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Hazard &
Operability
Studies
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HAZARD STUDY
HAZAN
SAFETY AUDIT
DOW INDICES (HAZARD RANKING)
ACCIDENT ANALYSIS
EIA
HAZOP
HAZARD & OPERABILITY
SCENARIO DEVELOPMENT
The above diagram of inter-relationships shows that there are there are four main areas of hazard study namely :
Hazard analysis (HAZAN), Hazard and Operability study (HAZOP), Scenario development, Quantitative Risk
Assessment (QRA) and finally Emergency Management Plan (EMP). These inter-relationships are more
elaborated in the following diagram :
SYSTEM DESCRIPTION
HAZAN
HAZARD IDENTIFICATION
DOW INDICES
ACCIDENT ANALYSIS
SCENARIO DEVELOPMENT
ACCIDENT PROBABILITY
HAZOP
ACCIDENT CONSEQUENCE
RISK DETERMINATION
RISK AND/OR HAZARD ACCEPTABILITY
QRA
NO
YES
EIA
EMP
HAZOPS - What ?
THE BASIC CONCEPT
Essentially the HAZOPS procedure involves taking a full
as
to
whether
such
deviations
and
their
If considered
HAZOPS - What ?
(Contd.)
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HAZOPS - Why ?
HAZOP studies are mainly intended to :
HAZOPS - Why ?
(Contd.)
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HAZOPS - When ?
HAZOP studies are best performed on:
and documented;
existing plants as part of a periodic hazard
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FUNDAMENTAL ASSUMPTION
HAZOPS - How ?
HAZOP studies the stages in the conduct of the study
Select a section (node)
Select a Parameter
Apply guidewords to identify potential deviations
Brainstorm all possible causes (stay within the section)
Select the first identified cause
Develop ultimate potential consequence(s) (look inside and outside
the section)
List existing safeguards (look inside and outside the section)
Develop risk ranking
Propose recommendations (weigh consequences and safeguards)
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Organize a team
Act as a facilitator to bring to bear the
expert knowledge of the team members in
a structured interaction.
Get the team to think the unthinkable.
Focus more on the human element.
Not to identify hazards and operability
problems, but rather to ensure that such
identification takes place.
Documents needed:
Design Basis
P&IDs
Cause & Effects Diagrams
Operating Philosophy/ Instructions..
(Contd.)
Scribe:
records proceedings,
prepares action lists after each session
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Selection of a Scribe
Another important member of the team will be the Scribe or
the Secretary.....
Start on time
All
peers
No bad ideas
Safe environment
Everyone contributes
Frequent breaks
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Diversity is good
Present your views but avoid arguing for them
Listen to others
Look for compromise
Do not change your views to avoid conflict
Be suspicious of agreements reached too
easily
Avoid majority votes, seek consensus
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Terminology
Section/Node
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Keywords/ Guidewords
An essential feature in this process of questioning and systematic analysis
is the use of keywords to focus the attention of the team upon deviations
and their possible causes. These keywords are divided into two sub-sets:
Keywords/ Guidewords
Primary Keywords:
These reflect both the process design intent and operational aspects of the
plant being studied. Typical process oriented words might be as follows.
Flow
Pressure
Separate (settle, filter, centrifuge)
Composition
React
Reduce (grind, crush, etc.)
Corrode
Temperature
Level
Mix
Absorb
Erode
Isolate
Purge
Maintain
Shutdown
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Keywords/ Guidewords
Secondary Keywords:
when applied in conjunction with a Primary Keyword, these suggest potential
deviations or problems. They tend to be a standard set as listed below
No
Less
More
Reverse
Also
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Keywords/ Guidewords
Secondary Keywords: (Contd.)
Other
Fluctuation
Early
Late
As for Early
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Guidewords:(Simple words used to qualify or quantify the intention and to guide and
stimulate the process for identifying process hazards)
Lines
X
X
X
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Brainstorming Causes
Deviations are used to help team identify causes of
upsets, i.e. how does the process break down ?
The same cause may apply to two or more deviations
Do not criticize causes during brainstorming
Do not argue about whether or not a cause belongs in a
particular deviation (no flow, less flow); develop it
when it comes up
Do not list the same cause twice; develop it the first
time; if a new deviation triggers some thoughts for
additional consequences of a previously developed
scenario, go back and revise the scenario
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Pressure
Temperature
Level
Part of
More, High
N/A
Open to atmosphere.
Generation of vacuum by
pump drain out of
vessels, cooling or
condensation from
vapour or gas dissolving
in a liquid.
Pump/compressor
suction lines blocked.
N/A
Freezing, loss of
pressure, loss of heating,
failed exchanger tubes.
N/A
N/A
Poor mixing, or
Passing through
interruption during mixing. isolations, leaking
exchanger tubes, phase
change, out of spec.
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(Contd.)
Heat Exchanger
Pump
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Equipment
PSVs
Redundant/ voting systems
Independent alarms/ shutdowns
Control instruments
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S
L
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Likelihood
1
2
3
4
5
1
1
2
3
4
5
2
2
4
6
7
8
Severity
3
3
6
7
8
9
4
4
7
8
9
10
5
5
8
9
10
10
Definition
Class
1 V High
2 High
V High
High
Medium
Low
V Low
5 V Low
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DEVIATION
CAUSE
CONSEQUENCE
SAFEGUARDS
ACTION
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V1
Dosing
Tank T1
P1
Strainer S1
Pump P1
Note that this is purely representational, and not intended to illustrate an actual
system.
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(Contd.)
Deviation
Cause
Consequence
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(Contd.)
Safeguards
Any existing protective devices which either prevent
the cause or safeguard against the adverse
consequences would be recorded in this column. For
example, you may consider recording "Local pressure
Action
Actions fall into two groups:
1.Actions that remove the cause.
2.Actions that mitigate or eliminate the consequences.
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(Contd.)
Preparatory Work
This preparatory work will be the responsibility of the
3.Subdivide the plant and plan the sequence (Split into manageable sections,
endeavour to group smaller items into logical units...)
4.Mark-up the drawings (use distinctive and separate colours, when node spans
two or more drawings, the colours used should remain constant)
7.Prepare a timetable
8.Select the team (chairman also to ensure the core team members are available for
the duration of the review,)
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(Contd.)
If discussion wanders away from the matter under consideration, refocus the attention of the team either by requesting that the Secretary
read out what he has recorded, or by asking for an action to be
formulated.
The Chairman should be independent and unbiased, and should not be
perceived as constantly favoring one section of the team as opposed to
another
Take as an example the situation where the client wishes to have an additional High Level Alarm, but the
contractor strongly disputes its necessity. Consider the following actions:
"Fit a High Level Alarm". In the view of the contractor, the Chairman has sided with the client. He may,
wrongly or otherwise, perceive this to be a biased decision.
The action "Justify the requirement for a High Level Alarm" is addressed to the client. The Chairman
favors the contractor's argument, but is not dismissing altogether the views of the client. Both parties are
likely to be content with this formula.
The action "Justify the absence of a High Level Alarm" is addressed to the contractor. The Chairman
favors the client's argument, but is not dismissing altogether the views of the contractor. As before, neither
party will have cause to feel aggrieved.
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The Report
The HAZOP Report is a key document pertaining to the safety of the plant.
It is crucial that the benefit of this expert study is easily accessible and
comprehensible for future reference in case the need arises to alter the plant
or its operating conditions.
The major part of such a report is the printed Minutes, in which is listed
the team members, meeting dates, Keywords applied, and every detail of
the study teams findings.
However, with this is included a general summary. The contents of such a
summary might typically be:
- An outline of the terms of reference and the scope of study
- A very brief description of the process which was studied
- The procedures and protocol employed.
- A brief description of the Action File should be included
- General comments
- Results. (usually states the number of recommended actions)
- Appendix (master copies of dwgs., studied, tech data used, cals produced,
C&E charts, corr. bet contractor to vendor, or client to contractor etc. )
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Explain
design intent
Select Process
Parameter
Apply
Guidewords
Identify
credible
Deviations
Identify
credible
Causes
Examine
Consequences
Select a Node
Identify
existing
Safeguards
Develop
Recommended
Actions
Assess Risk
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Select a vessel
11
11
12
12
Repeat 5-12
Mark vessel as
completed
Repeat 1-22 for all vessels
on flow sheet
Select a line
13
13
14
14
15
15
16
17
Examine Consequences
18
Detect Hazards
19
10
20
End
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Yes
No
Select a Primary Keyword not previously considered. (e.g. pressure)
Have all the relevant Secondary Keywords for this Primary Keyword been considered ?
Yes
No
Select a Secondary Keyword not previously considered. (e.g. More)
Are there any causes for this deviations not previously
discussed and recorded ?
No
Yes
Record this new cause.
No
No
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HAZOP Summary
HAZOP is a qualitative, verbal and an interactive group
process
that
attempts
to
identify
hazards
and
HAZOP Summary
Formal Record of Study
Minimizes cost to implement appropriate
safeguards in new or modified facilities
Participants gain a thorough understanding of
the facility
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