WHAT IS HAZOP?
HAZOP, or a Hazard and Operability Study, is a systematic way to identify possible
hazards in.a work process. in this approach, the process is broken down into steps, and
‘every variation in work parameters is considered for each step, to see what could go
wrong. HAZOP’s meticulous approach is commonly used with chemical production and
piping systems, where miles of pipes and numerous containers can cause logistical
headaches.
HAZOP and Hazard Analysis Systems
‘The task of analyzing hazards in a workplace or system can be daunting, However,
‘without an effective analysis, potential hazards may not be discovered before they result
in injuries and loss. The cost of an accident is often many times greater than the cost of
‘the analysis that could have stopped it. It's the old proverb: "An ounce of prevention is
‘worth a pound of cure.”
‘There are many ways to assess a process or workplace for hazards, and each approach
has strengths and weaknesses. For example, the worker-focused Job Hazard Analysis
(JHA) is particularly effective for protecting workers, because it considers each task that
a worker must perform,
However, if you need to assess a long and complex system, rather than individual
workers’ safety needs, a broader hazard analysis method may be needed. OSHA lists
‘several common methods of finding the potential hazards in these systems, including
What-If Analysis:
Hazard and Gperability Studies (HAZOP)
Failure Mode and Effects. Analysis (FMEA)
Fault Tree Analysis
HAZOP is a common hazard analysis method for complex systems. It can be used to
identify problems even during the early stages of project development, as well as
identifying potential hazards in existing systems,
The HAZOP Study Process
A Hazard and Operability Study systematically investigates each element in a process.
‘The goal is to find potential situations that would cause that element to pose.a hazard or
limit the operability of the process.as. a whole, There are four basic steps to the process:
Forming a HAZOP team
dentitying the elements of the system
Considering possible variations in operating parameters
Identifying any hazards or failure points
BONE
‘Once the four steps have been completed, the resulting information can lead to
improvements in the system. The best way to apply the results of a HAZOP study will
depend on the nature of the system.1. Form a HAZOP Team
Ta perform a HAZOP, a team of workers is formed, including people with a variety
of expertise such as operations, maintenance, instrumentation,
engineering/process design, and other specialists as needed. These should not be
“newbies,” but people with experience, knowledge, and an understanding of their
part of the system. The key requirements are an understanding of the system, and
‘8 willingness to consider all reasonable variations. at each point in the system,
2. Identify Each Element and its Parameters
The HAZOP team will then create a plan for the complete work process, identifying
the individual steps or elements. This typically involves. using the piping and
instrument diagrams (P&I), or a plant model, as a guide for examining every
section and component of a process. For each element, the team will identify the
planned operating parameters of the system at that point: flow rate, pressure,
temperature, vibration, and So on
3. Consider the Effects of Variation
For each parameter, the team considers the effects of deviation from normal. For
‘example, “What would happen if the pressure at this valve was too high? What if
the pressure was unexpectedly low? Would the rate of change in pressure (delta~
») pose its own problems here?” Don't forget to consider the ways that each
element interacts with others over time: for example, “What would happen if the
valve was opened too early, or too late?”
4. Identify Hazards and Failure Points
Where the result of a variation would be a danger to workers or to the production
process, you've found a potential problem. Document this concern, and estimate
the impact of a failure at that point. Then, determine the likelihood of that failure;
is there a real cause for the harmful variation? Evaluate the existing safeguards
and protection systems, and evaluate their ability to handle the deviations that
you've considered
Results of a HAZOP Study
Because HAZOP is a mental exercise, it can be implemented as part of the planning of a
new work process, even before a facility is built. Existing facilities and processes can also
be assessed with HAZOP.
Where a HAZOP study is performed in the planning stage of a new process, completing
the study means that all potential causes of failure will be identified. The HAZOP team
will write an assessment weighing the potential deviations, their consequences, their
causes, and the protection requirements. From this point, changes to the plan can be
made to prevent problems from arising, or to mitigate their effects.In existing facilities, a HAZOP may be ongoing, working to improve the process without
any specific end date. instead of a single, large assessment, the study's results will be
released as a stream of action items, as each problem is identified and a solution is
created,
in both cases, when a hazardous condition is identified, recommendations may be made
for process or system modifications, or further study by a specialist may be required. A
HAZOP study might recommend these typical actions:
+ Arreview of existing protection system designs by a specialist
* Adding oF modifying alarms that warn of deviations,
Adding or moditying relief systems
+ Adding or modifying ventilation systems
* Increasing sampling and testing frequency
Each of these steps might be recommended as part of the overall Hierarchy of Controls.
This way of addressing hazards is intended to prioritize the most effective steps.
The Role of Labeling in HAZOP
In the complex processes where the HAZOP approach is most effective, the size and
intricacy of the system can be overwhelming. Analysis and maintenance, as well as
ordinary, day-to-day operation, require workers to navigate these systems. To allow
effective work, system components such as pipes, valves, instruments, and vessels must
be identified and labeled.
Often, safely maintaining a system will require monitoring, When measurements must be
taken af the same point in a system, it makes sense to clearly mark that point with an
indication of the test to be performed. Bad data will ruin the usefulness of any monitoring
system.
Opening the wrong valve, or cutting into the wrong pipe, have often been the causes of
‘serious accidents. That's why the ANSI/ASME A13.1 standard is so widely used for
labeling pipe systems; it requires clear, bold labels in a highly-visible placement scheme.
Where hazardous chemicals are used as part of the process, OSHA's HazCom labeling
rules apply, The rules are meant to give workers the information they need to be sate,
and effective labeling serves that goal.
Labeling and signage are critically important in these cases. The DuraLabel tine of
printers from Graphic Products can help your facility create the signs and labels that you
need