© 2017 CEDCS Ltd

Hazard Study

An essential tool to help design a safe plant

Hazard Study is a time-proven and industry standard technique to examine a plant design and seek safety and operational issues so that they can be addressed and eliminated. If operational issues are considered as well as design ones, it is known as a Hazard and Operability (HazOp) study. It is usually carried out as a team activity, with representatives from all relevant engineering disciplines, operational staff and sometimes management and science representatives, depending on the plant and organisation. The team is usually led by a Chairman from outside the organisation. This brings impartiality, a fresh set of eyes, and a viewpoint not hindered by any internal issues, as well as guidance on the Hazard Study process and experience of similar and dissimilar processes. The Chairman should be a technically strong engineer, with good people and organisation skills. He must have a wide and deep background in chemical engineering design, plant operation and management. The Chairman usually has a Secretary (also known as a scribe) to operate the software and to record the discussions, conclusions, and actions developed by the team. The power of the Hazard Study process is its simplicity. Manageable chunks of the operational process are taken one by one and any significant deviations in key parameters from the design envelope are examined. The success of the work depends on having an experienced Chairman with the right information supported by knowledgeable people and facilitated by capable software. Actually, there are 7 stages of Hazard Studies, each one tailored for and ideally suited to different stages of plant design. the one referred to above is the 3rd stage, and can be used in isolation from the others. However the other stages also offer unique benefits to a design project Hazard Study 1 and Hazard Study 2 are carried out on preliminary designs. Proper execution of Hazard Studies 1 and 2 allow design changes to be accommodated cost effectively and prevent designs developing that are inherently flawed. This helps prevent making design mistakes or poor choices which can result in expensive solutions and/or project delay to reverse a poor decision. The most popular Hazard Study is Hazard Study 3 and is often carried out when the plant design is almost complete. For studies done at the final stage of design, Hazard Studies can also incorporate the effectiveness and of plant operations. These studies are known as Hazard and Operational Studies - 'HazOp Studies'. Hazard Studies 4 and 5 relate to the delivery of the design and are aimed at preventing new safety issues arising should practical concerns during construction attempt to override good design. Hazard Study 6 reviews the early operating experience of a new plant. Hazard Study 7 is a HazOp Study for a long running plant, either without an original HazOp Study or to take account of historical plant changes. I would recommend that all Hazard Study stages are used on major projects, and that they be carried out as early as possible in the design process to help designers identify where the major hazards lie. Changing the design at an early stage is much easier and cheaper. I can be your Hazard Study Chairman and can also provide a secretary (if required) to scribe and record all conclusions. Some clients ask me to Chair and Scribe, which is possible but extends the time required slightly. It is usually beneficial if a junior chemical engineer on the design team takes this role, provided they are conversant with the process and have competent IT skills. I have over 20 years experience of carrying out Hazard Studies and over the years have developed exclusive software to assist with the process. This can be provided at no cost if my client does not have any other preferred software for recording the study. I can provide a list of plants and technologies I have studied to clients.

CEDCS Ltd

The Hazard Study 3 / HazOp process

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Hazard Study

An essential tool to help

design a safe plant

Hazard Study is a time-proven and industry standard technique to examine a plant design and seek safety and operational issues so that they can be addressed and eliminated. If operational issues are considered as well as design ones, it is known as a Hazard and Operability (HazOp) study. It is usually carried out as a team activity, with representatives from all relevant engineering disciplines, operational staff and sometimes management and science representatives, depending on the plant and organisation. The team is usually led by a Chairman from outside the organisation. This brings impartiality, a fresh set of eyes, and a viewpoint not hindered by any internal issues, as well as guidance on the Hazard Study process and experience of similar and dissimilar processes. The Chairman should be a technically strong engineer, with good people and organisation skills. He must have a wide and deep background in chemical engineering design, plant operation and management. The Chairman usually has a Secretary (also known as a scribe) to operate the software and to record the discussions, conclusions, and actions developed by the team. The power of the Hazard Study process is its simplicity. Manageable chunks of the operational process are taken one by one and any significant deviations in key parameters from the design envelope are examined. The success of the work depends on having an experienced Chairman with the right information supported by knowledgeable people and facilitated by capable software. Actually, there are 7 stages of Hazard Studies, each one tailored for and ideally suited to different stages of plant design. the one referred to above is the 3rd stage, and can be used in isolation from the others. However the other stages also offer unique benefits to a design project Hazard Study 1 and Hazard Study 2 are carried out on preliminary designs. Proper execution of Hazard Studies 1 and 2 allow design changes to be accommodated cost effectively and prevent designs developing that are inherently flawed. This helps prevent making design mistakes or poor choices which can result in expensive solutions and/or project delay to reverse a poor decision. The most popular Hazard Study is Hazard Study 3 and is often carried out when the plant design is almost complete. For studies done at the final stage of design, Hazard Studies can also incorporate the effectiveness and of plant operations. These studies are known as Hazard and Operational Studies - 'HazOp Studies'. Hazard Studies 4 and 5 relate to the delivery of the design and are aimed at preventing new safety issues arising should practical concerns during construction attempt to override good design. Hazard Study 6 reviews the early operating experience of a new plant. Hazard Study 7 is a HazOp Study for a long running plant, either without an original HazOp Study or to take account of historical plant changes. I would recommend that all Hazard Study stages are used on major projects, and that they be carried out as early as possible in the design process to help designers identify where the major hazards lie. Changing the design at an early stage is much easier and cheaper. I can be your Hazard Study Chairman and can also provide a secretary (if required) to scribe and record all conclusions. Some clients ask me to Chair and Scribe, which is possible but extends the time required slightly. It is usually beneficial if a junior chemical engineer on the design team takes this role, provided they are conversant with the process and have competent IT skills. I have over 20 years experience of carrying out Hazard Studies and over the years have developed exclusive software to assist with the process. This can be provided at no cost if my client does not have any other preferred software for recording the study. I can provide a list of plants and technologies I have studied to clients.

The Hazard Study process

The Hazard Study

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