HAZOP Analysis As A Core Service
Written By Owen Llanwarne
HAZOPs are one of our core capabilities and since launching in 2018, OTECSA have delivered over 40 studies across the distillery, bio tech, chemicals, food, pharma, manufacturing and oil and gas sectors.
Over the years, we have seen the same mistakes being made and many are avoidable with effective planning and preparation. The outcome is inevitably additional cost for the customer and potentially, a sub optimal HAZOP outcome which in the long term, will also lead to further costs as systems are re-engineered and re-HAZOP’d at a later date.
Before I start any new work scope, I spent time with our clients to understand if they are ready to proceed. This includes making sure we don’t fall into any of my top 5 HAZOP pitfalls:
1. Make sure the HAZOP team are clearly briefed on the project
Otherwise they will find themselves learning the design and operating intent through the HAZOP meetings. This adds additional time to the meetings, a lack of engagement with operations on the basis of a “we’ve not been consulted on what we really want” attitude, and difficulties on agreeing what should actually be assessed, given there is clearly scope for variations on the design chosen.
We choose to produce a Terms of Reference (ToR) for every study, with all the relevant documentation and meeting details, this especially helps with remote studies where there are added considerations on how to engage and meeting etiquette.
2. Define the Control Systems and Cause and Effects
Poorly defined systems can make a smoothly run HAZOP difficult, leading to more time, cost and uncertainty as to what the design intent is. Often a client won’t have a cause and effect matrix, but we always emphasise the need to be coming into the study with the information available, otherwise it’s too easy to miss crucial details – or spend precious time trying to find it during the meetings.
3. Understand your Systems
When a HAZOP is carried out without prior thought to suitable protective measures for high severity events, this can lead to excessive instrumented systems or a requirement for high integrity systems (e.g. SIL rated systems). If this is captured too late in the design process, the impact on the project can be horrible, which leads us on to number 4.
4. Timing is Everything
HAZOP analysis studies are often carried out too early when the design is not complete or design reviews have not been finalised. This can lead to design within the meeting which is time consuming and can mean prior assessment needs revision. In some cases large parts of design can be incomplete, leading to a requirement for phasing of HAZOP as the design develops. If the study is carried out too late, it can become very costly to start introducing design changes and extra mitigation measures.
5. Closeout is Crucial
We often find a lack of clarity on HAZOP action close out procedures. Once you have done the assessment it is imperative that actions are followed through and responses adequately responded and documented. Always make sure you get close out agreement including a representative team similar to that of the original HAZOP and not just one powerful person deciding actions are complete. We have recently started offering HAZOP close out reviews as an added service, because we see a gap in how clients manage the output of studies.
Many of these issues can be prevented by following a more comprehensive hazard study process, including an initial hazard review and HAZID in advance of HAZOP.
However, there is also a need for a clear structured approach to the HAZOP analysis, with communication in advance of the meetings and clarity on what is expected of everyone once the HAZOP is complete.
