Smart HAZOP

Smart HAZOP – Innovate & Digitalize
Er. Srinivasan Premkumar

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Speaker/Author Director & Chief Process Safety Specialist
ALARP Process Safety Solutions
Disclaimer
No part of the material contained in the paper shall constitute a standard, or an

endorsement, recommendation or definitive guidance. Nothing in the paper shall
be directly applied without an independent professional advice. Though every
effort has been taken to assure the accuracy and reliability of the content,
neither the author nor the organization under which he is employed takes
responsibility for any errors or omissions.
HAZOP Review
• Hazard and Operability (HAZOP) review is a

commonly applied hazard identification
methodology in the process industries
• The primary objective is to identify the Safety,

Health, Environment (SHE) hazards and
operability concerns
• The methodology is in-use for more than 50 years

Case for Action
• The HAZOP review provides the

opportunity to identify the SHE hazards
so that adequate control measures can be
put in place
➢ Team based brainstorming activity
➢ Quality depends on the team
members knowledge, skills and
work experiences
➢ Challenge for the organizations to
retain team members with right
knowledge, skill-set and experience in
each discipline/role
Case for Action
• The existing work process is not robust enough to codify the lessons learnt from
the past process safety incidents/near misses
➢ Relies on the team members knowledge to incorporate the learnings
• The HAZOP review duration may range between a couple of hours and multiple
weeks, depending on the scope
➢ Time consuming activity with multiple people involved
➢ For a longer duration, there is a potential to have fatigue which may
potentially affect the quality
Innovation
• With the application knowledge and experience gained

over the last 50 years, it is possible to codify the
requirements into a software
• With the advanced software capabilities and by

embracing innovative ideas, there is a possibility to
automatically complete the HAZOP review using a
software
• It is time for ‘Smart HAZOP’

Smart HAZOP
• Critical Components
➢ Base Documents
➢ Software
➢ Grouping of Hazards and Concerns
• Methodology
Base Documents
• The critical information required for

the HAZOP review can be found in the
➢ Piping & Instrumentation Diagrams
(P&IDs) and
➢ Plot Plans
• The P&IDs and the Plot Plans will be

used as the base documents in the
Smart HAZOP
➢ Similar to conventional HAZOP
Software
• A software system with advanced technical

capabilities is required for the Smart HAZOP
• The software should be able to transfer the

critical information from the base
documents to a virtual interactive
platform where the review takes place
• The interactive platform should be able to hold

a database of information and be able to
perform the required algorithms and
complete the HAZOP review
Grouping
• The SHE hazards and the operability concerns that could be possibly present in
any process facility can be grouped into:
➢ Equipment (e.g. compressor, fired heater)
➢ Process Material (e.g. flammable, cryogenic)
➢ Process Technology (e.g. runaway reaction)
➢ Hazardous Inventory (e.g. storage quantity)
➢ Siting & Layout (e.g. atmospheric vent discharge)
➢ Activity (e.g. routine, non-routine)
• A comprehensive database should be developed for each of the above groups

and included in the software
Methodology
• The software transfers the facility details from the

base documents to the virtual interactive
environment
➢ The User defines the ‘HAZOP Node’
• The software compares the pre-loaded database

against the facility design details and completes the
HAZOP review with a ‘click of a button’
• If a gap is identified, the software suggests the

appropriate recommendation/s
Discussion
• The HAZOP review is one of the critical tools that provides the handle to the
process industries to identify the SHE hazards so that the hazards can be
managed properly
• It is important to ensure that the rigor of the HAZOP review is not affected by the
variations in the team members knowledge, skills and work experiences
• With the application knowledge and experience that has been gained by the
industry practioners over the last 50 years, there is a possibility to automate the
HAZOP review
Summary
• Smart HAZOP has the potential to enable us to:

➢ Automatically complete the HAZOP review
and develop recommendations of higher technical
quality
➢ Codify the lessons learnt from the past
process safety incidents/near misses so that the
hazards and the concerns can be addressed, and
similar events can be prevented from occurring
again in the future
➢ Significantly improve the work process
efficiency through automation
Acknowledgements
• Thanks to all my friends, colleagues, ex-colleagues and the HAZOP review team
members with whom I had great interactions while chairing the HAZOP reviews
for the past 14 years
• Thanks to Creative Commons for making the pictures (used in this presentation)
publicly available for use
Thanks and Questions

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Smart HAZOP – Innovate & Digitalize

Er. Srinivasan Premkumar

No part of the material contained in the paper shall constitute a standard, or an

• Hazard and Operability (HAZOP) review is a

• The primary objective is to identify the Safety,

• The methodology is in-use for more than 50 years

• The HAZOP review provides the

• With the application knowledge and experience gained

• With the advanced software capabilities and by

• It is time for ‘Smart HAZOP’

• The critical information required for

• The P&IDs and the Plot Plans will be

• A software system with advanced technical

• The software should be able to transfer the

• The interactive platform should be able to hold

• A comprehensive database should be developed for each of the above groups

• The software transfers the facility details from the

• The software compares the pre-loaded database

• If a gap is identified, the software suggests the

• Smart HAZOP has the potential to enable us to:

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