At OTECSA, we understand that conducting thorough Hazard and Operability (HAZOP) studies is essential to ensuring process safety. However, assessing road tanker loading and offloading operations can present unique challenges, particularly when critical information is missing or incomplete.
Challenging Aspects of HAZOP
Our Process Safety Lead, John Speirs, has facilitated several HAZOP studies where tanker operations played a significant role. Across these studies, teams consistently faced difficulties due to a lack of critical data, including:
- P&ID details outlining the configuration of pipework, valves, instruments, and pumps on the tanker
- Design specifications such as temperature, pressure, and vacuum data for the tanker barrel
- Pressure and vacuum relief information for the barrel, including set point pressures and relief capacity flow rates
- Driver procedures dictated by their employer, which can vary and are often not disclosed to the plant operator
- Materials of construction data for the tanker, including details on the barrel, pipework, valves, gaskets, and other components
These gaps in data often complicate the assessment of tanker loading in HAZOP, leading teams to question whether to exclude certain operations from the study or delay the process entirely. These gaps in information typically arise because the tanker is the only part of the process that is not owned or operated by the plant owner. As a result, plant operators often lack access to the detailed data required for a comprehensive HAZOP assessment.
This leads to a common set of questions for HAZOP teams:
- Should the tanker be treated as a “black box” and excluded from the HAZOP scope?
- Should multiple actions be raised for the plant operator to follow up with the tanker company?
- Should the tanker-related scope be delayed until sufficient information is gathered to properly assess it?
To address these challenges, John has introduced a proactive approach. Going forward, we will send a list of key questions to the plant operator well in advance of HAZOP sessions. The goal is for the plant operator to liaise with the tanker company ahead of time, ensuring that the necessary information is available before the HAZOP meeting takes place.
This method not only streamlines the HAZOP process but also helps ensure that tanker-related risks are properly identified and mitigated.
How do you handle tanker operations in your HAZOP studies?
We’re keen to hear about the strategies and solutions you’ve implemented to tackle similar challenges. Get in touch with us to share your experiences or to learn more about how OTECSA can support your process safety initiatives.