What is HAZOP

Green World Group is glad to present a video on the crucial topic of a HAZOP audit. This informative video is designed to educate viewers about what an HAZOP audit is, how to conduct an effective audit, a step-by-step approach, scenarios that require a HAZOP audit, and its benefits.

Let us walk through the content of the video in this blog.

Introduction to HAZOP

HAZOP stands for Hazard and Operability Study. It is an organized and systematic technique for process hazard analysis (PHA). This study is typically useful during design and operational phases in complex systems and is quite beneficial throughout business operations.

The core purpose of the HAZOP is to recognize deviations from the design perspective and identify potential risks, thus ensuring a safe and reliable operational system is in place.

Purpose of a HAZOP

The major purpose of a HAZOP audit is to determine the possible and related hazards and operability issues in the given processes.

  • It aims to foster the safety and reliability of operations
  • Achieving compliance with key standards such as the OSHA, COMAH and ISO 450001
  • By performing proactive assessment and control, organizations can avoid incidents and ensure improved safety performance.

What is COMAH?

COMAH represents Control of Major Accident Hazards. COMAH regulations are intended to reduce the risk of major accidents related to process safety, such as the release of toxic gases, flammable substances and more.

HAZOP Audit Procedure

Step 1: Preparation

  • Defining the objective and scope of the HAZOP study

  • Collect necessary documents such as Piping and instrumentation diagram (P&ID), Process flow diagram (PFDs) and Process data.

  • Build the audit team and schedule sessions

Step 2: Node Identification

  • Divide the process into logical sections (nodes)
  • Nodes are typically based on equipment/process steps

Step 3: Guide Word Application

  • Apply standard guide words (For example: more, less, reverse, No)
  • Determine the deviations when applying parameters such as pressure, flow, etc.

Step 4: Deviation Analysis

  • Find out the causes and possible outcomes
  • Review the current safety measures
  • Assess the likelihood and severity

Step 5: Recommendations

  • Recommend new/improved control actions
  • Rank based on risk priority

Step 6: Documentation

  • Record the comprehensive findings and team discussions
  • Assign responsibilities and due dates
  • Create a formal HAZOP audit report

When to conduct a HAZOP audit?

HAZOP audit is just not a single-time task; rather, it is a regular and situational requirement, which is typically performed in the below scenarios.

  • Required during a process or a project’s design and pre-start-up stages
  • After any major process modifications (MOC- Management of Change)
  • At regular or scheduled safety review intervals (for example, every 5 years)
  • Post-incidents or near-miss investigations

Benefits of an HAZOP Audit

  • A Structured Methodology for Hazard Identification
  • Improves the understanding of the process and fosters team collaboration
  • Early detection of design or any kind of operational flaws
  • Improved preparedness for emergencies
  • Compliance with national and international safety regulations

Challenges and limitations

There are certain challenges and limitations with HAZOP studies, which include:

  • Resource and time-intensive process
  • Needs an experienced facilitator and a focused team
  • If not properly scoped, there can be an over-recommendation risk
  • Effectiveness depends on action follow-up

To sum up

HAZOP is a crucial tool to manage process safety risks. It mainly focuses on identifying and analysing deviations that lead to unsafe conditions or process failures. To achieve a successful HAZOP audit, it must be conducted in a structured way and needs to be documented. Performing a successful audit helps in reducing incidents and improving compliance.