flow Wrong routing, blockage, blind flange left in, faulty non-return
valve, burst pipe, control valve, isolation valve, pump or vessel
failure
MORE Flow More than 1 pump operating, reduced delivery head, increased
suction pressure other routes, exchanger tube leaks greater
density
Pressure Surge, relief, leakage from an HP connection (lines and
flanges), thermal rate of pressurising lines
Temperature Fouled cooler tubes, cooling water failure, failed exchanger
tubes.
Level Vessel overfill, high static head
Viscosity Change of material, specification or temperature.
LESS Flow Partial blockage, vessel or valves failing, leaks, loss of pump
efficiency.
Pressure Generation of vacuum by pump drain out of vessels,
condensation from vapour or gas dissolving in a liquid. Blocked
pump or compressor suction lines
Temperature Freezing, loss of pressure, loss of heating, failed exchanger
tubes.
Level* Loss of interface, gas blowby, pump cavitation,
Viscosity Change of material, specification, or pressure.
REVERSE Flow As for NO FLOW, plus emergency venting, 2-way flow.
PART OF Composition Passing through isolations, leaking exchanger tubes, wrong
feed material Phase change, out of specification.
AS WELL AS Contamination Ingress of air, leaking isolation valves, filter failure, carry over
FAILURE Relief Relief valve, bursting disc, location of discharge, bellows type,
fire.
Instrumentation Control, pressure, temperature, level and flow measurement;
trips and testing, alarms, indicators, records, set points.
Sampling Type, location, cooling, response time
Corrosion Material specifications, dissimilar metals, pitting, external attack.
Erosion Choked valves, straight tees, localised failure, solids in flow
stream.
Service Failures Cooling Water, instrument air, steam, nitrogen or inert gas;
power to machines, control circuits and computers
Deposition Sand, wax, asphaltenes, hydrates.
Other Maintenance Isolation, drainage, purging, cleaning, drying, slip-plating,
access, catalyst change, start-up, foundations and supports.
Start-up and shutdown
Static Electrical grounding, low conducting liquids, insulated
conductors, fine strainers, dust (pouring, bagging, sieving, etc.).
Outside Conditions Fire, weather, environmental change impact, flood, etc.

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Attachment B – Page: 1/1

ATTACHMENT B - OVERVIEW OTHER GUIDE WORDS TO BE CONSIDERED

The guide words/parameter combination as shown in Attachment A are preferentially used during the
HAZOP sessions during project execution.
Dependent on the process facilities under investigation, the chairman can decide to consider other guide
word combinations to better carry out the HAZOP study. A suggested list of additional parameter/guide
words is provided below.
In the case where a safety review for certain packaged systems, such as HVAC, cylinder blocks etc, is to
be undertaken, or following modifications to project documentation post HAZOP, this list shall be used to
serve as a starting point for checklist/safety review purposes.

• Toxicity
• Commissioning
• Start Up
• Breakdown (Incl. Services Failure)
• Shutdown (Purging, Isolation)
• Effluent (Gaseous, Liquid, Solid)
• Accidental Release (Gaseous, Liquid, Solid )
• Noise
• Vibration
• Testing (Product or Equipment)
• Fire and Explosion
• Quality and Consistency
• Output (Reliability, Bottlenecks)
• Efficiency
• Simplicity

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ATTACHMENT C – EXAMPLE OF HAZOP TABLE AND HAZOP ACTION SHEET

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Attachment C – Page: 2/2

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Attachment D – Page: 1/1

ATTACHMENT D - GUIDELINES ON PLANNING AND SCHEDULING REQUIREMENTS

The table below provides guidelines on how to identify appropriate milestones for HAZOP study execution.

PHASE CONCEPTUAL BASIC, FEED EPCI

Number of HAZOP 1 1 2
sessions
Technique (see below) Coarse Coarse/detailed Detailed
Milestone End of conceptual During FEED End of process design
engineering. (Main)
Vendor packages
information available
(Vendor package)
Engineering Progress 90% 70% 30% (main)
key indicator 70% (vendor packages)

The basis for establishing the HAZOP duration is based on the number of installation units subjected to a
HAZOP review. As a guideline, for P&ID drafted according to Saipem s.a process and piping guidelines, the
number of P&IDs /day to be considered is 3-4/day for detailed HAZOP and 5-6/day for a coarse HAZOP.

Coarse and detailed HAZOP

The differences are highlighted in the table below:

COARSE HAZOP DETAIL HAZOP

HAZOP technique, Nodes Large sections selected. Typically Small sections selected.
process system based, which can Typically process unit/equipment
encompass several P&IDs based, on isolatable sections.
Process unit based, only 1 major
equipment per node. One P&ID.
HAZOP technique, Parameters Limit selection to flow, pressure, Full list is applicable
(guide word) temperature, level, loss prevention
and startup/shutdown.
HAZOP technique, Meeting Meeting notes limited to recording Details of all meeting discussions
notes, report parameter/guideword combinations on parameter/guideword
with actions/recommendations
combinations are recorded.

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Attachment E – Page: 1/3

ATTACHMENT E - HAZOP FOLLOW-UP

As per procedure, all HAZOP actions shall be resolved during the course of the engineering phase by the
engineering project team. All actions are assigned to a discipline, responsible for resolution until close-out by
Project (Saipem s.a. and Client).
How the HAZOP action follow-up is carried out within the Saipem s.a. organization is described in this
Attachment.

The status of the HAZOP actions or recommendations, as well as the actions responses available to date, is
presented in the present attachment.

1. INTRODUCTION
All formulated HAZOP actions and recommendations shall be formally recorded, assigned to a
responsible person, then evaluated and a resolution, acceptance or rejection, provided. The formal
tracking of the HAZOP actions is included in a HAZOP follow-up report.
The follow-up report shall provide the following:
• List of all actions raised during the HAZOP study sessions.
• List of responsible persons nominated for each action.
• Status of each action formulated.
• Responses obtained to each action.
• Approval by action responsible party, Saipem s.a. Project Representative and Client representative.

2. ORGANIZATION

2.1 METHODOLOGY
Resolution of all actions formulated during the HAZOP sessions shall be formally documented in a
dedicated HAZOP tracking system. All findings shall be documented in the HAZOP follow-up report.
The tracking system has been developed to ensure full transparency on the status of each action.
For each action, the following shall be provided:
• Action identifier and description: This refers to the action number as defined during HAZOP and full
HAZOP action wording.
• Action party: This refers to the person designated by the project team to be responsible for resolving
the action. Resolution involves:
− reviewing action content,
− evaluating whether the action shall be implemented,
− evaluating the impact of the action on project design and execution,
− providing cost impact of the action,
− providing time schedule for implementation of the action,
− providing reference to where implementation occurs.
Should an action be deemed not valid or not to be implemented, a justification shall be provided by the
action party and submitted to Project and Client for approval.

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• Response: This refers to the date at which the response was received from the action responsible
person.
• Status: This refers to action resolution status. The following codes shall be used:
− Open - not yet resolved, by discipline
− Pending - awaiting Client’s approval
− Rejected - to be resubmitted for Client’s Approval
− Closed - resolved and action implemented in project
• Approval: This refers to the approval date for close-out of action.
The HAZOP actions shall thus not be incorporated individually in the project action tracking system.
Each action shall however be evaluated for impact on overall project execution by the action responsible
party. If deemed necessary, this shall be communicated to project for inclusion as a separate item in the
Project Action Tracking System.

2.2 ORGANIZATION
The HAZOP follow-up shall be carried out as follows:
1. Issue of HAZOP action sheets to concerned disciplines.
2. Completion of action sheets by disciplines. Completed action sheets shall be directed to the
PSL Safety.
3. Issue of HAZOP follow-up report
4. Organization of HAZOP action close-out sessions with Client.
Action sheets for Client review are attached to each revision of the HAZOP follow-up report. In addition,
action sheets are assigned to each discipline concerned. Each discipline shall send completed action
sheets to HAZOP Coordinator for inclusion in HAZOP follow-up Report. Each action sheet shall be
completed and signed by PSL.
Following each HAZOP follow-up report issue, HAZOP close-out sessions shall be held with Client.
Attendees to such meetings shall be:
• Client’s representative,
• Project representative,
• Action responsible persons (for completed actions in document),
• HAZOP Coordinator (to represent HAZOP chairman).
These meetings shall serve to obtain Client’s approval for the actions under consideration. However,
Client may opt to provide approval without a dedicated close-out meeting.

2.3 TIMING
This HAZOP follow-up report shall be issued periodically, (as a function of project duration, typically
monthly) until close-out of all actions.
Each discipline shall provide a list of completed actions for inclusion in each revision of the HAZOP
follow-up report.
Close-out meetings shall be organized by project. HAZOP close-out meetings shall be organized 1 week
after the issue of follow-up report.

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2.4 RESPONSIBILITY
The HAZOP Coordinator shall be the custodian for the HAZOP close-out Report.
Each designated action responsible discipline is responsible to close out its assigned actions.
Project is responsible for providing approval of provided actions.
All actions shall be resolved in the HAZOP follow-up report.

A typical HAZOP follow-up status table is provided below:

ACTION ACTION RESPONSE APPROVAL DATE

NO. STATUS
DESCRIPTION PARTY DATE SAIPEM s.a. CLIENT

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