Role of HAZOP Team_1

The Role of the HAZOP team

IEDOSH JBSemester May 2012

Prepared by :Mohd Ismafazil Ismail

HAZOP Team Member - Before the HAZOP

Before the meetings start, as a team member you can expect to receive some information about the study

Preparation for a HAZOP Study before the study commences

(a) Establish the ground rules of the study

(b) Plan the study schedule(c) Identify the team members

and arrange for their assistance

(d) Organize the data base(e) Familiar with data base(f) Members familiar with the major design and operating principles(g) Arrange a suitable meeting place

Preparation for a HAZOP Study before the study commences

Establish the Ground Rules

Aims and objectives of the study must be defined before the study commences.

Identify all causes of deviations which could lead to a safety hazard/ operability problem

Recommend changes to overcome safety hazards/ operability problem


Provide training for inexperienced personnel in the design intentions and expected operation of the facility

Provide background for the preparation of plant manuals/ procedure

Review operating procedure (required by team)


Record the background to all recommendations made

Record all useful information from the study

“ Recording by Exception” – causes & consequences are recorded if lead to a recommendation

“ Full recording” – all issues identified are recorded, whether or not lead to a recommendation

Plan the Schedule

(b) Plan the schedule Session dates and times (most

difficult, leader appoint time keeper) Documents to be studied in each session (low hazard may be excluded)

Team members availability

Plan the Schedule

Immediate reporting arrangements if required and final reporting (project in the design phase, construction or commissioning)

Study sub session plan if required Plan for follow up action

Team Members

(c) Identify team members – team characteristicsMembers share common objectives.Everybody contributes and knows

his/her roles, not leader dependent too much.

Each members values and respects contribution of others.

Members learn while they work.

Team Members

Disagreement are worked through by discussion.

Members enjoy team meetings.Team size between 5 (if no recorder)and 8 is probably optimum

Team balance is the most important issue.

Organisation of the Database

Ideal database in the table form is required (page 75)

During design phase, time allocated to gather latest version for each documents

Any plant modifications must be reflected on the drawings

For a procedural process study sequence of operation needed

Become familiar with the Database

Familiar with data baseLeader need background knowledgeBriefing by design/operation engineer

Fundamental hazards should be identified

Detailed study of the operating principles

Team members are familiar with operations

Members familiar with operating principles

Pre-study operation for members who had no contact with plant

Circulate some of the data base material prior to the study

Leader to talk to each team member to assess the need for these actions

Organisation of the Database

Suitable meeting placeSufficient space for participants and observer

Enough space to lay out drawingsNo telephone availableNot conducted at operating sideTip top facility

HAZOP Leader

HAZOP leader characteristicClear idea of the objectivesPlan sessions and timetableControl discussionLimit discussionEncourage team to draw conclusion

HAZOP Leader

Ensure secretary has time for taking note

Keep team in focusEncourage imagination of team

membersMotivate membersDiscourage recriminationsJudge importance issues

HAZOP Leader

Major ResponsibilitiesSelection of the teamPlanning of the studyCarrying out the studyReporting the studyFollowing up the actions

HAZOP Leader

The Team Leader’s primary role is to facilitate the team discussion

Keep the team focused: Concentrate on identifying hazards, not

re-designing the plant

Where the data is insufficient, record questions and move on

HAZOP Leader

Respond to team personalities: Be tolerant and maintain a positive

atmosphere. Restrain the extroverts Draw out the quiet thinkers

Use own knowledge to: Encourage thoroughness Obtain consensus Phrase recommendations

HAZOP Leader

HAZOP leadership is an expression of personal style… but leaders can strengthen the range of skills and behaviours they have available

The leader must stick to the principles of the HAZOP procedure but the pace and manner allow wide latitude for personal style

Guidance for HAZOP leaders includes a flow chart to monitor progress and check completeness. For our own leaders we have developed files for planning, recording and assessing the results of the study

HAZOP Leader

Experience is an important factor helping to improve performance. For the recorder this means working with different leaders to experience the variety of approaches and recording styles

Questionnaire which provides a framework for the recorder to give feedback on the conduct of the study. If we approach the feedback positively, recognising that we all have room to learn and improve, we should improve our HAZOP facilitation

HAZOP Leader

The HAZOP leader needs to define with the commissioning manager study the extent of the facilities to be studied before the HAZOP starts

Technical drawings of the facility such as Piping and Instrumentation Diagrams (P&ID) are typically used to define the plant

HAZOP Leader

Supplementary materials are useful to clarify team discussions:

Process flow sheetsEquipment specifications and vendor detail

drawingsPiping class and relief valve specificationsPlot layout and classificationOperating manuals and emergency shut

down procedures

HAZOP Leader

Working from incomplete or out-of-date documentation is a serious pitfall

For a HAZOP on an existing facility “as built” P&ID are essential; if the plant is under design a consistent set of the latest revisions is required

HAZOP Leader

The HAZOP Leader must supervise study preparation

HAZOP Leader

The HAZOP meeting develops a rhythm after the first day which often includes some introductory discussion to orient the team

HAZOP Leader

Steps in a normal HAZOP day

HAZOP Leader

Details for study of a single plant section

HAZOP Leader

The leader must keep in mind a number of activities needed to conclude the study

HAZOP Leader

The HAZOP is completed with some activities outside the HAZOP sessions.

HAZOP Leader

The HAZOP is completed with some activities outside the HAZOP sessions.

Leadership Issues

Always prepare study program in advance.

Agree on the format or form to be used.Prepare follow up procedures.Brief members about HAZOP during first

meeting.Stop the team trying to redesign the

process.HAZOP is a team exercise. Do not let

anybody (including the leader himself to dominate).

Leadership Issues

If conflict arises, handle with care.Avoid long discussions by recording

areas which need to be resolved outside meeting.

Leader must be strong, yet diplomatic.Speak clearly. Make you point.Better have experience working as

team member previously.Do not skip anything….some time small

things may cause big accident.

Team Issues

Function effectively if it behaves as a group with common goals

Each member contributes to the common goal and remains motivated

Members are clear at all times about what point is being discussed.

Break time, story telling, games.Group dynamic and dealing with different

types of personality.Contributors to discussion, open mind,

ability to visualize situations.

Selecting a study section

Based on function of the process plant being studied and the overall HAZOP experience of the team.

HAZOP leader should review the drawings to be studied the next day and plan the sections.

Selecting the end point for the next study section refer to :(a) next change in design intent(b) significant change of state occurs(c) separate equipment items with different process parameters(d) each process vessel with its associated equipment


It can be established that there are 3 distinct design intentions in the system.

Feed tank – store the feed material for Process A Pipeline and pump – to transfer the feed from the storage tank to Process A Process A – to do something with the feed supplied to it.


3 distinct study sections because there are 3 definite design intents in the process system.

Each one would be a HAZOP study section.The important principle in conducting a

HAZOP study as a leader is to confine the causes of a guideword.

Follow consequences to the most severe situation

The selection of the study section is the TEAM LEADER’s responsibility.

Team Selection & TrainingTeam size is important, between 5 (no recorder)

and 8 is probably optimum.Team must have detailed knowledge of the way

the plant is intended to work.Technique of using guidewords generates a very

large number of questions.It is essential that the team contains enough

people with sufficient knowledge and experience to answer the majority of those questions without recourse to further expertise.

Team Selection & TrainingNew Project

System Design Engineer

Mechanical/Structural Engineer

Operation Supervisor/Foreman

Instrument/Control System Design Engineer

Safety/Quality Representative

Existing System

Shift Charge Engineer

Maintenance

Electrician

Instrumentation

Production Engineer

Design Engineer

Specialist Engineer

Responsibility of HAZOPteam member

HAZOP recorderTake adequate notesRecord documentationsInform leader if more time

required in taking notesIf unclear, check wording before

writing


Refrain from taking part in the debate

Produce interim lists of recommendations

Produce draft report of studyCheck progress of chase actionProduce final report


Process/System Design Engineer

Provide a simple description

Provide design intention for each

process unit

Provide information on process

conditions and design conditions

Provide information on hazards of

process/ operations


Mechanical Design Engineer

Provide specification details for

equipments

Provide vendor package details

Provide equipment and piping

layout information

Provide information on design codes


Instrument Engineer & Control

Specialist

Provide details of control philosophy

Provide interlock and alarm details

Provide info on shutdown, safety feature

Give information on hardware reliability

and modes of failure

Provide information on testing needs


Plant Engineer or ManagerProvide information on compatibility

with any existing adjacent plant

Provide details of site utilities and services

Provide (for study on existing plant) any update on maintenance access and modifications


Shift Operating Engineer or SupervisorProvide guidance on control

instrumentation integrity from an operating experience view point

Provide (for study on existing plant) information on plant stability at the specified control parameters

Provide information on experienced operability deviations of hazard potential


Operations’ RepresentativeCheck the design details against operating

philosophy

Ensure design is compatible with existing systems

Check design against maintenance requirements

Provide details of operating practice and procedures


ChemistProvide details of process chemistryProvide details of process hazards

(polymerizations, byproducts, corrosion etc)

Project EngineerProvide details of cost and time estimation

and also budget constraints.Ensure rapid approval if required

Training of HAZOPteam member

Formal training schemeTraining on HAZOP techniqueHAZOP leader : good grounding in the

technique & practical experienceHAZOP recorder : on-line recording packageHAZOP team : general introduction on

methodology & reasons for carrying out a study

Question Technique

Open questionsHelp person being asked to think – use

words how, what and why.

Closed questionsTo focus on an issue or problem. Start with

words who, when, where.Required answer yes or no only.

Question mixMix between open and closed questions.

Question Technique

Things to avoid

Ambiguous or vague questions. Double barrell/multiple questions. Long complicated questions. Interrogation type of questions. A loaded questions – implied judgement.

THANK YOU