hazopanalysiscompletereport-140422013331-phpapp01

8/12/2019 hazopanalysiscompletereport-140422013331-phpapp01

1/15

A Report on HAZOP Analysis


2/15

CONTENTS

1. Introduction2. HAZOP Preparation Selection of HAZOP study team members Information required for HAZOP study Other responsibilities

3. HAZOP Terminology System Design Intent HAZOP Guide words Safeguards & Recommendations HAZOP Study Record & Risk Assessment

4. HAZOP Meeting Procedure5. HAZOP Following Up actions6. HAZOP Closure7. Documentation


3/15

1. IntroductionIncreasing demand by governments and public bodies for improved safety in addition

to a strong awareness within the industry that safe operation can also be highly efficient

and profitable, support the need for plant safety and effective safety management.

Advances in technology and trends to highly complex and integrated plant designs have

sensitized people for systematic and sustainable methods to identify hazards of which the

HAZOPstudy is generally recognized as the foremost solution being able to cover standard

and also new complex technology.

A Hazard and Operability (HAZOP) study is a structured and systematic examination of

a planned or existing process or operation in order to identify and evaluate problems that

may represent a risk to personnel or equipment, or prevent efficient operation. A HAZOP is

a qualitative technique based on "guide words" and is carried out by a multi-disciplinary

team (the HAZOP Team) during one or more meetings.

A HAZOP is a design verification process. It should not be used as a design development

process. The HAZOP should be performed at the stage in the design process when all

preliminary engineering is complete and the basic design has been fixed. This includes

complete process design, process flow diagrams, P&IDs, plant and equipment layout,

operating philosophy, control and instrumentation philosophy, utilities requirements,specification and selection of major equipment items, protection systems, start up and

shutdown systems.

2. HAZOP PreparationIt is the responsibility of the Responsible Officer to initiate the HAZOP study where the

project or modification meets the criteria.

Selection of HAZOP study team members:The Responsible Officer will first appoint an independent HAZOP Leader to act as

the Chairperson for the HAZOP meetings. The HAZOP Leader must be trained in HAZOP

methodology and have successfully completed a suitably recognised HAZOP Leader

Course, or equivalent experience, as approved by the Manager - Project Engineering.

The HAZOP Leader should be independent, i.e. with no responsibility for the process or

operations in the area where the process being reviewed is located.


4/15

HAZOP studies will be conducted using a team approach, with a minimum of four

members. The Responsible Officer together with the HAZOP Leader will select the

HAZOP team members to achieve the spread of knowledge and skills required for the

particular project, and may include:

1. Representative of the customer2. A person with Process knowledge3. A person with Safety & Environmental knowledge4. A person with operating and/or maintenance experience in comparable

environment.

5. A person with Engineering/Design knowledge


5/15

Information required for HAZOP studyThe following information should be assembled by the Responsible Officer and the

HAZOP Leader before the HAZOP study team commences work.

Essential Items:

1. Functionally complete P & ID for the process2. System design philosophy and process description

Desirable Items:

1. Plot plans or layouts2. Process flow diagrams3. Piping class specifications4. Equipment data sheets and purchase specifications5. Vessel inventories6. Relief valve specifications7. Start up and emergency shut-down procedures8.

Emergency depressurizing system functions

9. Electrical area classification10.Standards used11.Procedures - operating and maintenance as applicable

Other responsibilitiesThe Responsible Officer is responsible for the following HAZOP study arrangements:

1. Organizing meeting dates, venue and notices to the attendees2. Layout of venue and supply of stationery and other resources for the meeting3. Provision of information required for the HAZOP study4. Close out meeting date, venue and notice to the attendees.


6/15

3. HAZOP Terminology

SYSTEMA System is a specific location or logical part of the process or operation in which

possible deviations from the design intent are to be evaluated. Examples might be a heat


7/15

exchanger, vessel, pump, compressor and interconnecting pipeline or group of lines.

Systems should be progressively identified on the P&ID as the HAZOP study proceeds.

DESIGN INTENTThe design intent is a description of how the process is expected to behave at the

system being studied. This is qualitatively described as an activity eg feed, reaction,

transfer, heating, and quantitatively in process parameters such as pressure, temperature,

flow rate.

HAZOP GUIDE WORDSAll possible deviations in process parameters in a reactor or a pipeline are

considered to determine their causes and consequences. If a hazard is identified, first the

existing protective measures are analyzed with respect to the intensity of the hazard. If the

protective measures are not adequate, recommendations are given to mitigate the hazard.HAZOP study involves a set of standardized GUIDEWORDS, which are required to initiate


8/15

analysis.

Examples of process parametersinclude the following:

Each guide word is combinedwith relevant process parameters and applied at each point

(study node, process section, or operating step) in the process that is being examined.


9/15

The following Table showed examples of creating deviation using guide words and

process parameters:

SafeguardsSafeguards are facilities, processes or procedures that help to reduce the likelihood

or frequency of the deviation, or to mitigate its consequences.

Examples of safeguards include the following.

1. Procedures to define what actions to take in the event of a deviation.2. Increased frequency of inspection, servicing or calibration of critical items.3. Facilities that draw attention to the deviation (eg indicators and alarms to inform

operators so that they can make the process safe).

4. Facilities that automatically compensate for the deviation (eg an automatic control.5. System, usually an integrated part of the process control).6. Facilities that prevent the deviation from occurring (eg excess flow valve).7. Facilities that prevent further escalation of the deviation (eg by total trip of the

activity or process by a safety interlock, control system, or emergency shutdown

(ESD) system).

8. Facilities that relieve the process from a hazardous deviation (eg pressure safetyvalve (PSV) and vent systems)

As each cause and consequence scenario is identified, planned safeguards should be

reviewed to determine if they are adequate to either prevent the deviation or to protect the

System if the deviation occurs. Any decision on the adequacy of the safeguards should takeinto consideration the magnitude of the potential consequences and the likelihood of the

event occurring with all the planned safeguards in place. This is reflected in the risk

assessment as below. Each scenario will usually have more than a single layer of protection.

For high risk deviations, it is useful to review each of the layers of protection before

determining the adequacy of the safeguards.


10/15

RecommendationsIf the HAZOP Team recommends that additional safeguards or changes to the design

should be made to ensure the safety of the system, these recommendations must be

recorded on the HAZOP Record for further action after the HAZOP study. The name of the

person who will be responsible for the further actions should be recorded on the form next

to the assigned action.

HAZOP study recordHAZOP Study Record form is used to create a historic record of the HAZOP Study.

Details of discussions, decisions taken, risk assessments made and further actions

recommended during evaluation of each of the HAZOP Study Cards will be progressively

recorded by the HAZOP Secretary on the HAZOP Study Record form.

Risk AssessmentRisk assessments should be carried out to quantify the risks associated with

deviations and their potential consequences, and to assist in determining the adequacy of

planned safeguards and the possible need for further action. An initial informal risk

assessment should be carried out on each cause - consequence scenario based on the

inherent risk in the unprotected state.

The Risk Matrix included in the below table should be used as a guide. The risk

should then be re-assessed taking into consideration the planned safeguards and risk

reduction measures. For less important risks, the need for further action can be based on

the experience and judgment of the HAZOP Study Team.


11/15

Once the reasonable consequence and likelihood of each potential unwanted event

is determined, the risk can be ranked using the Risk Assessment Matrix below andrecorded on the HAZOP Study Record sheet.

For high risk scenarios, several layers of protection will usually be necessary to

reduce the risk to an acceptable level. If the HAZOP team agrees that, so long as the planned


12/15

safeguards are in place, the risk of an unwanted event occurring is reduced to an acceptable

level, then no further action is required.

For extreme risk scenarios, the adequacy of safeguards and the need for further

action should be quantitatively assessed using higher level risk assessment techniques

such as Layer of Protection Analysis (LOPA), or Safety Integrity Level (SIL) analysis. The

risk assessment process and outcome should be recorded on the HAZOP Study Record form

against each item.

4. HAZOP Meeting ProcedureAt the HAZOP meeting, the HAZOP Leader will act as Chairperson to lead the team

through each of the following steps.

a) Introduce the project: Ensure all team members are familiar with the HAZOP process Define the project for the team Review the proposed process or modification using the Process and

Instrumentation Diagram (P&ID) and describe its operation

On the P&ID, divide the process to be studied into logical Systems.b) Carry out HAZOP Study: Select a particular System for detailed review and describe the design intent for that

System. Work through the guide words on the HAZOP Study Cards, following the

HAZOP Process Flow Chart.

For each guide word, establish if the deviation from normal conditions suggested bythe guide word could occur. If the deviation could occur, identify the possible causes

of the deviation.

Determine the possible consequences or problems if the deviation occurred. Carry out an initial assessment of the risk associated with the identified

consequences Review any proposed safeguards to prevent or mitigate the

consequences. Evaluate if the proposed safeguards adequately reduce the risk to an acceptable

level and if not, suggest further actions having regard to the consequences and the

safeguards already proposed.

Repeat procedure from [step (a)] above for the next System. Progressively completeHAZOP Study Record form including recording of further actions.


13/15

Modifications must be assessed for impact during a variety of plant conditions (ie.

startup, running, plant upset, and plant shutdown). This aspect will be formallydocumented where appropriate throughout the HAZOP, and must also feature as a specific

element considered within the agreement and sign-off of the final records of the HAZOP.

5. HAZOP Following Up actionsThe Responsible Officer shall ensure that all actions arising from the HAZOP are

properly managed and are completed prior to commencing the modification or

HAZOP PROCESS FLOW CHART


14/15

commissioning the modified plant as determined during the HAZOP. The items recorded on

the HAZOP Study Record form SF1309 as requiring action shall be numbered and a

required date of completion established. This information shall be entered into the

Recommendations column on the HAZOP Study Record.

6. HAZOP ClosureWhen all follow-up actions are complete, the Responsible Officer shall note on the

HAZOP Study Record of Discussions (SF 1909) that all items have been completed and

make reference to the Inspection Reference Number in Cintellate. To assist in later

verification, a copy of the complete Cintellate record should be printed out after all actions

have been completed and attached to the HAZOP Study Record in the Project file.

Close out meeting:

The Responsible Officer will arrange a close out meeting to record completion of

outstanding issues.

Once all parties are satisfied that all issues arising from the study have been

adequately addressed and are reflected in the project design documentation, form HAZOP

Study Record of Discussions form shall be completed and signed off by the Responsible

Officer and the Customer Representative.

No commissioning activities associated with the modification or the new plant

covered by the HAZOP shall commence until form HAZOP Study Record of Discussions

(SF1909) has been signed off.

7. DocumentationThe following HAZOP study information and documents are required for the files:

a) HAZOP Study Record which includes: Project title Project number (that is, work order number for the parent project) Project scope Study date Participant names, job titles, organisation, brief profile

b) Signed off HAZOP Study Record of Discussionsc) The original copy of all P&IDs used in the study (with lines clearly identified)d) Variations in guide words used.


15/15

e) Signed off Action Summary sheetf) Signed off HAZOP Action sheets

The study Responsible Officer is responsible for the preparation and collation of the

output documentation from the HAZOP study, and for forwarding it to all attendees,including the Chairperson who should sign off the HAZOP Study Record before filing by the

Responsible Officer.

The Responsible Officer ensures an electronic copy the documentation listed above

is filed in the Domino. Doc System in accordance with Management of Risk Assessment

Records. A hard copy of all this documentation will also be filed in the Project File by the

Project Officer.

Date post:	03-Jun-2018
Category:	Documents
Upload:	achyut
View:	215 times
Download:	0 times

hazopanalysiscompletereport-140422013331-phpapp01

Documents