Dynamic Simulations
Process Control
Process Engineering
HAZOP - LOPA studies

PCA-PROCESS consultancy is specialised in process safety management and risk assessment. With extensive experience across various industries, we are dedicated to helping our clients achieve the highest standards of safety and operational excellence. Our team of certified and highly experienced facilitators provides expert guidance in critical safety studies, ensuring compliance with international standards and best practices.

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PCA-PROCESS offers comprehensive HAZOP and LOPA facilitation services, designed to systematically identify, evaluate, and mitigate process hazards and risks, thereby enhancing the safety and reliability of your operations.

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HAZOP Study Facilitation

Our HAZOP facilitation service provides a structured and systematic examination of a planned or existing process or operation to identify and evaluate potential hazards and operability problems.

• Pre-Study Preparation:

  • Review of relevant documentation (P&IDs, PFDs, operating manuals, design specifications, cause & effect matrices).

  • Definition of study scope, objectives, and boundaries in collaboration with the client.

  • Selection and briefing of the HAZOP team members.

  • Development of a detailed HAZOP agenda and schedule.

  • Preparation of HAZOP worksheets and tools.

• HAZOP Workshop Facilitation:

  • Professional and impartial facilitation of HAZOP workshops, guiding the team through the systematic application of guide words to process parameters.

  • Ensuring active participation and consensus among team members (operations, engineering, maintenance, safety).

  • Systematic identification of deviations, causes, consequences, existing safeguards, and recommendations.

  • Documentation of all discussions, findings, and actions in real-time.

• Post-Study Activities & Reporting:

  • Consolidation and formalisation of HAZOP findings and recommendations.

  • Preparation of a comprehensive HAZOP report, including identified hazards, risks, existing safeguards, recommended actions, and responsible parties.

  • Presentation of the HAZOP report to relevant stakeholders.

  • Support in tracking and closing out recommendations (optional, as per client request).

 

LOPA Study Facilitation (IEC 61511 Compliant)

Our LOPA facilitation service builds upon the HAZOP findings to quantitatively assess the risk of identified scenarios and determine the necessary Safety Integrity Level (SIL) for Safety Instrumented Functions (SIFs), strictly adhering to the principles outlined in IEC 61511.

• Pre-Study Preparation:

  • Review of HAZOP output and other relevant safety documentation.

  • Identification and selection of high-consequence scenarios from the HAZOP for LOPA analysis.

  • Definition of risk tolerance criteria and target SILs in line with client's safety policies and IEC 61511.

  • Selection and briefing of the LOPA team members.

  • Preparation of LOPA worksheets and tools.

• LOPA Workshop Facilitation:

  • Expert facilitation of LOPA workshops, guiding the team through the systematic analysis of selected scenarios.

  • Identification and evaluation of Independent Protection Layers (IPLs) for each scenario, ensuring they meet the independence, effectiveness, and auditability criteria as per IEC 61511.

  • Quantitative assessment of the likelihood of initiating events and the Probability of Failure on Demand (PFD) for each IPL.

  • Calculation of the mitigated risk and comparison against predefined risk tolerance criteria.

  • Determination of the required Safety Integrity Level (SIL) for Safety Instrumented Functions (SIFs) where existing IPLs are insufficient to achieve the target risk.

  • Documentation of all LOPA calculations, assumptions, and conclusions.

• Post-Study Activities & Reporting:

  • Consolidation and formalisation of LOPA findings, including SIL assignments.

  • Preparation of a detailed LOPA report, documenting the analysis for each scenario, IPLs, calculations, assumptions, and SIL requirements.

  • Presentation of the LOPA report to relevant stakeholders.

  • Support in developing Safety Requirements Specifications (SRS) for SIFs based on LOPA outcomes (optional).

 

IEC 61511 Compliance Integration

Throughout both HAZOP and LOPA processes, PCA-PROCESS ensures:

• Lifecycle Approach: Alignment with the safety lifecycle phases as defined in IEC 61511.

• Competence: Facilitators possess the necessary competence and experience as required by the standard.

• Documentation: Rigorous documentation practices to provide clear, auditable records for the functional safety lifecycle.

• Risk Reduction: Focus on identifying and implementing adequate risk reduction measures, including SIFs where necessary, to achieve tolerable risk levels.

• IPL Validation: Strict evaluation of IPLs against IEC 61511 criteria for independence, effectiveness, and auditability.

 

Methodology

Our approach is collaborative, systematic, and data-driven:

• Structured Workshops: Utilizing proven methodologies and proprietary tools to ensure efficient and effective workshops.

• Experienced Facilitators: Leveraging the expertise of our certified facilitators to guide discussions, manage dynamics, and ensure thorough analysis.

• Client Engagement: Fostering active participation from client teams to leverage internal knowledge and ensure ownership of outcomes.

• Best Practices: Adhering to industry best practices and international standards (e.g., IEC 61511, CCPS guidelines).

• Clear Documentation: Providing transparent and comprehensive documentation of all findings and recommendations.

 

Key Benefits of Partnering with PCA-PROCESS

• Enhanced Safety: Systematic identification and mitigation of process hazards, leading to a safer operating environment.

• Regulatory Compliance: Assurance of compliance with IEC 61511 and other relevant safety regulations.

• Optimised Design & Operations: Identification of potential operability issues and opportunities for process improvement.

• Reduced Risk: Quantitative assessment of risks and determination of appropriate safeguards, including SIL assignments for SIFs.

• Cost Efficiency: Preventing costly incidents, downtime, and regulatory fines through proactive risk management.

• Expert Guidance: Access to highly qualified and experienced process safety professionals.

• Improved Decision-Making: Providing robust data and analysis to support critical safety-related decisions.

 

Deliverables

Upon completion of the services, the client will receive:

• HAZOP Study Report: A comprehensive document detailing the HAZOP findings, including identified hazards, causes, consequences, existing safeguards, and recommended actions.

• LOPA Study Report: A detailed report outlining the LOPA analysis for selected scenarios, including initiating event frequencies, IPL PFDs, mitigated risk calculations, and assigned SILs for SIFs.

• Workshop Documentation: All raw workshop notes, worksheets, and attendance records.

• Presentation: A summary presentation of key findings and recommendations.

 

Our Team & Expertise

PCA-PROCESS facilitators are certified professionals with extensive experience in process safety, risk assessment, and functional safety. Our team members possess:

• Deep understanding of process engineering, operations, and safety principles.

• Proven track record in complex HAZOP and LOPA studies across diverse industries.

• In-depth knowledge and practical application of IEC 61511 for functional safety.

• Strong communication and interpersonal skills to effectively manage workshop dynamics.

 

Client Responsibilities

To ensure the successful execution of the studies, the client will be responsible for:

• Providing all necessary documentation (P&IDs, PFDs, equipment specifications, operating procedures, incident reports, etc.) in a timely manner.

• Assembling and ensuring the availability of a competent and multi-disciplinary HAZOP and LOPA team.

• Providing suitable meeting facilities and necessary technical support during workshops.

• Reviewing and providing feedback on draft reports.

• Implementing the agreed-upon recommendations.

 

Pricing & Terms

Pricing for our HAZOP and LOPA facilitation services is determined based on the scope, complexity, duration of the studies, and the number of required facilitators. A detailed proposal, including a breakdown of fees and payment terms, will be provided upon review of your specific project requirements.

 

Next Steps

To discuss your specific HAZOP and LOPA facilitation needs and receive a tailored proposal, please contact us at info@PCA-PROCESS.com