Critical P & ID Reviews Using HAZOP/LOPA Methodology Overkill or Underrated? | AIChE

Critical P & ID Reviews Using HAZOP/LOPA Methodology Overkill or Underrated?

Type

Conference Presentation

Conference Type

AIChE Spring Meeting and Global Congress on Process Safety

Presentation Date

May 1, 2013

Duration

30 minutes

Skill Level

Intermediate

PDHs

0.50

Critical P&ID Reviews Using HAZOP/LOPA Methodology ? Overkill or Underrated?


Mr. John T. Perez, P.E.

Mr. Andrew Madewell

Cognascents Consulting Group, Inc.

11777-A Katy Fwy Ste 438

Houston, TX 77079


john.perez@cognascents.com


Keywords: Process Safety Management (PSM), HAZOP, LOPA, Process and Instrumentation Drawing (P&ID), Process Hazard Analysis (PHA), Inherently Safer Design (ISD).

Abstract

Prior to moving from define phase to execution phase on a given project, the typical project protocol is to perform a critical process and instrumentation drawing (P&ID) review as a transition from ?issued for information or preliminary design? to ?issued for design or HAZOP?.

The objectives of a critical P&ID review are to (1) identify commercially-positive design changes early in the project lifecycle to reduce downstream implementation costs, (2) identify operational concerns to ensure optimal resolution and long-term operational effectiveness, and (3) identify safety vulnerabilities for early application of inherently safer design (ISD) principles where possible and early identification of safety integrity levels (SIL) for required safety-instrumented systems (SIS).

Companies perform critical P&ID reviews using various evaluation methods, including P&ID symbology/element checklists, process hazard analysis (e.g. Checklist, HAZID, and HAZOP), and ?cold-eyes? review. Each of these approaches provides structure to a critical P&ID review; however, each also provides opportunities for commercial, operability, and safety vulnerabilities to remain in the design when applied independently.

The author posit that use of a hybrid HAZOP/LOPA process hazard analysis methodology to conduct critical P&ID reviews results in a more rigorous evaluation and reduces the likelihood for commercial, operability, and safety vulnerabilities to persist into the design/execution phase of projects. In this paper, the authors present the advantages and disadvantages of using a hybrid HAZOP/LOPA approach for critical P&ID reviews. They also provide recommendations to enhance the effectiveness of the HAZOP/LOPA methodology when applied to critical P&ID reviews. Specifically, the authors provide examples of commercial benefits realized, enhanced operational insight, ISD successes, and application pitfalls when applying a hybrid HAZOP/LOPA PHA methodology to a critical P&ID review.

The target audience for this paper includes project managers, project engineers, EH&S managers, PSM coordinators, and operators; however, anyone involved with small or large capital projects may also benefit from this paper's content.

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