HAZOP facilitation can be a minefield – we get it. This process can sometimes put people off doing a HAZOP, or lead to a substandard study if not properly facilitated. We’re here to demystify some of the unknowns around HAZOP facilitation to make this study more understandable.
Can I Handle My Own HAZOP Facilitation?
If you are the process owner or designer, it is generally advised that you do not facilitate your own HAZOP study. Why? Because true HAZOP facilitation requires independence between the facilitator and those with a financial or design stake in the project.
Bias in HAZOPs can arise from:
- Financial/Project bias: The facilitator may be influenced to avoid suggesting improvements that conflict with project budgets or timelines.
- Design bias: The facilitator may be too close to the design, leading to overlooked hazards or unchallenged assumptions.
This is why we always recommend using an independent HAZOP facilitator. Independence gives all stakeholders confidence that recommendations are based solely on safety and good practice—not financial or internal constraints.
Tip: When budgeting a project, include a separate line item for HAZOP facilitation and reporting to ensure objectivity.
Do We Need to HAZOP a Supplied Package?
If your facility includes packaged systems (e.g., a boiler skid), these must still be covered under a suitable risk assessment. If you plan to exclude them from your main HAZOP, the package must come with its own study that reflects your site’s specific conditions.
Key considerations include:
- Have the supplier’s assumptions been validated for your site?
- Do the HAZOP recommendations cover your operational context?
- Have you assessed the interfaces between the package and your systems?
For example, if a fuel supply is managed separately from a packaged boiler system, you still need to evaluate the impact of a fuel interruption. Likewise, if the steam output from the package affects other site processes, this needs to be addressed.
In cases of uncertainty, we recommend including the package in your HAZOP—ideally with the supplier participating in the session.
Can We Speed Up the HAZOP Process?
Speed concerns are common, especially when under cost or time pressures. However, HAZOP takes as long as it needs. One clear indicator of a slow HAZOP is a high number of actions—often a sign that the design is not mature enough.
A smoother HAZOP can be achieved by:
- Ensuring the design is sufficiently advanced before the session
- Conducting earlier-stage hazard studies like HAZID at the feed stage
- Involving all relevant stakeholders from the outset
Conclusion
HAZOP studies are vital for identifying hazards and ensuring operational safety, but they must be handled with independence and rigour. Whether you’re dealing with new designs, packaged equipment, or tight deadlines, OTECSA can help you facilitate a clear, objective HAZOP process that meets regulatory and safety expectations.
Need HAZOP Support?
Get in touch with the experts at OTECSA. We offer fully independent HAZOP facilitation, reporting, and consulting to help you reduce risks and ensure compliance.
We are always happy to have our proposals compared with other suppliers of HAZOP services and are certain due to our strength in numbers and experience we can be competitive on cost and delivery for any project.
This includes other suppliers including: DEKRA, Gexcon, TUV, ABB, Risktec, Arthian, Mabbett, Method, Sigma HSE and IDEA Integro Design Engineering Associates.