(100c) Critical P & ID Reviews Using HAZOP/LOPA Methodology – Overkill or Underrated?

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.