(55z) Practical Application of Mihazop® in a Non-O&G Facility

Hazard and Operability Analysis (HAZOP) is a structured and systematic approach to improve the safe operation of manufacturing plants; it enables the identification of risks associated with process deviations and provides recommendations to manage the risk. Mechanical Integrity is another element of Process Safety Management. A proper Mechanical Integrity (MI) program ensures the equipment is designed, fabricated, installed, operated, and maintained to safely achieve and sustain the required desired performance. Studies from reputable sources have shown that a high percentage of process and operational risks are related to MI; additionally, the NEP study (USA, 2010) shown many non-conformities associated to HAZOP and MI. A new method was proposed to integrate HAZOP and MI to leverage the benefits of both approaches for risk management called MIHAZOP®. This method enhances HAZOP approach by incorporating MI as part of the study: Improving Mechanical Integrity of the assets, addressing the causes of the deviations identified in the HAZOP is the MIHAZOP® goal. A practical application of MIHAZOP® in a non-O&G facility (Pulp & Power Facility) was performed in 2022/23 and it is presented in this paper.

The P&P facility, since startup in 1992, had gone throughout a series of uncontrolled MOCs; as a result, most of the critical knowledge was inadvertently lost, including knowledge related to maintenance and MI plans and strategies. MIHAZOP® was performed in the facility to evaluate the risk associated with the current operating strategies, and at the same time conduct a meticulous examination of maintenance limitations (MI), in order to comprehend the underlying reasons and mechanisms behind the existing risks. The new method allowed operators, maintenance, and engineers to evaluate the risk of the facility while focussing on the limitations and associated risk as a result of maintenance or mechanical integrity failures or limitations, and based on the findings define priorities and preliminary strategies to improve maintenance and reliability as the primary source for risk reduction.

By evaluating the maintenance practices and operating procedures simultaneously, the facility was able to validate the effectiveness of existing safeguards and identify the necessary measures to restore safe operations. As an example, MIHAZOP® process proved to be highly effective in analyzing the inherent risks associated with the plant condensate recovery system, presenting an opportunity to regain lost efficiencies. By scrutinizing the preconceived hazards within the system, the potential for recovering 125,000 tons of condensate per year, with an expected net financial gain of $200,000 year was clearly identified. The company is in the process of capitalizing on the benefits derived from this newfound knowledge. Furthermore, the assessment revealed neglected components within operations that posed a high potential for catastrophic losses. Armed with this insight, the company promptly revised their maintenance and operating strategies to ensure the longevity and reliability of their equipment. The implementation of the MIHAZOP facilitated a rigorous analysis of process safety risks, leading to the identification of areas for improvement, optimization of operations, and the mitigation of potential hazards.