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This is a Controlled Document that complies with

Wesfarmers Chemicals, Energy & Fertilisers formatting and Quality Control standards.Please check that this is the latest available version before use.

Title: HAZOP PROCESS

Number: GM-08-030-02

Version Number: 15.0

Date Revised: 08 May 2013

Owner: Harish Chopra

Authoriser: Manoj Thakur

Reasons for Creating

or AmendingDocument

New Owner

New Authoriser

Full Review of Document

Actual Change Details: Document reviewed and revised. Owner and authoriser changed.

Sections 5.1 to 5.5 changes made from SiteSafe to Cintellate plus

changes on how to action HAZOP's in Cintellate

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TABLE OF CONTENTS

FIGURE 1 -HAZOPPROCESS FLOW CHART ............................................................................................. 3

1. INTRODUCTION ..................................................................................................................... 42. HAZOP PREPARATION ........................................................................................................ 4

2.1 HAZOP LEADER ................................................................................................................. 42.2 SELECTION OF HAZOP STUDY TEAM MEMBERS ...................................................... 52.3 OTHER RESPONSIBILITIES .............................................................................................. 72.4 INFORMATION REQUIRED FOR HAZOP STUDY ......................................................... 7

3. HAZOP TERMINOLOGY ...................................................................................................... 83.1 SYSTEM ............................................................................................................................... 83.2 DESIGN INTENT ................................................................................................................. 83.3 HAZOP GUIDE WORDS ..................................................................................................... 83.4 HAZOP STUDY RECORD .................................................................................................. 83.5 RISK ASSESSMENT ........................................................................................................... 9

4. HAZOP MEETING PROCEDURE ...................................................................................... 105. HAZOP FOLLOW UP ACTIONS ........................................................................................ 11

5.1 ACTION PROGRESS MANAGEMENT ........................................................................... 115.2 FOLLOW UP ...................................................................................................................... 125.3 ACTION COMPLETION ................................................................................................... 135.4 CINTELLATE REPORTING ............................................................................................. 135.5 ALTERNATIVE HAZOP ACTION TRACKING PROCEDURE ..................................... 13

6. HAZOP CLOSURE ................................................................................................................ 156.1 CLOSE-OUT ....................................................................................................................... 156.2 CLOSE OUT MEETING .................................................................................................... 15

7. DOCUMENTATION .............................................................................................................. 158. RECORD KEEPING TABLE ............ ............. ............. ............. .............. ............. ............ ...... 16APPENDIX 1 - RISK ASSESSMENT TABLES ............................................................................. 17APPENDIX 2 - HAZARD STUDY CARDS ............ ............. ............ .............. ............. .............. ....... 18

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No

Yes

Selectguideword

eg High Flow

Select line

Can HighFlow

occur?

Reviews plannedsafeguards and

informally assess risk

Agree anyfurther actions

on this item

Yes

Is cost ofchanges

justified?

No

Agree and recordsuggested changesto plant design or

operation which willreduce risk to

acceptable level

Agree further actionsafter HAZOP toreduce risk to

acceptable levelGo to next

Guide Word

Areconsequencespotentially very

serious?

Review plannedsafeguards and carry out

Risk Assessment. For

events with extremeconsequences, a further

action may be recorded toconsider a SIL, LOPA orother process safety riskstudy outside the HAZOP

meeting

Yes

Aresafeguardsadequate?

No

No

Yes

No

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1. INTRODUCTION

A Hazard and Operability (HAZOP) study is a structured and systematic examination of aplanned or existing process or operation in order to identify and evaluate problems that mayrepresent a risk to personnel or equipment, or prevent efficient operation. A HAZOP is aqualitative technique based on "guide words" and is carried out by a multi-disciplinary team (theHAZOP Team) during one or more meetings.

This Guide Manual defines the principles for conducting a HAZOP study, the tools that will beused and the documentation that will be produced. It provides guidance on the information thatis required to prepare for and run a HAZOP study.

This Guide Manual does not define when a HAZOP study should be carried out. In the case ofmodifications, this is defined in Engineering Modification (GM-05-050-01). A HAZOP study isa mandatory requirement for any new plant and for modifications to "critical" plant items asdefined in the Modification Procedure.

A HAZOP is a design verification process. It should not be used as a design developmentprocess. The HAZOP should be performed at the stage in the design process when allpreliminary engineering is complete and the basic design has been fixed. This includes completeprocess design, process flow diagrams, P&IDs, plant and equipment layout, operatingphilosophy, control and instrumentation philosophy, utilities requirements, specification andselection of major equipment items, protection systems, start up and shutdown systems.

A HAZOP may be conducted on an existing facility to identify modifications that should beimplemented to reduce risk and operability problems.

The HAZOP process is most suited to analysis of piping systems and can extend to solidmaterials handling systems. For solid material handling projects that do not involve any pipingsystems, a design review as detailed in Engineering Project Design Review (EP-08-030-19)should be carried out instead of a HAZOP.

2. HAZOP PREPARATION

It is the responsibility of the Responsible Officer to initiate the HAZOP study where the project

or modification meets the criteria defined in Engineering Modification (GM-05-050-01).

2.1 HAZOP LEADER

The Responsible Officer will first appoint an independent HAZOP Leader to act as theChairperson for the HAZOP meetings. The HAZOP Leader must be trained in HAZOPmethodology and have successfully completed a suitably recognised HAZOP Leader Course or

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4. Daniel Massie5. Eli Knudsen

6. Kim Eng

7. Peter Hein

8. Phillip Brown

9. Sakar

10. Scott Olsen

11. Yvonne Darlow

12. Deepak Gupta13. Justin Manganaro

14. Jamal Fozdar

15. Vinod Verma

Note: If there is no CSBP HAZOP Leader available from within CSBP, an externalChairperson who is a qualified HAZOP Leader with experience in chemicalindustries may be engaged.

2.2 SELECTION OF HAZOP STUDY TEAM MEMBERS

HAZOP studies will be conducted using a team approach, with a minimum of four members.The Responsible Officer together with the HAZOP Leader will select the HAZOP teammembers to achieve the spread of knowledge and skills required for the particular project, andmay include:

1. Representative of the customer

2. A person with Process knowledge

3. A person with Safety knowledge4. A person with Environmental knowledge

5. A person with operating and/or maintenance experience in comparableenvironment

6. A person with Engineering/Design knowledge

7. Secretary

How this knowledge and experience is represented in the team depends on the size and nature ofthe change being reviewed by the HAZOP. As a guide in team member selection for projects of

different sizes, refer to the table below. However, the final selection will be at the discretion ofthe HAZOP Leader and/or the responsible officer having regard for potential risk.

It is expected (but not essential) that the people selected as members of the HAZOP team willalready have completed a suitably recognised HAZOP Team Member training course, orequivalent experience, and have a good understanding of the HAZOP process.

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At least one process knowledge representative in the HAZOP team must be of sufficientexperience having sound knowledge and understanding of the process fundamentals as well aspossess high abstract reasoning capabilities. This HAZOP team member is usually the mostexperienced resident process engineer responsible for the plant.

When requested by the HAZOP leader, the HAZOP leader can be supported by the processknowledge representative in the team.

TEAM MEMBERSHIP

SMALL PROJECT

for example

Minor Alteration

MEDIUM PROJECT

for example

Replacing Sections of Plant

LARGE PROJECT

for example

New Plant or Replacing

more than 50% of a Plant

Independent Chairperson Independent Chairperson External Chairperson

Process Designers

Design Engineer

Project Engineer/PlantEngineer (i.e., ResponsibleOfficer)

Project Engineer/PlantEngineer (i.e. ResponsibleOfficer)

Responsible Officer/SeniorProject Engineer

Plant Process Engineer orManufacture Team Leader

Plant Process Engineer orManufacture Team Leader

Plant Process Engineer

Manufacture Teamrepresentative

Manufacture Teamrepresentative/MaintenanceTeam representative

Manufacture Teamrepresentative/MaintenanceTeam representative

OSH Advisor andEnvironmental Advisor


Others as required: Others as required: Others as required:

Electrical/Instrumentrepresentative




Improvement Facilitator Improvement Facilitator

Improvement Facilitator Equipment vendorrepresentative

Maintenance Teamrepresentative

Other specialist knowledge. Other specialist knowledge

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2.3 OTHER RESPONSIBILITIES

The Responsible Officer is responsible for the following HAZOP study arrangements:

a. Organising meeting dates, venue and notices to the attendees

b. Layout of venue and supply of stationery and other resources for the meeting

c. Provision of information required for the HAZOP study (refer to Section 2.4)

d. Close out meeting date, venue and notice to the attendees.

2.4 INFORMATION REQUIRED FOR HAZOP STUDY

The following information should be assembled by the Responsible Officer and the HAZOPLeader before the HAZOP study team commences work.

a. ESSENTIAL ITEMS

1. Functionally complete P & ID for the process

2. System design philosophy and process description

b. DESIRABLE ITEMS

1. Plot plans or layouts

2. Process flow diagrams

3. Piping class specifications

4. Equipment data sheets and purchase specifications

5. Vessel inventories

6. Relief valve specifications

7. Start up and emergency shut-down procedures

8. Emergency depressurising system functions

9. Electrical area classification

10. Standards used

11. Procedures - operating and maintenance as applicable

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3. HAZOP TERMINOLOGY

3.1 SYSTEM

A System is a specific location or logical part of the process or operation in which possibledeviations from the design intent are to be evaluated. Examples might be a heat exchanger,vessel, pump, compressor and interconnecting pipeline or group of lines. Systems should beprogressively identified on the P&ID as the HAZOP study proceeds.

3.2 DESIGN INTENT

The design intent is a description of how the process is expected to behave at the system beingstudied. This is qualitatively described as an activity eg feed, reaction, transfer, heating, andquantitatively in process parameters such as pressure, temperature, flow rate.

3.3 HAZOP GUIDE WORDS

All HAZOP studies will be conducted using the HAZOP Study Cards included in Appendix 2.These HAZOP Study Cards provide guide words and prompts for a range of deviations fromacceptable conditions, and each of these must be individually considered by the HAZOP teamfor each System. This review is done "line by line" by selecting a line or System off the P&IDand reviewing each of the guide words on the HAZOP Study Cards for that System. When allguide words have been reviewed for a particular line or System, the process is repeated for thenext line or System selected off the P&ID.

3.4 HAZOP STUDY RECORD

HAZOP Study Record form SF1309 is used to create a historic record of the HAZOP Study.Details of discussions, decisions taken, risk assessments made and further actions recommendedduring evaluation of each of the HAZOP Study Cards will be progressively recorded by theHAZOP Secretary on the HAZOP Study Record form. Discussions on each of the followingitems should be recorded for each guide word.

3.4.1 Deviation

A deviation is a way in which the process conditions may depart from the design intent assuggested by each guide word, eg high pressure.

3.4.2 Cause

As each guide word is considered, if it is determined that a deviation, eg high pressure, could

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hazards and operability problems. Several consequences may follow from one cause. Oneconsequence can have several causes.

Each cause and consequence scenario identified should be recorded in the HAZOP StudyRecord form and must be comprehensive, realistic and sequential. eg "Closed valve in pumpdischarge causes high pressure which leads to pipe rupture which results in a loss of 20 kg ofammonia to atmosphere before a shut off valve closes".

3.4.4 Safeguards

Safeguards are facilities, processes or procedures that help to reduce the likelihood or frequencyof the deviation, or to mitigate its consequences. Examples of safeguards include the following.

a. procedures to define what actions to take in the event of a deviation

b. increased frequency of inspection, servicing or calibration of critical items

c. facilities that draw attention to the deviation (eg indicators and alarms to inform

operators so that they can make the process safe)

d. facilities that automatically compensate for the deviation (eg an automatic controlsystem, usually an integrated part of the process control)

e. facilities that prevent the deviation from occurring (eg excess flow valve)

f. facilities that prevent further escalation of the deviation (eg by total trip of the activity orprocess by a safety interlock, control system, or emergency shutdown (ESD) system)

g. facilities that relieve the process from a hazardous deviation (eg pressure safety valve(PSV) and vent systems)

As each cause and consequence scenario is identified, planned safeguards should be reviewed todetermine if they are adequate to either prevent the deviation or to protect the System if thedeviation occurs. Any decision on the adequacy of the safeguards should take into considerationthe magnitude of the potential consequences and the likelihood of the event occurring with allthe planned safeguards in place. This is reflected in the risk assessment as below.

Each scenario will usually have more than a single layer of protection. For high risk deviations,it is useful to review each of the layers of protection before determining the adequacy of thesafeguards.

3.4.5 Recommendations

If the HAZOP Team recommends that additional safeguards or changes to the design should be

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An initial informal risk assessment should be carried out on each cause - consequence scenariobased on the inherent risk in the unprotected state. The Risk Matrix included in Appendix 1should be used as a guide. The risk should then be re-assessed taking into consideration theplanned safeguards and risk reduction measures.

For less important risks, the need for further action can be based on the experience andjudgement of the HAZOP Study Team.

For high risk scenarios, several layers of protection will usually be necessary to reduce the risk

to an acceptable level. If the HAZOP team agrees that, so long as the planned safeguards are inplace, the risk of an unwanted event occurring is reduced to an acceptable level, then no furtheraction is required.

For extreme risk scenarios, the adequacy of safeguards and the need for further action should bequantitatively assessed using higher level risk assessment techniques such as Layer ofProtection Analysis (LOPA), or Safety Integrity Level (SIL) analysis.

The risk assessment process and outcome should be recorded on the HAZOP Study Record

form against each item.

4. HAZOP MEETING PROCEDURE

At the HAZOP meeting, the HAZOP Leader will act as Chairperson to lead the team througheach of the following steps.

a. Introduce the project

1. Ensure all team members are familiar with the HAZOP process2. Define the project for the team

3. Review the proposed process or modification using the Process andInstrumentation Diagram (P&ID) and describe its operation

4. On the P&ID, divide the process to be studied into logical Systems.

Note: Modifications that are prone to the potential of expected two phase flow orcondensation effects (eg. modifications to steam or chemical vapour systems) will be

highlighted during the introduction.

b. Carry out HAZOP Study

1. Select a particular System for detailed review and describe the design intentfor that System.

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8. Evaluate if the proposed safeguards adequately reduce the risk to anacceptable level and if not, suggest further actions having regard to theconsequences and the safeguards already proposed

9. Repeat procedure from step (a) above for the next System.

10. Progressively complete HAZOP Study Record form SF1309 includingrecording of further actions.

Note: Modifications mustbe asessed for impact during a variety of plant conditions

(ie. start up, running, plant upset, and plant shutdown). This aspect will beformallydocumented where appropriate throughout the HAZOP, and must also feature as aspecific element considered within the agreement and sign-off of the final records of theHAZOP.

5. HAZOP FOLLOW UP ACTIONS

The Responsible Officer shall ensure that all actions arising from the HAZOP are properly

managed and are completed prior to commencing the modification or commissioning themodified plant as determined during the HAZOP.

The items recorded on the HAZOP Study Record form SF1309 as requiring action shall benumbered and a required date of completion established. This information shall be entered intothe Recommendations column on the HAZOP Study Record.

If the HAZOP generates a large number of HAZOP Actions, the RO may seek approval fromthe Manager of the Area or the Project Engineering Manager to use the Alternative HAZOP

Action Tracking process described in 5.5 below.

5.1 ACTION PROGRESS MANAGEMENT

The basic HAZOP information needs to be entered into Cintellate, then Save. The HAZOPresults form will then be available to be populated, the actions can then be raised and assignedfrom this form.

The Responsible Officer shall arrange for the HAZOP to be entered in Cintellate as follows:

a. Open Cintellate and select Workspace then "Inspection".

b. Select "New" and a new Inspection form will be opened. An Inspection ReferenceNumber will be automatically allocated by the Cintellate system.

c. Enter the HAZOP details as follows:

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6. "Department Manager" - select the Manager of the Responsible Officer. Thisperson will be notified by email when the page is saved and will close out the

Inspection entry page by ticking the box at the bottom of the page.

7. Select Start Date, Frequency and Number of Occurrences

8. Hit "Save" to close the form after noting the Inspection Reference number.

Note: Be sure to note the Cintellate Inspection reference number on the originalHAZOP Study Report to enable the matching Cintellate record to be found.

This is essential for reporting from Cintellate where the Reference Number isthe only way to select an item for a report.

d. Create an Action in Cintellate for each HAZOP Action on the HAZOP Study Record asfollows.

1. Open basic HAZOP Inspection (double click the Inspection Number)

2. Move to bottom of form and click on Add new Inspection Results

3. Inspection Date and Inspector must be populated within the form. No

other fields on this form are mandatory, however may be populated ifwanted.

4. Move to bottom of form and click on Add New Actions

5. Fill in the mandatory fields (those with an orange asterisk against the field

name) and any non mandatory fields that you have information to suit.

6. Date Raised select todays date

7. Due Date Enter the date the Action is required to be complete

8. "Assigned To" - Assign the action to the appropriate person9. "Assigned By" - Select the Responsible Officer's name

10. Depatment Select the Department of the Assigned to

11. Action Title Type in a brief but explanatory description

12. Action Description Enter the description of the action exactly as it was

recorded in the HAZOP. Start each action description with the Cintellate

Inspection Reference Number and the Item Number on the HAZOP Study

Record (e.g. HAZOP 4782 Action 27)13. Hit "Save" button to close the form and return to the Inspection form. An

email will be immediately sent to the person to whom the "Action" has been

assigned

14. Create additional Actions to correspond to each of the Actions identified at

the HAZOP.

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5.2 FOLLOW UP

HAZOP actions will be managed in the Cintellate system. It will automatically generatereminders when actions are not complete by the due date. When complete, actions shall beclosed in Cintellate by the person to whom the action was assigned.

Note: Any Action not completed by the due date will appear in the overdue action listand will be subject to the usual Cintellate escalating notification.

5.3 ACTION COMPLETION

After completion of the action, the person to whom the "Action" was assigned must close theaction in Cintellate by completing the "Action Completion" form. This is done by

1. Selecting "Workspace then Action Management then Actions anddouble clicking on the required action.

2. Move to the "Action Completion" box at the bottom of the form.

3. Complete mandatory fields, Closure Evidence and Completion Date addnew file storage. If needed then Save.

Note: To allow for traceability at a later time, it is important to make reference toassociated documents such as drawing numbers, operating procedures, emailsor memos, etc when describing the action taken. The use of the words "Done"or "Competed" in the close out comments is not sufficient. Full details ofdocuments created or modified are required. Examples include: P&ID aaa wasupdated to Rev. bbb; Refer operating procedure OP-xxx, Rev ccc; Refer tomemo, email, etc dated dd/mm/yyyy

5.4 CINTELLATE REPORTING

Reports are available in Cintellate by selecting "Reports and Graphs" from the entry screen andthen selecting from the lists.

A comprehensive inspection report is available by selecting "Reports and Graphs" then Self

Assessment Reports and then Comprehensive Inspection Report". This report requires theuser to enter the inspection (HAZOP) number previously generated, and lists all actions whethercompleted or not.

5.5 ALTERNATIVE HAZOP ACTION TRACKING PROCEDURE

The alternative HAZOP Action Tracking procedure detailed below may be used when:

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Use of this Alternative HAZOP Action Tracking procedure must be approved in writing by theProject Director or Project Manager for major projects, Business Unit Manager or ProjectEngineering Manager for plant projects.

5.5.2 Procedure

a. The HAZOP shall be completed and Actions identified and assigned as detailed in thisGuide Manual.

b. After the HAZOP, an Action Summary sheet shall be produced by either1. manually entering all Actions into an Excel spreadsheet; or

2. using a software based HAZOP recording system to create the documentedrecord.

c. The Action Summary sheet shall provide a direct cross reference to the original HAZOPrecord and will show for each Action:

1. a brief description of the action required

2. the person or organisation to whom the Action has been assigned3. the required completion date

4. completion status

d. A single Cintellate entry making direct reference to both the original HAZOP and theAction Summary sheet shall be made by the RO. The Cintellate entry shall have oneAction on the RO to close out all HAZOP Actions before commissioning the new plantwhich was the subject of the HAZOP.

e. The RO will then send out individual Action requests to each person or organisation towhich an Action has been assigned. This request will be accompanied by a copy (paperor electronic) of the HAZOP Action sheet for that Action.

f. When the Action is complete, the person or organisation to whom an Action has beenassigned will complete and sign a paper copy of the HAZOP Action sheet and return thesigned original to the RO.

g. On receipt of each signed HAZOP Action sheet, the RO will review the sheet and ifsatisfied that the Action is truly complete, will

1. countersign the form (subject to note below)

2. insert the signed-off HAZOP Action sheet in the Project file

3. change the status for that Action on the Action Summary sheet to complete.

Note: Each completed HAZOP Action sheet shall have two signatories in order toverify that the appropriate action has been implemented The person verifying

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i. The Cintellate Action item covering all the items on the Action Summary sheet will thenbe signed off.

j. All HAZOP Actions must be complete and the Cintellate entry signed off prior tocommissioning. If any HAZOP actions that require data obtained during or postcommissioning cannot be completed (eg maintenance PMs, some plant alarm settings,etc.), these can be considered complete when the relevant actions are captured in draftprocedures.

k. If an Action item cannot be completed until after plant commissioning eg whereoperating plant data or experience is required, and is not covered by item j. above, then anew entry and associated outstanding action shall be created in Cintellate for eachAction item. The original Cintellate action covering all the HAZOP Actions can then beclosed with a cross-reference to the new Cintellate outstanding action item.

6. HAZOP CLOSURE

6.1 CLOSE-OUT

When all follow-up actions are complete, the Responsible Officer shall note on the HAZOPStudy Record of Discussions (SF 1909) that all items have been completed and make referenceto the Inspection Reference Number in Cintellate.To assist in later verification, a copy of thecomplete Cintellate record should be printed out after all actions have been completed andattached to the HAZOP Study Record in the Project file.

Note: The impact of the modification(s) during all plant conditions (ie. start up, running, plantupset, and plant shutdown) musthave its related HAZOP conditions revisited during the Close-

out process.

6.2 CLOSE OUT MEETING

The Responsible Officer will arrange a close out meeting to record completion of outstandingissues.

Once all parties are satisfied that all issues arising from the study have been adequatelyaddressed and are reflected in the project design documentation, form HAZOP Study Record of

Discussions form shall be completed and signed off by the Responsible Officer and theCustomer Representative.

No commissioning activities associated with the modification or the new plant covered by theHAZOP shall commence until form HAZOP Study Record of Discussions (SF1909) has beensigned off.

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4. Study date5. Participant names, job titles, organisation, brief profile

Note: Any generic issues or matters requiring further study but not considered to bepart of the HAZOP should still be recorded on the HAZOP Study Record and aperson nominated to follow up

b. Signed off HAZOP Study Record of Discussions (SF 1909)

c. The original copy of all P&IDs used in the study (with lines clearly identified)

d. Variations in guide words used.

e. Signed off Action Summary sheet (if generated in accordance with 5.5.1)

f. Signed off HAZOP Action sheets (if generated in accordance with 5.5.1)

The study Responsible Officer is responsible for the preparation and collation of the output

documentation from the HAZOP study, and for forwarding it to all attendees, including theChairperson who should sign off the HAZOP Study Record before filing by the ResponsibleOfficer.

The Responsible Officer ensures an electronic copy the documentation listed above is filed inthe Domino.Doc System in accordance withManagement of Risk Assessment Records (GM-04-041-14). A hard copy of all this documentation will also be filed in the Project File by theProject Officer.

8. RECORD KEEPING TABLE

RECORDIDENTIFICATION

StorageMedia

StorageLocation

IndexingMethod

RetentionPeriod

AuthorisedDisposer

DisposalMethod

FormNo.

Document Title

SF1309 HAZOP StudyRecord

Paper

Electronic

Project File

Domino Doc

ProjectNumber

Indefinite

SF1909 HAZOP StudyRecord ofDiscussions

Paper

Electronic

Project File

Domino Doc

ProjectNumber

Indefinite

Record ofActions arisingfrom the HAZOP

Paper

Electronic

Cintellate

Project File

Domino Doc

Cintellate

ProjectNumber

Indefinite

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APPENDIX 1 - RISK ASSESSMENT TABLES

CONSEQUENCE

DESCRIPTION

Injury / Illness EnvironmentProperty Damage /

Process Loss

Insignificant Minor Injury / Illness Little or no environmentalimpact Low financial loss($500,000)

LIKELIHOOD DESCRIPTION RISK RANK IMPACT

Rare Only by exception L Low risk

Unlikely Could occur at some stage M Medium risk

Possible Might occur at some time H High risk

Likely Will probably occur E Extreme risk

Almost certain Is expected to occur

Table 1 HAZOP Risk Assessment: Consequence, Likelihood and RiskRanking Definitions

Once the reasonable consequence and likelihood of each potential unwanted event isdetermined, the risk can be ranked using the Risk Assessment Matrix below and recorded onthe HAZOP Study Record sheet.

LIKELIHOOD CONSEQUENCEInsignificant Minor Moderate Major Catastrophic

Rare L L M H H

Unlikely L L M H E

Possible L M H E E

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Version No. 15.0 Page 18 of 62

Document last modified: 08 May 2013. Date printed: 08 May 2013.

APPENDIX 2 - HAZARD STUDY CARDS

NEW DRAWING1. DESCRIPTION OF PURPOSE OF PLANT SHOWN2. BROAD OUTLINE OF OPERATION

NEW LINE OR SYSTEM1. PURPOSE OF LINE AND ASSOCIATED EQUIPMENT2. NORMAL OPERATING CONDITION3. NORMAL METHOD OF OPERATION4. DESCRIPTION OF EQUIPMENT, VALVES, INSTRUMENTS5. GENERAL BROAD DISCUSSION

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HIGH FLOW

HIGH LEVEL

PUMP RACING, DELIVERY VESSEL PRESSURE LOST, SUCTION PRESSURISED, SCALE DISLODGED,LEAK IN HEAT ECHANGER, LOSS OF AUTO CONTROL, OPERATOR ERROR, FAILURE OF PIPE, TRAP,ETC.

FOR SOLIDS HANDLING PROCESSES!

BLOCKED OR ARCHED CHUTES, LUMPS FALLING ONTO BELT, CLEAN OUT SAFETY, BELT RUN"ON,

SEQUENCING, OBSTRUCTION, CONVEYOR BELT BROKEN, DRIVE BELT BROKEN, BELT RUN" BACK,BUCKET RUN" BACK.

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LOW FLOW

LOW LEVEL

PUMP FAILURE, SCALING OF DELIVERY, FOREIGN BODY OR SEDIMENT, POOR SUCTIONCONDITION, CAVITATION, LEAK IN HEAT ECHANGER, DRAIN LEAKING, VALVE #AMMED, LOSS OFAUTO CONTROL, OPERATOR ERROR, FAILURE OR #OINT, PIPE, TRAP ETC.


BLOCKED OR ARCHED CHUTES, LUMPS FALLING ONTO BELT, CLEAN OUT SAFETY, BELT RUN" ON,SEQUENCING, OBSTRUCTION, CONVEYOR BELT BROKEN, DRIVE BELT BROKEN, BELT RUN" BACK,BUCKET RUN"BACK.

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ZERO FLOW

EMPTY

PUMP FAILURE, DELIVERY VESSEL$MAIN PRESSURISED, GAS LOCKING, BLOCKAGE PRESENCE OFFOREIGN BODY, SCALE ETC. SUCTION VESSEL EMPTY, LOSS OF AUTO CONTROL, OPERATORERROR, FAILURE OF #OINT, PIPE ETC.


BLOCKED OR ARCHED CHUTES, LUMPS FALLING ONTO BELT, CLEAN OUT SAFETY, BELT RUN" ON,SEQUENCING, OBSTRUCTION, CONVEYOR BELT BROKEN, DRIVE BELT BROKEN, BELT RUN" BACK,BUCKET RUN"BACK.

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REVERSE FLOW

PUMP FAILURE, PUMP REVERSED, DELIVERY VESSEL$MAIN OVER PRESSURE, POOR ISOLATION,GAS LOCKING, SURGING, BACK SIPHONING, LOSS OF AUTOMATIC CONTROL, OPERATOR ERROR,PIPE FAILURE, ETC.


STOP BEFORE START, WARNING FOR TAIL DISCHARGE ELEVATOR ROLL"BACK.

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HIGH PRESSURE

- VENTING

- RELIEF RATE

BOILING, CAVITATION, FREE%ING, CHEMICAL BREAKDOWN, FLASHING, CONDENSATION,SEDIMENTATION, SCALING, FOAMING, GAS RELEASE, PRIMING, EPLODING, IMPLODING, CHANGES INVISCOSITY, DENSITY, ETERNAL FIRE, WEATHER CONDITIONS.

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LOW PRESSURE

- VENTING

- RELIEF RATE


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HIGH TEMPERATURE


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LOW TEMPERATURE


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IMPURITIES

- GASEOUS

- LIQUID

- SOLID

INGRESS OF AIR, WATER, STEAM, FUEL, LUBRICANTS, CORROSION PRODUCTS, OTHER PROCESS

MATERIALS FROM HIGH PRESSURE SYSTEM, LEAKAGE FROM HEAT ECHANGER SYSTEM.


CONTAMINANTS, MATERIAL CHARACTERISTICS DEVIATION, TRAMP METAL.

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CHANGE IN COMPOSITION

CHANGE IN CONCENTRATION

2 PHASE FLOW

REACTION


ACIDIC FUMES, BUILD" UP, OVER GRANULATION, SCREEN BLINDING,

SETS TOO FAST, STICKS TO BELT$IDLERS, HARD TO CLEAN.

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TESTING

- EQUIPMENT (INCL. TRIPS & ALARMS)

- PRODUCT

HOW DO WE KNOW THEY ARE OK&

VACUUM ' PRESSURE TESTING WITH HARMLESS MATERIAL.

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PLANT ITEMS

- OPERABLE

- MAINTAINABLE

ACCESS, ISOLATION, SPARES, PURGING, DRYING, COOLING, WARMING


LACK OF ACCESS (IDLERS, SCRAPERS), BUILD" UP CAUSING DIFFICULTY MOVING, LONG CLEANINGREACH, CONFINED SPACE.

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ELECTRICAL

- AREA CLASSIFICATION

- ISOLATION

- EARTHING

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INSTRUMENTS

" SUFFICIENT FOR CONTROL

" TOO MANY

" CORRECT LOCATION

" INFORMATION FOR OPERATORS

THIS LINE IS NOW COMPLETE. NOW DO NEXT LINE.

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OVERVIEW

" TO BE DONE WHEN ALL LINES ARE COMPLETE." CONSIDER CUMULATIVE AND POTENTIAL OFFSITE IMPACTOF THE REVIEWED PROCESS (SUCH AS IMPACT ONUPSTREAM AND DOWNSTREAM OF THE PROCESS DUE TOMODIFICATIONS$CHANGES).

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SERVICES REQUIRED

" AIR" NITROGEN

" WATER

" ETC.

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MATERIALS OF CONSTRUCTION

" VESSELS" PIPELINES

" PUMPS

" OTHERS

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COMMISSION

" BROADLY HOW WILL IT BE DONE" WHAT DIFFICULTIES ' HA%ARDS CAN BE FORESEEN

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STARTUP

" FIRST STARTUP METHODS, DIFFICULTIES," HA%ARDS ROUTINE STARTUP METHODS, DIFFICULTIES,

" HA%ARDS TOO MANY INTERLOCKS&

HAZOP P

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SHUTDOWN

- ISOLATION

- PURGING

DIFFICULTIES, HA%ARDS

HAZOP Process

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BREADOWN

- POWER FAILURE

- AIR

- STEAM

- WATER

- VACUUM

- FUEL

- VENTS- COMPUTER

- OTHER

MA#OR CAUSES OF BREAKDOWN EMERGENCY PROCEDURES ' COMMUNICATIONS

WHICH WAY SHOULD VALVES MOVE

HAZOP Process

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EFFLUENT

- GASEOUS

- LIQUID

- SOLID

CONTAINMENT

REACTIONS IN DRAINS

TREATMENT METHODS

HAZOP Process

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NOISE

SOURCES

PROBLEMS&

CONTROL MEASURES

HAZOP Process

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FIRE

EXPLOSION

BROAD OVERVIEW " PROTECTION, PREVENTION, CONTROL

LOCATION OF SAFETY SHOWERS, DELUGES, SHUT"OFF VALVES ' CONTROLS.

HAZOP Process

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SAFETY EQUIPMENT

" PERSONAL" FIRE DETECTION

" FIRE FIGHTING

" MEANS OF ESCAPE

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PERSONAL HAZARD

SOLIDS HANDLING!

FUMES,

LUMPS OFF CONVEYORS,

EPOSURE TO MAGNETIC FIELD,

DUST,

LOCATION OF NORMAL ACCESS TO EQUIPMENT,

POTENTIAL FOR LOOSE OB#ECTS TO FALL (EG ACCESS DOORS ' WEDGES.

HAZOP Process

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GUIDE WORDS AND DEVIATION FOR COMPUTERISED ANDDISTRIBUTION CONTROL SYSTEMS.

ITEMS LISTED ON THE FOLLOWING CARDS CAN BEADDRESSED BY ASING THE FOLLOWING QUESTIONS

HAZOP Process

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DOES IT MATTER!

RISK ASSESSMENT

LIKELIHOOD

CONSEQUENCE

HAZOP Process

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WILL THE OPERATOR NOW!

HAZOP Process

GM 08 030 02

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ANY ACTIONS REQUIRED BY THE OPERATOR OR OTHER SYSTEMS!

HAZOP Process

GM 08 030 02

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ANY CHANGES NEEDED!

HAZOP Process

GM 08 030 02

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PURPOSE

METHOD OF OPERATION, CONTROL PHILOSOPHY, SAFETY RELATED FUNCTIONS

HAZOP Process

GM-08-030-02

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MORE OF

SIGNAL ACTION, BLOCK OF DATA, TRANSFER FREQUENCY.

HAZOP Process

GM-08-030-02

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LESS OF

SIGNAL ACTION, INCOMPLETE TRANSFER, SYSTEM CRASHES DURING TRANSFER.

HAZOP Process

GM-08-030-02

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NONE OF

SIGNAL ACTION, NO TRANSFER, ACTUATOR STUCK.

HAZOP Process

GM-08-030-02

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OTHER THAN

MISMATCH DUE TO SOFTWARE CHANGE OR REFORMAT, INCORRECT ACTION OR SIGNAL.

HAZOP Process

GM-08-030-02

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SOONER " LATER THAN

PROCESSING OF MEASUREMENTS, TIME OUT, OUT OF SEQUENCE, AVERAGING ASSUMPTIONS.

HAZOP Process

GM-08-030-02

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CORRUPTION

NOISE, MAGNETIC FIELDS, RADIO INTERFERENCE, WELDING, LIGHTNING, HIGH VOLTAGE

HAZOP Process

GM-08-030-02

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REVERSE

LOOK AT ABOVE POINTS WITH DATA TRANSFER IN THE OPPOSITE DIRECTION

HAZOP Process

GM-08-030-02

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INTERACTION

WITH OTHER SYSTEMS, START"UP, SHUT"DOWN, NORMAL OPERATION, EPECTED OR REQUIRED

OPERATOR ACTIONS, SYNCHRONISATION AND TIMING ISSUES AND ALARMS, PLANT UPSETS

HAZOP Process

GM-08-030-02

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TUNING PARAMETERS

ARE THEY CORRECT, ANY CHANGES REQUIRED

HAZOP Process

GM-08-030-02

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SECURITY

SECURITY ACCESS LEVEL, PROTECTION AGAINST UNAUTHORISED MODIFICATION

HAZOP Process

GM-08-030-02

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OTHER

TRAINING

TESTING

gm-08-030-02.pdf

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