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Introduction 

The effectiveness of Hazard and Operability (HAZOP) studies depends on the adept orchestration of a diverse team, each member contributing distinct expertise and perspectives. The core roles within the HAZOP team are integral to the efficacy of the study, each playing a pivotal part in unraveling potential hazards and ensuring the safety and operability of complex processes.

While regulations may not explicitly delineate the ideal team composition for Process Hazard Analysis (PHA) or HAZOP studies, Saltegra Consulting’s years of experience have unearthed a fundamental truth: certain roles significantly amplify the value derived from these sessions. Through our expertise, we offer services that can help companies in the USA and abroad assemble a team of experts for their HAZOP studies. Recognizing the importance of these key contributors is paramount to the success of the analysis.

A Multidisciplinary Approach 

The dynamic nature of modern industrial processes demands a multidisciplinary approach to HAZOP studies. HAZOP’s goal is clear: to uncover scenarios where the process may deviate and, in doing so, mitigate risks that could compromise safety, environmental integrity, and overall operational efficacy.

Since the balance between safety and operability is paramount, the effectiveness of the undertaking hinges on the adept orchestration of a multidisciplinary team. The HAZOP process is not merely a checklist to be followed; it is an intricate dance of expertise, where each participant plays a vital role.

This guide prepared by Saltegra Consulting LLC aims to shed light on the nuanced responsibilities of the core team members, providing insights into how their distinct contributions collectively lead to a comprehensive exploration of potential hazards.

The Facilitator 

At the forefront of the HAZOP team stands the facilitator, a role that entails dual responsibilities as a project manager and meeting facilitator. Their primary objective is to plan and execute a comprehensive study by orchestrating a team’s efforts effectively. It is crucial for the facilitator to engage in the team selection process, ensuring the facilitation aspect is streamlined.

However, a key aspect to emphasize is that the facilitator should abstain from assuming the role of a technical expert. While possessing technical knowledge is beneficial, the facilitator’s role is to extract pertinent technical information from the team through astute questioning. This ensures a collective exploration of the process without overshadowing the team’s expertise.

The facilitator’s multifaceted role as a project manager and meeting facilitator demands careful navigation. As a project manager, they are required to conduct meticulous planning and execution, which are imperative to ensure the study’s success. This involves coordinating team members, establishing timelines, and managing resources.

Simultaneously, as a meeting facilitator, they must foster an environment conducive to collaborative exploration. This dual role aims to achieve a thorough and effective study, emphasizing the facilitator’s pivotal position in driving the team toward a collective understanding of potential hazards.

The Process Expert 

The linchpin of technical understanding within the team lies with the process design role, typically filled by a process (chemical) engineer. This individual holds the responsibility of elucidating the design intent for each node under scrutiny. In the context of a new design or modification, the process designer is the ideal candidate, while for an existing operating plant, it often falls to the process engineer overseeing the facility.

The process design representative must be prepared to expound on design intricacies and actively participate in discussions related to deviations from the established design intent. Vigilance is essential as they might occasionally feel exposed to scrutiny, necessitating supportive intervention from the HAZOP leader to maintain the study’s effectiveness.

Navigating the intricate web of process dynamics and design intent requires the process design representative to articulate complex engineering concepts to the team. In the context of a new project, this role becomes even more critical, as decisions made during the HAZOP study can significantly impact the project’s trajectory. The process design representative must balance the theoretical understanding of design intent with practical implications, ensuring the team collectively explores potential deviations while adhering to safety and operability principles.

The Operations Expert 

Experience from day-to-day operations is a crucial facet, particularly in studies involving existing facilities. This role can be assumed by a process operator or supervisor. Selecting an operations representative requires considering the breadth and depth of their experience, along with their willingness and capability to navigate the meeting room environment.

Challenges may arise in maintaining continuity due to shift-based operations, introducing potential disruptions to group dynamics. The HAZOP leader must be attuned to signs of discomfort or stress, offering timely support when required.

The operations role serves as a bridge between theoretical design and practical implementation. While process designers focus on the design intent, operations representatives bring valuable insights into the day-to-day challenges of running a live process. Their frontline experience contributes a practical dimension to the study, ensuring the team explores deviations not only from a design perspective but also in the context of real-world operational challenges.

The inherently dynamic nature of operations, often dictated by shift-based schedules or rotational arrangements, introduces unique challenges. The identity of operations representatives may change, bringing new perspectives but also potential disruptions to group dynamics. The HAZOP leader’s role becomes crucial in navigating these changes, ensuring that the transition is smooth and that the team benefits from the varied experiences brought in by different operations representatives.

The Instrumentations and Control Expert 

In the ever-evolving landscape of industrial processes, the role of a person knowledgeable about instrumentation and control systems is paramount. This expert contributes insights into the intricacies of control systems, ensuring the HAZOP study comprehensively considers potential deviations related to instrumentation. This role requires a keen understanding of control logic, sensors, and actuators, providing valuable perspectives on how deviations in these systems could impact overall process safety.

For both new projects and existing facilities, the instrumentation and control systems expert plays a pivotal role in evaluating scenarios where control systems may deviate from their intended functionality. Their expertise extends to understanding the logic programmed into control systems, offering valuable input on potential failure modes and the implications for safety. Collaboration with the process design and operations roles becomes essential to ensure a holistic exploration of deviations involving instrumentation and control systems.

The dynamic nature of control systems introduces a layer of complexity to the HAZOP study. Changes in setpoints, sensor failures, or communication issues within control systems can have profound effects on process safety. The instrumentation and control systems expert must navigate these intricacies, providing the team with a nuanced understanding of how deviations in this realm can cascade through the overall process.

The Scribe

The often undervalued yet indispensable role of the scribe is to translate real-time discussions into an accurate, comprehensive, and readable record. This is achieved through the meticulous generation of HAZOP worksheets, capturing the essence of the team’s deliberations. The scribe’s responsibilities extend beyond mere documentation; they play a critical role in maintaining the study’s flow and ensuring discussions are accurately summarized for future reference.

Typically misunderstood in the past, the scribe’s role has gained recognition as an essential component of a successful HAZOP study. The ability to generate real-time records on screen demands strong concentration, listening skills, and literacy proficiency. The recorder’s aptitude for anticipation and timing is crucial, enabling them

to produce succinct summaries that enhance the overall efficiency of the study. It is imperative to understand that the recorder’s role is fundamentally different from that of the facilitator, necessitating a dedicated individual for optimal results.

Many organizations in the USA have requested services from us to help them assemble a team of experts for their HAZOP studies. As a trusted consultant, we know that careful selection of the scribe is paramount, considering attributes such as concentration, listening skills, literacy proficiency, technical background, and a keen sense of anticipation.

Young engineering graduates often embody such attributes, bringing enthusiasm and a fresh perspective to the role. While typing skills are important, they pale in comparison to the cognitive skills required for effective recording. Attempts to use nontechnically trained individuals or solely rely on typing skills have proven ineffective, highlighting the nuanced nature of the recorder’s responsibilities.

Tailoring the Core Roles 

While the core roles of facilitator, process design representative, operations role, instrumentation and control systems expert, and recorder form the backbone of a competent HAZOP team, additional considerations are vital to address specific aspects of the study.

Project Engineer 

The inclusion of a project engineer in the HAZOP team may be warranted, particularly when the study is deemed critical or concerns arise regarding process design quality. The project engineer brings a unique perspective, aligning the study with budgetary constraints and timelines. However, caution is advised as the project engineer’s primary focus on financial and temporal aspects may inadvertently divert attention from the creative exploration of process design intricacies.

The project engineer’s involvement necessitates a delicate balance between financial prudence and the need for a comprehensive understanding of potential deviations. Their insights into budget constraints and project timelines are valuable, but it’s essential to ensure that the HAZOP study maintains its exploratory nature, uncovering scenarios beyond the confines of financial considerations.

Vendor 

In scenarios involving vendor-supplied equipment, the inclusion of a specialized team member with intricate knowledge of the equipment design is crucial. Typically, this role is filled by an engineer from the vendor organization. Their involvement, however, should be confined to the study of their equipment and its interfaces with the main process. The HAZOP leader must adeptly navigate potential challenges, including the vendor engineer’s defensive stance and the potential involvement of a commercial representative in discussions surrounding equipment modifications.

Vendor-supplied equipment introduces a unique set of challenges and considerations. The vendor engineer’s expertise is invaluable in understanding the intricacies of the supplied equipment, ensuring the HAZOP study comprehensively evaluates potential deviations specific to these components. The HAZOP leader’s role becomes pivotal in facilitating open communication and collaboration while avoiding conflicts of interest.

Equipment Design Expert 

Assessing equipment vulnerabilities and conditions falls under the purview of a team member with specialized knowledge and experience in equipment design. In new projects, this role often involves an engineer with expertise in mechanical design, while in the context of existing facilities, it may be the engineer responsible for maintenance or asset integrity. Understanding the design conditions of equipment and evaluating its current state are critical for uncovering scenarios where equipment failure could lead to loss of containment.

This role acts as a bridge between theoretical design specifications and the real-world condition of equipment. The team member responsible for equipment design and condition brings insights into potential failure modes, considering factors such as age, maintenance history, and vulnerabilities to corrosion or erosion. By considering the intricacies of equipment specifications and the practical aspects of wear and tear, the team gains a holistic perspective on potential deviations that could compromise safety and operability.

Safety Managers 

In some organizations, the inclusion of a safety manager or a process safety technical authority in the HAZOP team is a requirement. This aligns with the logic that HAZOP is intricately linked with the realm of process safety. However, not all safety managers are well-versed in process safety, and their inclusion might burden the facilitation load without substantial value addition. On the other hand, a process safety manager or technical authority could bring valuable knowledge and experience to the team, especially if they have an understanding of the facility in relation to major hazards regulations.

The necessity of a safety manager or technical authority depends on their ability to contribute significantly to the team’s expertise. A safety manager without specialization in process safety may not bring substantial value, potentially becoming an additional facilitation burden. While their knowledge of major hazards regulations can be beneficial, it might not be adequate to justify a constant presence. In such cases, having the safety manager on call or remotely accessible when required might be a more efficient approach.

In HAZOP studies, where the objective is to uncover ways the process can deviate from normal operation, the equipment design and condition role is pivotal. It ensures that the team explores deviations not only from a theoretical design perspective but also by considering the practical implications and potential challenges posed by the equipment in real-world operational scenarios.

Ideal Team Size 

The delicate balance of team size plays a pivotal role in session efficiency. Industry-tested and proven, a team comprising 8 to 10 members emerges as the sweet spot for PHA/HAZOP studies. This range ensures optimal participation, harnessing the diverse expertise of each member without compromising the efficiency of the session. Beyond this threshold, challenges may arise, diluting the collaborative essence of the exercise.

In shaping the team, it is not just about numbers but about fostering an environment where every member actively contributes. Acknowledging this, a carefully crafted script serves as a gentle reminder to those involved in assembling the team. By imparting the knowledge that 8 to 10 members are ideal, the script tactfully communicates that this number strikes the perfect chord between inclusivity and efficiency, maximizing the effectiveness of the session.

Harmonizing Team Expertise 

In the evolving landscape of HAZOP studies, the intricate facilitation of diverse roles within the team defines the success of the endeavor. The facilitator, process design representative, operations role, instrumentation and control systems expert, and scribe, when harmoniously orchestrated, create a synergy that unravels potential hazards and ensures the safety of complex processes.

The challenges inherent in coordinating a team with diverse expertise underscore the pivotal role of the HAZOP leader. The team composition is instrumental in navigating the intricacies of modern processes. As industries advance and technologies evolve, the HAZOP study remains a linchpin in ensuring safety and operability.

In conclusion, meticulous procedural adherence alone cannot guarantee the success of HAZOP studies. The true essence lies in the harmonious synergy of a well-balanced and expertly guided team.

Saltegra Consulting LLC offers services to companies in the USA and abroad looking to assemble a team of experts for their HAZOP studies. We recognize the unique strengths each member brings and help our clients embark on a journey of comprehensive exploration and safeguarding the integrity of complex processes.