Risk + Safety + AMC

Mechanical Asset Integrity Programmes

Q: How long does a typical HAZOP take?

A small unit (< 200 P&ID line items): 3-5 days workshop + 4-6 weeks reporting. A full refinery process unit: 2-4 weeks workshop + 8-10 weeks reporting. Cycle time depends heavily on P&ID readiness.

Q: What's the link to SIL and LOPA?

HAZOP identifies hazardous deviations + raises safeguard recommendations. Where safeguards are insufficient, SIL/LOPA quantifies the risk gap and sizes the Safety Instrumented System (SIS) needed to close it.

Q: Do you handle re-HAZOP only, or first-time HAZOP for new units?

Both. First-time HAZOP is typically done at 90% engineering design (before procurement). Re-HAZOP is done every 5 years and after any major MOC. Our chair pool covers both.

Q: Will you also handle the recommendation closure tracking?

Yes · we offer recommendation tracking as part of the 5-year Safety AMC retainer. Quarterly review of open items + escalation to plant safety committee. Critical for actually closing the recommendations, not just raising them.

Process hazard analysis · structured deviation review of every node.

Guideword-driven, node-by-node, deviation-by-deviation. HAZOP led by a CEng MIE India-qualified chair, supported by your operations and process engineering team. IEC 61882 compliant. Recommendations tracked to closure. The foundation for SIL and LOPA.

Why this matters

Why HAZOP can't be done from drawings alone · and why most third-party reports miss this

A good HAZOP requires more than a credentialled chair and a copy of IEC 61882. It requires P&IDs that match field reality (most don't), a knowledge of your operating procedures (most third-party chairs don't), and a discipline of capturing recommendations that survive into closure (most reports don't). Our HAZOP delivery is structurally different · we update the P&IDs first if needed, the chair reads the operating procedures before the workshop, recommendations track to closure with named owner and date. The output is not a 200-page PDF that gets filed; it's a recommendation register that drives real change.

Method

How we deliver Mechanical Asset Integrity

CEng MIE India-signed deliverables · LiDAR-powered where applicable · digital twin handover ready · routes to the Risk + Safety + AMC practice lead within 24 hours.

Pre-workshop · P&ID + ops procedure review

P&IDs verified against field. Operating procedures, alarm rationalisation, SIS philosophy reviewed by HAZOP chair.

Workshop facilitation

Node-by-node, guideword-driven (more, less, none, reverse, as well as, part of, other than). Causes, consequences, safeguards captured. Recommendations raised.

Recommendation review

Each recommendation reviewed for actionability, owner, target date. Recommendations escalated to SIL / LOPA as appropriate.

Report + closure tracking

IEC 61882-compliant report. Recommendation register linked to your action tracking system (PHA-Pro, Plant Doctor, your CMMS).

Sign-off + governance

CEng MIE-signed. Re-HAZOP triggered by MOC, every 5 years per standard, or on any significant incident.

Standards + compliance

Built to the standards your auditors quote

Reports reference the international and national standards your regulators, F500 audit teams, and corporate process safety leads cite. Every deliverable signed by a Chartered Engineer (CEng MIE India).

IEC 61882 · Hazard and Operability Studies (HAZOP)
API RP 750 · Management of Process Hazards
OSHA 29 CFR 1910.119 (PSM) · Process Safety Management of Highly Hazardous Chemicals
EU Seveso III Directive (2012/18/EU) · major accident hazards
IS 18001 / IS 17893 (India) · HAZOP guidelines

Anonymous case anchors

What this looks like in production

Three landmark engagements from our verified roster · quantified outcomes, no client names disclosed without written permission.

Refinery, India · CDU re-HAZOP

Crude Distillation Unit re-HAZOP after 5-year cycle + MOC backlog. 87 recommendations · 12 high-severity. All closed within 18 months.

Petrochem, KSA · MOC-triggered re-HAZOP

Steam reformer retrofit triggered HAZOP refresh. New deviation cases (reformer tube rupture) added to existing baseline.

Pharma, USA · GMP + PSM combined HAZOP

Cleanroom + utility HAZOP combined with GMP risk assessment. Single workshop, dual deliverable.

Frequently asked

Mechanical Asset Integrity · the practical questions

Who leads the HAZOP?

A CEng MIE India-qualified chair from our Risk + Safety practice. Always external to your team, always neutral, always familiar with your specific industry and regulatory regime.

How long does a typical HAZOP take?

A small unit (< 200 P&ID line items): 3-5 days workshop + 4-6 weeks reporting. A full refinery process unit: 2-4 weeks workshop + 8-10 weeks reporting. Cycle time depends heavily on P&ID readiness.

What's the link to SIL and LOPA?

HAZOP identifies hazardous deviations + raises safeguard recommendations. Where safeguards are insufficient, SIL/LOPA quantifies the risk gap and sizes the Safety Instrumented System (SIS) needed to close it.

Do you handle re-HAZOP only, or first-time HAZOP for new units?

Both. First-time HAZOP is typically done at 90% engineering design (before procurement). Re-HAZOP is done every 5 years and after any major MOC. Our chair pool covers both.

Will you also handle the recommendation closure tracking?

Yes · we offer recommendation tracking as part of the 5-year Safety AMC retainer. Quarterly review of open items + escalation to plant safety committee. Critical for actually closing the recommendations, not just raising them.

Scope your Mechanical Asset Integrity engagement.

Tell us your plant, region, and scope · a named Chartered Engineer responds within 24 hours.

4 fields. No phone interview to start.
Per-discipline routing to the Risk + Safety + AMC practice lead.
Anonymous case anchors sent with first reply.
Same-day callback for deadline-driven enquiries.

Risk + Safety + AMC Scoping

HAZOP/LOPA/SIL/QRA · 5-year AMC retainer · Practice Lead Safety responds in 24 hr.