HAZOP analysis

In a Hazard and Operability Study (HAZOP), a multidisciplinary team of experts uses a systematic approach to identify potential hazards resulting from deviations between the process design and actual operation of a process plant.  

TÜV SÜD supports customers with the moderation of HAZOP studies and sharing of experience.

The HAZOP team evaluates the causes and consequences of each deviation, existing safeguards, and preventive measures to develop corrective actions.

The HAZOP process is applicable to all types of process plants and useful for both planned and existing plants. It is most effective when conducted during the conceptual design phase, when recommendations affecting the overall design are possible.

HAZOP studies offer a systematic method to improve plant safety and efficiency by considering technical and organisational aspects, potential human error, and external influences.

In addition to determining which safety measures provide real benefits, HAZOP studies can also help identify the best solutions for functional safety systems. The results can reduce the likelihood of costly and time-consuming failures and downtime while increasing operational safety and availability.

TÜV SÜD is an independent and trusted service provider with decades of experience and expertise in conducting HAZOP studies around the world according to IEC 61882 and other systematic analyses. TÜV SÜD supports with traditional HAZOP procedures and methods, but also offers services that utilise the possibilities and advantages of modern digital technologies.

Our renowned experts produce reference books and frequent technical publications on manufacturing assessments. They provide high quality services in the areas of risk analysis, thermal process safety, explosion prevention and protection, electrostatic risk prevention, and product safety for the process industry. 

We pride ourselves on our neutral and objective approach. Our team develops customised safety concepts for you, focusing on optimised cost-benefit solutions and incorporating state-of-the-art know-how.

We comply with the ISO 9001:2008 certified quality management system. What this means for you is a flawless service, both technically and administratively.

HAZOP analysis includes:

• Comprehensive technical advisory services for a systematic analysis
• A competent team with a HAZOP moderator (ISO 17034 accredited) and further experts as required 
• Encouragement of creative solutions
• Thorough documentation of the HAZOP procedure’s results

This HAZOP study can give you the following benefits: 

• Process plant safety
• Enhance plant and resource efficiency
• Reduced downtime caused by incidents
• Less damages to equipment / Failures of equipment

Depending on your needs, we can provide additional customised services to enhance the HAZOP process:

Chemical Laboratories 

• In process manufacturing – such as pharmaceutical, chemical, food, and similar industries – materials go through multiple stages in the production process where problems can arise. Passing different types of materials through industrial processes can lead to unintended consequences if chemicals react in unexpected ways, thermal runaway occurs, or if contaminants enter the process.
• Our ISO 17025 accredited laboratory is available to assist in the determination and evaluation of desired and undesired reactive potentials, safety properties, flammability, electrostatic properties, and characteristic data according to the applicable testing standards. 
• iaHAZOP for Smart Manufacturing and Modular Plants
• Interactive HAZOP (iaHAZOP) translates the knowledge stored in a HAZOP study and the belonging FMEA into the digital world and represents a modern advancement. iaHAZOP enables partial automation of regulatory respectively HSE matters. It also bridges the gap between offline assessment and online operations or planning. Hence, it helps to get much more out of your HAZOP expenses. Moreover, iaHAZOP is connected to the Digital Twin of your plant and provides you with further benefits of digitalisation for example in terms of reporting or predictive maintenance activities.

iaHAZOP during commissioning has the following benefits:

• Accelerate your time to market with ongoing feedback of a digital risk assessor according to the progress of the design phase.
• Speed up your approval process with prefabricated assessments.
• Increased flexibility through modular safety assessments, similar to the structure of modular plants themselves.
• Introduce a plant change to your digital twin and keep your HAZOP automatically up-to-date. 
  
  

iaHAZOP during operations has the following benefits:

• Runtime risk calculation and management to increase operating profitability.
• More resilient operations by identifying events fast, preventing incidents and improving the daily safety life.
• Enhanced decision support in Last Minute Risk Assessments (LMRA).
• Tailored information and warnings important to the attention of the workforce.
• Reduced risk of costly consequences after seemingly harmless modifications in the plant.

Other challenges iaHAZOP can help you manage include:  

• All challenges arising of digitalisation
• Faster changing market requirements 
• Turbulences in supply chains 
• Further efficiency gains
• Tackle shortage of skilled workers and experts