Index

Note: Page numbers followed by “f” and “t” refers to figures and tables respectively.

A

Accidents, 36
Actions, 3, 21–22, 67
and recommendations, 21–22
Alarms, 19, 63, 63, 65, 65, 67, 80
Approved for design (AFD), 5
Area classification, 5
Audit, 29, 47, 50, 53, 55–57, 94
Auditing
external, 55–57
internal, 55–57

B

Batch, 13
Batch processes, 13, 37–38, 39–41, 61, 67, 80
Batch/sequential operations, 123
Blowdown, 104
Boundaries, 30, 30, 30, 36

C

Cause and Effects Diagrams, 89
Causes, 17–19, 66, 74, 75
Central process facility (CPF), 101, 102
Checklists, 7f, 17, 90, 99–100
Chemical Industries Association (CIA), 1
Clients, 90
Commissioning, 1, 10, 34, 34, 39, 48, 64, 84–85
Company procedures, 60
Complexity, 2, 8, 45
Compressors, 37, 39, 84, 84
Computer control, 39
Computer controlled processes, 62–69
Computer HAZOP (CHAZOP) study, 64–65, 67–69
enhanced HAZOP, 65–67
legislation, 64–65
use of HS2, 62, 62–63
Computer recording, 33, 54–55
Conceptual model, 10, 13, 16–17, 38
Consequences, 3, 10, 11, 17–18, 18, 18, 18–19, 19, 21, 66
evaluation of, 17–18, 19
Construction, 5, 5, 89–90
Continuous operation, 101
Continuous processes, 37–39
Contract operations, 90–91
Contractors, 90–91, 91
Control, 5, 16t, 34

D

Decommissioning, 1, 84–85
Demolition, 89–90
Design, 1
Design intention, 2–3, 13–15
Deviations, 2–3, 10, 13, 13
generating, 15–17
Down hole safety valve (DHSV), 101
Drains, 82–84

E

Enhanced HAZOP, 65–67
Environment, 2–3, 4
Environmental risk, 29
Ergonomics, 11
European Process Safety Centre (EPSC), 1–2

F

Failure modes and effects analysis (FMEA), 67–68
Functional safety, 64–65

G

Generic actions, 21
Guideword-first approach, 15, 95–98
Guidewords, 2–3, 15, 16t, 17t, 22, 37–38, 42, 53–54, 61, 66, 68, 79–80, 130, 138t

H

Hardware, 21, 21, 47, 62, 62, 67–68
Hazard identification, 2, 3, 4, 5, 7, 8, 74–75, 77, 78
Hazard studies, 4
checklist, 8–9
HS 0-7, 4–5, 5, 5, 5, 6, 6, 6, 6
overview, 30
Hazards, 2–3, 4, 63, 74–75, 82, 89–90
HAZOP, 1, 1, 1–2, 2, 2, 2–3, 13, 29, 55–57, 60, 62, 77, 92
analysis, 14f, 18, 22
applications, 77
existing plant, 78–79
pitfalls, 92
purpose, 11
HAZOP example batch operation, 123
documentation, 125–128
guidewords, 129–130
P&ID, 125–128
parameters, 130
plant and process, 123
process description, 128
reaction stage description, 131
team members, 123, 130
HAZOP example continuous process, 101
issues, 104–105
methodology, 105–121
node 1 records, 114t
node 2 records, 118t
P&IDs, 109f, 111f, 113f
process data, 104
process description, 101
team members, 105–106
HAZOP example procedure, 139
description, 139–141
operating sequence, 142
P&ID, 140f
review, 149–150
study records, 149
team members, 139
HAZOP sequence flow chart, 14f, 96f
HAZOP study
alternatives, 7f
background, 1
batch processes, 39–41
boundaries, 29–31, 43, 77–78
commissioning, 84–85
completion, 22–23
computer-controlled process, 62–69
conceptual model, 10
construction, 89–90
continuous processes, 37–39
contract operations, 90–91
decommissioning, 84–85
demolition, 89–90
description, 13–15
design envelope, 10
design intent, 13–15
deviations, 15–17
drains and vents, 82–84
enhanced, 65–67
essential features, 2–3, 10–11
examples, 2, 16t
existing plant, 10–11
ground rules, 46
illustration, 23–26
interconnections, 82–84
laboratory operations, 80–82
legislation, 4
limitations, 11–12
links to LOPA, 74–76
meetings, 35, 46–47, 46–47
methodology, 10, 31–32, 59, 61, 79, 105–121
modifications, 50, 53, 77–78
objectives, 29, 29–31
operating procedures, 79–80
operational modes, 31
pilot plants, 80
pitfalls, 92
planning, 31–32, 45–46
procedures, 13, 41–42
purpose, 11
recording, 22, 50, 52–54, 54–55
records, 15, 47, 53, 54, 55–57
repeat designs, 78
reports, 29, 50, 50, 53, 94, 128
scope, 11, 12, 29–31
scribe, 32–33, 58
shutdown, 88–89
stages/steps, 20, 24, 124–125
start-up, 85–89
successful, 92
team leader, 31–36, 58–59, 90, 130
team members, 32, 34–35, 35, 45, 58, 91
team membership, 33–36, 90
team size, 33–36
HAZOP study meetings
follow up, 48–49
initial meeting, 46
planning, 45–46
responses, 47
signing off, 48
study sessions, 46–47
Human behavior, 71, 74
knowledge-based mode, 69–70
rule-based mode, 69–70
skill-based mode, 69–70
Human error, 10, 69, 70, 72, 72–73, 74
Human factors, 69–74, 139–150
Human Reliability methodology, 72

I

ICI, 1
ICI six stage hazard studies, 4, 7f
IEC 61508, 64–65
Inherent safety, 6
Interfaces, 30, 30, 83, 83
Interfaces high/low pressure, 83
International Electrotechnical Commission (IEC), 2, 64–65

L

Laboratory operations, 80–82
Layer of protection analysis (LOPA), 74–75, 75
Licensors, 90

M

Maintenance, 10, 11, 26t, 60, 64, 64–65, 71–72
Major Accident Prevention Policies, 4
Management of change (MOC), 50, 54–55, 68, 77, 78, 94
Management of Change Procedure, 48
Material properties, 37
Material Safety Data Sheet (MSDS), 51
Meetings
duration, 45–46
initial, 46
planning, 45–46
Mentoring, 59
Modifications, 50, 53, 64, 77, 77–78

N

Near misses, 39
Node, 37–38, 41–42, 42, 68, 86

O

Office of Safety and Health Administration (OSHA), 4, 53–54, 78
Operability, 4, 5, 11, 11, 12, 29, 30, 40, 79, 90, 125
Operability problems, 4
Operator, 19, 66, 66, 66
Operator training, 50

P

Parameter-first approach, 14f, 15, 22
Parameters, 10, 13, 13, 15, 16t, 17t, 22, 32, 37, 38, 41, 66, 83, 138t
Performance-influencing factors (PIFs), 72–73
Periodic hazard studies, 78–79
Pilot plant, 80–82
Pipe, 37, 44, 103
Piping, 82, 84, 84, 85–86, 89, 104, 104
Pitfalls, 92, 94
Planning, 37–38
Plant safety dossier, 50
Post-HAZOP work, 94
Pre Start-up Safety Review (PSSR), 6
Pre-meeting with client, 43–45
inclusions, 43
terms of reference, 43
Preparation, 36–42
Probability of failure on demand (PFD), 64, 74–75
Procedure HAZOP, 139
Procedures, 13, 60, 79–80
Process and instrumentation diagram (P&ID), 5, 37, 43, 44, 65, 79, 82, 82, 83, 92–93, 109f, 111f, 113f, 125–128, 140f
Process hazard studies, 4
Process safety management (PSM), 4
Programmable electronic systems (PES), 62
Project life cycle, 7
Protection, 19
Pump, 18–19

Q

Quality, 12
Quality assurance (QA), 29
Quantitative risk assessment (QRA), 12

R

Reaction stability, 80–81
Realistic causes, 18
Recommendations, 21–22
Record, content, 54
Recording, 22, 50, 51, 51, 51–52, 52–54, 54, 54–55
background information, 51
computer recording, 54–55
content, 54
format, 51–52
level, 52–54
section headings, 51
uses, 50
Relief, 5, 82
Repeat designs, 78
Report completing, 48
Reporting, 67
Responses
coordinating and reviewing, 47
Risk, 2–3, 64, 70
assessment, 5, 20–21
environmental, 29
Risk graph, 3f
Risk ranking, 52, 52

S

Safe Holding Position, 88
Safeguards, 3, 10, 18, 19, 20–21, 52, 52, 53, 66
safety, health, and environmental (SHE) hazards, 1, 4–5
Safety and Operability Review (SOR), 63
Safety instrumented systems (SISs), 5, 8, 63, 74–75
Safety integrity levels (SILs), 5, 64, 64, 74–75
Safety management systems (SMSs), 4
Safety-related systems, 62, 64, 64
Scribe, 24, 32–33, 58
Sequential operations, 39–41
Seveso II Directive, 4
Shutdown, 31, 61, 85–89, 106
Software, 20, 54, 67
Special skills, 82–83
Start-up, 6, 31, 39, 85–89
Sub-surface safety valve (SSSV), 101, 102, 104
System parameters, 2–3
Systems, 7f, 30, 39, 54, 54, 55, 62, 63, 64, 64, 64, 64–65, 65, 65–67, 81, 82

T

Team, 10, 10, 12, 15, 17–18, 22, 22, 29, 32, 33–36, 36, 40–41, 43, 50, 50, 53, 56
members, 22, 33–36, 34, 34–35, 35, 45, 58
membership, 33–36
scribe, 32–33
selection, 31–36
size, 33–36
Training, 58
leader, 58, 59
members, 58
scribe, 58
team leader, 58–59
Trips, 19, 30, 39, 65

V

Valves, 40, 40, 40, 40, 40, 41–42, 71
Vents, 19, 30, 36–37, 42, 82, 83, 83
Vessels, 37, 37–38, 39–40
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