Avoiding Quality Pitfalls for HAZOP/LOPA Sessions and Documentation

Although Process Safety Management (PSM), requiring a good-quality Process Hazard Analysis (PHA), was promulgated in the United States in 1992, and HAZOP Study techniques date back to the mid-1970's, the HAZOP Study technique (and companion techniques such as LOPA) can still present challenges in consistently applying PHA in a high-quality fashion. Many challenges can exist for the implementation of PHA, and each PHA is unique due to variables such as team composition, the individual HAZOP/LOPA facilitator, process unit history and past upsets, regulatory environment, safety culture, and available process safety information. These variables can have an impact on the HAZOP/LOPA results; however, the value of HAZOP/LOPA sessions and quality/usability of resultant HAZOP/LOPA documentation is a critical objective and the primary responsibility for achieving this objective must fall on the shoulders of the facilitator. Key topics addressed within the paper include:

- Quality objectives, including setting-the-pace for subsequent HAZOP/LOPA usage/updates

- Need for uniform, high-quality application

- Experienced-based tips for driving high-value sessions and for developing high-quality HAZOP/LOPA documentation

- Checklist for assessing the quality of individual HAZOP/LOPA Studies

- Key indicators that a reviewer can use to validate the acceptability of the PHA

- Structuring the PHA to be useful for supporting other PSM elements and safe plant operation

- Tips for structuring the HAZOP/LOPA to facilitate later updates and revalidation