HAZOP : guide to best practice : guidelines to best practice for the process and chemical industries

173 Pages·2015·3.1 MB·English

by  Frank Crawley

HAZOP: Guide to Best Practice
Guidelines to Best Practice for the
Process and Chemical Industries
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HAZOP: Guide to Best Practice
Guidelines to Best Practice for the
Process and Chemical Industries
Third Edition
Frank Crawley
Atkins, University of Strathclyde
Brian Tyler
S&T Consultants
(based upon the earlier editions by
Frank Crawley, Malcolm Preston, and Brian Tyler)
AMSTERDAM(cid:129)BOSTON(cid:129)HEIDELBERG(cid:129)LONDON(cid:129)NEWYORK(cid:129)OXFORD
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CONTENTS
Foreword.............................................................................................ix
Acknowledgments..............................................................................xiii
Chapter 1 Introduction.........................................................................1
1.1 Aims and Objectives.....................................................................1
1.2 Essential Features of HAZOP Study............................................2
Chapter 2 Process Hazard Studies........................................................4
2.1 HS 1—Concept Stage Hazard Review........................................4
2.2 HS 2—HAZID at Front-End Engineering Design (FEED) or
Project Definition Stage..............................................................5
2.3 HS 3—Detailed Design Hazard Study........................................5
2.4 HS 4—Construction/Design Verification....................................5
2.5 HS 5—Pre-Commissioning Safety Review..................................6
2.6 HS 6—Project Close-Out/Post Start-Up Review.........................6
2.7 HS 0—Consideration of Inherently Safer or Less Polluting
Systems.......................................................................................6
2.8 HS 7—Demolition/Abandonment Reviews................................6
2.9 Overview of Hazard Studies.......................................................7
2.10 Illustrative Checklist for HS 2....................................................8
Chapter 3 The HAZOP Study Method..............................................10
3.1 Essential Features.......................................................................10
3.2 The Purpose................................................................................11
3.3 Limitations.................................................................................11
Chapter 4 The Detailed HAZOP Study Procedure.............................13
4.1 The Description and Design Intention......................................13
4.2 Generating a Deviation............................................................15
4.3 Identifying Causes.....................................................................17
4.4 Evaluating Consequences..........................................................19
4.5 Safeguards (Protection).............................................................19
4.6 Risk Assessment.......................................................................20
4.7 Recommendations/Actions.......................................................21
vi Contents
4.8 Recording.................................................................................22
4.9 Continuing and Completing the Analysis.................................22
4.10 An Illustration of the HAZOP Study Process...........................23
Chapter 5 Organizing a HAZOP Study.............................................29
5.1 Defining the Scope and Objectives of the Study and Establishing
the Boundaries............................................................................29
5.2 Appointing a Team Leader and Selecting the Team...................31
5.3 Preparation.................................................................................36
Chapter 6 Carrying Out a Study........................................................43
6.1 Premeeting with Client...............................................................43
6.2 Planning the Meetings................................................................45
6.3 The Study Meetings....................................................................46
6.4 Coordinating and Reviewing Responses.....................................47
6.5 Completing and Signing Off the Report(s).................................48
6.6 Follow-Up of Actions and Management of Change...................48
Chapter 7 Recording and Auditing......................................................50
7.1 Background Information............................................................51
7.2 Section Headings........................................................................51
7.3 The Recording Format for the Detailed Examination................51
7.4 The Level of Recording..............................................................52
7.5 The Content................................................................................54
7.6 Computer Recording..................................................................54
7.7 Auditing a HAZOP Study..........................................................55
Chapter 8 Training.............................................................................58
8.1 Team Members...........................................................................58
8.2 Scribe..........................................................................................58
8.3 Team Leader..............................................................................59
Chapter 9 Company Procedures for HAZOP Study...........................60
Chapter 10 Advanced Aspects of HAZOP Study................................62
10.1 HAZOP Study of Computer-Controlled Processes...................62
10.2 Human Factors.........................................................................69
10.3 Linking HAZOP Studies to LOPA...........................................74
Contents vii
Chapter 11 Specific Applications of HAZOP.....................................77
11.1 Modification of Existing Operations.......................................77
11.2 Repeat Designs—HAZOP-by-difference.................................78
11.3 Periodic Hazard Studies and the HAZOP of an Existing
Plant........................................................................................78
11.4 Operating Procedures..............................................................79
11.5 Pilot Plant and Laboratory Operations...................................80
11.6 Drains, Vents, and Other Interconnections Between Plants....82
11.7 Commissioning and Decommissioning...................................84
11.8 Start-Up and Shutdown..........................................................85
11.9 Construction and Demolition.................................................89
11.10 Contract Operations...............................................................90
Chapter 12 Factors for a Successful HAZOP Study...........................92
12.1 Throughout the Study...............................................................92
12.2 Before the Study.......................................................................92
12.3 During the Study......................................................................93
12.4 After the Study.........................................................................94
Appendix 1: The Guideword-First Approach to HAZOP.....................95
Appendix 2: The Use of Checklists Within HAZOP Study.................99
Appendix 3: An Illustration of HAZOP Study for a
Continuous Operation....................................................101
Appendix 4: An Illustration of HAZOP Study for a
Batch Operation............................................................123
Appendix 5: An Illustration of HAZOP Study for a Procedure.........139
Acronyms and Abbreviations.............................................................151
References and Bibliography.............................................................153
Index.................................................................................................155
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FOREWORD
FOREWORD TO THIRD EDITION
It is with great pleasure that I have been invited to offer a preface to
this, the third edition of HAZOP Guide to Best Practice which is cer-
tainly one of the most popular IChemE texts that has been developed
by EPSC members since the inception of the Centre in 1992.
This particular book has fond personal memories because several
years ago when working in industry I attended an IChemE HAZOP for
Team Leaders course with one of its authors, Brian Tyler, which was
heldattheformerUMISTcampusinManchester.Theopportunitypre-
sented during that course of managing a HAZOP study team gave me
thenecessaryconfidencebackattheworkplacetotrainfrontlinestaffin
theuseofthetechnique,thenleadateaminastudyonafullyfunction-
ing gin distillery, and finally present the recommendations to the site
executive team. I still have the course folder, and I am glad to see that
muchofthatcontentstillformsthecoreofthiscurrenttext.
Nevertheless much has happened since the first edition and nothing
stands still for long and so for the technique of HAZOP. There is now
much greater appreciation in HAZOP studies of human error in acci-
dent causation and more broadly human factors and the role of
automation.HAZOPstudiesarenowperformedroutinelyoncontinuous
plants at various stages of operation such as start-up and shutdown,
batch processing plants, and even packaging plants. The technique
of deviation analysis inherent in the method lends itself with care and
imaginationtomanydiversemajorhazardenvironments.
Asforthisthirdedition,theauthors,BrianTylerandFrankCrawley,
aretobepraisedfortheircollectiveeffortsinrevisingthisbookyetagain
and keeping the content as fresh and topical as possible. HAZOP pro-
videsbothastructurefortheteamidentificationofhazards,accidentsce-
narios, and operability issues while offering the chance for an element
of creative thinking for a team whose time and effort is well managed.
IfanythingthepressureinrecentyearshasgrownonthetypicalHAZOP
team to identify and address all conceivable hazards arising from