Electrical-HAZOP (Hazard and Operability) and SAFOP (Safety and Operability) studies are essential approaches to Industrial safety. These structured approaches aim to identify possible hazards and operability concerns within Industrial processes. The main goals are to prevent accidents, protect the environment, and ensure the safety of workers and assets.
Objectives of EHAZOP / SAFOP Studies
These studies help achieve key safety and operational objectives:
- Optimize Reliability, Safety, and Operability: Improve plant or facility design to meet operational objectives.
- Identify Major Hazards: Address risks to personnel during the construction, commissioning, and operation of high-voltage installations.
- Front Load Design Process: Reduce rework and modifications by identifying issues early in design, ensuring budget and schedule compliance.
- Facilitate Organizational Learning: Embed prior experiences and lessons into the design process for continuous improvement.
- Build Stakeholder Commitment: Engage stakeholders and end users early to foster support and alignment with design objectives
What is SAFOP
SAFOP is a technique used to evaluate the safety and operability of an electrical installation, focusing on the following areas
- Design Philosophy
- Electrical Safety
- Construction Factors
- Maintenance and Operational Considerations
Purpose of an EHAZOP/SAFOP Study?
The goal of an EHAZOP/SAFOP study is to systematically identify and assess possible hazards and operability problems in a process plant or system, aiming to prevent accidents, enhance safety, and optimize operability.
Every Project is different in terms of funding, infrastructure, and the intricacy of the setup and design of the electrical system and the team members must possess working knowledge/qualifications of all stakeholders in the Project.
Criteria for SAFOP Study Requirement
SAFOP studies are recommended based on objective criteria, including:
- Project Complexity: Complexity of design, technology, and interface with utilities influences risk.
- Design Team Experience: Familiarity with standards and operating environments impacts safety.
- Standardization Level: Aligned with the company’s safety culture and work environment
Methodology Followed during SAFOP Workshop
- The SAFOP workshop shall be performed with a multidisciplinary team consisting of Electrical, and other disciplines (Safety, Operation & Maintenance Engineers).
- Define the boundaries – Generation plant and all associated equipment.
- Breaking down the Electrical Plant into various nodes such as electrical equipment, bays, control systems, communication systems, etc.
- Apply a guideword e.g. identify, protect, operate, etc. to each node to identify potential deviations & hazards.
- For each guideword applied to a node, analyze in detail the deviations, causes, consequences, and safeguards.
- Assess unmitigated risks (qualitatively) for the identified hazards and deviations.
- Provide recommendations to mitigate risks and enhance safety.
- Reassess mitigated risks for the identified hazards and deviations.
Key Components of SAFOP: A SAFOP review typically comprises,
- SAFety ANalysis (SAFAN)
- Examining the plant layout to determine the possible risks.
- SYstem Security and OPerability Analysis (SYSOP)
- SYSOP is that which reflects the designed philosophy limitation and effects on the system operability.
- Reviewing the design and assessing the security of supply (It covers the main equipment items and auxiliaries including multiple supplies, On-site generation, changeover schemes, Standby generation, and UPS systems).
- OPerator Task ANalysis (OPTAN)
- Examining probable tasks to be undertaken by local and remote Operators during both normal and abnormal conditions
- Examining operator Competency (Capable to review the sequence to prevent operational errors)

Advantages of EHAZOP / SAFOP Studies
- Risk Recognition: Identifies potential risks and operability challenges.
- Improved Safety: Enhances safety protocols and risk mitigation.
- Increased Efficiency: Boosts process reliability and effectiveness.
- Cost Reduction: Reduce operational and maintenance expenses.
- Regulatory Compliance: Ensures adherence to standards and regulations.
- Informed Decision-Making: Supports strategic process design and operational decisions
Key Elements of a SAFOP Report
- Summary of Findings
The SAFOP report provides a summary list of acceptance, recommendations, and action items derived from the study, using keywords and a structured approach. - Information Worksheets
Worksheets within the report are populated with data collected during SAFOP study sessions, capturing relevant insights from the analysis. - Non-Binding Guidance
While non-binding, the report offers valuable background information for the project owner to support informed decisions. - Safety in Design and Construction
The report outlines recommendations for implementing effective safety measures in the Project’s design and construction phases. - Safe Operability and Maintenance
It also covers guidance on ensuring safe operational practices and ease of maintenance.
TYPICAL DRAWINGS & DOCUMENTS USED IN SAFOP STUDY
- Basis of Design
- Single Line Diagrams
- Power System Study Reports
- Equipment Layouts
- Cable Routing Layouts
- Lighting Layouts
- Earthing and Lightning Protection Layouts
- Vendor Data
- Protective Relay Coordination Study & Relay Settings
- 3D Models, as applicable
- Operating Philosophy
The Future of Safety in Industrial Processes:
- The future of Industrial safety will focus on proactive strategies, including E-HAZOP/SAFOP studies.
- As Industries face new challenges in technology, environmental regulations, and workforce changes, prioritizing safety is crucial.
- E-HAZOP/SAFOP studies offer a systematic approach to identifying hazards and operability issues in industrial processes.
- These Assessments help Industries proactively identify risks and develop effective mitigation strategies.
- The future of safety will also see a greater emphasis on digitalization, automation, predictive maintenance, and advanced safety technologies.
- Technological advancements will improve the ability to identify potential hazards and implement control measures.
- Proactive safety approaches like E-HAZOP/SAFOP studies will ensure the well-being of workers, the public, and the environment.
- Continued investment in safety initiatives will help to maintain safe, efficient, and sustainable Industrial operations for the future.