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Risk Management Professionals
Preparing for a Successful
HAZOP/LOPA
(Making or Breaking Quality & Efficiency)
(GCPS-2018 – Paper 513595)
Steven T. Maher, PE CSP / Carine M. Black / John M. Johnson
Risk Management Professionals
949/282-0123
www.RMPCorp.com
Presentation/Handout – http://www.RMPCorp.com/Events-and-Resources/Conferences/GCPS/
Risk Management Professionals
Steven T. Maher, PE CSPRisk Management Professionals
• 38-Year Engineer – 34 in Process Safety Consulting Specializing in
Hazard Analysis and QRA
• Mechanical Engineering
– BS – Duke University
– MS – Carnegie-Mellon University
• Professional Engineer – Mechanical & Chemical Engineering
• CCPS Technical Steering Committee – mid-1980s
• Past-President Southern CA Society for Risk Analysis
• Landmark Efforts
– Platform Safety Shutdown System Effectiveness Study
– Torrance Refinery Safety Advisor for MHF Conversion
• Paper & Book Publications
– See www.RMPCorp.com
Risk Management Professionals
Carine M. BlackRisk Management Professionals
• Chemical Engineer – University of California, Santa
Barbara
• Extensive HAZOP/LOPA Scribe Support
• CalARP / RMP / PSM Program Development
• Auditing
• P&ID Development
• Dispersion Modeling
• Webinar / Presentation Speaker
on RMP / PSM Related Issues
Risk Management Professionals
Preparing for a Successful
HAZOP/LOPA
(Making or Breaking Quality & Efficiency)
(GCPS-2018 – Paper 513595)
Steven T. Maher, PE CSP / Carine M. Black / John M. Johnson
Risk Management Professionals
949/282-0123
www.RMPCorp.com
Presentation/Handout – http://www.RMPCorp.com/Events-and-Resources/Conferences/GCPS/
Risk Management Professionals
Key Topics
• Importance of a Quality PHA
• PHA History and Regulatory Requirements
• Defining Objectives and Approach
• HAZOP/LOPA Planning Tips
• HAZOP/LOPA Preparation Tips
• HAZOP/LOPA Venue Tips
• Final Readiness Tips
• Summary
• Questions
Risk Management Professionals
Why is a Quality Process Hazard
Analysis Important
Tragedies to Avoid
Risk Management Professionals
Brief History of Key PHA
Techniques and Regulatory
Requirements
Evolution of SMS Guidelines & Regulations to
Performance (Goal) – Based Standards
Onshore Process Safety (USA)
Offshore Safety Management Systems (USA)
Offshore Safety Management Systems (UK)
HAZOP & LOPA are Core Elements of
Hazard Evaluation
LV-1
Malfunctions
Open
LT/LIC-1
Fails High
Bypass Valve
Inadvertently
Open by
Operator
Alarm
Fails
to
Annunciate
LT/LIC-1
Fails High
Operator
Fails to
Respond to
Alarm
PSV-1
Fails to Open
on Demand
PSV-2
Fails to Open
on Demand
Significant Damage
due to Fire / Explosion
LV-1 or
Bypass Open
Operator
Response to
Alarm Fails
Pressure
Relief
Failure
Protection Layers (OP Action,
Control Sys, Prot Sys)
Null
Null
Flange Leakage
Vessel Failure
What-If
HAZOP
Checklist
FMECA
CHAZOP
LOPA
Risk Management Professionals
Defining Objectives and
Approach
Risk Management ProfessionalsRisk Management Professionals
General Objectives
• Identify potential safety, environmental, or
operability issues.
• Recommend vulnerability corrections and
document bases.
• Provide training to personnel.
• Provide background and bases for the safety
programs & procedures.
Risk Management ProfessionalsRisk Management Professionals
Approach Can Vary
• Quality
• Team Utilization & Effectiveness
• Session Time
• Capital Projects vs. Operating Facilities
Risk Management Professionals
HAZOP/LOPA Planning Tips
Risk Management Professionals
Timeline for PHA Planning/Preparation
Week 7
•Team Invitation & Schedule*
•Define Objectives and Scope*
Week 6
•Conduct Final Des. Review*
Week 5
•P&ID Walkdown / Field Verification*
Week 4
•Arrange PHA Venue*
Week 3
•Determine PHA Tools
•Arrange for PHA Meeting Equipment*
Week 2
•Begin Preparing PHA Elements
•Resolve Final Des. Review Items (if applicable)*
•Final P&ID / PFD / C&E Revisions*
•Define Sections (Nodes)
Week 1
•Pre-load Risk Ranking Matrix, Design Intentions & Consequence Categories, Deviation Matrix & Template
•Populate Causes
•Training & Reference Materials
•P&ID / PFD Copies*
PHA Study
Risk Management ProfessionalsRisk Management Professionals
Key Disciplines Useful for a
HAZOP/LOPA
• Facilitation/Leadership (R)
• Team Scribe/Recorder
• Process/Project Engineering (R)
• Operations (R)
• Maintenance (R)
• Control/Protection Instrumentation Engineer
• HSE Engineering
• Rotating Equipment Specialists
• Specialists to Address Unique Requirements, e.g., DMR, SPA,
HCA
(R = Required by PSM/RMP)
Risk Management ProfessionalsRisk Management Professionals
Planning Tips - Scribe
• Quality Scribe Support is Essential
– Familiarity with HAZOP/LOPA techniques
– Familiarity with reading engineering drawings
– Familiarity with the software
• Scribe Support Cost-BalanceWith Scribe Without Scribe
Risk Management Professionals
HAZOP/LOPA Preparation Tips
Risk Management Professionals
Key Information Requirements
• Process Flow Diagrams
• Piping & Instrumentation Diagrams (with
changes identifiable from any previous HAZOP
Studies)
• Cause & Effect Diagrams
• Alarm & PSV Setpoints
• Site Layout / Platform Location Drawings
• Access to All Other Process Safety Information
Risk Management Professionals
Beware of Common Design
Information Gaps
• P&ID Information Content
• Control Valves
• Relief Valves
• Pumps
• Block Valves
Risk Management Professionals
Be Prepared to Discuss Details
• Heat Exchangers/Coolers
• General Process Condition Changes
• Instrumentation
• Electric Immersion Heaters
• Other (primarily applicable for lube oil
systems)
• Tanks
Risk Management Professionals
HAZOP/LOPA Venue Tips
Risk Management ProfessionalsRisk Management Professionals
General Venue Tips
• Venue Location
• Team Member Distribution & Room Set-up
• Venue Amenities
Risk Management ProfessionalsRisk Management Professionals
Including Remote HAZOP/LOPA
Team Members
• Adequate Computers/Displays
• Arrange Communications Access and IT Support
• Power and Communications Connections for All Computer Equipment
– Verify sufficient communications bandwidth!!!
– Verify that equipment is contemporary.
• Cameras
• Testing
Risk Management Professionals
Final Readiness Tips
Risk Management ProfessionalsRisk Management Professionals
Final Readiness
• Pre-define and Communicate Causes
– Completeness
– Future Use
– Quickly locating Equipment on P&ID During
Session
– Grouping Causes
• Pre-define and Communicate Questions
• P&ID Grid Format
Risk Management Professionals
Summary
Risk Management ProfessionalsRisk Management Professionals
Success = Planning + Preparation
• Optimize Quality & Efficiency!
• Capital Projects
– Optimize process design
– Minimize design and operation costs
– Minimize start-up challenges
• Operating Facilities
– Mitigate risks
– Minimize vulnerabilities
– Address regulatory requirements
Risk Management ProfessionalsRisk Management Professionals
Success = Planning + Preparation
• Advance Scheduling
– Team members
– Optimal venue
• Obtain/Develop
– Necessary PSI
– Initial causes/questions
• Maximize HAZOP/LOPA Investment!
Risk Management Professionals
Questions?
Steven T. Maher, PE [email protected]
Carine M. [email protected]
877/532-0806
www.RMPCorp.com
Risk Management Professionals
