HAZOP Process-what does it mean? The word HAZOP is an acronym for HAZard and Operability Study, which is a Risk Assessment technique used extensively in the process industries (such as Oil and Gas, Chemicals, Petrochemicals, Power, Pharma and others). The HAZOP Process is a structured method that is a part of a PHA (Process Hazard Analysis), in which one examines a small part of a plant or facility (called as a Node) using a set of Guide Words that seek to examine all the permutations and combinations possible in a particular plant operation. For example, if one is analyzing the flow of a liquid from say a day tank (lets call it Tank A) to another tank (say Tank B) then there are several things that can go wrong with this simple process, such as Low Flow, Reverse Flow, No Flow and so on. These guide words (Low, Reverse, No) are combined with a parameter (such as Flow) to generate possibilities of what could go wrong in the operation.
Then each combination gives us an opportunity to think what can happen. For example if the normal operation of the process is to transfer liquid from Tank A to Tank B, then Reverse Flow will be from Tank B to Tank A. Will this cause any problems? We then list all these problems under the heading of "consequences" and for each consequence we can think of a protective method by which this consequence can be avoided. Thus if we determine that reverse flow will have dangerous consequences, then we can prevent it by having a Non Return Valve in the line that connects Tank A to Tank B.
Thus each such condition will be evaluated for consequences and protective measures designed. If we do this diligently for the entire plant, we will have a much safer operation!
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