STANDARDS PUBLICATION

QP GUIDELINE FOR
HAZARD & OPERABILITY STUDIES

DOC NO: QP- GDL- S-001

REVISION 2

CORPORATE HSE SUPPORT DEPARTMENT

 QP GUIDELINE FOR HAZARD & OPERABILITY STUDIES

DOC. No. QP-GDL-S-001 R2

TABLE OF CONTENTS

FOREWORD
1.0 OBJECTIVE…………………….…………………………………...…… 4
2.0 SCOPE……….………………………………….………………………… 4
3.0 APPLICATION…………………………………………………………….. 4
4.0 TERMINOLOGY……………………………………………….…………… 4
5.0 RELATED DOCUMENTS………………………………….…….………… 5
6.0 STRUCTURE & RESPONSIBILITIES…………………..……………….. 5
6.1 TEAM STRUCTURE ……………………………………………………………… 5
6.2 HAZOP CHAIR…………………………………………………….………………. 6
6.3 PROGRAMMING………………………………………………………………….. 6
7.0 GUIDE………………………………………………………………………… 6
7.1 HAZOP PREPARATION…………………………………………………………. 6
7.2 STUDY SESSIONS………………………………………………………………. 8
7.3 DELIVERABLES………………………………………………………………….. 9
8.0 APPENDICES
8.1 APPENDIX I - HAZOP GUIDE WORDS………………………………… 11
8.2 APPENDIX II – HAZOP PARAMETERS………………………….…….. 12
8.3 APPENDIX III – EXPANSION OF HAZOP DEVIATIONS……….…..…. 13
8.4 APPENDIX IV – EXAMPLE HAZOP RECORD SHEET………………… 15
8.5 APPENDIX V – EXAMPLE HAZOP ACTION SHEET………………….. 16
REVISION HISTORY LOG……………………………………………………….. 17

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FOREWORD

This document has been developed by Corporate HSE Support Department (ST),
reviewed by Corporate Quality and Management Systems Department and circulated for
user departments‟ review before endorsed by Corporate Management for use as
Corporate Guideline for Hazard & Operability Studies.

This document is published for QP Departments/Contractors/Consultants utilisation. It

should be emphasised that the document is to be used for QP operations wherever
applicable and appropriate.

This document in its present form reflects as far as possible the current QP requirements
taking into account the known available industry practices and the applicable latest
national and international codes and standards.

This document is subjected to periodical review to re-affirm its adequacy or to conform to

any changes in the corporate requirements or to include new developments on its subject.

It is recognized that there will be cases where addenda, data sheets, or other clarifications
need to be attached to the standard to suit a specific application or service environment.
As such, the content of the document shall not be changed or re-edited by any user (QP or
its contractors, suppliers, agents, etc.), but any addenda or clarifications entailing major
changes shall be brought to the attention of the Custodian Department.

The custodian of this document is Corporate HSE Support Department (ST). Therefore, all
technical comments, views, recommendations, etc on this document shall be forwarded to
the same and copied to Manager, Corporate Quality & Management Systems Department
(QA).

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1.0 OBJECTIVE

The technique for a Hazard & Operability Study, (HAZOP), has been developed to provide a
systematic method of analysing the causes and effects of abnormal plant operations.

This guideline describes the organisation, study methods and recording requirements for
HAZOP studies. Its purpose is to advise both HAZOP team members and other members of a
project, of the approach to be adopted as well as the other contributions required from
individuals. It is based upon considered worldwide best practices and international
benchmarks in HAZOP deployment and management.

2.0 SCOPE

This guideline specifies the structure, responsibilities and techniques of the Hazard &
Operability Study.

3.0 APPLICATION

This guide is applicable to plant, process and utility systems. Coverage shall include all lines
containing hydrocarbons or fluids which could pose a hazard and utilities e.g. flare, open &
closed drainage systems, fire fighting systems, and emergency systems cause and effect
logic.

4.0 TERMINOLOGY

4.1 DEFINITIONS

HAZARD An entity that has a potential to cause harm, including death

or injury to people; damage to the environment or property; or
other form of loss (e.g. loss of production)

HAZOP The application of a systematic critical examination, to the

process and engineering intentions, of a facility to assess the
hazard and operability potential of mal-operation or
malfunction of individual items of equipment and the
consequential effects on the facility as a whole

INDEPENDENT In terms of HAZOP Chairperson and Secretary shall mean

having no association with the project under review.

THIRD PARTY In terms of HAZOP Chairperson, shall mean external to QP or

any associated contracting company.

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4.2 ABBREVIATIONS

HSE Health, Safety & Environment

PCR Plant Change Request

P.E. Project Engineer

PFD Process Flow Diagram

P&ID Piping and Instrumentation Diagram. (Generic term

used for both PEFD and UEFD)

PEFD Process Engineering Flow Diagram

QRA Quantitative Risk Assessment

UEFD Utility Engineering Flow Diagram

5.0 RELATED DOCUMENTS

IP-ENG-008 Major Capital Projects Approval Procedure

IP-ENG-009 Non-major Capital Projects Approval Procedure

IP-ENG-019 Hazard and Operability (HAZOP) Procedure

6.0 STRUCTURE & RESPONSIBILITIES

6.1 TEAM STRUCTURE

6.1.1 All Capital Projects under DT (Director Technical) shall be led by an „independent‟, “third party”
Chairperson, approved by Corporate HSE Support and assisted by an independent secretary
(scribe). In-house FEED Projects and PCRs may be chaired by an “independent” but non third
party Chairperson. All HAZOP team members shall be required to undertake an internationally
recognised HAZOP training course provided by Corporate Training, within 5 years of issue of
the second revision of this guideline.”

6.1.2 HAZOP Team membership shall be categorised into Core and Non-Core Teams. Non-core
team members shall participate in “as required” basis.

a. The core team shall consist of:

 Corporate HSE Project Design Representative
 Project Engineer
 Operations Representative
 Maintenance Representative
 Process Engineer
 Instrumentation Engineer

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 Loss Prevention Engineer

b. Non-core team shall consist of:
 Specialist Engineering Representatives
 Regional / Operational HSE Representative

6.1.3 Where the HAZOP study is on a Contracted engineering project the core team shall
incorporate additionally representation from the Contractor as follows:
 Process Engineer
 Instrument Engineer (optional)
 Loss Prevention Engineer

Non-core team shall consist of:

 Other Specialist Engineers as and when required by HAZOP

It is essential that the team composition be appropriate for the plant or design being studied.
All persons attending a HAZOP study must be available for its full duration, without
substitution.

6.2 HAZOP CHAIRPERSON

Responsibility for the conduct of the HAZOP lies with the Chairperson. The Chairperson
should be an experienced engineer with relevant knowledge in the oil and gas industry but a
generalist rather than an "expert" and should have experience in chairing HAZOP studies of a
similar level of complexity. All HAZOP Chairperson should have undertaken a certified HAZOP
Chairpersons course.

The task of the Chairperson is to ensure that the HAZOP proceeds smoothly, effectively,
comprehensively and expeditiously. The Chairperson is responsible for maintaining the
essential flow of the study, its vigour and the active participation of all team members.

The Chairperson produces the HAZOP report and the Record sheets, with the assistance of
the secretary (scribe), for agreement by the team, but not responsible for the implementation
and close out of action items arising from the HAZOP. Each sheet shall be signed by QP core
team representative i.e. P.E. and a representative from the Contractor core team as a true
record of the proceedings, prior to formal issue.

6.3 PROGRAMMING

HAZOP shall be conducted during FEED and EPIC on the “issued for HAZOP” P&IDs and key
documents as listed in 7.1.2, after these Project design documents have undergone a Design
review. It is preferred to complete the detail design stage HAZOP and its recommendation
incorporated before freezing the design phase and the Approved for Design (AFD) document
is issued.

7.0 GUIDE

7.1 HAZOP PREPARATION

A significant amount of preparatory work is required both by the HAZOP team and by the
discipline Engineers concerned, prior to each session. This work typically comprises:

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 Briefing of team members;

 Collecting the relevant data;
 Converting the data into a suitable form;
 Planning the sequence of the study;
 Arranging the necessary meetings

7.1.1 Briefing

It is important that members of the team are trained and familiar with the HAZOP technique.
QP team members shall be suitably trained in the HAZOP technique. If some of the team
members (e.g. Contractor participants) are not trained, they may be given a brief, with respect
to the requirements of HAZOP team members, by the HAZOP Chairperson.

7.1.2 Data Collation

The P.E. (from Engineering Contractor or QP depending on the Project being in-house or
contracted) will be responsible for assembling the relevant data to meet the requirements of
the Independent Chairperson. Individual discipline Lead Engineers will be responsible for
supplying the data to the P.E. and where necessary, advising the P.E on the available data
and other issues of interest.

The following documents shall be required by the HAZOP team:

a. PFD's;
b. P&ID's for Process & Utilities;
c. Plot Plans;
d. Material Specifications and Selection Charts;
e. Cause and Effect Diagrams;
f. Process Design Basis
g. Process Operation & Control Philosophy

The following documents can be consulted by the HAZOP team depending upon the stage of
the Project:

a. Single Line Diagrams;

b. Equipment Specifications;
c. Vendor data & drawings;
d. Fire & Gas Detection Drawings;
e. Hazardous Area Classification Drawings.

Other documents may also be called for, to amplify or verify information on the P&ID's.

The HAZOP package (documents listed above) shall be issued 1 week in advance to all
participants for their review and preparation for the HAZOP.

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7.1.3 Data Presentation

To save time during the study meetings, some documents used during the review may be
marked up with additional information, e.g. P&ID's annotated with normal and design
conditions, instrument set points etc. Any marking shall be done by the relevant discipline
engineer either on his own behalf or at the request of the Independent Chairperson.

7.1.4 Phasing the activities

The Independent Chairperson will plan the sequence of the study, dividing each P&ID into
nodes, which can be examined in a logical fashion, so that the results of earlier studies
contribute to subsequent studies.

7.1.5 Scheduling the Meetings

The P.E. will be responsible for arranging the study sessions and any other relevant meetings.
Booking of the venue and alerting personnel to their attendance requirements shall be
undertaken by the P.E., who will also arrange for the necessary visual aids, black/(white)
boards or flip-over pads, and computer printout facilities to be available.
It is a prerequisite that the HAZOP should maintain continuity. Therefore the sessions should
follow on, on a daily basis. HAZOP sessions are intensive and more than 5 study hours per
day becomes counter productive. Breaks for coffee and lunch are essential.

7.2 STUDY SESSIONS

The basic requirement is that the HAZOP team question every aspect of the design to
determine how deviations from normal operations can lead to hazardous situations or
operability problems.

The HAZOP Chairperson shall plan and control the sequencing of the study. The strategy
involves a brief description of the system by the Process Engineer, after which the Chair-
person selects the first item of equipment or process path (Node) to be examined.

The function/intent of the equipment or system within the Node is explained and its explicit
purpose agreed by the team. The Chair-person selects „process parameters‟ and "guide
words" in sequence, to examine all parts of the system. A listing of generic parameters and
guide words is provided in Appendices I & II, together with an expansion of common
parameters and deviations in Appendix III.

HAZOP study shall be undertaken using software such as PHA Works.

The examination proceeds orally and as each plant item / process parameter / guide word /
deviation is resolved a written note is made of the potential hazards or operational concerns;
their causes, consequences and safeguards. Remedial actions / recommendations may be
made for incorporating more safeguards and these actions are assigned to a responsible party
for resolution. Reporting can be, “in full” or "by exception", in which case only those items
requiring Actions are noted. The former is the preferred QP report format. This format provides
a robust demonstration of Hazard Identification, even when there are no apparent issues
identified.

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Problem-solving during the sessions is discouraged. However, simple problems may well be
solved and decisions taken to modify the design. Such actions shall be recorded.

Normally the problem will be merely recorded and an Action listed for further examination
outside the main study session.

7.3 DELIVERABLES

HAZOP Record sheets and Actions sheets are prepared at the end of each HAZOP session
by the Chairperson, assisted by the Secretary. The Action sheets and Record sheets may be
of the format used by Contractor, but they have to include all QP requirements. During the
HAZOP, the Secretary will record all potential hazards, their causes, safeguards and actions
arising. Immediately after each session the Chair-person will check the Record sheets to
ensure that all actions are properly recorded and numbered. The Record sheets will then be
copied and distributed to all team members, action addressees.

The nominated P.E. will maintain the overall progress schedule, the outstanding Actions Log
and pass a copy of the Record sheets for word processing. He will be responsible for
updating the Record sheets following evaluation and action meetings.

Team members are to pass any comments on the Record sheets to the Chairperson within a
maximum of two working days. The Chairperson shall make any amendments, if necessary,
after discussion with the HAZOP team.

7.3.1 Records

All the drawings, reference data, evaluations, Record sheets, Action sheets etc., used or
developed during the course of the HAZOP are reproduced and filed for future reference by
the Secretary. A master copy of each P&ID is to be signed and dated by the Chairperson
when all systems on that drawing have been examined and marked up. An example of a
HAZOP Record sheet is provided in Appendix IV.

7.3.2 Reporting

On completion of the HAZOP, the Chairperson shall compile a report, describing the scope of
the work and containing copies of the main documents and drawings used. A typical report will
contain an introduction, list of team members, dates of meetings, pertinent facts, actions
summary and recommendations. Other principal documents, including P&IDs, Record sheets
and important minutes of meetings will be presented as an Appendix.

The report shall be circulated and agreed to by all team members.

7.3.3 Actions Follow-up and Close-out

Follow-up actions by discipline engineers are to be passed back to the nominated P.E. under
cover of dated memoranda.

Once a hazard has been identified, a wide range of actions may be possible. These fall into
three broad categories:

 Actions which remove the cause of the hazard;

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 Actions which break the chain of events between cause and consequences;
 Actions which reduce the consequences.

The nominated P.E. is responsible for nominating an individual to follow up all actions agreed
at HAZOP sessions and also state the target time by which the actions shall be completed.
The action addressee will normally be the Discipline Engineer who attended the HAZOP
session at which the particular problem was discussed. All correspondence relating to a
„HAZOP Action‟ shall be logged on HAZOP Action sheet. An example of a HAZOP Action
sheet is provided in Appendix V.

The P.E. will hold follow-up meetings (Evaluation and Action Meetings), probably covering
several HAZOP sessions, to discuss and agree the completed "Actions". He will be
responsible for progress chasing during this phase and will track the progress of all follow-up
actions and maintain an "Outstanding Actions Log", giving the status of any action at any time.

The follow up meetings are complete when all Actions have been satisfactorily resolved, i.e.
the final Actions can be listed as:

 Recommended design changes;

 Amendments to operating procedures; or
 No further action required.

These requirements will then be passed to the discipline concerned. The discipline Lead
Engineer will be responsible for raising the necessary variation order(s) for approval prior to
incorporating the change into the design.

The P.E. is responsible for the implementation and close out of action items arising
from the HAZOP.

Note that any design alteration agreed by the team should be examined in a similar
fashion to the original design, to ensure that no new hazard is introduced.

Whilst a HAZOP study proceeds without reference to event probabilities, events with very low
probability may be disregarded unless the consequences are extremely serious. In areas
where doubt exists, Hazard Analysis (HAZAN) is recommended and may also involve QRA,
where appropriate, to quantify associated risks.

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8.0 APPENDICES
8.1 APPENDIX I - HAZOP GUIDE WORDS

GUIDE WORDS MEANINGS COMMENTS

NO, NOT or NONE The complete negation of the design No part of the intentions is
intentions. achieved and nothing else
happens.

MORE (OF) Quantitative increase of any relevant These refer to quantities +

physical parameters relevant physical properties such
as flow rates and temperatures as
well as activities like “HEAT” and
“REACTION”.

LESS (OF) Quantitative decreases

AS WELL AS A qualitative increase All the design and operating

intentions are achieved together
with some additional activity.

PART (OF) A qualitative decrease Only some of the intentions are

achieved; some are not.

REVERSE The logical opposite of the intention This is mostly applicable to

activities, for example reverse flow
or chemical reaction. It can also
applied to substances, e.g.
“POISON” instead of “ANTIDOTE‟
or “D” instead of “L” optical
isomers.

OTHER THAN Complete substitution No part of the original intention is

achieved. Something quite
different happens.

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8.2 APPENDIX II – HAZOP Parameters

 FLOW

 PRESSURE

 TEMPERATURE

 LEVEL

 VISCOSITY

 COMPOSITION

 CORROSION/EROSION

 RELIEF/VENTING

 INSTRUMENTATION

 MAINTENANCE/MAINTAINABILITY

 SAFETY

 UTILITIES

 DRAINAGE

 START-UP & SHUTDOWN

 OTHER (e.g. SAMPLING)

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8.3 APPENDIX III – EXPANSION OF HAZOP DEVIATIONS

No flow Wrong routing - blockage - incorrect slip plate - incorrectly fitted N.R.V. –
ruptured pipe - large leak - equipment failure (C.V., isolation valve, pump,
vessel, etc ) incorrect pressure differential - isolation in error -etc. )

Reverse flow Defective N.R.V.- syphon effect -incorrect differential pressure -two way
flow -emergency venting -incorrect operation - etc.

More flow Increased pumping capacity - increased suction pressure - reduced delivery
head - greater fluid density - exchanger tube leaks - restriction orifice plates
deleted - cross connection of systems - control faults - etc.

Less flow Line restriction - filter blockage - defective pumps - fouling of vessels,
valves, restrictor or orifice plates - density of viscosity problems - incorrect
specification of process fluid - etc.

More pressure Surge problems - leakage from interconnected H.P.System gas

breakthrough (inadequate venting) - isolation procedures for relief valves
defective - thermal overpressure - positive displacement pumps - failed
open PCV‟s - etc.

Less pressure Generation of vacuum condition - condensation - gas dissolving in liquid -

restricted pump/compressor suction line - undetected leakage - vessel
drainage - etc.

More temperature Ambient conditions - fouled or failed exchanger tubes - fire situation -
cooling water failure - defective control - fired heater control failure - internal
fires - reaction control failures - etc.

Less temperature Ambient conditions - reducing pressure - fouled or failed exchanger tubes -
loss of heating - etc.

More viscosity Incorrect material specification - incorrect temperature

Less viscosity Incorrect material specification - incorrect temperature

Composition leaking isolation valves - leaking exchanger tubes - phase change -

Change incorrect feedstock/specification - inadequate quality control - process
control procedures - etc.

Contamination Leaking exchanger tubes or isolation valves - incorrect operation of system

-interconnected systems -effect of corrosion - wrong additives - ingress of
air - shutdown and start-up conditions etc.

Corrosion / Erosion Cathodic protection arrangements – internal/ external corrosion protection –

engineering specifications – stress corrosion cracking – fluid velocities –
etc.

Relief Relief philosophy (process/ fire, etc.) – type of relief device and reliability –
relief valve discharge location – pollution implications – two phase flow –
effect of debottlenecking on relief capacity – inlet and outlet piping – etc.

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Instrumentation Control philosophy – location of instruments – response time – set points of

alarms and trips and ability to change – time available for operator
intervention – alarm and trip testing –– trip/control amplifiers – panel
arrangement and location – auto/manual facility and human error – fail safe
philosophy – etc.

Maintenance Isolation philosophy – drainage – purging – flushing – cleaning – drying –

slip plates – access – rescue plan – pressure testing – work permit system
– condition monitoring – lifting and manual handling – etc.

Safety Toxic properties of process materials – fire and gas detection system/
alarms – fire protection system - fire fighting response time – emergency
response plans and major emergency training – contingency plans – TLVs
of process materials and methods of detection – noise – knowledge of
hazards of process materials – first aid/medical resources – effluent
disposal – hazards created by others (adjacent storage areas/process plant
etc.) – testing of emergency equipments – compliance with local/ national
regulations – etc.

Utilities Failure of instrument air / steam / nitrogen / cooling water / hydraulic power
/ electric power/ water or other – contamination of instrument air, nitrogen
etc. - telecommunications – heating and ventilation systems – computers –
etc.

Start-up start-up – normal shutdown – emergency shutdown etc.

& Shutdown

Sampling Sampling procedure and operator safety – time for analysis result –
calibration of automatic samplers – reliability/ accuracy of representative
sample – diagnosis of result – loss of sample flow – etc.

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8.4 APPENDIX IV – EXAMPLE HAZOP RECORD SHEET

HAZOP Title:
Present:
Drawing No: Date:
Line/Item Description: Node XX, Line/Item No:
Design Intent:

Pressure Temperature Flow Composition

Design Conditions
Operating Conditions

Ref Deviation Cause Consequence Safeguards Actions Comments

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8.5 APPENDIX V – EXAMPLE HAZOP ACTION SHEET

HAZOP ACTION SHEET
Action Sheet No.
Project Title: Location:

HAZOP STUDY REPORT

Drg No. Rev: Action No.

Action By:

ACTION

Item: Deviation:
Cause:
Consequence
Action:
By:
REPLY

Reply Produced By: Date:

STATUS: ACCEPTED/REFERENCED/REJECTED
Signed for: Date:

INCORPORATED into Design – Reference Drg No.:

By: Date:

INCORPORATED in Field
Signed for: Date

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REVISION HISTORY LOG

Revision Number: 2 Date 14/4/2010

Item Revised: This guideline (R2) is a new revision of the same document developed to
cover a new requirements for HAZOP members, Chairperson competency
and to include HAZOP software requirement and additional HAZOP
Guidewords.
Item Revised: Rev. 1 – Renumbered and reformatted to reflect change from QGPC to
QP
Whole document re-structured to meet the Corporate Standard Document
requirements and document re-numbered
From EG-S-01 to QP-GDL-S-01 rev. 1
Item Revised Rev. A – Issued for Approval as Corporate Standard

Note:

The revision history log shall be updated with each revision of the document. It shall
contain a written audit trail of the reason why the changes/amendments have occurred,
what the changes/amendments were, and the date at which the changes/amendments
were made.

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