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Foil HAZOP Failings

Poor preparation and follow-up undermine safety reviews

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Appropriate action on most items flagged in a hazard and operability (HAZOP) evaluation too often doesn’t take place before the next HAZOP. Some key items from the checklist will roll into projects and process studies but the vast majority will get ignored. That’s the harsh reality that I’ve witnessed over and over again for more than thirty years. For instance, two years after a HAZOP, I found plant staff hadn’t touched 90% of the items from a chlorine checklist. (By the way, I was able to reduce that number to 10% in only three months.) Why does this happen?Well, the most obvious reason is personnel are busy and management doesn’t have the resources. The…

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