HAZOP: Guide to Best Practice - 3rd Edition - ISBN: 9780323394604, 9780128035801

HAZOP: Guide to Best Practice

3rd Edition

Authors: Frank Crawley Brian Tyler
eBook ISBN: 9780128035801
Paperback ISBN: 9780323394604
Imprint: Elsevier
Published Date: 21st April 2015
Page Count: 168
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HAZOP: Guide to Best Practice, 3rd Edition describes and illustrates the HAZOP study method, highlighting a variety of proven uses and approaches. This updated edition brings additional experience with which to assist the reader in delivering optimum safety and efficiency of performance of the HAZOP team. HAZOP is the most widely-used technique in the process industries for the identification of hazards and the planning of safety measures.

This book explains how to implement HAZOP techniques in new facilities and apply it to existing facilities. The content covers many of the possible applications of HAZOP and takes you through all the stages of a study. This simple, easily digestible book is a favorite in the chemical and process industries.

Key Features

  • A concise and clear guide to the do's and don'ts in HAZOP
  • New edition brings additional experience to help you deliver optimum safety and efficiency of performance.
  • Updated material includes a section on HAZOP study of a procedure with a detailed example, new sections on pre-meeting with the client auditing a study, human factors and linking HAZOP study to LOPA. A section on start-up and shutdown has been added to the chapter on specific applications of HAZOP.


Functional safety professionals; process engineers; chemical engineers; engineering managers; junior engineers; university students.

Table of Contents

Chapter 1. Introduction

  • 1.1 Aims and Objectives
  • 1.2 Essential Features of HAZOP Study

Chapter 2. Process Hazard Studies

  • 2.1 HS 1—Concept Stage Hazard Review
  • 2.2 HS 2—HAZID at Front-End Engineering Design (FEED) or Project Definition Stage
  • 2.3 HS 3—Detailed Design Hazard Study
  • 2.4 HS 4—Construction/Design Verification
  • 2.5 HS 5—Pre-Commissioning Safety Review
  • 2.6 HS 6—Project Close-Out/Post Start-Up Review
  • 2.7 HS 0—Consideration of Inherently Safer or Less Polluting Systems
  • 2.8 HS 7—Demolition/Abandonment Reviews
  • 2.9 Overview of Hazard Studies
  • 2.10 Illustrative Checklist for HS 2

Chapter 3. The HAZOP Study Method

  • 3.1 Essential Features
  • 3.2 The Purpose
  • 3.3 Limitations

Chapter 4. The Detailed HAZOP Study Procedure

  • 4.1 The Description and Design Intention
  • 4.2 Generating a Deviation
  • 4.3 Identifying Causes
  • 4.4 Evaluating Consequences
  • 4.5 Safeguards (Protection)
  • 4.6 Risk Assessment
  • 4.7 Recommendations/Actions
  • 4.8 Recording
  • 4.9 Continuing and Completing the Analysis
  • 4.10 An Illustration of the HAZOP Study Process

Chapter 5. Organizing a HAZOP Study

  • 5.1 Defining the Scope and Objectives of the Study and Establishing the Boundaries
  • 5.2 Appointing a Team Leader and Selecting the Team
  • 5.3 Preparation

Chapter 6. Carrying Out a Study

  • 6.1 Premeeting with Client
  • 6.2 Planning the Meetings
  • 6.3 The Study Meetings
  • 6.4 Coordinating and Reviewing Responses
  • 6.5 Completing and Signing Off the Report(s)
  • 6.6 Follow-Up of Actions and Management of Change

Chapter 7. Recording and Auditing

  • 7.1 Background Information
  • 7.2 Section Headings
  • 7.3 The Recording Format for the Detailed Examination
  • 7.4 The Level of Recording
  • 7.5 The Content
  • 7.6 Computer Recording
  • 7.7 Auditing a HAZOP Study

Chapter 8. Training

  • 8.1 Team Members
  • 8.2 Scribe
  • 8.3 Team Leader

Chapter 9. Company Procedures for HAZOP Study

Chapter 10. Advanced Aspects of HAZOP Study

  • 10.1 HAZOP Study of Computer-Controlled Processes
  • 10.2 Human Factors
  • 10.3 Linking HAZOP Studies to LOPA

Chapter 11. Specific Applications of HAZOP

  • 11.1 Modification of Existing Operations
  • 11.2 Repeat Designs—HAZOP-by-difference
  • 11.3 Periodic Hazard Studies and the HAZOP of an Existing Plant
  • 11.4 Operating Procedures
  • 11.5 Pilot Plant and Laboratory Operations
  • 11.6 Drains, Vents, and Other Interconnections Between Plants
  • 11.7 Commissioning and Decommissioning
  • 11.8 Start-Up and Shutdown
  • 11.9 Construction and Demolition
  • 11.10 Contract Operations

Chapter 12. Factors for a Successful HAZOP Study

  • 12.1 Throughout the Study
  • 12.2 Before the Study
  • 12.3 During the Study
  • 12.4 After the Study

Appendix 1. The Guideword-First Approach to HAZOP

Appendix 2. The Use of Checklists Within HAZOP Study

Appendix 3. An Illustration of HAZOP Study for a Continuous Operation

  • A3.1 Methanol Injection
  • A3.2 General Process Data
  • A3.3 The Issues
  • A3.4 Methodology

Appendix 4. An Illustration of HAZOP Study for a Batch Operation

  • A4.1 Introduction
  • A4.2 The Company, Site, Plant, and Process
  • A4.3 The Process Stages Selected for HAZOP Study
  • A4.4 HAZOP Study of Steps 9 and 10, the Reaction Stage and Workout
  • A4.5 A Section of the HAZOP Study Report for the Batch Reaction (See Table A4.1)

Appendix 5. An Illustration of HAZOP Study for a Procedure

  • A5.1 Background
  • A5.2 Detailed Proposed Sequence
  • A5.3 The HAZOP Study
  • A5.4 Final HAZOP Study Report
  • A5.5 Authors Notes on this Procedure

Acronyms and Abbreviations

References and Bibliography

  • Bibliography


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About the Author

Frank Crawley

Frank Crawley worked for ICI for 17 years as Plant and Commissioning/Start up Manager on Olefin Plants and “Special Duties Engineer” on Nylon Intermediates. During the latter he was won over to Loss Prevention by the late Trevor Kletz and also to HAZOP by the late Bert Lawley.

After 10 years in the Offshore O & G Industry, retiring from BP, Crawley split his time as LP Consultant and Senior Lecturer in Academe. It was during his time in the O & G industry that he learned different ways in which the HAZOP tool could be used more, particularly the first “Drilling HAZOP” in UKCS some 33 years ago. This in particular revealed a number of deficiencies in the design of drill rigs which produced novel design changes.

HAZOP has been his fascination and he believes that it is a very flexible tool which has more potential for development.Charter Chemical Engineer. 7 Years of experience in Production, Commissioning and Start Up of Olefine Plants (1963 – 70). 10 years of special duties on Nylon Intermediates much as the result of the Flixborough Explosion under the tutelage of the late Trevor Kletz (1970 – 81). 10 years of leading the Loss Prevention group in an oil major (1981- 91). 10 year consultancy in the oil industry (1991 – 2001) and 15 years in Academe (Chem Eng) (1991- 20006). Over 50 refereed technical papers under IChemE and others. IChemE Franklin Medal for teaching Safety at under and post graduate levels. Co-author of the IChemE books: HAZOP: Guide to best practice and Hazard Identification Methods with Brian Tyler.

Affiliations and Expertise

University of Strathclyde and Atkins, UK

Brian Tyler

Brian Tyler established his consulting company with his colleague Bob Simmons in 1990. At that time he was also on the staff of the chemistry department at the University of Manchester Institute of Science and Technology (UMIST). His research work at that time focused on the areas of fire, explosion, self-heating and kinetics, including work on industrially related problems. By 1990 he had over 20 years’ experience of organising meetings and courses under the general heading ‘Safety in the Chemical Industry’. These included HAZOP and HAZAN, Fire and Explosion, Accident Investigation, Gas Dispersion and many others. His course “HAZOP study for team leaders and team members" is still run by the IChemE under the leadership of Phil Aspinall. Another major activity has been the authorship to two IChemE monographs. The first, written with Frank Crawley and Malcolm Preston, is ‘HAZOP, Guide to Best Practice’; the second with Frank Crawley is ‘Hazard Identification Methods’. In 2011 he was one of the first group elected to the newly established class of Associate Fellow of the Institution of Chemical Engineers.Physical chemist. Cambridge University and UMIST. Research into gas phase processes and explosions including self-heating of solids and gases. Organiser of the Safety in the Chemical Industry postgraduate courses held at UMIST from 1969 to 1990, especially covering HAZOP and HAZAN. With S&T Consultants from 1990-2015 delivering training courses on HAZOP and other safety methods within the UK and overseas. Co-author of the IChemE books: HAZOP: Guide to best practice and Hazard Identification Methods.

Affiliations and Expertise

S&T Consultants, UK

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