Using the HAZOP Method to Conduct a Risk Assessment on the Dismantling of Large Industrial Machines and Associated Structures: Case Study

Abstract

This paper presents a method that can be used to conduct a safety risk assessment prior to the dismantling of large bulk materials handling machines. The method was developed during a dismantling project that involved the decommissioning and dismantling of two shiploaders and two stacker reclaimers that had been in operation for more than 40 years. The hazard and operability (HAZOP) risk assessment method was selected as a suitable risk assessment method. A research gap related to the availability of suitable HAZOP guide words for the safe dismantling of these machines was identified early in this project. The research method included (1) confirming the appropriateness of the HAZOP risk assessment method for this application; (2) the development and testing of a context-specific set of guide words, with input from appropriate standards; (3) applying these guide words to the dismantling HAZOP for the shiploaders; (4) incorporating lessons learned into the guide words and process for the HAZOP for the stacker reclaimers; and (5) presenting a proposed set of guide words. The proposed set of guide words may be practically applied in any dismantling project that involves large outdoor machines where the dismantling process includes a significant amount of rigging and lifting.