KOC.ge.021 - HAZOP Study Procedure

KOC.GE.021 – HAZOP Study Procedure Page 1 of 6

HAZOP STUDY PROCEDURE Document Number: KOC.GE.021 Approver: (Technical) Approver: (Administrative)

Manager - HSE

Author:

TL Standards

Manager - HSE

Document Coordinator:

TL Standards

Scope:

All KOC Directorates

Control Tier:

Tier 3

Issue Date: Revision/Review Date:

July 27, 2004

Issuing Group: Next Review Date:

HSE Group

October 10, 2011

October 11, 2014

1.0 Purpose/Scope The purpose of HAZOP Study is to identify the hazard and operability problems and to reduce the probability and consequences of an incident in the process facilities that would have a detrimental impact to the personnel, plant, properties, environment and company reputation. The HAZOP Study is intended to examine the overall process design through brain storming sessions and search for operating deviations and process interactions, that can lead to hazardous situations or operability problems, which may include: 

Safety and Occupational Health hazards to personnel;



Damage to equipment / asset / environment;



Operability / maintainability problems;

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Plant non-availability / limitation and lack of product quality / production loss;

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Environmental emissions;

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Demolition / Decommissioning / Abandonment reviews;

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Construction and commissioning hazards.

2.0 Definitions Design intent Designer’s desired, or specified range of behavior for elements and characteristics. Deviation Departure from the Design and / or operability intention and / or condition. Guideword Word or phrase, which expresses and defines a specific type of deviation from an element’s design intent. HAZOP Study Team A Team constituted for conducting HAZOP Study of a particular Facility. Study Node or Process Section Location on P&ID / Section of various equipment with definite boundaries within which process parameters are investigated for deviations. Control Tier: 3

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3.0 General Requirements  HSEMS Element - HSE: 04 - Facilities Design and Construction 4.0 Key Responsibilities The following are defined roles and responsibilities for carrying out HAZOP Studies in KOC: 4.1 Major Projects For Major Projects, the Controlling Team of the Project shall be responsible for ensuring that the HAZOP Study is conducted in co-ordination with the PMC / Contractor. 4.2 In House Projects For In-house Projects, the Controlling Team of the Project shall be responsible for ensuring that the HAZOP Study is conducted in co-ordination with KOC Engineering Group / General Projects / Ahmadi Services / Contractor. The responsibility for action monitoring and close-out shall be assigned, agreed and documented by the respective HAZOP Study Team. Note: The nominated HAZOP Study Team Leader shall be independent of the Project Team (not associated with the design of the project under review). 5.0 Procedure 5.1 Applicability 

HAZOP studies shall be applied to all new, continuous process designs, including package units & utility systems.



This technique is normally applied, when the design is essentially complete and the P&IDs have been developed and contain all essential information. However, the applicability of HAZOP during the various life cycle phases of the system is described below: a)

Conceptual Design Phase -Capital Project Proposal (CPP) stage In this phase, the design concept and major system components are decided, but the design and documentation to conduct the HAZOP do not exist. However, it is necessary to identify major hazards at this stage itself, to allow them to be considered in the design process and to facilitate future HAZOP studies.

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b)

Front End Engineering Design (FEED) phase During this phase, the design is developed, methods of operation are decided and documentation is prepared. The ideal period to carry out a HAZOP Study is just before the design is frozen, as at this stage the design is sufficiently detailed, to allow the HAZOP questioning mechanism to obtain meaningful answers.

c)

Detail Design / Engineering Phase HAZOP Study during this phase shall be conducted after finalizing the detailed design, before the issue of important engineering drawings and documentation including P & IDs, C&E etc., with Approved for Construction (AFC) stamp.

d)

Installation and Commissioning Phase In case where the proper operation sequences and instructions are critical and the commissioning and operation of the system can be hazardous or when there has been a substantial change in the design intent at a late stage of the project, it is advisable to carry out a HAZOP review before the system is started up.

e)

Operational Phase HAZOP Study shall be considered during Operational Phase before implementing any changes to the existing system (for example, through MOC Procedure) that could affect the safety / operability or impact the environment.

5.2 Applicability-New Facilities a)

HAZOP studies shall be applied to all new continuous process designs, including package units & utility systems.

b)

Systematic HAZOP studies conducted at the appropriate stages of the project ensures identification of any potential hazard(s) and operability problems; and initiation of early actions to mitigate such problems, which will help in smooth start up and safe operation of the process unit.

c)

This technique is normally applied, when the design is essentially complete and the P&IDs have been developed and contain all essential information. For new Projects, the HAZOP Studies shall be conducted during FEED Phase, Detail Design / Engineering Phase and Installation & Commissioning Phase, unless otherwise specified or approved by KOC. NOTE: HAZOP Study conducted after finalization of FEED will improve the process safety to a great extent and will help in reducing high risk recommendations at a later stage.

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5.3 Applicability-Existing Facilities a)

The application of HAZOP shall be considered before implementing any changes to existing Facilities (for example, through MOC Procedure) that would affect the safety or operability of a system or have environmental impacts.

b)

This technique shall also be applied to review existing plant P & ID’s or procedures to identify potential hazards / operability problems which have not already become evident from operating experience or to review nonstandard operation / procedures not previously covered.

c)

Modifications involving changes to P & ID’s, changes in operation and the associated safety systems shall also be subject to HAZOP studies, unless otherwise agreed by Operations, Design and respective Asset / Directorate HSE Teams of KOC.

d)

The scope of HAZOP Study should clearly indicate whether the HAZOP is to be limited to the modifications only or be applied to the whole plant. All interfaces (process/utilities) between existing plant and modifications should be identified and reviewed. Particular attention should be paid to tie-ins to existing plant.

5.4 Applicability - Other Areas HAZOP Studies shall be applied to identify Hazard and Operability problems associated with other areas in KOC, including Drilling & Workover. 5.5 HAZOP Study-Process 

The process of HAZOP analysis is based on a “guide word examination”, which is a deliberate search for deviations from the design intent of study nodes / process section.

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The review shall follow a structured step by step format, as given below: a) b) c) d) e) f) g)

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The complete process to be studied is divided into various study nodes. For each node, various parameters, guidewords and deviations are considered. For each deviation, causes are identified (if any cause is not credible, it is ignored). For each credible cause, consequences are identified assuming no safeguards are present. For each consequence, existing protections are identified. Assess severity & likelihood and identify Risk Rank for the consequence. After considering existing protection, if the risk level is considered unacceptable, recommendations for mitigation of the risks are made.

A typical flowchart showing HAZOP examination procedure is given in Figure-1.

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Figure-1

HAZOP EXAMINATION PROCEDURE - FLOW CHART

Start Explain overall design

Select a node

Examine and agree design intent

Identify relevant elements

Identify whether any of the elements can be usefully sub-divided into characteristics

Select an element (and characteristic if any)

Select a guide word

Apply the guide word to the selected elements (and to each of its characteristics as relevant) to obtain a specific deviation Yes Is deviation credible?

Investigate causes, consequences and protection or indication and document

No No Have all interpretations of the guide word and elements/characteristics Yes combinations been applied? Yes

Assess severity, likelihood and assign Risk Rank for each consequence and provide recommendation. No risk ranking is necessary where there is no recommendation.

No Have all guide words been applied to the selected element? No

Yes Have all elements been examined? Yes

No Have all nodes been examined? Yes

Stop

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6.0 Key Documents / Tools / References  

KOC Recommended Practice for HAZOP Studies (KOC-L-017, Rev. 2). Procedure for the Preparation of Project HSE Plan (KOC.GE.048).

7.0 Abbreviations / Acronyms C&E CPP FEED HAZOP HSE HSEMS KOC MOC QRA P&ID PMC

Cause and Effect Capital Project Proposal Front End Engineering Design Hazard and Operability Health Safety and Environment HSE Management System Kuwait Oil Company Management of Change Quantitative Risk Assessment Piping and Instrument Diagram Project Management Consultant

8.0 HSE Records (Retention Period)  

Final HAZOP Study Report / Recommendations (Indefinite) Related Correspondence / Transmittals (Min.5 Years

Review and Revision Log Review/ Revision Date th

Sept. 12 , 2006

Document Approver

Document Author

Revision Details

Manager HSE

TL Standards

Clause 3: Revised reference documents. Clause 6: Revised reference documents. Clause 7: Abbreviations / Acronyms added.

th,

2007

Manager HSE

TL Standards

Clause 6: Revised reference document number from “GE.KOC.048” to “KOC.GE.048”.

th,

2008

Manager HSE

TL Standards

The document format revised in line with the latest revision of HSEMS Document Control Procedure KOC.GE.013.

Nov. 18

Nov. 16

st

Manager HSE

TL Standards

Clause 1.0, Clause 5.0 and Figure 1: Revised according to the latest revision of KOC RP for HAZOP Studies (KOC-L-017, Rev.2). Clause 7.0 Added few abbreviations. Clause 8.0 is introduced in line with the latest revision of HSEMS Document Control Procedure KOC.GE.013.

th

Manager HSE

TL Standards

Clause 7.0 Added few abbreviations. Clause 8.0 Added HSE Records

Nov. 1 , 2010

Oct. 10 , 2011

Control Tier: 3

Revision Date: October 10, 2011 Uncontrolled Copy if Printed