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PURPOSE
This procedure defines requirements for the assessment and elimination or
control of hazards associated using a series of six hazard studies.
It is based on the premise that the preferred approach to the control of hazards is
their elimination where reasonably practicable. This is aided by application of the
hazards study process from the earliest stages of project development where the
application of the concepts of inherent HSE and corresponding techniques for
protection of the environment and health can be utilized.
SCOPE
This procedure defines the purpose, key aspects and content of hazard studies,
timing of hazard studies and hazard study team membership roles and
responsibilities.
APPLICATION
This procedure should be read in conjunction with applicable legislation and
customized critical procedures needed to incorporate relevant legislative and
license requirements.
DEFINITIONS
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HAZARD STUDY
PROCEDURE TITLE:
HAZARD STUDIES
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PURPOSE................................................................................................................................................... 1
SCOPE........................................................................................................................................................ 1
APPLICATION............................................................................................................................................. 1
DEFINITIONS.............................................................................................................................................. 1
1.0
GENERAL......................................................................................................................................... 3
2.0
KEY REQUIREMENTS..................................................................................................................... 3
2.1
Hazard Study 1.............................................................................................................................. 3
2.2
Hazard Study 2.............................................................................................................................. 3
2.3
Hazard Study 3.............................................................................................................................. 4
2.4
Hazard Study 4.............................................................................................................................. 4
2.5
Hazard Study 5.............................................................................................................................. 4
2.6
Hazard Study 6.............................................................................................................................. 4
3.0
PROCEDURE................................................................................................................................... 5
3.1
General Requirements.................................................................................................................. 5
3.2
Hazard Study 1.............................................................................................................................. 6
3.3
Hazard Study 2.............................................................................................................................. 7
3.4
Hazard Study 3.............................................................................................................................. 8
3.5
Hazard Study 4............................................................................................................................ 10
3.6
Hazard Study 5............................................................................................................................ 11
3.7
Hazard Study 6............................................................................................................................ 11
4.0
ROLES OF HAZARD STUDY TEAM MEMBERS...........................................................................12
4.1
Hazard Study Leaders Role........................................................................................................ 12
4.2
Project Managers Role............................................................................................................... 12
4.3
Site Representatives Role.......................................................................................................... 13
4.4
Area Managers or Project Engineers Role................................................................................13
4.5
Functional Engineers Role......................................................................................................... 14
5.0
PREPARATION FOR HAZARD STUDY MEETINGS......................................................................14
5.1
Team Responsibilities for Review Meetings and Quantification...................................................15
6.0
HAZARD QUANTIFICATION.......................................................................................................... 15
7.0
HSE DOCUMENTATION................................................................................................................ 16
8.0
REFERENCES............................................................................................................................... 16
9.0
ATTACHMENTS.............................................................................................................................. 16
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HAZARD STUDY
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GENERAL
Hazard studies shall include appropriate representation from the business/facility
and the project team.
2.0
KEY REQUIREMENTS
All projects will conduct hazard studies upon award. Personnel with appropriate
training and experience, in accordance with company requirements must deliver
hazard studies. All identified hazards are to be recorded and where practical
corrective action taken to eliminate/remove or mitigate the consequence.
Individual projects may choose to develop a different series of studies, but all
aspects of the studies described here must be incorporated.
2.1
Hazard Study 1
Hazard Study 1 and, where required, Hazard Study 2 shall be completed prior to
the production of the project definitive cost estimate.
2.2
Hazard Study 2
Hazard Study 2 shall identify and eliminate the significant HSE and Physical
Security hazards. Where elimination is not practicable, Hazard Study 2 shall
identify control measures to reduce the risk to below the acceptable levels
identified in Hazard Study 1. Hazard Study 2 shall initiate the identification and
design of any Critical Systems.
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Hazard Study 3
Hazard Study 3 shall be conducted as a series of Hazard and Operability
(HAZOP) studies to identify any hazards or obstacles to design, construction or
operability and where necessary initiate appropriate corrective actions.
Following the completion of Hazard Study 3 any modification made to the design,
including those made during the commissioning stage, shall be controlled by
means of engineering change notices.
2.4
Hazard Study 4
Hazard Study 4 shall check that:
The project has been completed in accordance with the intended design;
That actions from previous hazard studies have been incorporated into the
design and are installed; and
2.5
Hazard Study 5
Hazard Study 5 shall provide detailed review of the project implementations to
confirm that the new facilities meet company and legislative requirements for
protection of the safety and health of personnel, company assets and the
environment.
2.6
Hazard Study 6
Hazard Study 6 shall:
Check that the actions from previous hazard studies have been completed
or have been formally handed over to operations for completion;
Review early operation to verify that it is consistent with the design intent
with regard to HSE and Physical Security issues; and
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PROCEDURE
3.1
General Requirements
The hazard studies comprise a series of six distinct studies, which are carried out at
defined points throughout the project, from initial process and project development
through to early operations.
Local legislation may require that a HSE representative be consulted, where practicable,
during the identification of hazards and assessment of risk arising from projects and
changes to the project or associated systems of work. Refer to relevant local legislation
regulations.
The Project Manager arranges for the required hazard studies to be conducted in
accordance with the timing and guidelines outline in Attachment 1 (Hazard study time
line). Hazard Studies 1 and 2 are completed prior to the production of the project
definitive cost estimate.
The Project/Business Manager appoints an accredited Hazard Study Leader and
recommends team members to conduct Hazard Studies 1 to 3, as required. Hazard
Study Team Leader agrees the final team composition for each hazard study and leads
the study teams through consideration of the issues listed below. He/she fully documents
the hazard study considerations and actions
Where the project could create significant on-site or off-site risks, a suitably experienced
risk analyst also completes a quantified risk assessment.
The Project Manager implements the actions from Hazard Studies 1, 2 and 3 in a costeffective way. He/she examines any changes to the design after completion of Hazard
Study 3 for possible hazards and documents the results in accordance with the
guidelines for Hazard Study 3. The Project Manager arranges for incorporation of the
hazard study records into the Project Documentation prior to commissioning.
The Project Manager/Commissioning Manager confirms that the actions from all previous
hazard studies have been completed and coordinates completion of Hazard Studies 4
and 5 prior to commissioning. In the event that completion of an action from Hazard
Studies 1 5 prior to introduction of hazardous materials or commencement of
operations is not warranted or is impracticable, the Commissioning Manager justifies and
documents the basis on which process materials are introduced or operations are
commenced.
Prior to closure of the project, the Project Manager/Commissioning Manager appoints an
accredited Hazard Study Leader, in consultation with the Business Manager, to conduct
Hazard Study 6.
The Project Manager arranges for incorporation of the records from Hazard Studies 4, 5
and 6 into the Project Documentation. The Site/Operations Manager verifies that the
required people are trained and changes to operating and maintenance procedures are
fully implemented. He/she implements any requirements for occupational hygiene and/or
environmental monitoring in accordance with the Project HSE Management system.
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Hazard Study 1
Purpose
The purpose of Hazard Study 1 is to confirm that the understanding of the
project, the process and the materials involved is sufficient to enable the HSE
issues to be properly assessed. It also contributes to key policy decisions (e.g.,
equipment siting) and verifies that contacts are established with the functional
groups, site management and the authorities who may contribute to or impose
constraints upon the development of the project.
Key aspects include:
Reviewing the environmental statement for the project and verifying that it
covers all relevant on-site and off-site environmental issues. Hazard Study 1
identifies actions of the project designed to meet the company objectives for
environmental performance;
The use of standards, which will meet the most demanding environmental
legislation reasonably, anticipated for the project;
Minimization of waste;
Waste recycling;
Considering the human and organizational aspects of the project and its
subsequent operation, including emergency services and security;
Setting the project criteria for HSE aspects for employees and the public in
accordance with company and statutory guides (e.g., on the tolerability of
risk and on environmental standards);
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Establishing the likely control and protection structure needed to meet the
general control and protection requirements;
Establishing broad control and protection objectives for the process and
personnel;
Confirming that the proposed Project manning policy is consistent with the
proposed control and protection systems;
Setting up specialist investigations as maybe required into control/protection
requirements (e.g., critical HSE needs, Advanced Process Control
opportunities, operability reviews, etc); and
Agreeing the extent and timing of further hazard studies and the need for
any additional specific studies or assessments (e.g., chemical process
hazards assessment, quantified risk assessment, hazardous area
classification, quality studies, construction/demolition hazard studies
(HAZCON etc.).
The full team must agree to the final outcome of the Hazard Study 1. Separate
subgroups may be formed to conduct specific parts of Hazard Study 1.
A Hazard Study 1 report (refer to Attachment 2 Hazard study report.) is prepared
for inclusion in the Project Documentation. The report summarizes the findings of
the study team, including details of information that is still lacking, and is issued
as soon as practicable. Outstanding actions from Hazard Study 1 are reviewed at
the commencement of Hazard Study 2.
3.3
Hazard Study 2
Purpose
The purpose of Hazard Study 2 is to identify significant hazards, providing the
opportunity for their elimination by redesign. Where this is not practicable,
protective measures may need to be incorporated to meet the relevant criteria.
The study produces the majority of the information and assessments needed to
meet company and regulatory authority requirements for HSE protection.
Key aspects include:
Agreement of the broad structure of the control and protection systems and
the basis for safe operation;
Agreement of what will broadly be manual control and what will broadly be
automatic control;
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The study forms the basis for discussions with regulatory authorities.
At the end of Hazard Study 2, all project information necessary for the completion
of a project Environmental Plan will have been assembled.
Where the Project could create significant on-site or off-site risks, or where
required by the applicable regulatory authorities, a quantified risk assessment is
completed by a qualified risk analyst.
A Hazard Study 2 report (refer to Attachment 3 Hazard study report c) is
prepared for inclusion in the Project Documentation summarizing the Hazards
identified together with any quantified assessments necessary to show that the
HSE criteria have been met. Any areas lacking firm definition are identified in the
report.
3.4
Hazard Study 3
Purpose
The purpose of Hazard Study 3 is to review the design and/or procedures to
identify any hazards or obstacles to operability, which could arise, particularly
through deviations from the design intent. In the case of process project, this will
be based on the study of firm engineering line diagrams that have already been
subjected to design review, and on outline operating procedures. The
consequences of deviations are identified and where necessary, appropriate
corrective actions initiated. The study also provides an opportunity to review
potential maintenance and quality problems. Hazard Study 3 is conducted as a
series of hazard and operability (HAZOP) studies.
Key process aspects include:
A detailed systematic study of the design and outline operating and maintenance
procedures using guide word lists to identify the consequences of deviation from
the design intent;
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Hazard Study 4
Purpose
The purpose of Hazard Study 4 is to check that the project has been built to the
intended design. To check that action from previous hazard studies have been
incorporated into the design and are installed on the project. And to check that
the operating instructions and emergency procedures comply with any
requirements identified by previous hazard studies and are satisfactory for the
safe operation of the project.
Key Aspects
Key aspects include confirmation that:
Actions agreed at earlier hazard studies have been completed, or that any
alternative actions are justified;
Changes made following Hazard Study 3 have been hazard studied, actions
have been recorded and followed up, and P&IDs and operating instructions
have been updated;
Testing manual and automatic control and protection systems (hardware and
software) against functional specifications agreed during Hazard Study 3;
Demonstrating that test methods for critical trip and alarm loops are effective
and testing procedures are established;
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Hazard Study 5
Purpose
The purpose of Hazard Study 5 is to provide an opportunity for those responsible
for personal safety, employee health and environmental protection in the
business unit to satisfy themselves that the detailed implementation of the project
meets company and legislative requirements.
Key aspects included:
A review of the arrangements for the protection of employee health covering the
facilities provided and the arrangements for workplace monitoring;
A review of the equipment and systems proved to protect and monitor the
environment;
3.7
Hazard Study 6
The purpose of Hazard Study 6 is:
To check that Hazard Studies 1 to 5 have been completed and relevant
documentation exists in the Project Documentation. This includes hand-over of
documents to the operations team;
To review early operation to confirm that it is consistent with the design intent with
regard to HSE issues, and that the assumptions defined in earlier hazard studies
are borne out in actual project operation
To identify and record operating and maintenance difficulties and provide feed
back to the project engineering organization
To check that any outstanding actions from previous studies have either been
completed or handed over formally to operations for follow-up; and
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Quantified hazard analysis may also be carried out to enable, for example,
the integrity required of trip systems to be specified, especially at Hazard
Study 2; and
4.2
Identifying the HSE hazards of the process by a rigorous Hazard Study and
that the design meets the appropriate targets;
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Understanding the basis for safe operation and the hazard control
philosophy, so that he/she can:
Confirm that any changes made at commissioning, or subsequently, do
not increase the hazards; and
Fully inform the rest of the commissioning team and other disciplines
about hazards and operating constraints.
Check that all the requirements from the Hazard Studies have been
incorporated and function correctly (including communications systems,
relief devices, major control/protective systems, emergency supplies, etc)
and that the project as constructed is as shown on the line diagrams.
(Hazard Study 4);
Initiate the production of process operating instructions;
Consider the special hazards of the initial start-up, emergency procedures,
start-up and shutdown, maintenance isolation and testing procedures;
Verify the training of operating personnel in the particular hazards; and
Set up the HSE Documentation.
4.4
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5.0
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HAZARD STUDY
leader needs to have received suitable training for the study being carried
out;
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5.1
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The Hazard and Reliability Engineer will have been trained in Hazard
Analysis. This may be needed to help in making decisions about the
acceptability of particular hazards or about modifications proposed to make
the design acceptable. It will also be required for specifying trip or alarm
systems for HSE Protection; and
The Hazard Study Leader needs training in the use of the appropriate guide
diagrams and in the development of proposals for actions. He will also need
to recognize when hazard analysis is required and enlist the help of a
Hazard and Reliability Engineer. An understanding of common mode or
common cause failures is also important.
6.0
HAZARD QUANTIFICATION
When hazards are to be quantified, this will be primarily the responsibility of the
person trained in Hazard Assessment, but he may be assisted by a small working
party. The working party would typically consist of the following:
The trained Hazard and Reliability Engineer, who leads the team and
develops the hazard analysis.
The Site Representative, who agrees the basis for quantification, including
expected operator actions, operating and maintenance philosophies, etc.
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HSE DOCUMENTATION
A great deal of information about safe design and operation, about health
hazards and effects on the environment is generated throughout the life of a
project. This should be readily available to all personnel involved in management
of the project or operation.
The information should be:
Compiled with minimum effort using, where possible, the paperwork which
already exists. For example, project notes, Hazard Study records, letters,
etc.;
8.0
REFERENCES
Practice/Procedure #
Corporate HSE
Table of Contents for Practices and Procedures
General Health, Safety and Environmental Practice
Office Health, Safety and Environmental Practice
Engineering Health, Safety and Environmental
Practice
9.0
ATTACHMENTS
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Attachment #
Attachment 1
File Title
Composition of Hazard Study Teams (a)
Attachment 2
Attachment 3
Attachment 4
Attachment 5
Procedure
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