Platform for the food and beverage industry
In industrial facilities of food processing plants, all sorts of hazards and undesirable situations lurk. In practice, numerous product flows - water, air, oil, chemicals - pass through equipment via valves and instruments. One mistake can have serious and costly consequences. Therefore, it is important to make potential risks manageable. A reliable way to identify this is through a so-called HAZOP study. Christophe Huyghe, Technical Safety Expert at DD Engineering, explains the method and added value.
For more than 30 years, DD Engineering has been a trusted partner for companies in conducting safety and risk assessments. "Our approach is based on four pillars," Huyghe said. "We work around plant engineering, logistics consulting, digital innovation linked to Industry 4.0 and finally translating complex safety legislation into customized solutions. As part of this last pillar, we regularly conduct HAZOP studies."
"HAZOP stands for Hazard and Operability Analysis," Huyghe confirms. "A HAZOP study is a well-known method for identifying hazards and undesirable situations in industrial facilities. It is applied to a chemical or physical process or to the performance of operations. In the first case we focus on process risks, in the second case on human failure. In other words, together with the client, we examine how to turn potential hazards and risks into action points for a safer, more reliable and healthier working environment. By the way, a HAZOP study is typically done when a new plant installation is installed, in order to proactively identify possible weak spots."
Conducting a HAZOP study is becoming more common in the food industry. Huyghe explains: "It used to be mainly chemical companies - more specifically Seveso companies - that did this. Today we notice that production companies in the food sector are also discovering the added value of this tool. For example, with DD Engineering we advise some French fries producers and dairy companies. In the first group, many process flows come together, such as steam, compressed air, cooking oil, water and cleaning products."
To clearly map a process, correct P&IDs are indispensable. "P&ID is short for process and instrumentation diagram," Huyghe explains. "These are diagrams of product flows that pass through the equipment via the necessary valves and instruments, such as flow meters and temperature sensors. Then we cut a process into pieces - so-called 'nodes' or nodes - where we analyze each node in detail in terms of deviations from the normal process."
That analysis is always done at DD Engineering under the direction of two experienced specialists, with strong analytical skills and a solid track record on process safety. "The unique thing about a HAZOP study, by the way, is that a multidisciplinary team takes action to discuss any bottlenecks in the process," says Huyghe. "Such a team is composed of internal people from different disciplines - production, maintenance, engineering, programming, external experts ... - who know the process well. This creates an exciting cross-pollination of ideas and expertise. Through various HAZOP meetings, bottlenecks are discussed, both in terms of safety and reliability." Huyghe admits that such intensive approach comes at a cost. "Freeing up several internal employees during multiple consultation moments effectively comes at a cost. But at the same time, it is an important investment in anticipating potentially dangerous and expensive risks. And that, in turn, can save a lot of money in the long run."
When is a HAZOP study definitely useful? Huyghe cites some criteria: "When your business processes have parameters, such as flows, pressure or temperature, then such analysis is definitely appropriate. We also recommend a study when these processes are complex, with multiple safeguards, and/or when you want to proactively prevent industrial accidents. At DD Engineering we always think along with our clients in order to work out practical and efficient solutions. As an independent partner we suggest the best possible solution suppliers and always go a step further than the minimum legal requirements. That way we go for maximum safety!"
