Industrial companies are currently being confronted with dynamic transformations. Production processes are becoming more modular and flexible, markets demand shorter response times, while requirements for efficiency and sustainability are increasing. At the same time, valuable knowledge is being lost as many experienced professionals retire. This makes comprehensive and reliable risk assessment increasingly difficult, in particular when it is still based on static paper reports or isolated files.
Traditional HAZOP technique captures hazards and their potential impacts, but they are usually static and tied to a specific point in time, often established during construction of the plant. This creates dangerous gaps between documented and actual plant conditions, especially when processes are changed at short notice. In this context, approaches that not only preserve past analyses but also actively interact with live process data are gaining importance. The described method is in its application not limited to modular process plants – it also supports regular plants.
An adaptive approach
The essence of interactive HAZOP (iaHAZOP) lies in merging proven HAZOP principles with modern digital technologies. Rather than relying purely on manual assessments, the system integrates data streams from sensors, digital plant models, and predefined safety rules into a single framework. This transforms static risk assessment into a continuous, adaptive process.
Unlike conventional spreadsheets or document collections, iaHAZOP provides a platform that mirrors the real-time status of a facility. It makes it possible to both access stored safety information quickly and identify hazards instantly. The software is designed to support, not replace, human expertise: automated evaluations provide guidance, but critical decisions remain with qualified staff.
Core components
The functionality of iaHAZOP is built on several technological and methodological pillars, including:
- Digital twins that simulate the behaviour of machines and systems virtually to test scenarios that would pose risks in real operations. These models can be hosted locally or in the cloud.
- Knowledge graphs combine available information such as HAZOP studies, expert knowledge, and incident records into networks, making hidden interrelations visible.
- Real-time sensors continuously provide data on parameters such as pressure, temperature, and flow. Deviations from safe ranges can be detected immediately.
- Hazard rules inform operators on the fundamental physical and chemical properties which need to be observed to prevent potentially hazardous situations.
- Regulatory requirements are integrated into the system so that evaluations are always checked against applicable standards.
These elements combined provide a dynamic and comprehensive perspective on safe plant operation.
A concrete impact
How can run-time risk assessment impact a process facility in the real world? The following examples illustrate incidents where iaHAZOP could have supported in early anticipation or prevention:
- Faulty valve leading to explosion: A valve appeared closed in the control system but was leaking internally due to wear and tear. Because this information was not shared between departments, the hazard went unnoticed, resulting in an explosion due to unwanted backflow. iaHAZOP could have indicated the risk with the help of information sourced from its various core components, such as sensor readings or digital twin simulations.
- Residual pressure in boiler: During maintenance, it was assumed that a vessel was depressurised. Undetected residual pressure caused steam to escape, injuring staff. Cross-checking live sensor data with digital twins would have provided an early warning.
- Outdated risk assessment after process changes: Following operational modifications, risk documentation was not updated. This led to an acid leak, costly cleanup, and weeks of downtime. iaHAZOP would have adjusted the risk status in real time and highlighted the inconsistency.
Benefits for modular and large plants
The process industry increasingly operates in two directions: flexible modular plants and large, complex facilities. In modular plants, each change requires a complete reassessment of risks. iaHAZOP accelerates and standardises these evaluations by applying safety rules automatically to the new configurations. In large, static plants, the system connects data from otherwise isolated departments. This creates a unified view of the actual safety status, making dependencies more transparent and enabling faster intervention in emergencies. But safety is not the only benefit — by mapping hazards and their triggering events (failure modes) semantically, departments beyond just safety gain advantages. Added value is also generated for operations and maintenance teams.
Compliance and documentation
Beyond hazard prevention, iaHAZOP supports companies in meeting legal and organisational requirements. Documentation, which is often time-intensive, can be partially automated. Risk reports can be generated directly from the system, improving transparency and traceability. This reduces administrative burdens and increases legal certainty.
Flexible implementation and outlook
Not all companies have the same digital maturity. iaHAZOP is therefore designed for phased implementation. For operators with more advanced infrastructures, it can be incorporated into the system more promptly, whereas others might need to start small and build up to a modern risk management system progressively.
The long-term vision is to embed safety as an integral part of daily operations rather than treating it as a periodic obligation. By incorporating intelligent analytics into routine workflows, companies foster a culture of foresight that minimises both accidents and downtime.
Conclusion
The demands on risk management in the process industry continue to grow. Traditional methods based on periodic reviews are no longer sufficient. iaHAZOP bridges the gap by combining the strengths of established HAZOP studies with digital capabilities. It provides a real-time view of plant conditions, connects knowledge and data, and empowers experts to make well-founded decisions. In doing so, it shows how safety, productivity, and regulatory compliance can be aligned. Companies adopting such dynamic solutions position themselves to thrive in an increasingly complex environment.
