Help on HAMS-GPS HAZOP Analysis Module:

 

 

Sr. No.

Contents

1.0

About HAZOP

2.0

What is Hazard Study?

2.1

When to do Hazard Study?

3.0

Inter-relationship  between  HAZAN, HAZOP and Quantitative Risk Assessment (QRA)  and EMP

4.0

Nodes and Guide Words

4.1

Storage and Insertion of Zero Node data in other HAZOP Project s

5.0

Installation of HAMS-GPS HAZOP Software:

6.0

HAMS-GPS HAZOP Analysis Module

7.0

Your First HAZOP Study

7.1

Setting your Organization and HAZOP Study data

7.2

Start your First HAZOP Study

7.3

Common features of HAZOP Forms

7.4

HAZOP Forms and Guidewords

7.5

Any other observations

8.0

Viewing and Printing Reports

8.1

[Report-1]: Recommendations only

8.2

[Report-2]: Full HAZOP Report

8.3

[Report-3]: Gives two options for summary reports of selected HAZOP Studies.

8.4

[Risk level report]

8.5

[RBI-matrix report]

8.6

[Category wise Reports]

8.7

[Action by Report]

8.8

[Risk level summary]

8.9

[Print Report]

8.10

Summary of Printing Reports

9.0

Conclusions

 

 


 

1.0       About HAZOP:

 

The following quote from Bhagawatgeeta

:

 

 

 "Wikaranscha  Gunashaiwa  Prakruti  Sambhavan".

 

Gives the full and realistic definition of “HAZOP”!

 

 Translation  by  Eminent  Scholars:

 

 

"Deviations  Bring  to  the  Fore,  the  Attributes  of  Nature".

 

Relevance  to  HAZOP by the Author:                                                                                                                              Back

 

 

 

 "HAZOP  is  the  study  of  the  Deviations  in  the  Process Conditions,  that  bring  to  the  Fore,  the  HAZARD  Attributes  inherent  in  the  System".

 

 

 

 

 

So HAZOP is not a original idea but an application of the universal principle enshrined in the Bhavatgeeta!

 

HAZOP short for Hazard and Operability is one of the several tools of Process Safety Management (PSM) which covers the entire domain of Hazard Studies and may be seen in the following hazard study chart:

 

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Fig-1: Overview of Hazard Study techniques.

 

HAZOP is essentially the result of interactive sessions among HAZOP study team consisting of a very senior HAZOP study specialist as Chairperson along with experts directly associated with the operation, maintenance, design and training of personnel of the plant. Application of advanced HAZOP Software greatly supports in providing advanced capabilities that include the following features:

 

Development of Risk Levels of all Hazardous operations through evaluation of Chance (C) of occurrence of an accident and its Severity (S) of damage consequence levels to life and property, determined by the HAZOP team through a semantic scale of 1 to 5 that includes Nil, Low, Medium, Medium High and High. These evaluations of Chance and Severity are used by the HAZOP software to compute the following:

 

(i)                 (i)                 Integrated Protection Layers (IPLs): including Safety Integrity Level (SIL)/Levels of Protection (LOP) requirements for optimal safety. These (SIL) requirements are based on Risk evaluations conforming to ANSI/ISA S84.01 on “Application of SIL to Safety Instrumentation Systems (SIS)” based on the International Electro-technical Commission’s (IEC) standard IEC 61508 on “Functional Safety of Electrical/ Electronic/ Programmable Electronic (EEPES) Safety-Related Systems”, 1998 as an umbrella standard applicable to all industries. The recommendations also include LOP if the risks refer to an equipment or other facility. All these are supported by OSHA PSM 1910.119, Seveso II regulations, ANSI/ISA S84.01, IEC 61508 and IEC 61511.

(ii)               (ii)               Risk Based Investigation (RBI) – Matrix conforming to European Process Safety Centre’s Model as a coloured graphic presentation,

(iii)             (iii)             Percent Safety Level of the facility,

(iv)            (iv)             HAZOP Reports in a variety of ways.

 

2.0       What is hazard study?

 

 

Hazard study is the process of systematic identification and quantification of hazards in a given activity under study. The total hazard study consists of the following steps (Fig.-2):

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Fig.-2: Steps in Hazard Study

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2.1             When to do Hazard Study?

 

Table-1: When to undertake hazard study:

 

Hazard Study No.

Project Stage

Comments

1.

Process selection

 

 

 

Select the least hazardous route for the process. See if less hazardous chemicals and solvents and reactions can be selected even at some compromise on cost other considerations.

2.

Process development

Select safer process conditions like temperatures close to ambient, pressures close to atmospheric choice of low temperature and low pressure catalysts etc.

3.

Project and process definition

Consolidate on stages 1  and 2 optimize

4.

Project design

Select most appropriate MOC, minimize open manual handling of hazardous chemicals, provide Local Exhaust Vents for areas of vapour/dust emissions etc. Provide sufficient, interlocks, trips and other safety features and redundancies etc.

5.

Procurement and construction

Standardize specifications of all items and ensure products of maximum built in safety features for off the shelf items.

6.

Commissioning

Develop pre-commissioning checks and ensure compliance before commissioning

7.

Handover

Review safety performance before handover

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3.0       Inter-relationship  between  HAZAN, HAZOP and Quantitative Risk Assessment (QRA)  and EMP (Fig.-3):

 

 

                                                                                 

Fig.-3: Hazard Study

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The above diagram of inter-relationships shows that there are there are four main areas of hazard study namely : Hazard analysis (HAZAN), Hazard and Operability study (HAZOP), Scenario development, Quantitative Risk Assessment (QRA) and finally Emergency Management Plan (EMP). These inter-relationships are more elaborated in the following diagramme (Fig.-3.1):

 

                                                                      

Fig.-3.1: Inter relationships of the four main areas of Hazard Study.

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 4.0      Nodes and Guide Words:

 

A Node is an Operational step or a Unit of Operation involved in a system of P&ID with connected equipments having a set of parameters and activities to be controlled within a designed range.

 

Before we begin HAZOP, must understand the process steps and then mark the Nodes along piping in distinct colours, number them serially and prepare a list of all Nodes whose parameters and activities we are to study for possible deviations, their causes, consequesces, existing controls and their sufficiency, if not what more can be done.

 

              i.            Typical Nodes for batch operations:

sequential charging of chemicals to a reactor, control of reaction parameters and associated activities, cooling reactor, draining the product etc.

            ii.            Typical Node for a continuous operation:

Pumping/Fflow from …..through….up to…….

          iii.            What is design intention?                                                                                                                                                                              Back

Design intention is the operation to ensure preset parameters and activities associated with it for which the Node is designed.

           iv.            What are parameters? Parameters are measurable process conditions of flow, temperature, pressure, quantities etc.

             v.            What are activities? Activities are actual operations like starting a pump, charging a reactor etc.

 

Nodes are to be Generated before HAZOP starts: Nodes are to be Marked on P&IDs with Node-No. and Node Description and Identifying Unique Coloured Line (Continuous-Thick, Medium, Thin, Dashed, Dotted, Dash-Dot etc,)

 

The Concept of Zero-Nodes: HAMSAGARS’ have found that The conventional P&ID based Nodes do not cover 12-Distinct Areas of Hazards an Safety and remain un-covered in HAZOP. These 12-Non-P&ID based Nodes are termed as Zero Nodes and are designated as 01, 02, 03…012. These 12-Zero Nodes are as under:

 

                                                              i.            Node-01: Safety Department: Control USAs and USCs to Achieve 6-Sigma Accident Prevention,

                                                            ii.            Maintenance Departments:

a.                  Node-02: FMECA for Determining MTBF of Critical Equipments for Plant Shutdown Schedule to Prevent Unscheduled Breakdown of Critical Equipments like Boilers, Turbines etc,

b.                  Node-03: Practice of Lock-Out and Tag-Out (LOTO) to Prevent Accidents during maintenance,

c.                   Node-04: Work Permit System as per OISD-105 to be Enforced,

                                                          iii.            Node-05: Pre-Startup Safety Procedures:

                                                           iv.            Node-06: Earthing and Bonding Practices as per applicable OISD-Standards,

                                                             v.            Node-07: Protection of Piping from Vibrating Machines like Turbines etc,

                                                           vi.            Node-08: Protection of Over Ground (OG) Piping adjacent to Roads from Impact by Vehicles,

                                                         vii.            Node-09: Natural hazards like Earthquakes, thunder Storms etc. damaging Piping, Equipment and Structures, whether appropriate reinforcements taken based on history of Worst natural Disasters?,

                                                       viii.            Node-010: Dedicated Piping and Couplings for Non-Compatible Chemicals to Prevent Bhopal like Disasters,

                                                           ix.            Node-011: Corrosion of Underground (UG) Piping, especially Hydrant lines that are normally UG by Acidic ground water flow from Loss of Integrity of AR-Linings of Acid Storages.

                                                             x.            Node-012: Fire Protection of Cable Entry: Points in to Building and Floor to Floor, Cable Rack Columns.

 

Total Zero Nodes=12;

4.1      Storage and Insertion of Zero Node data in other HAZOP Project s: All These 12-Zero Node details are Stored in an Organization named “ZeroNodes”. In order to insert the Data from this “ZeroNodes” Organization to any Other Organization, do the following:

                                                                                                                                                                                                                                    Back

                                                               i.                                      First Create all 12-Nodes: 01, 02, 03 ……012 in the Organization where the “ZeroNodes” data is to be Inserted,

                                                             ii.                                      Open Node-01 in ZeroNodes Organization: Copy Node 01 and Open Organization where data to be inserted and Paste at Node, Design Intention and at “Describe Design Intention” Edit Box (Top Right),

                                                           iii.                                      Individually Copy from “ZeroNodes” and Paste in the Organization under Review, each of the “Existing Controls”, “Units” and  Control Range”,

                                                          iv.                                      Then Click [HAZOP Study] Button under “Form for Data Entry” (Left Bottom): Form-1 with Guide Word NO or NOT opens.  If the data is in this Data Entry Form, then Click [Get Data] or gop to the Data Form of the desired Guide Word by Pressing [Alt][N] and at the required Guide Word Form Click [Get Data] Button.  The following Dialog Box Opens:

 

 

 

 

 

 

 

 

                                                           v.                                         Now Click on “ZeroNodes” in Organization (Left Top): and Select the Node from where data is to be inserted and [Find Data] Button gets Enabled.  Click on [Get Data] Button. [Insert Data] Button gets Enabled. Click and Data gets Inserted in the Organization required.

                                                         vi.                                        Repeat iv and v for all Guide Words applicable for the Node,

                                                       vii.                                        Then skip all other Guide Word Data Forms and go to “Any Other Observations” Dialog Box: At the Bottom of this Dialog Box you find the following Controls:

 


 

 

 

 

 

 

 

 

                                                    viii.                                       Now Select “ZeroNodes” Organization in the Upper Combo Box: Then Select the Zero Node from where the Data is to be Inserted in the Organization under Review, Then Click the Button [Get HAZOP team/Observations]

                                                        ix.                                      You get  a Dialog “Wish to Get HAZOP Team”: Click [Yes], then you get a Dialog Box “Wish to Get Observations”. Click [Yes] and the Observations get inserted in the Organization required.

                                                          x.                                      If you do not need either the “HAZOP Team” or the “Observations” you Un-Check the desired Check Box.

                                                        xi.                                      Finally Click [Done] Button,

                                                      xii.                                     

Select the Department/Person etc. for from the Combo Box and Click [Close] Button. If any new Department, Person etc. needed, then Double Click on the Combo Box and you find the following Dialog Box:

 


 

                                                    xiii.                                      To Delete any Pes-Set item, Select it and Click [Delete] Button. The Item gets Deleted.

                                                   xiv.                                      To Add a New Item, Click on [ADD] Button and the following appears:

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

                                                 xv.                                           Enter the New Item in the Edit Box under “Name, Designation, Department” Edit Box: Click [Insert] Button and the New Item gets Inserted.

 

 

 

 

 

 

 

 

 

 

 


 

 

5.0       Installation of HAMS-GPS HAZOP Software: Please read the installation procedure before starting installation. The installation is simple. Simply download our link and run setup and follow up the instructions.

 

5.1       HAMS-GPS HAZOP Analysis Module is one of the most advanced HAZOP Softwares that provides for the following features:

 

  1. 26-Preset design intentions of most common usage fully HAZOP analysed,
  2. Option to insert all the HAZOP observations and recommendations on selected deviation of your project from corresponding deviation of any of the preset design intentions,
  3. Add and Edit option to change the current focus space of your HAZOP study,
  4. Use data option in your current focus space of your HAZOP study from any of your previous HAZOP study deviations.
  5. The most innovative Provision of HAMS-GPS HAZOP Module is availability of Risk Based Investigation (RBI) Matrix conforming to European Process Safety Centre’s Process Safety Review (PSR) system. This facility enables quantified picture in tabular and coloured matrix form the Damage and Chance levels of the potential accidents revealed by HAZOP study.
  6. Provision for Action by information on Department and Persons responsible for implementing the HAZOP recommendations.
  7. Provision for Summary report1 giving only those deviations where recommendations have been made for improvement and Summary report2 where all HAZOP guideword forms have been edited.
  8. Provision for RBI-Matrix report,
  9. Provision for full HAZOP study report.

 

The above unique and innovative provisions make HAMS-GPS HAZOP Module one of the most advanced HAZOP software available.

 

6.0       Stepwise instructions for HAMS-GPS HAZOP Software application:

 

6.1       The HAZOP Study Main Menu: As soon as you run HAMS-GPS HAZOP Module, you get the following HAZOP Study Main Menu dialog box (Fig.-5):

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Fig.-5: Main Menu of HAZOP Software.                                                                         Back

 

 

 

6.2       Enabling Record Entry for HAZOP Study: As may be seen from the top left button on the Main Menu on [Enable Record Entry], to proceed with HAZOP Study, it is necessary to enable the system to function and requires user’s name and password to be given. The new HAMS-GPS HAZOP Module comes with a default name as “abc” and password as “123”. You can click on the [Enable Record Entry] button where by the following User name/Password dialog box appears (Fig.-6):

 

 

              

                                                                             Fig.-6: User name / Password dialog.                                                                                                                                                      Back

 

First time entry requires the preset name as “abc” and password as “123” without inverted commas as shown below (Fig.-7). Note the Password would be shown as only stars to maintain secrecy of the Password. Click [OK] button. The [Enable data Entry] dialog is replaced by [Unlock Data Entry] button if the name and password entered are correct and the HAZOP software [Enable Data Entry] button is now replaced by the [Unlock data entry] button, otherwise error message is displayed saying the “Name and Password are invalid”.

 

Fig.-7: User name / Password dialog with default name and Password entered.

 

If you have successfully entered the default name and password and the [Unlock data Entry] button appears, you may click on it to enable data entry in the HAZOP software.

 

6.3       Restricting data entry by only authorized persons: To enable the data entry in the HAZOP software only by authorized persons, it is now necessary to provide actual user name and password and delete the default built in user name “abc” and password “123”. This is done by click on the Right hand top button [Add/Edit Password] where by you find the following (Fig.-8):

 

 

 

Fig.-8: Adding/Deleting User name / Password dialog.

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Click on the [Add new user] button and you will find the default name “abc” and password “123” disappear. You can then enter your name up to 10 digits maximum and password also up to maximum 10 digits (Recommend use only 5-digits for name and password that would be easy to remember and sufficiently secure). Following is a sample of new user name “Ram” and password Pass word “002” entered (Fig.-9):

Fig.-9: A sample of new User name / Password entered.

 

Then click on [close] button. Your new user name and password is established. You may then delete the default user name and password. For this you click on the [Delete user] button whereby the following dialog appears. Select user name “abc” and click [Delete] button and then [Done] button. Now your HAZOP Software is fully secured for Data entry and the only person registered in user name and password data base can  handle data entry and authorize others to join in the authorized users of the HAZOP Software as required (Fig-10):

 

Fig.-10: Deleting User name / Password dialog.

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Select the default user name “abc” and click [Done] button to remove the default user name and password. The HAZOP software has now the desired security for data entry, The new user now can only authorize other users to establish user name and password. Any number of persons can be so authorized to have their user name and password to have access to data entry.

 

6.4       Universal accessibility for reports: Only data entry that enables new data entries and modifications of existing data of HAZOP studies is possible through registered user name and password use. Otherwise any one can access the reports and take printouts of reports on any HAZOP study.

 

6.5       Accessibility on the Network: HAMS-GPS HAZOP Software enables access through Network by loading the software on the Server Hard Disk.

 

 

7.0       Your first HAZOP-Study: After customizing HAZOP Software for user name and password, you can close the HAZOP module by click on the [Close] button (Caution: remember your name and password as entered including spaces, otherwise you will have to uninstall the software and reinstall and start all over again) and reopen the programme and enable data entry and then unlock the data entry system. You will now find your new user name displayed in the Top right corner Text box and the curser is on the “Organization” Text box.

 

7.1              Setting your Organization and HAZOP Study data: First there is a Combo box for “Project/Plant Stage at HAZOP. You may enter the stage of your Project/Plant at this time of HAZOP Study., There are several options for this and you may select one of them or add your own as required. Then enter the name of your Organization pres [Tab] button the curser moves to “HAZOP Study Number” Text box. Enter a HAZOP Study number and press [Tab] button. You will find there is a HAZOP Study list box opening up showing your first HAZOP Study displayed there. Once you have entered the HAZOP Study number and pressed [Tab] button or clicked any other control, you cannot change the HAZOP Study number. If you wish to change this HAZOP Study number, then you have to click on the [Delete HAZOP Study number] button on the right side of the HAZOP Study number Text box and re-enter your new HAZOP Study number.  Press [Tab} button the curser moves to “Date” Combo box where the current is displayed. Click open the Date Combo to see the current Month calendar.  There is option to move to earlier or later months. You can choose any date of any month you like or leave the current date as you require. You may change the date any time later also. Press [Tab] button to move the curser to “P&I Drawing No.” Text box. Enter your P&I Drawing Number and press [Tab] button. The curser moves to “SOP Number” Text box. Enter your Safe Operating Procedure (SOP) reference number if any or leave it blank and press [Tab] to move to the most important Combo box

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7.2   “Design intention (Operation): ” Here you will find a series of preset design intentions with full HAZOP Studies built in and these are most commonly encountered Design intentions (Operations). You can enter you HAZOP Study design intention in this very Combo box or select one of the preset design intentions. Then press [Tab] button to move on to data on existing controls. You may enter various critical parameters like quantity, flow/addition rate, temperature, pressure etc. their units and set ranges. You may enter up to six control parameters, their units and range.

 

Note: the Project/Plant stage at HAZOP, P&I Number, SOP Number, and data on control parameters are not essential and there will be no problem in going ahead without these but the Organization, HAZOP Number and Design Intention are critical and definitely required.

 

Following is the Main Menu dialog with a sample of an Organization name and HAZOP Study number and other data given in Fig.-11. Just note all other features on the Main Menu.

 

 

                                                  Fig.-11: Main Menu with data entered for a HAZOP study.                                             Back

 

 

7.2       Start your First HAZOP Study: After entering the HAZOP Study data in the Main Menu, you are now ready to start the actual HAZOP Study. Click on rge [HAZOP Study] button or press [Alt]+[S] and find the following HAZOP Study Form :[1] NO  “NOT or NONE” opening (Fig.-12):

 

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Fig.-12: HAZOP study Form :[1] NO (NOT or NONE” as Guide word.

           

 

 

Study the details of the Form and all the succeeding Forms are very similar except for the Guide word on deviation changing.

 

7.3       Common features of HAZOP Forms: Note the following common features of HAZOP Forms:

 

  1. Preset Design intentions: Top mid Combo is on Preset Design intentions. You can select the nearest Design intention from this Combo that is similar to your design intention and use [Preset] button on the left to insert all the observations and recommendations from Preset HAZOP Study corresponding Form in to your HAZOP study Form that is opened. You may then modify / Format data as required or insert customized data for each column of HAZOP Table as required using the [Add and Edit data] button below.
  2. Design intention: Just below this Preset Design Intention intension Combo, is a Text Box that displays your current HAZOP Study Design intention,
  3. The HAZOP Table: Next are the set of Six-column table for HAZOP Study showing Guideword followed by 1. Likely deviation, 2. Likely causes, 3. Likely consequences, 4. Present controls, their limitations and finally 5. Recommendations for better Hazard Control. Important Note: When you wish to add either “N.A.” or “None.” (without the inverted commas) you must exactly enter these including full stop. If the entered “N.A” or “None.” do not match with the standard format, then the computer will take these as valid observations and use them in the reports for action. To prevent this to happen better insert “N.A.” or “None.” from [Add and Edit data] button which has correct formats of these.
  4. [Add and Edit option button]: Below the Six-column table on HAZOP, there is a list box showing alternate observations corresponding to the columns 2-5 of HAZOP table where the curser focus exists. You may start entering your observation directly in the HAZOP Table columns and move to next column by [Tab] press or you can click on [Add and Edit data] button to customize your HAZOP observations by adding requisite observations as required and also insert any of these in to the current and future into the Column in focus of HAZOP table .                                                                                                                                                                                                                        Back
  5. [Get data button}: The [Get data] button enables you to find data from your other HAZOP study observations corresponding to any Guideword. Since this is your first HAZOP, this option will have no application now till you complete one HAZOP and start another when you will be able to insert observations from that HAZOP in to your next current HAZOP study. However, you may click this [Get data] button and find a HAZOP Table opening with List box for HAZOP Study Number and Guide words from where you can select and add the observations made there in to your second and later HAZOP studies. Presently for the first HAZOP, this option will be blank.
  6. Risk ranking for RBI-Matrix: On the right side, you will find Risk ranking scale and radio buttons. This is one of the unique features of HAMS-GPS HAZOP Module. This Risk ranking facility enables you to develop Risk Based Investigation (RBI) Matrix conforming to the European Process Safety Centre’s RBI-Matrix system. The Risk evaluation is for the Damage and Chance levels of the Hazards revealed in the consequences of the deviations likely as recorded in column3 of the HAZOP Table. There is help on Risk ranking and for this click on the [Risk ranking help] button whereby you find the following help displayed (Fig-13):

 

Fig.-13: Help on Risk Ranking

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Based on the likely damage consequence recorded in column-3 of your HAZOP study Table, you can select the Damage level and corresponding Chance level. Note that the Chance level of occurrence of the accident depends on the control level and for this purpose, you have to decide the control level of the organization in to High, Medium and Low level control based on the skills, sophistication and management controls and then use the corresponding Chance level. The Risk ranking help box can be closed by click on the [Close] button at the top in the help box itself at the right hand top corner. The abbreviations H1, H2, H3 stand for High-1, High-2, High-3 respectively, MH stands for Medium High, M for Medium and L for Low and each of these have three levels. The scale is from top to bottom and levels 1, 2, 3 depict successive lower levels of hazard. If you hold the curser on the Radio button, it displays the level of Hazard. On top of the Risk scale you will find two buttons one on [Damage] that is clicked in default as you open the HAZOP Form and the other on its right is the [Chance] button. After selecting the required Damage level radio button, you click on the [Chance] button and then select the Chance level radio button.

 

Important points to note on Damage and Chance level relationship: The universal law of Risk of Damage and the chance of its occurrence in accidents of common day-to-day activities is their inverse relationship. Thus High-Damage accidents have Low-Chance of occurrence and vice versa. So in industrial and other common human activities this inverse relationship holds true and you should not rank Damage and Chance both at similar levels. Following Table illustrates this:

 

Damage level

Chance level

Remarks

HIGH

HIGH

Exists only in adventure sports like mountaineering and war. Not possible in day to day activities in industry.

LOW

LOW

Unlikely in accidents associated with manual labour. Might be possible in sophisticated safe machinery and toys.

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Finally there is a button on [Next Guide word] to move on to Form-2 from Form-1 and so on.  For this purpose you may press [Alt]+[N] b Keys also as a short cut. You can also navigate back and fourth from Form-2 on wards. So you can always go back and change any observations etc. on any form.

 

Important Note: Once you begin a HAZOP Study by opening the Form-1, you have to go through the entire process and there is no way of quitting in between. For this purpose if you wish to close in between for any reason simply keep [Alt]+[N] keys pressed and the Forms keep moving forward till the last dialog box on “Any other observations is reached. Here you press [Done] button and close the next dialog on “Action by: Name, Designation, Department”. The HAZOP gets normally closed and later when you start again, open Form-1 and proceed to complete in a proper way.

 

7.4       HAZOP Forms and Guidewords: The HAMS-GPS HAZOP Module has the following Forms with Guidewords on deviation:

 

HAZOP Study Form No.

Guide word on Deviation

Meaning

Example

1.

NO (NOT or NONE)

Intended activity does not take place or ceases to take place

No flow, No addition, No temperature control etc.

2.

MORE OF

More than intended has occurred i.e. a quantitative increase.

More quantity of a chemical added, higher than required temperature, flow, pressure etc.

3.

LESS OF

Less than intended has occurred i.e. a quantitative decrease.

Less quantity of a chemical added, less than required temperature, flow, pressure etc.

4.

MORE THAN OR AS WELL AS

Further activity takes place beyond intended.

Impurities present, another material added, some other control other than intended is activated etc.

5.

PART OF

Incomplete performance of an activity.

Missing component, part of an operation like purging, decontamination done.

6.

REVERSE OF

Opposite of an activity takes place

Back flow, cooling instead of heating etc.

7.

SOONER / LATER THAN

Activity done at wrong time earlier or later than required.

Temperature raised earlier or later than required.

8.

OTHER THAN

Something other than intended happens.

Wrong material charged, temperature instead of pressure controlled.

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9.

ALL

All Guide words

If full design details are not available, then HAZOP is to be done after full design details are available

10.

DEVIATIONS IN OTHER ACTIVITIES

Start-up, shutdown procedures, testing, inspection, commissioning, dismantling, weather, seismic, physical impact, containment loss, domino effects, purging, washing out etc.

Any thing other than Guide words 1-8.

11.

RELIEF MAL FUNCTION

Mal functioning of relief system

Relief valve does not pop up on high pressure.

12.

CONTROL SYSTEM

Any control fails

Temperature control fails.

13.

SAMPLING SYSTEM

Sampling hazards

Spills, exposure hazard.

14.

CORROSION EROSION

Corrosion / erosion hazard

Use of corrosive materials, abrasive materials

15.

SERVICE FAILURE-1

Steam Failure

Boiler trip, main steam line leak.

15a.

SERVICE FAILURE-2

Water failure

Water pump fails, water tank empty

15b.

SERVICE FAILURE-3

Power failure

Power trips.

15c.

SERVICE FAILURE-4

Any other service failure if any as relevant.

Compressed air supply fails.

15d.

SERVICE FAILURE-5

Any other service failure if any as relevant.

Instrument air supply fails.

16.

MAINTENANCE

Any failures in maintenance that needs specific mention  in view of hazards

Schedules replacement.

17.

STATIC CHARGE

Likely development of static charge

Flammable liquid charging

18.

STAND BY EQUIPMENT

Is there a need for any stand by equipment

Critical pumps.

19.

SAFETY

Any specific safety aspect not covered above

As found necessary to mention.

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7.5       Any other observations: Any observations on the whole and not brought out in the previous HAZOP Forms may be mentioned., Some thing that needs special mention at the end. An overall observation.

 

Following are some examples under “Any other observations” dialog box. You may develop similar appropriate “Any other observations” sa found appropriate for various consequences:

 

Sr. No.

Consequence type

Suggested text under “Any other observations” dialog box

1.

Fire / Explosion consequences

Fires and Explosions can have serious Domino effects and damage neighbouring facilities. Hence it is desirable to locate such hazardous facilities upwind of dominant wind orientation to minimize Domino effects.

2.

Toxic Gas releases

Toxic gases disperse downwind affecting on-site and off-site facilities. It is desirable to locate such facilities such that other sensitive on-site and off-site facilities fall upwind of these hazard of Toxic releases.

 

 

Fig.-14: Dialog box on “Any other observations.

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7.6       Action on Recommendations: After completing the HAZOP right through all the Forms-1 to 19 and final any other observations, there appears a dialog for entering the Department and person with designation responsible for action on the recommendations made. This dialog shows the HAZOP Guide word and the Recommendation made. It is necessary to enter the Department and person with designation who is responsible for action on the recommendation.

 


Fig.-15: Dialog box for Action by: Name, Designation, Department for implementing recommendations

 

To add new name, designation and department, double click on the “Action by: Name, Designation and Department” Combo box whereby you get the following dialog box. Click on [ADD] button and enter requisite name, designation and department and click [Insert] button. You can enter more than one names here.

 

 

Fig.-16: Dialog box for Adding and inserting name, designation and department of persons for Action on recommendations.

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7.7           Risk Level summary: Once you have completed a HAZOP study and come back to the HAZOP study module (Main menu), and select your HAZOP study in the list box of HAZOP studies, you will find on the top right hand side just below the [Help] button the following button:

 


Fig.-17: Risk summary button

 

You click on the [Click] button to open the “Risk level summary”. This dialog at the top right hand side, there is a [View print preview] button which on click opens the print preview of the Risk level report and you can print the same. To close the “risk level dialog box, you have to again click on the [Click] button.

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7.8             Summary of HAZOP Study options:   

 

Sr. No.

Option

Applications

1.

Inserting Preset HAZOP data from RefNode and Completed HAZOP

Procedure for inserting data from RefNode HAZOP or other completed HAZOP:

 

i.                    First Create all Required Nodes in the New Organization, Ensure that you do not loose Focus UNLESS the HAZOP Study Number is Entered. This will create Errors,

ii.                  Select First Node to be Copied to a New Organization HAZOP and copy by [Ctrl+C] and then Select the Organization Title->Select the First Node and Paste by [Ctrl+V] in the “Design Intention (Operation)” Combo Box. Note this Node Text does not get entered in the Combo Box.

iii.                Also Paste the same Text in “Describe Design Intention” Edit Box on Right Hand Top corner,

iv.                 Then Click on [HAZOP Study Button at Left Hand Bottom. This opens the First HAZOP Data Entry Dialog for “NO or NOT” Guide Word. If your RefNode or Completed HAZOP from where Data is to be inserted is under “NO or NOT” else Proceed to the Guide Word where your Data is required,

v.                   Then Click on [Get data] Button whereby “Get data” Dialog Box opens. In this Dialog Select the RefNode or Completed HAZOP,

vi.                 Select the Node whose Data is to be inserted. You Get [Find data] Button. Click on this [Find data] Button and you get display of the Data from the Completed HAZOP Node Selected.,

vii.               Check and confirm the data is the one to be Inserted in the New HAZOP and Now Click on [Insert] Button and the data gets inserted in the New Data Entry Dialog Box.

viii.             You have to select required buttons from Risk of [Damage] and [Chance] Tabs,

ix.                 Also Select from [Category] Combo Box..

x.                   At the End in “Action by” Form Select the Required “Action by” option or Create a New Option by Double Click and Select [ADD] Button, Create a New Option and [Insert].

 

2.

Finding HAZOP data from your other HAZOP studies

Once you have done a few HAZOP studies, you can find and insert any data in any column of HAZOP table where curser focus exists in a given Form from any of your previous HAZOP study. For this you have to click on the [Find data] button and the “Find data” dialog that opens has two combo boxes one for list of HAZOP studies you have done before and another for “Guide word” which by default is for the corresponding Guide word of the current Form in your HAZOP study. You have to select the previous HAZOP study from where you wish to insert the data. You can also change the Guide word combo selection (This may not be needed as the observations are specific to “Guide word”).

3.

Not Applicable Form

If any Form whose Guide word is not applicable, and your Form is blank (If you have first run of your HAZOP) you may simply press [Alt]+[N] to move to next Form and the computer sets “N.A.” to each column automatically and moves to next Form. If there is some data in various columns of the HAZOP Table, simply set curser focus to “Likely deviation” column and select “N.A.” from “Add and Edit data” dialog box (that opens on click on [Add and Edit data] button) and click [Alt]+[N] whereby the computer sets “N.A.” to all columns and moves to the next Form.

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8.0             Viewing and Printing Reports: There are the following Report buttons: Details are given under

 

Fig.-18: HAZOP Report options

 

8.1                                    [Report-1]: Recommendations only: Gives those HAZOP Tables where there is specific recommendation (i.e. there does not exist either “N.A” or “None.” Without the inverted commas. Note as mentioned under Para-7.3.3 Important Note: You should ensure that the “N.A.” or “None.” entries without the inverted commas, should exactly match the standard format of these and to ensure this do not enter “N.A.” or “None.” manually but insert using the [Add and Edit data] button.). There are two types of Report-1. One is for selected HAZOP Number and the other for all HAZOP study numbers of the organization. This selection may be made by click on the [Option for Select/Full reports] button.

8.2                                     [Report-2]: Full HAZOP Report: Gives those HAZOP Tables where all columns do not have either “N.A.” or “None.” i.e. there is some observation made whether there is any recommendation or not. The full HAZOP Report is available also for select HAZOP Study number and for all.

8.3                                     [Report-3]: Gives two options for summary reports of selected HAZOP Studies. On clicking the [Report-3] button you get a HAZOP study selection dialog box giving a list of all the design intentions for which HAZOP studies have been done with a check box for selection of each study for summery report. You have to click the check boxes of HAZOP studies which are to included in the summary reports. After this click on the [Update] button whereby the buttons for the two reports get enabled. The two summary report option buttons are: 1. [Open selected set of design intention report] and 2. [Open selected set of Damage-Consequence] or press short cut key [Alt]+[d] for report-1 and [Alt]+[q] for report-2 whereby you get the relevant reports. These two summary reports along with the risk level reports form the most important outcomes of a group of HAZXOP studies conducted for a facility.

8.4                                     [Risk level report]: See 7.7 above.

8.5                                     [RBI-matrix report]: Gives the RBI-Matrix in colour with summary.

Important Note: The RBI-Matrix Report is a massive graphics file and printing requires that you exit from Print Preview. Also this report requires Landscape page setting. So to print the RBI-matrix report, first go to Print preview and then do Landscape page set-up. Close Print Preview and then give print command by clicking [Print report] button for printing the RBI-matrix. For all other reports, there is no problem in giving print command while in print preview mode.

8.6                                     [Category wise Reports]: There is option in each HAZOP Form to select the Category of Recommendation. This identifies the nature of recommendation like Documentation, Training, Soft, Hard, SOP, PMP etc. One can add more categories. The report under this category wise HAZSOP recommendations helps in understanding and implementing the recommendations.

8.7                                     [Action by Report]: Gives designations or names of persons who are to implement the recommendations.

8.8                                     [Risk level summary]: The button on the top right hand corner of the main dialog box gives Risk Level summary.

8.9                                     [Print Report]: Prints the report selected for preview except in case of RBI-Matrix where you make Landscape page setup and close print preview and the click [Print Report] button.

 

Note: The SIL/LOP information is available in most tabulated HAZOP Reports.

 

8.10    Summary of Printing Reports: The HAZOP-Software provides for the following Report Generation:

 

            Reports are available in 3-Forms:

                       

i.                    Recommendations only,

ii.                  All Guidewords used,

iii.                RBI-matrix.

 

These are available in 2-Forms:                                                                                                                                                             .Back

 

i.                   

Selected Reports as shown in the Default Option for All 3-Types of Reports as listed above and shown in the Report Button Box as shown below:.

 


 

Option-1

 

                         If you clock on                this button, you get the following Report Button Box:

Option-2

 
 


 

In this, as is clear, you get Full Reports for all Nodes. Under Full Report 1, you get Recommendations only and under Full Report 2, you get Report for all Guide Words used.

 

Under both Options The Report 3 Refers to RBI-Matrix conforming to the European Process Safety Centre’s Model.

 

9.0       Conclusion: Wish you enjoyable HAZOP sessions with the advanced HAMS-GPS HAZOP Module. We welcome comments, suggestions and recommendations for further improvements in HAMS-GPS HAZOP Module