The HAZOP Leader's Handbook : How to Plan and Conduct Successful HAZOP Studies

The HAZOP Leader’s Handbook is designed specifically to help HAZOP leaders plan and execute successful HAZOP studies, based on the author’s many years of experience of participating in, observing and facilitating HAZOP studies, as well as observing, training, mentoring and assessing HAZOP leaders. The book assumes that the reader understands the methodology and has experienced HAZOP meetings and does not seek to explain the methodology itself. Rather, it focuses on the application of the methodology and the responsibilities and skills of the HAZOP leader in the preparation, execution and reporting of the study. Although the principal subject is HAZOP, much of the content equally applies to other facilitated hazard identification techniques such as Hazard Identification (HAZID) or Failure Modes Effects and Criticality Analysis (FMECA). The prime purpose of this book is to provide guidance specific to HAZOP leaders to help them to maximise the effectiveness of their HAZOP studies, thereby getting the most benefit from the methodology, promoting consistency and rigour in its application and sustaining its well-earned reputation. Includes HAZOP leader’s responsibilities and competence requirements and how to plan, prepare and manage a HAZOP study from its conception through to delivery of the final report Describes current best practice in the application of the HAZOP technique Explains the role of the HAZOP leader as a facilitator of study meetings using examples of facilitation techniques Discusses ways in which the leader can maximize the effectiveness of HAZOP technique in identifying and analyzing process hazards Front Cover The HAZOP Leader’s Handbook Copyright Page Dedication Contents Preface Acknowledgements 1 Introduction 1.1 Reputation and reality 1.2 Why this book? References 2 More than just a chair! 2.1 The HAZOP leader’s responsibilities 2.2 Are you ready for the challenges? 2.2.1 Time and resource constraints 2.2.2 Design completeness 2.2.3 Quality of information 2.2.4 Facilitation and group dynamics 2.2.5 Customer expectations 2.2.6 Measurement of effectiveness 2.3 Qualifications, experience and skills 2.4 Developing and demonstrating your competence 2.5 Make sure you are independent! 2.6 Still want to be a HAZOP leader? References 3 Fail to prepare, prepare to fail 3.1 Is it HAZOP that you need? 3.2 Can you plan for success? 3.3 Terms of reference 3.3.1 Put the client’s agreement front and centre! 3.3.2 Describe the background or context of the study 3.3.3 Be clear about your objectives 3.3.4 Carefully define the scope of the study 3.3.5 Specify how you will apply the methodology 3.3.6 Decide what process safety information you need 3.3.7 Who needs to be involved? 3.3.8 Schedule and deliverables 3.3.9 Report content and distribution 3.4 The HAZOP team 3.4.1 The core HAZOP roles 3.4.2 Additional roles (if you must) 3.4.3 Independent process engineer 3.4.4 Safety manager 3.4.5 Preparing the team 3.5 Node selection 3.5.1 Node selection for a continuous process 3.5.2 Nodes for complex systems 3.5.3 Different operating modes 3.5.4 Parallel trains 3.5.5 Study boundaries or interfaces 3.5.6 Node selection for batch and procedural HAZOP 3.6 Deviations from design intent 3.6.1 Continuous HAZOP 3.6.2 Batch and procedural HAZOP 3.7 How much time do you need? 3.7.1 Rules of thumb based on P&IDs and nodes 3.7.2 Rules of thumb based on equipment 3.7.3 More complex methods 3.7.4 Preparation and reporting time 3.8 Preparation you can start immediately 3.8.1 P&ID management 3.8.2 Software pre-population 3.9 Preparations nearer the study 3.9.1 General considerations 3.9.2 The HAZOP environment 3.9.3 The opening meeting 3.10 Summary: critical success factors References 4 Apply best practice 4.1 Constructing scenarios: the ‘golden rules’ 4.1.1 Detailed node description and design intent 4.1.2 Causes in the node, consequences anywhere 4.1.3 Ultimate, unmitigated consequences 4.1.4 Actions of the safeguards 4.1.5 What-where-why-stand-alone recommendations 4.1.6 Full recording 4.2 A summary of scenario development 4.3 Tools for stimulating creativity 4.3.1 Modes of loss potential causes 4.3.2 Process flow failure modes 4.3.3 Consequence pathways 4.4 Some technical challenges 4.4.1 Double jeopardy 4.4.2 Common mode failure 4.4.3 Process dependency or interaction 4.5 Policy challenges 4.5.1 Overflows 4.5.2 Tank bunds 4.5.3 Positive displacement pumps 4.5.4 Nonreturn valves (check valves) 4.5.5 Emergency shut-off valves References 5 Facilitate! 5.1 The role of facilitator 5.1.1 Ground rules 5.2 Group dynamics 5.3 Team development 5.4 Individual communication styles 5.5 Facilitation skills 5.5.1 Facilitation skills for HAZOP leaders 5.5.2 Some techniques to apply in HAZOP 5.6 Consensus and disagreement 5.7 Dysfunctional behaviour 5.7.1 HAZOP leader behaviour 5.7.2 Role-induced behaviours 5.7.3 Dealing with dysfunctional behaviour 5.8 Crisis? What crisis? References 6 Focus on effectiveness 6.1 What do we mean by effectiveness? 6.2 Maintaining effectiveness: avoiding or overcoming common problems 6.2.1 Maintaining attendance 6.2.2 Maintaining energy 6.2.3 Managing time pressure 6.3 Stopping the study 6.4 Assessing effectiveness 6.4.1 Quality assurance 6.4.2 Effectiveness questionnaire 6.4.3 How else could we assess effectiveness? References 7 Develop your product 7.1 What should go in the report? 7.2 Presenting the key findings 7.3 Analysing recommendations 7.4 Should opinions relating to quality be included? 7.5 Building up the report: before, during and after 8 How to be a better HAZOP leader Appendices Appendix 1 HAZOP practitioner assessment protocol Appendix 2 HAZOP preparation guide Appendix 3 Typical structured what if? or SWIFT checklist Appendix 4 Terms of Reference Appendix 5 Process safety information Appendix 6 Node selection guidance Appendix 7 HAZOP deviations Appendix 8 P&ID management protocol Key principles There is only ever one master version! Appendix 9 HAZOP event checklist Appendix 10 Modes of loss and potential causes Appendix 11 Process flow failure modes—“The List” Appendix 12 Consequence pathways Appendix 13 Ground rules Appendix 14 Group dynamics Leadership Participation Communication patterns Task and maintenance behaviours [2] Psychosocial considerations [1] Decision-making Conflict resolution Appendix references Appendix 15 Facilitation styles and group maturity Appendix references Appendix 16 Communication styles in facilitated sessions Appendix 17 Managing dysfunctional behaviour Appendix 18 HAZOP progress tracker Appendix 19 HAZOP progress report Appendix 20 Quality assurance checklist Appendix 21 Effectiveness assessment questionnaire Preparation The study meetings After the study Appendix 22 Final report contents List of abbreviations Index Back Cover The Hazop Leader's Handbook: How To Plan And Conduct Successful Hazop Studies Is Designed Specifically To Help Hazop Leaders Plan And Execute Successful Hazop Studies. It Is Based On The Author's Many Years Of Experience Of Participating In, Observing And Facilitating Hazop Studies, As Well As Observing, Training, Mentoring And Assessing Hazop Leaders. The Book Assumes That The Reader Understands The Methodology And Does Not Seek To Explain The Methodology Itself. Rather, It Focuses On The Application Of The Methodology And The Responsibilities And Skills Of Hazop Leader In The Preparation, Execution And Reporting Of The Study. The Book's Primary Purpose Is To Provide Guidance To Hazop Leaders To Help Them Maximize The Effectiveness Of Their Hazop Studies, Thereby Getting The Most Benefit From The Methodology, Promoting Consistency And Rigor In Its Application, And Sustaining Its Well-earned Reputation. Includes Hazop Leader's Responsibilities And Competence Requirements And How To Plan, Prepare And Manage A Hazop Study From Its Conception Through To Delivery Of The Final Report Describes Current Best Practice In The Application Of The Hazop Technique Explains The Role Of The Hazop Leader As A Facilitator Of Study Meetings Using Examples Of Facilitation Techniques Discusses Ways In Which The Leader Can Maximize The Effectiveness Of Hazop Technique In Identifying And Analyzing Process Hazards