DEKRA Process Safety

HAZOP analysis - DEKRA Process Safety

Safe operations with expert HAZOP analysis

The Hazard and Operability (HAZOP) study is the most widely used Process Hazards Analysis (PHA) technique in the chemical, pharmaceutical, food, oil and gas, nuclear, and other process industries worldwide. HAZOP is used during the design stages of a new process or project, for major process modifications, and for periodic review of existing operations. The U.S. Occupational Safety and Health Administration (OSHA), as well as other regulators around the world, recognizes the HAZOP technique as an acceptable methodology for evaluating risk.

The quality and effectiveness of the HAZOP study depends on the leader’s experience with the HAZOP technique, as well as with the process being analyzed, with process-control systems, and with unit operations in general. Our large team of highly-qualified HAZOP leaders and process-safety experts has facilitated numerous HAZOP-based PHA’s worldwide, in virtually all sectors of the process and processing industries.

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Hazard and operability (HAZOP) study - DEKRA Process Safety
Applications of HAZOP analysis

We can facilitate HAZOPs, and other types of PHAs, in English, Spanish, Chinese, French, German, Italian, Arabic, Hindi and other languages. Our worldwide presence helps ensure intimate knowledge of local codes, standards, and cultures. Combined with our expertise in process safety engineering, extensive laboratory and large-scale testing capabilities, interpretation of test results, and ready access to process safety data, our HAZOP capability is unrivalled in our market.

Comprehensive HAZOP studies for sustainable safety

We provide a semi-quantitative HAZOP risk analysis that incorporates the philosophies of Layers of Protection Analysis (LOPA), Safety Instrumented Systems (SIL), and Fault Tree Analysis (FTA). We use these tools to assess the reliability of process controls and number and type of risk reduction measures that might be needed.

HAZOP scenario overview - DEKRA Process Safety
Overview of a HAZOP scenario

We begin with a review of the available Process Safety Information (PSI) and identification of missing PSI required to support our analysis. The HAZOP study would involve the following procedure:

  • Establishing the “Design Intent” for the process, including the desired and/or safe ranges for each of the operating parameters
  • Applying the Guide Words (No, Less, More, Reverse, etc.) to each of the Process Parameters (Temperature, Pressure, Flow, Level, etc.), to identify deviations from the design intent
  • Determining if the control system and emergency systems are adequate and are sufficiently reliable to prevent each deviation from escalating to an undesirable process incident
  • Estimating the severity of the consequences of each undesired incident. Consequences can be further evaluated using our expertise in consequence modeling with specialist software such as PHAST® and Effects®
  • Estimating the likelihood of occurrence of each undesired incident
  • Utilizing a Risk Matrix to determine the relative risks of the undesired incidents
  • Comparing the risk of occurrence for each incident with corporate guidelines for process risk
  • Determining the number and types of safeguards and/or process improvements that would be needed to reduce the risks to tolerable levels

Our process safety specialist’s report will present the HAZOP team’s recommendations and suggestions for improvements to the process, based on the site’s experience and on recognized and generally-accepted good engineering practices. Following the receipt of comments from the client, a final report is issued.

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Questions and answers about HAZOP analysis

Knowing what to expect before implementing a HAZOP analysis makes for a more successful and efficient process. To that end, here are some frequently asked questions and answers about how our HAZOP studies work.