HEALTH SAFETY & ENVIRONMENT

(HSE)

HAZARD & OPERABILITY STUDY (HAZOP)

Reference: HSEMS Expectation No. 35 - 37

1
Contents

Title of the Slide Slide No.

1. Introduction 4
2. Risk Management 5-6
3. Hazard Identification (HAZID) Techniques 7-8
4. Hazard & Operability Study (HAZOP) 9 - 20
5. Types of HAZOP Study 21
a. HAZOP Methodology Flow Diagram for Continuous 22
Process
b. Batch HAZOP 23
b (i). HAZOP for Batch Operations – ‘Step by Step’ 24
Method
b (ii). HAZOP for Batch Operations – ‘Section by 25
Section’ Method
2
Contents…contd.

Title of the Slide Slide No.

c. HAZOP of Procedures 26
d. HAZOP of Instrument – control systems & Electrical 27
systems
e. HAZOP of Emergency Response Plan 28
e (i). ER HAZOP – Overall Process for each accident 29
scenario
6. STRUCTURED WHAT – IF ANALYSIS (SWIFT) 30 - 33

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1. Introduction

• Risk – It has two dimensions, chance of something to happen & the

consequence should that thing does happen
• Risk analysis – Assessment of potential severity of loss along with
the probability & exposure of hazard
• Hazard – A condition or practice with a potential for loss
• Safety – Control of accidental loss
• Risk control – Anything done to reduce loss from the business. It
includes:
– The elimination or reduction of loss exposures
– The minimization of loss when loss producing events occur.
– The termination or avoidance of risk
• Risk management – It is the application of management policies,
procedures & practices for analyzing, evaluating & controlling risk

4
2. Risk Management

People Property Environment

Harm

Hazard Accident

Likelihood Consequences

Risk

5
2. Risk Management…contd.

• It is the application of management policies, procedures & practices

for analyzing, evaluating & controlling risk & can be illustrated by
IEDIM -
Identification of loss exposures

Evaluation of risk

Develop the plan –

i. Terminate ii. Treat iii. Tolerate iv. Transfer

Implement the plan

Monitor/Review
6
3. Hazard Identification Technique (HAZID)

• What is HAZID?
– The most critical step involved in a risk assessment
– A qualitative review of possible accidents that may occur, in order
to select failure cases for detailed modeling
• Key objectives of HAZID:

- Primary objectives:

Completeness – Full list of potential hazards

Knowledge based – Be aware of past accidents and other work
Multi - disciplinary – Allow lateral thinking from diverse experiences

- Secondary objectives:

Auditable – Possible to track the process, well documented

Structured – To ensure completeness & quality of documents
Efficient – Focus on immediate problem, useful purposes

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3. Hazard Identification Technique (HAZID)
…contd.

• Some techniques of Hazard Identification:

– Past experience
– Methodical Leak/Rupture
– Engineering Codes & Standards
– Hazard Review
– Hazard Checklist
– Structured What – If Analysis (SWIFT)
– Hazard & Operability Study (HAZOP)
– Failure Modes, Effects & Criticality Analysis (FMEA)
– Fault Tree Analysis (FTA)
– Event Tree Analysis (ETA)

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4. Hazard & Operability Study (HAZOP)

• HAZOP is:

– A formal procedure to review design & operation of

hazardous process facilities
– “Structured brainstorming” or “Formalized
Imagineering”
– Identifying deviation from normal operation which
could lead to hazard or operability problems
– Identifying the possible causes of the deviations

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4. Hazard & Operability Study (HAZOP)
…contd.

• It is based on:

– Normal operation is a safe operation

– A deviation of a system parameter:
• Can be absorbed in the system if change is within
limits
• Has an effect & can cause change
– Deviations cause problem

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4. Hazard & Operability Study (HAZOP)
…contd.

• Advantages of HAZOP:

– Systematic examination of a restricted system

– Level of the examination can be chosen according to
the goal
– Good method for training operating personnel &
designers & for obtaining deeper knowledge of the
system behaviour
– Gives the basis of modelling & quantification of
hazards by other methods
– Can be used as a way of rigorously & systematically
checking a design for safety, operability & conformity
with codes of practice, etc
11
4. Hazard & Operability Study (HAZOP)
…contd.

• Disadvantages of HAZOP: It does not reveal

– Hazards generated by factors outside the system

– Occupational accident failures, hazards of chemicals
& chemical reactions are only partly within the scope
of the analysis
– The consequences of complicated chain of events
– The deficiencies in the installation & location of the
equipment

12
4. Hazard & Operability Study (HAZOP)
…contd.

• Various steps involved in the development of HAZOP

study are –

4 a. Defining the objectives & scope

4 b. Selecting the HAZOP team members
4 c. Preparing for the study
4 d. Undertaking the study
4 e. Recording the result
4 f. Conducting the follow up actions

13
4. Hazard & Operability Study (HAZOP)
…contd.

4 a. Defining the objectives & scope – A no. of

factors will influence the study objectives & scope,
among which are:

– The nature & stage of the project

– The requirement of full documentation
– The availability of personnel for the HAZOP team
– The no. of P & ID’s
– The timing & the duration allowed for the study
– The degree of the authority given to the study team
– Budget
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4. Hazard & Operability Study (HAZOP)
…contd.

4 b. Selecting the HAZOP team members – This should comprise

of:

– HAZOP Leader

– HAZOP Scribe

– Process Personnel
– Safety Personnel
– Maintenance Personnel
– Operation Personnel
– Instrumentation Personnel

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4. Hazard & Operability Study (HAZOP)
…contd.

4 c. Preparing for the study –

– Establish the ground rules of the study

– Plan the study schedule
– Identify the team members & arrange for their
assistance
– Organize the data base
– Become familiar with the data base
– Ensure that all team members are familiar with the
design & operating principles
– Arrange a suitable meeting place.

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4. Hazard & Operability Study (HAZOP)
…contd.

4 d. Undertaking the study – After breaking the P & ID into

different nodes, there are seven stages which are repeated
many times during a HAZOP –

– Apply a guideword
– Develop a deviation
– Examine possible causes
– Examine consequences
– Consider hazards, or operability problems
– List existing safeguards
– Decide upon action
– Make a record of the discussion & decision

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4. Hazard & Operability Study (HAZOP)
…contd.

4 e. Recording the result – The following points should

be kept in view –

– While making the recommendations, 3 W’s should be

answered : “What do I do?”, “Where do I do it?” &
“Why do I do it?”
– The team leader & scribe should review & edit the
record of each day’s study
– The record after completion should be printed &
distributed for the team to review its accuracy
– The leader should ensure during his review that none
of the recommendations are open ended.

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4. Hazard & Operability Study (HAZOP)
…contd.

4 f. Conducting the follow up actions – It can be done by the preparation of

report – Draft Report & Final Report

4 f (i). Draft Report – The format of the draft report could be as

follows:
– Introduction
– Description of the study method
– Objective & scope of the study
– Description of the unit/process studied
– List of HAZOP team members with location & job titles
– Study period & list of P & ID’s studied
– Major recommendations
– Appendices:
• HAZOP study log sheets
• Complete list of recommendations
• Team members and P & ID’s studied by session

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4. Hazard & Operability Study (HAZOP)
…contd.

4 f (ii). Final Report – The contents of the final report

could be as follows:

– Introduction
– Description of the study method
– Objective & scope of the study
– Description of the unit/process studied
– List of HAZOP team members with location & job titles
– Study period & list of P & ID’s studied with identification codes
– Major recommendations
– Major actions taken
– List of recommendations rejected & reason for rejection
– List of recommendations being evaluated

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5. Types of HAZOP

5 a. HAZOP for Continuous process

5 b. HAZOP for Batch Operations
5 c. HAZOP of Procedures
5 d. HAZOP of Instrument – control systems & Electrical
systems
5 e. HAZOP of Emergency Response Plan

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5 a. HAZOP Methodology Flow Diagram for
Continuous Process
Start

Decide on SCOPE & OBJECTIVE of study

Choose a study section

Clearly set out operating conditions & design intent

Apply first (next) guideword to generate deviations

Identify possible causes for each deviation in turn & record

Decide on potential consequences for each cause & record

List safeguards against causes or consequences of deviation

Decide on any necessary recommendations & record

Yes
More guideword?
Yes No
More section?
No
Finish
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5 b. HAZOP for Batch Operations

• Approach to Batch HAZOP –

1. Understand steps of the process.

2. Prepare the matrix of steps & sections (active &
inactive)
3. Each step becomes a node, carry out continuous
HAZOP & also consider when inactive becomes active
4. Use additional guidewords

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5 b(i). HAZOP for Batch Operations –
‘Step by Step’ Method
1st Step

Take 1st Active Section

Complete Log sheet

Take next Active Section No Last Active Section?

Yes

Take other inactive sections Next Step

Complete Log sheet

Last Step?
Yes

Finished
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5 b(ii). HAZOP for Batch Operations –
‘Section by Section’ Method
1st Section

Take 1st Step in which this section

is active

Complete Log sheet

Take next step in which No Last step in which this section

this section is active is active?
Yes
Take steps in which this section
Next Section
is not active

Complete Log sheet

Last Section?
Yes

Finished
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5 c. HAZOP of Procedures

• It is concerned with the software (practices) rather than

the hardware
• The procedure is a set of instructions to be followed in a
sequence
• To achieve the objective in a safe manner

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5 d. HAZOP of Instrument – control systems
& Electrical systems

• HAZOP of Instrument – control systems would consider

the reasons for the sequence of the control logic, as well
as reviewing the control philosophy & design

• HAZOP of Electrical systems – An electrical distribution

system HAZOP can be carried out to identify the
consequences of power failure to the individual
components, as well as total power failure.

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5 e. HAZOP of Emergency Response Plan

• For the ER HAZOP the structure is provided by

accident scenarios, ER stages, property words &
guidewords
• It enables a more systematic review of emergency
response arrangements as compared to purely brain
stormed ideas
• It is very effective method for transferring valuable
information between project phases.
• It is considered to be suitable for application at various
periods in the lifecycle of plant development &
operation
• It can highlight possibilities that had not been expected

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5 e (i). ER HAZOP – Overall Process for
each accident scenario
Start

Decide study

Select Node

Apply Guideword & Deviation

Identify possible causes

Select cause

Assess Consequences

Assess Safeguards

Assess need for Recommendations

Repeat for all causes until complete

Repeat for all guidewords/deviations until complete

Repeat for all nodes until complete

End 29
6. Structured What – If Analysis (SWIFT)

• It is a thorough, systematic, multidisciplinary team oriented analytical

technique
• Application of SWIFT – To identify the different risks areas & to
identify those risks that when addressed will make the biggest impact
on the overall risk.
• Conducting a SWIFT –
The following issues can be taken up Hazards of the process
– Hazards of the process
– Previous incidents with catastrophic potential
– Engineering & administrative controls
– Consequences of failures of engineering & administrative
controls
– Unit layout
– Qualitative evaluation of safety & health effects
– Other regulatory issues

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6. Structured What – If Analysis (SWIFT)
…contd.

• The structure for questioning is provided by the following

categories:

– Equipment/Instrumentation malfunction
– Utility failures
– Integrity failure or loss of containment
– Environmental release
– Operating errors & other human factors
– Material problems
– External effects or influences
– Analytical or sampling errors
– Process upsets of unspecified origin
– Emergency operations

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6. Structured What – If Analysis (SWIFT)
…contd.

• Advantages of SWIFT –

– It is efficient because it generally avoids lengthy discussion of

areas where the hazards are well understood or where prior
analysis has shown no hazards are known to exist.
– It’s effectiveness in identifying hazards comes from asking
questions in a variety of important areas.
– Hazards are identified according to a structured plan to help
ensure complete coverage of all the various types of failures or
errors which are likely to result in hazards within the system being
examined.
– The SWIFT analysis is further strengthened through the use of
the checklists at conclusion of each question category resulting in
an additional level of thoroughness

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6. Structured What – If Analysis (SWIFT)
…contd.

• Disadvantages of SWIFT –

– Although risk reduction measures will be obvious for

some of the issues raised, further analysis methods
need to be applied to determine exactly how risks can
be reduced.
– The quantification of the risk relies on a ‘gut feel’ in
many cases, & again it must be realized that other
techniques need to be employed to determine the
magnitude of the risk more accurately

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THANK YOU

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