MYTHS – PROCESS HAZARD ANALYSIS ‘HAZOP’ STUDIES

Most common misunderstanding is that HAZOP is only applicable to large-scale industrial facilities. In reality, HAZOP can be applied to any process or system where there is potential for hazards or operability issues, irrespective of facility size. It is evenly effective in small-scale operations, such as pilot plants or laboratories.

There is a misconception that HAZOP is only applicable during the design phase of a new process. However, it can be practical at different stages of the process lifecycle, including during the design, any process modification or facility expansion, commissioning and operation. Furthermore, steering cyclic HAZOP reviews can help ensure that existing processes remain safe and reliable over time.

HAZOP is a structured methodology, it is not a rigid, one-size-fits-all approach. It can be altered and tailored to suit the specific needs based on complexity of different industrial processes. For example, the depth of analysis and the selection of guidewords can be modified based on the nature and the level of the process detail required.

It is also assumed that HAZOP studies are extremely time-consuming and expensive. Yes, HAZOP studies do require an investment and commitment of time and resources, the benefits typically overshadow the costs. Furthermore, progressions in technology and software tools have streamlined the HAZOP process, making it more time efficient and cost effective than ever before.

There is also a thought that conducting a HAZOP study promises the elimination of all hazards from a process. However, HAZOP is not a solution for all safety issues. It is a tool assist to identify the potential hazards and operability issues, but not a guarantee of their elimination. It provides valuable insights at all levels that inform risk management decisions, but implementation of control measures and continuous monitoring are vital for effective hazard mitigation.

It is often seen as a standalone safety management tool. However, it is most effective when incorporated into a broader safety management system that includes other practices such as risk assessment (e.g. HAZAN. HAZID, etc.), safety audits, facility siting, incident investigation, and emergency response planning (ERP). HAZOP should be seen as an individual component of a comprehensive approach to process safety.