Top 5 Considerations to Ensure Successful Execution of HAZOP Studies

HAZOP is an OSHA-recognized Process Hazard Analysis (PHA) methodology that identifies deviations and hazards in complex industrial processes found in high-risk sectors (e.g., Chemical, Petrochemical, Manufacturing, Oil and Gas). The origins of this methodology can be traced back to the 1960s, when safety experts – including Trevor Kletz, widely recognized as the “Father of Process Safety” – at Imperial Chemical Industries (ICI) first applied it to investigate design deficiencies in the company’s phenol plant.

Top 5 HAZOP Needs

While there are multiple advantages to implementing HAZOP, it is advantageous for technical teams to understand how to conduct studies that improve the likelihood of achieving high-quality results, benefiting clients and their respective stakeholders.

To secure quality results, teams must first consider key aspects of a highly effective HAZOP study.

• Excellent P&IDs – An effective study begins with high-quality and up-to-date reference documents, including Piping and Instrumentation Diagrams (P&IDs). P&IDs are integral to a HAZOP study, as they provide on-site technical teams with detailed illustrations of a facility’s piping, equipment specifications, safety systems, and other components. This vital data is then used to dissect the facility into nodes (manageable sections) that allow teams to analyze each process thoroughly for potential deviations.
• Quality Team Members – Running a study is a coordinated effort. It is essential to incorporate knowledgeable, dedicated team members with diverse viewpoints to ensure its successful execution. From BakerRisk’s point of view, the team should be comprised of just enough people to support the client, but not so many that it overrides the purpose of the study. In terms of team size, the HAZOP study team can comprise anywhere from 2 to 20 team members, excluding the facilitator/scribe. Note that there must be a concerted effort to ensure that no team members working onsite have personal agendas or viewpoints that could interfere with the success of the HAZOP study.
• Skilled HAZOP Facilitator – To ensure smooth sailing, or at least as much as possible to that idea, a facilitator is a must. When there are a considerable number of individuals (personalities), there is bound to be disagreement. This is where the facilitator comes into play. A good facilitator needs solid interpersonal skills to control and lead groups with diverse personalities and cultures, both at the individual and corporate levels.
• Effective Methodology Protocols – When it comes to methodology protocols, one area of concern among facilitators is the optimal size of a node. To address this concern, a balance should be drawn that depends on the facilitator’s organizational skills, the team’s knowledge, their alertness at that point in the day, whether the study is on its first day, and more. Other methodology protocols to consider are the guideword/deviation lists.
• Enough Time – It is also important to consider the length of study. If a study is lengthy, efforts must be made to support team members. Remember, a HAZOP is a mental effort; many studies can go on for weeks, with HAZOP study sessions running up to 8 hours per day. The likelihood of fatigue among team members increases significantly; therefore, breaks between studies are a must.

Conclusion

HAZOP studies, among other PHA methodologies, highlight the power of collaboration. Precise studies depend on the findings of not one person but a team of dedicated technical professionals with differing perspectives who work together to find solutions through well-designed studies, ultimately providing clients with the assurance needed to execute sound tactics that address operational efficacy and personnel safety.  For more insights, access BakerRisk’s Best Practice, “Hazard and Operability (HAZOP) Studies – Creating High-Value Results,” today.

To learn more about how our teams support asset owners and operators through tailored HAZOP studies and other PHA methodologies, contact our process hazard analysis experts today.