SAFETY AND SECURITY
REVIEW FOR THE
PROCESS INDUSTRIES
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SAFETY AND SECURITY
REVIEW FOR THE
PROCESS INDUSTRIES
Application of HAZOP, PHA
and What-If Reviews
2nd Edition
Dennis P. Nolan
N o r w i c h , N Y, U S A
Copyright © 2008 by William Andrew Inc.
No part of this book may be reproduced or utilized in any form or by any means, electronic or me-
chanical, including photocopying, recording, or by any information storage and retrieval system,
without permission in writing from the Publisher.
ISBN: 978-0-8155-1546-3
Library of Congress Cataloging-in-Publication Data
Nolan, Dennis P.
Safety and security review for the process industries : application of HAZOP, PHA and what-if
reviews / Dennis P. Nolan. -- 2nd ed.
p. cm.
Rev. ed. of: Application of HAZOP and What-If safety reviews to the petroleum, petrochemical
and chemical industries. c1994.
Includes bibliographical references and index.
ISBN 978-0-8155-1546-3
1. Chemical engineering--Safety measures. I. Nolan, Dennis P. Application of HAZOP and What-
If safety reviews to the petroleum, petrochemical and chemical industries. II. Title.
TP150.S24N65 2008
660’.2804--dc22
2008007932
Printed in the United States of America
This book is printed on acid-free paper.
10 9 8 7 6 5 4 3 2 1
Published by:
William Andrew Inc.
13 Eaton Avenue
Norwich, NY 13815
1-800-932-7045
www.williamandrew.com
NOTICE
To the best of our knowledge the information in this publication is accurate; however the Publisher
does not assume any responsibility or liability for the accuracy or completeness of, or consequenc-
es arising from, such information. This book is intended for informational purposes only. Mention
of trade names or commercial products does not constitute endorsement or recommendation for
their use by the Publisher. Final determination of the suitability of any information or product for
any use, and the manner of that use, is the sole responsibility of the user. Anyone intending to rely
upon any recommendation of materials or procedures mentioned in this publication should be inde-
pendently satisfied as to such suitability, and must meet all applicable safety and health standards.
Dedicated to
Kushal, Nicholas, & Zebulon
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Contents
List of Figures and Tables xi
Preface xiii
1 Purpose 1
2 Scope 5
3 Objective and Description of PHA, What-If,
and HAZOP Reviews 7
3.1 Definition 8
3.2 Objectives 8
3.3 Origins of Qualitative Safety Reviews 8
3.4 Limitations or Disadvantages 9
3.4.1 Limitations 9
3.4.1.1 Preliminary Hazard Analysis 9
3.4.1.2 What-If Reviews 10
3.4.1.3 HAZOP Reviews 10
3.4.2 Advantages 11
3.4.2.1 Preliminary Hazard Analysis 11
3.4.2.2 What-If Reviews 11
3.4.2.3 HAZOP Reviews 11
4 Adaptation to Security Vulnerability Analysis (SVA) 13
4.1 Comparison to Process Hazard Analysis Reviews 14
4.2 Overall Procedure for SVA 14
4.3 Major Differences between SVA and Process
Hazard Analyses 14
4.4 Necessity of Threat Analysis 15
5 Team Members, Qualifications, and Responsibilities 17
5.1 Team Members 17
5.1.1 Minimum Team Members 18
5.1.2 Supplemental Members 19
5.2 Qualifications of Team Members 20
5.2.1 Team Leader 20
5.2.2 Scribe 20
5.2.3 Project Manager (Project, Process,
Manufacturing, or Facility Engineer) 20
vii
viii Contents
5.2.4 Operations Representative 21
5.2.5 Loss Prevention or Safety Representative 21
5.2.6 Security Officer or Representative (for SVA) 21
5.2.7 Supplemental Team Member 21
5.3 Team Responsibilities 21
5.3.1 Team Leader 22
5.3.2 Scribe 22
5.3.3 Project Manager (Project, Process,
Manufacturing, or Facility Engineer) 23
5.3.4 Operations Representative 24
5.3.5 Loss Prevention or Safety Representative 24
5.3.6 Security Officer or Representative (for SVA) 24
5.3.7 Supplemental Team Member(s) 25
5.4 Team Dynamics 25
5.4.1 Leadership Influences 25
5.4.2 Lines of Communication 26
5.4.3 Efficiency Factors 26
5.5 Use of Consultants 28
5.5.1 Qualifications 28
5.5.2 Advantages 29
5.5.3 Disadvantages 29
5.6 Record of Employee Experience 30
6 Management Support and Responsibilities 31
7 Review Applications for Typical Facilities 33
7.1 PHA Review Applications 34
7.2 What-If Review Applications 35
7.3 HAZOP Review Applications 35
7.4 SVA Review Applications 37
7.5 Application during Changes at a Facility 39
8 Review Procedures 41
8.1 Review Preparation and Setup 41
8.1.1 Location 41
8.1.2 Administrative Support 41
8.1.3 Facility Documentation 42
8.1.4 PHA Consequence and Likelihood Data Resources 47
8.1.5 SVA Threat Analysis Data Resources 47
8.1.6 Computer Hardware and Software Support 47
8.1.7 Node Identification 49
8.1.8 SVA Area Identification 50
