Hazard And Operability (HAZOP) Studies
We understand that the efficient identification of potential hazards, ensuring regulatory compliance and improved operational safety and reliability is fundamental to the success of your operation. Even the best design may not mitigate every risk without a structured methodical approach, leading to equipment damage, production downtime, serious accidents or regulatory fines.
Our multi-disciplinary team brings deep experience across food and beverage, dairy, brewing, and industrial sectors, combining practical know-how with experienced HAZOP facilitation and scribing competence.
Why HAZOP Matters
As the global benchmark for process hazard analysis, a HAZOP study is a structured, guideword-driven workshop that systematically explores credible deviations from design intent or normal operations to identify causes, consequences, safeguards, and required subsequent actions. The benefits of a good HAZOP during the design phase extend across the entire project lifecycle and to existing operations. It reduces costly late-stage design changes, prevents operational disruptions, and ensures compliance with regulatory requirements, and potential failure outcomes.
By identifying risks early, HAZOPs enable companies to plan and deliver safer, more efficient projects and improve long-term operational reliability. In addition to the normal detailed design review, a HAZOP workshop can also help your team carry out root cause analysis/ incident reviews, map out the impacts of non-standard operations or support the Management of Change process.
Our HAZOP Studies Approach
We deliver HAZOP Studies that are efficient, collaborative, and scalable, whether for a single production line on site or multi-location, multi-stage projects. We manage the entire process from preparation to close-out, ensuring your team’s time is used effectively and outcomes are actionable. TEG has experience facilitating the traditional in-person workshop, as well as a hybrid approach incorporating online or remotely linked meeting venues across time zones and international borders.
- Scoping & Terms of Reference (ToR) - we take care to define objectives, boundaries, and team roles
- Pre-Work Review - we undertake a desktop review of P&IDs, layouts and process descriptions
- Facilitation - we lead structured workshops using guidewords to identify hazards and operability issues
- Action Management - we prioritise and assign actions for resolution, holding stakeholders accountable to agreed deadlines
- Close-Out Deliverables - we deliver comprehensive reporting and documentation to demonstrate practicable outcomes are achieved in a timely manner
Safety in Design – Tauriko Greenfield Winstone Wallboards Gib Plant
Winstone Wallboards (WWB), part of the Fletcher Building group, planned to construct a large greenfield plasterboard plant (GIB) to supply plasterboard to the NZ construction market. They needed to ensure the highest safety standards were achieved and that the equipment coming out of Europe and North America would comply with NZ standards. Prior to the installation of equipment in the new facility, TEG Risk facilitated Process Safety HAZOP’s (Hazard And Operating Analysis) across all plant areas where Process Safety Risk existed. This commenced during COVID lockdowns of 2020 and 2021 so the HAZOP’s were facilitated over video call with teams located in Canada, Sweden, Germany and multiple New Zealand locations.
Detailed assessments and improvement actions were identified, which the supplier and WWB then integrated into the new Gib plant design.
What Is The Difference Between HAZOP And Risk Assessment?
A HAZOP (Hazard and Operability Study) is a type of Risk Assessment. It's a very structured, guideword driven process used to identify potential hazards and operability issues that may come from deviations away from the design intent.
A risk assessment, on the other hand, is a broader evaluation that identifies hazards, analyses their likelihood and consequences, and prioritises actions to control overall risk.
What Are The Four Stages of HAZOP?
The four main stages of a HAZOP (Hazard and Operability Study) are:
- Preparation – Define the scope, assemble a multidisciplinary team, gather process information, and set objectives.
- Examination – Systematically review the process using guide words to identify deviations, hazards, and operability issues.
- Documentation – Record findings, potential consequences, existing safeguards, and recommendations for improvements.
- Follow-up – Implement and track corrective actions, verify effectiveness, and update the study as processes or regulations change.
Why Choose TEG Risk To Manage Your HAZOP Requirements?
We Are Safety Engineering Experts
When it comes to safety engineering, TEG Risk's world class team is highly skilled in technical, industrial workplace health and safety.
Our Engineers have extensive, specialist and practical industry experience supported by a variety of industry leading training and certifications in machinery, functional safety, HAZOP and Hazardous Areas.
We Are Experienced Engineers
We have decades of experience between us, and pride ourselves on practical solutions.
As experts in specification, planning, prioritisation and project management, we always suggest solutions and programmes that not only comply, but are practical and make the best use of your resources and budget.
We Add Value To Your Workplace Safety
Our team identifies and prioritises risks using structured assessments and advanced tools like MinRisk, then translates findings into cost-effective, actionable plans.
Whether it's machine guarding, hazardous area compliance, or safety in design, we help clients reduce incidents, meet regulatory obligations, and protect their most valuable asset: their people.
We Work As Part Of Your Health And Safety Team
We tailor our processes and reporting to suit your team's requirements. Stakeholder engagement is a priority for us and we spend time on the factory floor, talking to your operators and understanding your processes to deliver the exact solutions your company needs.
We establish your objectives and how best to deliver those, so we work efficiently and effectively, minimising disruption and providing results or outcomes that you can more easily integrate into your existing systems.