Preparing Preparing for a for a Succe Successful ssful HAZOP/LO - - PowerPoint PPT Presentation

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Preparing Preparing for a for a Succe Successful ssful HAZOP/LO - - PowerPoint PPT Presentation

Oct 06, 2023 100 likes •401 views

Preparing Preparing for a for a Succe Successful ssful HAZOP/LO HAZOP/LOPA PA (Making or Breaking Quality & Efficiency) (GCPS-2018 Paper 513595) Steven T. Maher, PE CSP / Carine M. Black / John M. Johnson Risk Management

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SLIDE 1

Risk Management Professionals

Preparing Preparing for a for a Succe Successful ssful HAZOP/LO HAZOP/LOPA PA (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/

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SLIDE 2

Risk Management Professionals

Steven T. Maher, PE CSP

Risk 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

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SLIDE 3

Risk Management Professionals

Carine M. Black

Risk 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
  • n RMP / PSM Related Issues
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SLIDE 4

Risk Management Professionals

Preparing Preparing for a for a Succe Successful ssful HAZOP/LO HAZOP/LOPA PA (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/

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SLIDE 5

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
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SLIDE 6

Risk Management Professionals

Why hy is is a Qu a Qual alit ity y Pr Proc

  • cess

ess Haz azard ard An Anal alys ysis is Im Impor

  • rtant

tant

Tragedies to Avoid

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SLIDE 7

Risk Management Professionals

Brie ief f His isto tory ry of

  • f Key

ey PH PHA A Tec echn hniques iques an and Reg egulatory ulatory Req equirem uirements ents

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SLIDE 8

Evolution of SMS Guidelines & Regulations to Performance (Goal) – Based Standards

Onshore Process Safety (USA) Offshore Safety Management Systems (USA) Offshore Safety Management Systems (UK)

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SLIDE 9

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
  • n Demand
PSV-2 Fails to Open
  • n 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

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SLIDE 10

Risk Management Professionals

De Defi fining ning Objec jectives tives an and d Ap Appro proach ach

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SLIDE 11

Risk Management Professionals Risk Management Professionals

General Objectives

  • Identify potential safety, environmental, or
  • perability issues.
  • Recommend vulnerability corrections and

document bases.

  • Provide training to personnel.
  • Provide background and bases for the safety

programs & procedures.

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SLIDE 12

Risk Management Professionals Risk Management Professionals

Approach Can Vary

  • Quality
  • Team Utilization & Effectiveness
  • Session Time
  • Capital Projects vs. Operating Facilities
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SLIDE 13

Risk Management Professionals

HAZO AZOP/LOP P/LOPA A Pla Planni nning ng Tip ips

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SLIDE 14

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

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SLIDE 15

Risk Management Professionals Risk 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)

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SLIDE 16

Risk Management Professionals Risk 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-Balance

With Scribe Without Scribe

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SLIDE 17

Risk Management Professionals

HAZO AZOP/LOP P/LOPA A Pre Preparati paration

  • n Tip

ips

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SLIDE 18

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
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SLIDE 19

Risk Management Professionals

Beware of Common Design Information Gaps

  • P&ID Information Content
  • Control Valves
  • Relief Valves
  • Pumps
  • Block Valves
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SLIDE 20

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
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SLIDE 21

Risk Management Professionals

HAZO AZOP/LOP P/LOPA A Ve Venue nue Tip ips

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SLIDE 22

Risk Management Professionals Risk Management Professionals

General Venue Tips

  • Venue Location
  • Team Member Distribution & Room Set-up
  • Venue Amenities
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SLIDE 23

Risk Management Professionals Risk 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
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SLIDE 24

Risk Management Professionals

Fi Fina nal l Re Readi adiness ness Tip ips

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SLIDE 25

Risk Management Professionals Risk 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
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SLIDE 26

Risk Management Professionals

Su Summ mmary ary

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SLIDE 27

Risk Management Professionals Risk 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

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SLIDE 28

Risk Management Professionals Risk Management Professionals

Success = Planning + Preparation

  • Advance Scheduling

– Team members – Optimal venue

  • Obtain/Develop

– Necessary PSI – Initial causes/questions

  • Maximize HAZOP/LOPA Investment!
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SLIDE 29

Risk Management Professionals

Questions?

Steven T. Maher, PE CSP

Steve.Maher@RMPCorp.com

Carine M. Black

Carine.Black@RMPCorp.com 877/532-0806 www.RMPCorp.com Risk Management Professionals