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Hazard and Operability Analysis (HAZOP)

Hazard and Operability Analysis (HAZOP) is a structured and systematic technique for system examination and risk management.

What is HAZOP

Hazard and Operability (HAZOP) Study is a structured and systematic technique used in process engineering to identify potential hazards and operability issues in a process. HAZOP focuses on examining deviations from design intentions, assessing the causes and consequences of these deviations, and identifying safeguards to mitigate risks. The goal of HAZOP is to ensure that hazards are managed to an acceptable level by pinpointing weaknesses in the process design and implementing effective control measures.

When to use HAZOP

HAZOP is typically used during the design, modification, or operation of a process to identify potential hazards and operability issues before they result in incidents. HAZOP is particularly valuable in the early stages of a project or when a process involves complex or unfamiliar operations. It focuses on exploring deviations from intended design and examining how these deviations could lead to hazardous events. By systematically identifying hazards and assessing potential impacts, HAZOP helps teams evaluate the adequacy of existing safeguards and provides a foundation for further risk assessments, such as Layer of Protection Analysis (LOPA), if additional detail is needed.

Steps Taken:

1. Preparation for Study

  • Define the time required and the team members needed to attend to complete the workshop. Preparation of the process documentation and worksheet to record the study.

2. Facilitating the study

  • An experienced chair will attend the site to facilitate the HAZOP workshop by leading the team through the process detailed below.

3. Identify Potential Deviations and Hazards

  • Define potential hazards by identifying deviations from intended design, such as overfilling a storage tank or excess pressure in a pipeline.

4. Assess Potential Consequences

  • Evaluate the potential consequences of each hazard, including impacts on people, equipment, the environment, and business operations if the hazard materialises.

5. Identify Possible Causes

  • Determine potential initiating events or causes for each hazard, such as equipment failures, human error, or external conditions.

6. Evaluate Existing Safeguards

  • Identify and assess the effectiveness of current safeguards and protective layers for each hazard, including alarms, physical barriers, and procedures.

7. Assess Risk Levels

  • Using the identified hazards and their causes, analyse the potential risk level for each scenario and compare it to acceptable risk criteria defined by company or industry standards.

8. Recommend Additional Protections

  • If the existing protections are insufficient to bring the risk to an acceptable level, additional or enhanced safety measures are recommended, such as improving equipment reliability, upgrading control systems, or adding emergency shutdown functions.

9. Review and Document Findings

  • Document each finding, recommendation, and the rationale behind each decision, providing a comprehensive overview of identified hazards, assessed risks, and the required safety measures for continuous process safety improvement.

Typical industries Finch can Support

Finch can support industries such as chemical, mining, and oil & gas. These sectors are mature in their application of process safety methodologies such as HAZOP to ensure that systems operate as safely as possible and that high-risk events are minimised to a level that is as low as reasonably practicable (ALARP). The HAZOP process is not only useful in high hazard industries but can be applied to many other industries. We also support clients in the manufacturing, food & drink, and pharmaceuticals to apply the same HAZOP methodology to help identify their risks and ensure they are correctly managed.

Outcome

HAZOP systematically identifies potential hazards and operability issues within a process, ensuring that effective safeguards are in place to minimise the likelihood and impact of these hazards. By thoroughly examining each process deviation and its consequences, HAZOP helps ensure that overall risk is reduced to an acceptable level, leading to a safer and more reliable operational environment.

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