PRESENTATION SLIDES & SUPPLEMENTAL NOTES

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1. INTRODUCTION – WHY IS SAFETY SO IMPORTANT?
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The industrial workplace is a hazardous place because of the scale and complexity of its
operation and equipment in use. At one time in industrial history, accidents, injuries or death
were viewed as inherent risks when signing up for a job. But things are different now.

• Nowadays, all accidents are preventable.

Legislation, expectation from society and our conscience demand industries to provide workers
with a safe working environment because of the terrible cost of accidents to people, society and
industries.

A safe plant is also a profitable plant due to higher morale and pride, greater employee
participation and fewer interruption to the production processes.

1.1 CODE OF ETHICS OF ENGINEERS

In accidents, there is a huge human cost to the victim, their family and the society. As engineers
we are reminded that there is a human face behind any engineering project. Our first duty
therefore is to protect their safety.
Our commitment to safety is clearly spelled out in the code of ethics of engineers below,
To protect ’ , first and foremost.

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1.2 HOW TO IDENTIFY HAZARDS IN A SYSTEM?

To protect employees as well as plant integrity, safety hazards need to be identified and mitigated.
Identify and evaluate hazardous conditions is a core foundation of any safety program. The field of
identifying and assessing hazards is called Risk Assessment.

There are several qualitative methods which can be used to analyze a System to identify potential safety
hazards and their impact to the System under study: HAZOP, Creative Checklist, What IFs, FMEA (Failure
’ be discussing in
details here.

HAZOP, for Hazard and Operability Study, is a structured and systematic method widely used in the
chemical process industries to identify potential hazards and operability problems in a System (process,
facility, procedure, etc.) at various stages of its life cycle: final design, commissioning, plant test, plant
modification, shutdown, etc.) The method is especially useful when the study is carried out, 1) at design
stage when System final design is complete so that design deficiencies can be corrected before
construction begins, and 2) when there are changes to an existing System, such as modification to existing
process, equipment, procedure, etc.

A unique characteristic of HAZOP is that it is based on the concept that hazard and operability problems
occur ONLY WHEN the System operates outside a plan, design conditions or intent. Hence, in
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he search for potential hazards is

narrowed down to 7 directions along which the System may deviate from a plan or design. A set of 7
Guide Words is used to prompt the study team into imagining all possible deviating scenarios to be
examined for hazards. 4

1.3 PURPOSE OF PRESENTATION (please refer to slide above)

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2.1 WHAT IS HAZOP ?

Introducing hypothetical but meaningful changes to system baseline is a powerful technique to judge the
robustness of the system, and discover its weakness. ’ very much like taking the current system design
to new territories for a stress test.

HAZOP essentially is a Potential Problem Analysis method, in the sense that the aim of the study is to
envisage ALL the particular circumstances (beyond Design Intent) which could negatively affect the
System. This effort is facilitated by the use of Guide Words, which stimulate the imagination of deviation
scenarios in a structured fashion.

Creation and examination of deviations is the most important step of HAZOP.

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2.1 W N DO S A “SA ” SYS B O S “ NSA ”?

HAZOP is a systematic process for identifying potential hazards and operational problems due to
deficiencies in system design and due to human error.

It is based on the concept that hazard and operational problems do not occur when a System
“ ” “ ”
“ ” ne can expect troubles to
surface. In the HAZOP world, each case of wandering away is called a DEVIATION from design
intent. There are 7 directions along which a System can deviate from its design intent, hence 7
possible types of DEVIATIONS.

In HAZOP, System means an operating plant, equipment, process or an entity being examined to
“ ”
Design Intent. Design intent describes the design conditions, the expected performance of the
System and more importantly, a safe operating zone when the System operates within these
boundaries.

The Design Intent (or Intention) defines the boundaries of this safe operational zone. As long as
the System operates within the “ ”
expected to occur.

 Design Intent = Normal & Safe operating zone

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There are other operational scenarios when the System deviates from its Design Intent.

In HAZOP there are 7 different ways a System can deviate from its Design Intent. These variant
“ ” for deviating scenarios) to underline the fact the System drifts
there as a result of its elements or process parameters deviating from the normal conditions
specified in the Design Intent. With 7 different ways in which a System can deviate from Design
Intent, there will be 7 types of Deviations the conditions of which may result in hazards or
operability problems.

 Deviations = Abnormal & Potentially hazardous operating scenarios.

Key concept of HAZOP analysis

Essentially, HAZOP systematically questions every aspect of a System to understand how
deviations from normal conditions could occur, and identify weaknesses in system design so that
these can be corrected.

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How do we define a System in HAZOP?
To support the requirement* in HAZOP analysis, a System is represented by the following diagram:

Note: Use of Process

1.MATERIAL
Parameters in place of
3.SOURCE 4.DESTINATION
Material, Activity, Source &
2.ACTIVITY
Destination is another valid
+ option.

DESIGN INTENT (*) Requirement: generate

& examine deviations.

T “ ”. It describes the system’ structure (what the

system is made of), its pathway, function and design intent (performance it’ deliver).

Design intent is an important aspect of a System, and should be well defined and understood because it forms the
baseline from which deviations are to be created and examined.

In HAZOP there are 2 ways to describe a System:

1. By System Elements (4): material, activity, source and destination as shown in diagram above,
OR alternatively,
2. By Process Parameters which describe relevant aspects of Material, Activity, Source or Destination. In IEC
61882 (International Electrotechnical Commission) Standard, Process Parameters are called
“ ” “ ” s a property, measurement or attribute
describing or characterizing a System Element that is relevant to the purpose of the analysis.

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2.6 DESIGN REPRESENTATION BY “PROCESS PARAMETERS” (CONT’D) – Slide 27
MATRIX OF MEANINGFUL HAZOP DEVIATIONS BASED ON PROCESS PARAMETERS. (Adapted from Sea Jay Engineering
Services Ltd & Suncor Energy Inc.)

PARAMETERS NO MORE LESS AS WELL AS PART OF REVERSE OTHER

THAN
No Flow High Flow Low Flow Misdirection Missing Flow Reversal Wrong
Flow Material Material

Open to High Pressure Low Pressure

Pressure atmosphere

Line Freezing High Temp Low Temp

Temperature
Empty High Level Low Level
Level
Increase Decrease
Composition
High Visc Low Visc
Viscosity
No Reaction Excessive Insufficient Secondary Incomplete Inverse Different
Reaction Reaction Reaction Reaction Reaction

No Mixing Excessive Insufficient e.g. Foaming Incomplete Settling

Mixing (e.g. Fish Eyes)

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2.8 SEQUENCE OF CREATING & EXAMINING DEVIATIONS (FLOWCHART)

START

1) Select a Study Node

2) Select Parameter within study node

3) Apply Relevant Guide Word to Parameter to Generate Deviation

N Is CAUSE Likely or
Credible?

N
Does this create SIGNIFICANT
Hazard or Operability problem?

Y Is Safeguard
Adequate?

4) Record Recommendation/ Follow-up Action

(for the particular Hazard or Operability Problem)

5) Select next relevant Guide Word (for same Parameter) & Go to Step 3).

When all Guide Words have been examined, Select Next Parameter & Go To Step 2.

When all Parameters (within a subject Study Node) have been examined, Select Next Study
Node & Go to Step 1.

When all Study Nodes have been examined, Examination is complete. Prepare Study Report.
Slide 34
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2.9 SAMPLE OF HAZOP STUDY REPORT

Project Title Date

HAZOP type Parametric
Node No. Node Description
Line/Part Considered
Material Source
Design Intent
Activity Destination

RECOMMENDATIONS
MITIGATING
MEASURES
ELEMENT/ DEVIATION (Additional
SITUATION
ITEM

safeguards or actions RECOMMENDATION

GUIDE WORD PROCESS (WHAT'S THE CONSEQUENCE (SAFEGUARDS IN
required to be / ACTION OWNER
(CAUSE) PLACE AND
PARAMETER ISSUE ?) SAFEGUARD
implemented to
reduce Residual Risk
CATEGORIES)
to acceptable level)

1
2
3

Note:

Safeguard Categories: 1 = Detect, 2= Compensate, 3 = Prevent from happening, 4 = Prevent further escalation, 5 = Safety Relief

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 HAZOP Procedure
(British Standard IEC 61882 2001 HAZOP Studies – Application Guide)

Slide 41

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4.4 CREATIVE CHECKLIST HAZOP - template

LIST FOR MATERIAL & BLOCK HAZARDS CHECKLIST HAZOP

Project Name: ACTIVITY
Project Number:
Drawing Number:
Block Name:
Date:
Sheet: Of
Team:
HAZARD & NUISANCES INV. Specific Hazard Action

MAIN SUB-TYPE DETAIL REF

FIRE Combustion 1
& Deflagration 2
EXPLOSION Explosion 3
Detonation 4
E Incompatibles 5
N CHEMICAL Instabilities 6
E Exotherms 7
R Hi/Low Temps 8
G THERMAL Phase Changes 9
Y Thermal Radiation 10
Hi/Lo Pressure 11
PHYSICAL Electrostatic 12
Electromagnetic 13
Radiation 14
MECHANICAL Kinetic 15
Potential 16
Vibration 17
I TOXICITY Inhalation/Ingestion 18
N Topical/Eyes 19
T
E CORROSION Chemical 20
R Erosion-Corrosion 21
A
C PEOPLE Maloperation 22
T Contamination 23
I
O EQUIPMENT Contamination 24
N Degeneration 25
S
E T EFFLUENTS Solids/Liquids 26
N O Gases 27
V NUISANCES Smell/Dust 28
I Mist/Fog/Glare 29
R Noise/Vibration 30
O ___ Extreme Temps 31
N ___ Wind/Tornadoes 32
M __ WEATHER Lightning 33
E Precipitation/Flood 34
N Ice/Fogs 35
T F GEOLOGICAL Geo Technical 36
A R Geological 37
L O BIOLOGICAL Bacterial 38
M Insects/Rodents/Wildlife 39
SPARE

Record chemicals & blocks in Column Header. Work down columns, record with a check mark when special care is needed along detail hazard row.
Use a question mark when relevant data are lacking.

(Source: HAZOP Leadership Training Course, Sea Jay Engineering Services Ltd/Suncor Energy Inc.)

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 SW FT’s 0 ATEGOR ES FOR WHAT-IF QUESTIONS

1. Material 2. External effects 3. Operating 4. Analytical & 5. Equipment/

problems of influence errors & other sampling errors Instrumentation
human factors malfunction

6. Process upsets 7. Utility failure 8. Integrity 9. Emergency 10.

(unknown) failure/loss of operations Environmental
containment release

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FMEA Methodology
FMEA Analysis Form

Col. 1 2 3 4 5 6 7 8 9 10 11 12
System/Ele Function Failure mode Effect of S Cause of O Existing D RP Recommend Responsi
ment (unwanted failure E failure C controls E N ed action bility
event) V C T

FMEA is a risk assessment tool used widely in the manufacturing industries to improve the reliability and
quality of a design, equipment/product, or services. It is generally conducted at 3 different stages in a
system life cycle. Design FMEA: identifies potential deficiencies in a system design at conceptual or design
stage. Process FMEA: identifies potential deficiencies in the manufacturing processes, and Equipment
FMEA: identify potential failures on equipment itself so that additional controls need to be implemented.

Process steps in FMEA analysis (refer to FMEA Analysis Form above).

1. (Cols 1-4). Identify all potential failures & effects by brainstorming, using What-IF questions, team
experience & expertise.
2. (Col 5). Determine severity S (1-10, 10 = worst)
3. (Col 6-7). Determine root cause of failure and estimate likelihood of occurrence O (1-10, 10= 100% sure
to occur)
4. (Col 8-9). Failure detectability. Assess ability of existing control system to detect such failure, rating D
(10= unlikely to detect failure)

Risk Priority Number, RPN = S*O*D, is a measure of the seriousness of the risk.
Priority of remedial actions, in order or preferences, includes: eliminate failure, reduce severity (S), reduce
likelihood (O) and increase detection (D).
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 Node 2
Node 1

Slide 67
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