Hazard And Operability (HAZOP)

Hazard Identification (HAZID)

The difference between
HAZOP and HAZID
Dr. Essam Hassan Ph.D. Sciences
Senior Sustainability Advisor & Environmental Consultant
G.C.C. , Asia Region and Middle East
Mobile : 00965 55143241
what is basic difference between
HAZOP and HAZID
 HAZOP
Hazard and Operability (HAZOP) study for continuous
or batch processes, or procedural operations is an
excellent tool to identify potential hazards and
operability issues and recommending preventive
actions.
HAZOP study identifies the following:
1. The hazards of the process
2. The identification of any previous incident which
had a likely potential for
3. Engineering and administrative controls
4. Consequences of failure of engineering and
administrative controls
5. Facility siting
6. Human factors
7. A qualitative evaluation of a range of the possible
safety and health effects of failure of controls on
employees in the workplace.

A good HAZOP study is also used as an input for proceeding

with Layers of Protection Analysis. It must be remembered
that a good HAZOP study is only as good as the skills of the
facilitator and team members.
 HAZID
•The Hazard Identification (HAZID) is a high level
review of potential hazards, based on checklists.

•Cover facility siting, human factors and best

engineering practices.

•HAZID is the first step in primary risk assessment

for a new facility.
Hazard And Operability (HAZOP)
 The HAZOP Method
• HAZOP analysis is a systematic technique for identifying
hazards and operability problems throughout an entire
facility. It is particularly useful to identify unwanted hazards
designed into facilities due to lack of information, or
introduced into existing facilities due to changes in process
conditions or operating procedures.
• The objectives of a HAZOP study are to detect any
predictable deviation (undesirable event) in a process or a
system. This purpose is achieved by a systematic study of the
operations in each process phase.
 The HAZOP Method
• The system is divided into functional blocks
• Every part of the process is examined for possible
deviations from the design intention
• Can the deviations cause any hazard or inconvenience?
• Every phase of the process
• Each system and person
• Questions formulated around guide words
• Each deviation is considered to decide how it could be
caused and what the consequences would be
• For the hazards preventive/remedying actions are defined
 HAZOP Study Consequence
1. Definition of the objectives and scope of the study, e.g.
hazards having only off-site impact or only on-site impact,
areas of the plant to be considered, etc.
2. Assembly of a HAZOP study team.
3. Collection of the required documentation, drawings and
process description.
4. Analysis of each major item of equipment, and all
supporting equipment, piping and instrumentation
5. Documentation of the consequences of any deviation
from normal and highlights of those which are considered
hazardous and credible.
 HAZOP Study team
• HAZOP studies are normally carried out by multi-disciplinary teams.
There are two types of team members, namely those who will make
a technical contribution and those play a supporting and structuring
role.
 Example of HAZOP Matrix
Guide
word
No Low High Part of Also Other than Reverse

Process-
variable
No Low High Missing Wrong Reverse
Flow flow flow flow ingredients Impurities material flow

Low High Low High - -

Level Empty interface interface
level level

Open to Low High - - -

Pressure atmosphere pressure pressure Vacuum

Temperature Low High - - - Auto

Freezing temp. temp. refrigeration

No Poor Excessive Irregular- Foaming - Phase

Agitation mixing mixing
agitation mixing separation

No Slow "Runaway Partial Side Wrong Decom-

Reaction reaction
reaction reaction reaction" reaction reaction position

Utility External External - - Start-up -

Other Shutdown
failure leak rupture
Maintenance
 HAZOP Criticality analysis
Criticality - combination of severity of an effect and the probability
or expected frequency of occurrence.
The objective of a criticality analysis is to quantify the relative
importance of each failure effect, so that priorities to reduce the
probability or to mitigate the severity can be taken.

Example formula for Criticality:

Cr = P  B  S

Cr: criticality number

P: probability of occurrence in an year
B: conditional probability that the severest consequence will occur
S: severity of the severest consequence
 HAZOP Criticality analysis
The criticality number
- used to rank the identified deviations in a HAZOP or FMEA
study
- cannot be used as a risk measure
- product of three rough estimates

Before a criticality analysis can be performed guidelines

have to be developed on how to determine P, B and S.
There are no generally accepted criteria for criticality
applicable to a system.
 Principles of HAZOP
Concept
•Systems work well when operating under design conditions.
•Problems arise when deviations from design conditions occur.

Basis
•a word model, a process flow sheet (PFD) or a piping and
instrumentation diagram (P&ID)

Method
•use guide words to question every part of process to discover
what deviations from the intention of design can occur and what
are their causes and consequences may be.
 PRINCIPLES OF HAZOPS

GUIDE WORDS*
NONE
MORE OF
LESS OF
PART OF
MORE THAN
OTHER

CAUSE DEVIATION CONSEQUENCES

(from standard (trivial, important,
condition catastrophic)
or intention) -hazard
-operating difficulties
*COVERING EVERY PARAMETER RELEVANT TO THE SYSTEM
UNDER REVIEW:
i.e. Flow Rate. Flow Quantity, Pressure, Temperature, Viscosity, Components
Hazard Identification (HAZID)
 Hazard Identification
• The process of identifying and fixing potential hazards in the
workplace is called hazard management .

• A hazard may include sources or situations with a potential for

harm in terms of injury, ill health, damage to property, damage
to the environment or a combination of these.
 Safety Inspections

• Carrying out regular safety inspection can identify unsafe

conditions.
• A safety inspection is a procedure carried out in all
organisations.
• The purpose of a safety inspection is to:
1. Determine the hazards in the workplace
2. Identify any unsafe acts
3. Determine the risk associated with the hazard
4. Put in place control measure to eliminate the risk or at the
very least, reduce it.
 How to Identify a Hazard
• Review hazard identification techniques and tool in consultation with
staff and students in the area.
• Check records of injuries and illnesses that have occurred in the
workplace that could help identify less obvious hazards.
• Regularly conduct inspections in the workplace, looking for any
potential hazards that could cause harm.
• Use a checklist as a guide for types of general hazards when
conducting inspections.
• Talk to other staff or students if they have noticed anything that they
feel is unsafe as it may not be obvious to you.
• If a hazard is found, they must then be reported to the OHS
Representative using a Hazard Report Form.
 Hazard Categorisation

• A hazard is placed in one of three categories based on the likelihood

of risk, these categories are;

• Category “A” – type hazard is regarded as dangerous and requires

immediate corrective action.
• Category “B” – type hazard is less dangerous and corrective action must
be taken within three weeks.
• Category “C” – type hazard must be corrected within eight weeks.
 Risk Management: Assessing Risk
• Hazard identification, risk assessment and risk control are three
principles used in workplaces to manage safety and health.
• Risk means a combination of the severity and likelihood of harm arising
from a hazard.
• Risk assessment is the process of evaluating the severity and likelihood
of harm arising from a hazard.
 Step 1: Identifying or Spotting the Hazard
• The hazards can be identified by observing, inspecting, investigating,
communicating and consulting with staff/ students in the workplace

• Watch out for hazards in the workplace and report to immediate

supervisor
 Step 2: Assess and priorities Risk

• Analyzing the risk involves determination of the:

• Consequences – outcome of an incident

• Exposure – interaction with hazard
• Probability – likelihood that consequences will occur once individual
is exposed
 Step 3: Make the Changes

• Making changes means to work for fixing hazards to make

the workplace safe.

• This can be replacing damaged cords/wires, re-organising

the workspace or adjusting the lighting and ventilation.
• 1st step – to eliminate and identify hazards

• 2nd step – to rank the risk associated with the hazards

• 3rd step – to use control strategies to remove hazards

A Procedure for Controlling Risks

 The Hierarchy of Control
• Hazard identification is ongoing and progressive so it requires a
multitiered approach.
• Hierarchy provides a comprehensive control measures with preferred
order of control to eliminate and reduce the risk.

• These steps are:

• Elimination
• Substitution
• Administrative
• Engineering
• Personal protective equipment
 Elimination
Removing the hazard from the workplace.
• Modifying workstation design

• Modifying work organisation with task analysis and job redesign

• Modifying work shifts

• Replacing faulty equipment

 Substitution

Substituting or replacing a hazard with a less hazardous one.

• Replacing equipment
• Reorganising workstations to better suit the employee
• Substituting a product for a less hazardous one
 Isolation

Isolating or separating a hazard from people involved in the work.

• Locating fax machines further away from employees

• Ensuring noisy work areas such as printers and photocopiers are
located away from employees
 Engineering
If the hazard cannot be eliminated, substituted or isolated, an engineering
control is the most preferred measure.
• Repairing and maintaining equipment
• Promptly repairing network faults
• Installing a caustic shock prevention devices in telephone sets
• Reducing background noise levels
• Providing more space between operators groups or installing acoustic
barriers
• Adjusting lighting to reduce glare
 Administrative Control

Introducing work practices that reduce the risk such as implementing

measures to ensure procedures, instruction and training are provided.
• Implementing acoustic incident report and action plans
• Implementing or improving customer contact and dispute resolution
procedures
• Implementing job rotation
 Personal Protective Equipment

• provides personal safety devices.

In some instances, a combination of control measures may be

appropriate.
 Monitoring and Review of Control
Measures
• Deciding and implementing a risk control measure is not the end of the
risk management process.

• It is important to monitor and review control measures to ensure

preventing exposure to hazards.

• Level of risks should be prioritised. The high risk hazards need more
frequent assessment.
Every organisation should:
• Have a planned program of inspections and maintenance
• Undertake a review of work environment changes
• Have a regular review of the process for hazard identification
• Review risk assessment and risk control measure to ensure it is effective
• Review maintenance and repair program