The HAZOP technique has been in use for many years and has proven to be an excellent tool to help identify process hazards, allow companies to control major accident risks and prevent operability issues.
The technique has traditionally been applied during projects and modifications. However, an increasing use of the HAZOP technique is to apply it in a ‘retrospective’ manner to existing facilities and not only on new projects or for modifications. BP require HAZOPs to be conducted on their existing assets in order to ensure that they are operated to the highest safety standards.
ABB Consulting were approached by personnel at the BP CATS gas terminal to conduct a retrospective HAZOP. This involved utilising an experienced HAZOP leader and scribe from ABB, BP process and mechanical engineers, senior operators and other specialist disciplines. The study was conducted over a number of months utilising a highly structured approach to HAZOPs.
BP CATS Terminal, Teesside, UK.
BP have set new, higher standards for conducting HAZOPs. HAZOP is a rigorous, searching technique and when applied utilising a multi-disciplined team can help identify many issues that the original designers may have overlooked. Similarly, personnel who have operated and maintained such processes can highlight problems they have faced during day to day operations.
Many recommendations are generated from such an in depth, critical review of production facilities. The recommendations are aimed at continually reducing risks to as low as reasonably practicable levels such that incidents are prevented and companies continue to operate successfully.
The partnership between ABB skilled HAZOP resources and BP’s experienced operations personnel can yield significant business benefits for successful continued operation.
A retrospective HAZOP provides BP with a new ‘baseline’ study which can further be used and kept ‘evergreen’, as future process improvements are identified and subjected to the HAZOP methodology. The HAZOP report thereby becomes a living document that reflects current understanding of hazards and risks.
ABB is now supporting BP CATS in the close out of the actions. This is a prioritised programme of work to ensure that the risk reduction benefits of the HAZOPs are fully realised in a timely manner.