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G E N E R A L FA C T S H E E T

Hazard studies

The foundation of effective process

safety and integrity management is
a full identification and assessment
of potential hazards.

Hazards on process plants must be identified, HS 1 - Feasibility stage: Process safety information
eliminated where possible or otherwise controlled in This checklist-based study ensures personnel have
order to improve safety, reduce operating costs, an adequate understanding of the project,
comply with legal requirements and benefit from processes and materials to address safety, health
increased efficiency and profitability. and environmental issues effectively. Consideration
is given to what other studies are needed, and the
What we offer need for contact with regulatory bodies who may
ABB can facilitate a series of hazard identification place restrictions on the project to avoid any
and assessment studies throughout a project expensive delays at a later date.
lifecycle, from the early R&D phase through to
ongoing operation. Every project gives unique HS 2 - FEED stage: HAZID study
challenges and we can help you select the right This is a hazardous event based study of the
approach. ABB’s Hazard Study (HS) methodology preliminary process flow diagrams which aims to
has been developed and refined over many years, identify and eliminate major accident hazards
building on an ICI heritage (ICI invented HAZOP wherever possible. If this cannot be achieved, the
studies). Up to eight studies can be utilised at team will specify what safety measures are needed
various stages of a plant lifecycle, mostly covering and further quantify risk assessments to ensure
the design stages of a project or modification. that the risk is reduced to an acceptable level.

HS 0 - Concept stage: Inherent safety workshop HS 3 - Detailed process design stage: HAZOP study
Here, development chemists and engineers work to This is a detailed and systematic study of process
reduce or eliminate the hazard potential of a design and outline operating procedures. Using
process, and reduce the need for extra safety deviation analysis, the team will identify any
measures and waste treatment facilities. The outstanding hazards or operability problems and
methodology provides demonstration of a make recommendations based on the application of
structured hierarchical approach, as required in the ‘relevant good practice’ to allow the process design
UK under the COMAH regulations. The aim is to to be finalised. HAZOP studies utilise a multi-
increase the inherent safety of the design. functional team of project and operations staff and
require a flexible approach depending on the nature
of the process being assessed.
 Hazard study
HS0 HS1 HS2 HS3 HS4 HS5 HS6 Revalidate
process

Detailed
Project process Feasibility FEED
design
Construction Commission Operation

— HS 4 and 5 - Pre-start up safety review Benefits

Above: Hazard
study process and These checklist-based studies take place prior to -- Compliance with the legal requirement for risk
project process. construction hand-over and prior to start up. This assessment
will ensure the plant has been installed and pre- -- Inherently safer processes with reduced capital
commissioned as designed and has incorporated and operating costs
key safety features from earlier studies, focusing on -- Early identification of hazards and contact with
process safety hazards. Staff responsible for the regulatory bodies avoiding expensive delays in the
operation of the plant also have the opportunity to project
review the facilities for personal health and safety -- Minimisation of problems during commissioning
issues, and measures needed for environmental and early operation
protection. -- Time efficient assurance of suitability of existing
assets for ongoing operation
HS 6 - Early operational stage -- Opportunity for shared decision making and
Using this checklist-based study, the team will learning across engineering functions
review early operation and ensure the level of safety
Study Description Timing
developed during the plant design stage is reflected
Inherent safety workshop: Eliminate or minimise
by actual experience during the first months of 0
hazards at source
R&D

operation. The findings from the study can also 1 Ensure information available on basic hazards Concept

provide feedback to the design team to promote 2

HAZID: Identify major accident hazards and agree
FEED
basis of safety
continuous improvement in process design.
HAZOP: Identify deviations from design intent,
3 Detail design
ensure all safeguards are in design

HS 7 - Operational stage re-validation: PHR / HAZOP 4&5

Pre start-up safety review: Plant as built meets
Commissioning
process safety and SHE requirements
Many companies are required to carry out periodic Process safety audit: Review of early stages of
6 Early operation
revalidation of their safety reviews, typically every 5 operation to identify key concerns

Revalidation: Review ongoing operation and

years, as part of their process safety management 7
experience, ensure safeguards are effective
Every 5 years

systems and to meet legal obligations. ABB

developed the time efficient Process Hazard Review Why ABB?
(PHR) method focussing on loss of containment and ABB has extensive experience of hazard
release of energy events. PHR allows an experienced identification and risk assessment, based on our ICI
team to assess the adequacy of existing protective heritage. Our hazard study leaders have extensive
measures, using the learning from operations, experience across a wide range of industry sectors,
assessing plant changes and ensuring compliance and come from an operational background. They use
with relevant standards. For companies requiring a their experience to make pragmatic technical
more thorough assurance, ABB offers retrospective judgements and lead the team to extract and share
HAZOP studies using a ‘line-by-line’ deviation all their experience.
analysis approach developed from design stage
studies. ABB are leaders in process safety, offering a wide
range of services, including SIL determination and
Action close-out LOPA, which address the way in which people, plant
In addition to facilitating HS, ABB can help manage and systems inter-relate to ensure good safety
closure of the actions identified during each stage management. We can provide support throughout
of the project. This ensures rapid efficient and the risk assessment process, from identifying the
appropriate closure, allowing the project to risks, developing solutions, right through to
continue without delay. implementation in order to gain the risk benefits
sought by our clients.
Training and procedures
ABB also offers training in Hazard Study methods
and can provide a licence for the detailed guidance
documents.
Process safety/PRS150a/09/19

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