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How can you ensure a thorough and accurate HAZOP study for gas processing plants?

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A HAZOP study, or hazard and operability study, is a systematic and structured method of identifying and evaluating potential hazards and deviations from normal operation in a gas processing plant. A HAZOP study can help you improve the safety, reliability, and efficiency of your plant, as well as comply with regulatory requirements and industry standards. However, a HAZOP study is not a one-off activity, but a continuous process that requires careful planning, execution, and follow-up. In this article, you will learn how to ensure a thorough and accurate HAZOP study for gas processing plants, by following six key steps.

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Chukwuma Emordi

Principal Process Engineer (R.Eng)

1 Define the scope and objectives

The first step of a HAZOP study is to define the scope and objectives of the analysis. You need to specify the boundaries of the plant or system that you want to examine, the level of detail that you want to cover, the criteria for identifying and ranking hazards, and the expected outcomes and deliverables of the study. You also need to consider the relevant codes, standards, regulations, and best practices that apply to your plant or system, and how they will guide your HAZOP study.

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In general, preparing for the HAZOP study is the most crucial step towards a successful outcome. Defining the scope, allocating resources, assigning team members and most importantly gathering all necessary documents will eventually provide a well- structured and systematic approach to conduct the HAZOP and follow through on all recommendations.

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2 Select the HAZOP team and leader

The second step of a HAZOP study is to select the HAZOP team and leader. The HAZOP team should consist of multidisciplinary experts who have knowledge and experience in the design, operation, maintenance, and safety of the plant or system. The HAZOP leader should be an independent and qualified facilitator who can coordinate the team, guide the discussion, record the findings, and ensure the quality and consistency of the study. The HAZOP team and leader should also have adequate time and resources to conduct the study.

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3 Divide the plant or system into nodes

The third step of a HAZOP study is to divide the plant or system into nodes. Nodes are the smallest units of analysis that can be examined independently and comprehensively by the HAZOP team. Nodes can be defined by physical boundaries, such as equipment, piping, valves, or instruments, or by functional boundaries, such as process stages, operating modes, or control loops. The nodes should be clearly identified and labeled, and their design and operational parameters should be documented.

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Chukwuma Emordi

Principal Process Engineer (R.Eng)
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Dividing the system into loops is very essential. The system can easily be examined thoroughly and it also help in tracking Job completion and analysis across the system.

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4 Apply guidewords and parameters

The fourth step of a HAZOP study is to apply guidewords and parameters to each node. Guidewords are standard terms that describe possible deviations from normal operation, such as no, more, less, reverse, or other than. Parameters are the variables that characterize the normal operation of the node, such as flow, pressure, temperature, level, or composition. By combining guidewords and parameters, the HAZOP team can generate a series of scenarios that represent potential hazards or operability problems.

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5 Identify causes, consequences, and safeguards

The fifth step of a HAZOP study is to identify the causes, consequences, and safeguards for each scenario. Causes are the factors that can trigger or contribute to the deviation, such as human error, equipment failure, external events, or design flaws. Consequences are the effects or impacts of the deviation, such as injuries, fatalities, environmental damage, production loss, or quality issues. Safeguards are the existing or proposed measures that can prevent, mitigate, or control the deviation, such as alarms, interlocks, relief valves, or emergency procedures.

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6 Recommend actions and follow up

The sixth and final step of a HAZOP study is to recommend actions and follow up on the results. Actions are the corrective or preventive actions that need to be taken to eliminate or reduce the risks associated with the deviation, such as design changes, operational modifications, maintenance improvements, or training programs. The HAZOP team should prioritize the actions based on the severity and likelihood of the deviation, and assign responsibilities and deadlines for their implementation. The HAZOP team should also monitor and review the progress and effectiveness of the actions, and update the HAZOP study as needed.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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The time allocated for the HAZOP study should be determined and discussed with management beforehand. If you have a large number of loops/nodes to evaluate thoroughly, the more time you will need and the more detailed and accurate your findings and recommendations will be.

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How can you ensure a thorough and accurate HAZOP study for gas processing plants?

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1 Define the scope and objectives

2 Select the HAZOP team and leader

3 Divide the plant or system into nodes

4 Apply guidewords and parameters

5 Identify causes, consequences, and safeguards

6 Recommend actions and follow up

7 Here’s what else to consider

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