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

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/ 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 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 on RMP / PSM Related Issues 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 Risk Management Professionals Presentation/Handout – http://www.RMPCorp.com/Events-and-Resources/Conferences/GCPS/

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 hy is is a Qu a Qual alit ity y Pr Proc ocess ess Haz azard ard An Anal alys ysis is Im Impor ortant tant Tragedies to Avoid Risk Management Professionals

Brie ief f His isto tory ry of of Key ey PH PHA A Tec echn hniques iques an and Reg egulatory ulatory Req equirem uirements ents Risk Management Professionals

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 Significant Damage due to Fire / Explosion Protection Layers (OP Action, LV-1 or Control Sys, Prot Sys) Bypass Open Operator Pressure Bypass Valve Response to Relief LV-1 LT/LIC-1 Inadvertently Alarm Fails Failure Malfunctions Fails High Open by Null Open Operator Alarm Operator PSV-1 PSV-2 Fails LT/LIC-1 Fails to Fails to Open Fails to Open to Fails High Respond to on Demand on Demand Annunciate Alarm Flange Leakage Null Vessel Failure HAZOP LOPA CHAZOP What-If FMECA Checklist

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

Approach Can Vary • Quality • Team Utilization & Effectiveness • Session Time • Capital Projects vs. Operating Facilities Risk Management Professionals Risk Management Professionals

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

Timeline for PHA Planning/Preparation PHA Week 7 Week 6 Week 5 Week 4 Week 3 Week 2 Week 1 Study • Team • Conduct • P&ID • Arrange • Determine • Begin • Pre-load Risk Invitation & Final Des. Walkdown / PHA Venue* PHA Tools Preparing Ranking Schedule* Review* Field PHA Matrix, Design Verification* • Arrange for Elements Intentions & • Define Consequence PHA Meeting • Resolve Final Categories, Objectives and Equipment* Deviation Scope* Des. Review Matrix & Items (if Template applicable)* • Populate • Final P&ID / Causes PFD / C&E Revisions* • Training & • Define Reference Materials Sections (Nodes) • P&ID / PFD Copies* 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) 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 Risk Management Professionals Risk Management Professionals

HAZO AZOP/LOP P/LOPA A Pre Preparati paration on Tip ips 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

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

General Venue Tips • Venue Location • Team Member Distribution & Room Set-up • Venue Amenities 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 Risk Management Professionals Risk Management Professionals

Fi Fina nal l Re Readi adiness ness Tip ips 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 Risk Management Professionals Risk Management Professionals

Summ Su mmary ary 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 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! Risk Management Professionals 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 Risk Management Professionals