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Scope This procedure should be used for all HAZOP activities associated
with EPE operations. Contractors may have their own HAZOP
procedures but these should align with the requirements in this
procedure, in particular the competency requirements for HAZOP
chair persons and the involvement of the Shell Process Engineering
Technical Authorities (TAs) in the Management of Change process.
The procedure provides specific instructions on the HAZOP process
and identifies good practice beyond that covered by the existing EP
Standards [1] and industry guidance [3] and [4].
HAZOP Chairman
HAZOP Secretary
process Engineer
Co-ordinator
Independent
Close-out
members
Sponsor
HAZOP
Task definition References
Note 1 – The Sponsor will be the Engineering Lead for the particular study/opportunity/project/change
proposal
Note 2 – Sponsor and Co-ordinator may be the same person for small, low risk HAZOPs
Note 3 – The Close-out co-ordinator may be the same person as the HAZOP Co-ordinator
Note 4 – The Chairman may perform the secretary role and record his own output for small, low risk
HAZOPs
Note 5 – The relevant Shell Process Engineering Technical Authority Level 2 (TA2) for the business
process or asset. If the HAZOP Chair is available then it may be preferable that the review and
approval of the proposed close-out actions is performed by the Chair. In practice this may not
be practical and therefore by default this role is assigned to the TA2 although the TA2 can
delegate this to the Chair.
TASKS
The key roles and responsibilities are summarised below with more detail provided in the task
descriptions
The HEMP Standard [1] requires HAZOPs for all new processing facilities, major modifications and
changes in operating conditions.
For new facilities HAZOPs shall be performed as key deliverables from the EP64 engineering process.
The timing and scope shall be defined in the Project HSSE Plan and shall be approved by the appropriate
Process Engineering TA2 for the project.
For existing facilities, not all modifications or changes will require a HAZOP. Competent technical
engineers involved in the change process shall determine whether a HAZOP is required and if so, the
proposed scope and timing of the HAZOP. The relevant Shell Process Engineering TA2 shall approve
this decision. The outcome of the assessment of the need for a HAZOP shall be documented as part of
the Management of Change process.
A list of current Shell TA2s is maintained in Facility Status Report (FSR) which can be accessed via
http://fsr.shell.com/.
Engineering or operational changes that are likely to require formal safety assessment including a
HAZOP are defined by Lees [5] which is reproduced as follows:
“(1) Any change in the equipment, temporary or permanent, which may affect the safety of the process or
safety and integrity of the plant. It does not include changes in engineering equipment which are not in
contact with the process and cannot affect the safety of the process or the safety and integrity of the
plant.
(2) Any change in process materials, services, operating conditions, or operating procedures, and
including experimental programmes, which fall outside established practice.”
HAZOPs should not be restricted to just the hydrocarbon processing systems. Systems that interface
with these systems or utility systems that could affect the performance of these systems may also need to
be subject to HAZOP.
The EP HAZOP Manual [6] provides a method on how to assess whether an engineering change will
require a HAZOP. This methodology is reproduced in Appendix 7and can be used, however any decision
on whether to HAZOP or not still needs to be approved by the Shell Process Engineering TA2.
For other types of changes Appendix 1 provides guidance on whether a HAZOP is likely to be an
appropriate tool.
The HEMP Standard [1] also requires a 5-yearly review of the HAZOPs performed for a facility to confirm
that they still accurately reflect the current situation and current understanding of the hazards.
The precise scope of any HAZOP should be defined in a clear Terms of Reference with the objectives
and deliverables of the HAZOP specified by the Sponsor.
The HAZOP Co-ordinator must be a senior project or discipline engineer with experience of the HAZOP
process.
The Chairman shall be selected from a list of competent personnel maintained by the safety engineering
function. Details of the current custodian of the list and the list of approved chairs can be found on the
safety eng web portal:
http://sww.shell.com/ep/epe/engineering_maintenance/safety_engineering/safety_engineering_hazop_intro.html
If a preferred HAZOP chair is not on the list of competent personnel, details of the individuals
qualifications and relevant experience should be communicated to the custodian of the list who will
assess the individual against the criteria listed in Appendix 5. Depending on the outcome of the
assessment the individual will either be approved and have their details added to the list or rejected with
feedback on the reasons.
Depending on the complexity and duration of the HAZOP the Chairman should then use his or her
preferred Secretary. This will enable the sessions to be summarised and recorded most efficiently. For
small or low risk HAZOPs the Chairman may record the output but the workload should not be allowed to
compromise the quality of the deliverables.
The Co-ordinator and Chairman should discuss a preliminary estimate of the cost, time and resources for
the HAZOP at this stage and agree full or exception reporting and the format of the final report and action
close-out process. Full reporting is the expected norm.
The Co-ordinator must discuss the composition of the team with the Chairman. Essentially the skills,
experience and number of attendees should be appropriate to the exercise. Operator involvement and an
independent process engineer should be considered essential for any HAZOP and it is the Sponsor’s
responsibility to ensure suitable personnel are provided. Other expertise or disciplines should be
represented as determined by the scope e.g. HSSE, Production Chemist, Well Engineering, Maintenance
representatives though they may not need to attend all sessions. Vendor representatives are essential to
explain the operation and control of self-contained vendor packaged equipment. The Chairman must
satisfy himself of the role and experience of all personnel proposed for the team and confirm the HAZOP
is suitably staffed for the study. More than 10 people in any session is likely to reduce efficiency and add
little to the identification of potential hazards.
For HAZOPs undertaken in a design contractor’s office the team may comprise a mix of Shell and
contractor personnel but 'doubling up' of functions should be avoided.
If the Chairman and/or Secretary are contracted for the work a contract must be in place before work
starts.
The PFDs, P&IDS including vendor packages that comprise the design or change under review at a
suitable stage of refinement (discipline checked and frozen – commonly referred to as Rev. A) should be
available and a copy then provided for each team member. Large scale reproductions may assist
explanation. Provision of key drawings electronically may be beneficial for projection and presentation
purposes. The safeguarding philosophy should be available. Other inputs could be operating,
maintenance and safety philosophies, also Fire & Gas Cause and Effects, active fire protection, passive
fire protection, emergency shutdown and emergency depressurisation philosophies, procedures and
drawings etc.
A room of sufficient size and arrangements to ensure smooth running of Team sessions is essential.
An off-site venue limits the opportunities for team members to absent themselves.
The Chairman should use his experience to divide the scope into logical and manageable sections
(nodes) to conduct the review. He should consult with suitable personnel egg the process engineer to
confirm understanding of the systems. As a result of this preparation the Chairman should be able to
prepare an accurate assessment of cost and time for the review. He should then prepare an agenda and
programme to present at start of session and monitor progress against it.
Node selection and size will depend on system complexity and experience of the team in addition to other
factors. Too small a node may create minimal potential process deviations and lead to repetition in
subsequent nodes. Too extensive a node may create multiple interfaces, complex control issues and
repeated referencing of several P&IDs.
A general rule of thumb is that 4 P&IDs is the maximum that may be reviewed in a six hour day but
variations in system complexity and P&ID congestion may make this target optimistic. Conversely,
simple, well separated systems on P&IDs may make six P&IDs achievable in a day.
Appendices 2, 3 and 4 provide possible structures for Coarse, Detailed and Procedural HAZOPs. These
are not exhaustive and there are other examples in industry guidance. It is the Chairman’s responsibility
to ensure an appropriate structure is used and described in the HAZOP report.
The Chairman is responsible for the direction and recording of the sessions. At the start of the review the
Chairman should;
A PC based system is strongly recommended as it speeds up reporting and issuing of actions and
enables all the team members to see the full worksheet entries. Specific HAZOP software may be used
or templates in word processing may be considered appropriate. HAZOP software has the advantage of
being able to renumber actions or allocate actions to multiple parties. The possible use of voice recording
should not be excluded.
An appropriate person should introduce each node and explain the key parameters and safeguarding
arrangements. The design intent of each node should be recorded.
The Chairman will typically use a brainstorming technique to stimulate thinking into how hazardous
conditions may occur. During the brainstorming the Chairman is expected to moderate discussions
around frequency and severity and challenge the assembled specialists on the robustness of controls.
The brainstorming must give consideration to the possibility of human error.
For issues or concerns that raise actions generally only actions and action party and dates are recorded.
The actions must be recorded in sufficient detail to give complete understanding when transferred to the
action tracking system and read in isolation.
Further considerations and categorisations can be made dependent upon HAZOP requirements. The
actions raised may be categorised to assist management review / monitoring as follows:-
It is inevitable that minor corrections (egg spectacle blind shown in wrong position) or minor additions
(e.g. relief valve settings not shown) to the drawings under review will be identified during the HAZOP
study sessions. It is sufficient to list these corrections under one (only) recommended action item or by
grouping separate actions in a special worksheet. The latter approach may also be used for general
issues that would otherwise be repeated in several worksheets. One of the HAZOP team members
supplied from the Project should compile the list of drawing errors. The HAZOP team shall not spend
time redesigning the facility, egg add valves, relocate lines etc. during the HAZOP. This is the function of
the Project or Asset. If however the solution to the problem is obvious to the team, it should be stated in
the recommended action.
HAZOPs should ideally not exceed six hours per day and this is particularly relevant for larger studies
which are run over several days or weeks where team fatigue and other work priorities may accumulate.
This could cause a reduction in quality and indeed extend the overall time requirements.
On completion of HAZOP sessions the Secretary will prepare the first draft of the HAZOP report. The
Chairman is accountable for the contents and technical accuracy of the report. The minimum contents for
a report should be;
• Scope
• Objectives
• Team, place, date
• Action Summary describing the rationale behind critical actions
• Method
• Guidewords
• Worksheets
• Actions
• Marked up P&IDs and documents used or traceable references to them
Wherever possible, major HAZOPs should be finished with a 'Closing Meeting', in which the main
recommended actions are presented to local management and the nomination of the follow up Co-
ordinator is confirmed.
The HAZOP Sponsor must formally accept the final report from the Chairman.
The HAZOP close-out co-ordinator will monitor and manage close-out of the actions raised in the
HAZOP. The co-ordinator will pass responses to appropriate parties for review or acceptance. Ideally
this involves the Chairman reviewing each action and confirming the proposed action fully meets the
intent of the original action. The Chair may not be available to perform this duty so this role defaults to
the Shell Process Eng TA2 (as shown on the activity responsibility matrix), however the TA2 can delegate
this role to the Chair, if available.
Issue a brief summary report with signed, accepted action sheets included. As well as those involved in
the change management process other recipients of HAZOP reports may include Shell process
engineers, Shell safety engineers or compliance focal points.
The HAZOP Co-ordinator is responsible for arranging that relevant correspondence up to the completion
of the HAZOP report be archived for a minimum period of five years. This includes the original study
session notes, technical correspondence (including comments on the draft report) and covering letter for
issuing the HAZOP report. The Co-ordinator should also issue the closeout report.
The Co-ordinator should provide feedback on the performance of the chairman to both the chairman and
the holder of the competency register.
Other References
Ref. Title Document No.
[1] EP Standard ‘HSE Hazards and Effects EP2005-0300-ST
Management Process’
Identifying potential hazardous events and YES Various types of HAZOP are used at
operability problems on new process facilities different stages of the project [2]
Identifying latent hazardous events and YES Recommended for the HSE Case
operability problems on existing processing
facilities
Checking a process design for compliance with NO A HAZOP is only used when all
standards conventional engineering checks have
been completed
Routine drilling, workover and pipeline NO The technique is not very cost effective
operations for reviewing routine procedures
Non-routine drilling, workover, and pipeline YES A high level procedural HAZOP can be
operations egg SIMOPS, snubbing, hot useful in identifying potential hazards
tapping etc. and operability problems
Reviewing ESD system design YES A high level review can be used to
reveal potential deficiencies
Service Cooling Water, instrument air, steam, nitrogen or inert gas; power to
Failures machines, control circuits and computers.
Maintenance Isolation, drainage, purging, cleaning, drying, access, incorrect installation
of equipment, hydrotest, lifting.
Static Electrical grounding, low conducting liquids, insulated conductors.
Outside Fire, weather, environmental change, impact flood, etc.
conditions
Operation Start up, shut down (normal, emergency), maloperation, pigging, layout,
different modes.
In order to be satisfied that the proposed Review Chairman/ Leader/ Facilitator has the required competency
the following factors will be considered:
The critical questions to answer before deciding on the re-HAZOP of an existing facility are:
• How complete is the existing site HAZOP documentation?
• Is there a good understanding of the effect of recent changes to hardware, throughput and
composition, legislation, technology, and standards?
• Have any incidents or near misses identified a lack of understanding of the safeguarding
arrangements?
• Are the HP/LP interfaces and hazardous/non-hazardous separation robust?
• Do the existing PEFS, mass balance and P&IDs accurately reflect the process, packaged units and
utilities?
• Have organisational changes introduced changes to manning and procedures?
• Have there been so many incremental developments that the overview of potential hazards on the
facility has been lost?