Why, When, and How to Implement Layer of Protection Analysis (LOPA)

Importance and Benefits

Developed in the 1990s, LOPA evolved from hazard identification techniques like Process Hazard Analysis (PHA) and Hazard and Operability Study (HAZOP). While these serve distinct roles, they are complementary. LOPA, a more detailed risk assessment method done after HAZOP, is crucial to ensure the effectiveness of the safeguards and provides the following:

• Increased safety – Because LOPA offers a structured approach to risk assessment, health and safety teams can effectively identify gaps and weaknesses in existing safeguards and justify the need for additional independent layers of protection.
• Improved cost efficiency – LOPA helps identify the most effective IPLs, allowing organizations to prioritize their safety investments and better allocate resources.
• Enhanced system reliability – With a clear basis for comparing risks and risk reduction measures, Environment, Health, and Safety (EHS) personnel can decide on risk management and optimization efforts. Improving Safety Management Systems (SMS) guarantees the organization’s compliance with industry best practices.

Practical Applications of Layer of Protection Analysis

A proven risk assessment methodology done after PHA and HAZOP, LOPA is integral to safeguarding operations across diverse industries. Here are some layer of protection analysis examples:

• Chemical manufacturing and testing – Chemical releases have severe environmental and health consequences. A common hazard is equipment failure that can be resolved with engineering controls, such as emergency shutdown systems.
• Oil and gas operations – Because the industry manages highly flammable substances, explosions or fires due to hydrocarbon leaks are possibilities. IPLs include hot work permits and emergency response plans to help prevent catastrophic accidents.
• Pharmaceutical manufacturing – Product contamination is a common concern in this sector. Personal Protective Equipment (PPE) is a LOPA-based safety measure that can mitigate this issue.
• Mineral mining – Miners work in extremely hazardous environments with dangers like cave-ins or rock falls. Engineering controls such as rock bolts and mesh netting are the most appropriate safety measures based on LOPA.
• Food and beverage industry – Pathogen contamination is a risk in food processing and packaging. Good Manufacturing Practices (GMP) and Hazard Analysis Critical Control Points (HACCP) are layers of protection that can be implemented and continuously reassessed.
• Water treatment plants – LOPA can help prevent waterborne disease outbreaks by prioritizing treatment methodologies, such as water disinfection and filtration during the purification process and distribution.
• Hazardous material handling – These materials pose serious risks to human health and the environment. By identifying potential hazards like chemical spills or leaks during storage, transport, and disposal, companies can ensure that appropriate safety measures are in place.

Steps in Analyzing Layers of Protection

LOPA is a structured approach to assessing and managing risks that ensures the safety and reliability of the operations. Carefully following the steps in the system ensures that safety managers, process engineers, maintenance teams, and other relevant personnel acquire an accurate evaluation.

Here’s a step-by-step guide to follow:

Step 1: Identify hazards and initiating events.

Hazard identification sets the foundation for the entire process. The results define the situations that could lead to undesirable outcomes. Accuracy is vital as it impacts the effectiveness of LOPA.

• Involve various departments (e.g., engineering, maintenance, and safety teams) to capture different perspectives.
• Utilize HAZOP studies, what-if analysis, or Failure Mode and Effects Analysis (FMEA) to examine potential hazards.
• Document all assumptions about scenarios to ensure transparency and consistency in the analysis.

Step 2: Determine the consequences.

Understanding the outcomes is critical for determining the level of risk and the required strength of IPLs because this helps in resource prioritization.

• Consider the worst-case scenario to ensure sufficient protection is in place.
• Review historical data to inform the analysis and improve the accuracy of results.
• Use scenario-specific criteria when determining the outcomes. For example, capture the type and quantity of hazards, the operating conditions, the proximity to people or the environment, and the potential for escalation.

Step 3: Evaluate existing layers of protection.

Identifying and evaluating IPLs or current safety measures, such as physical devices, alarms, and emergency protocols, help pinpoint gaps where additional safety measures may be needed.

• Use quantitative data to assess the reliability of each protection layer.
• Verify that protection layers are independent of each other to prevent common mode failures.
• Periodically review the effectiveness of the IPLs to account for changes in the process.

Step 4: Determine risk reduction and acceptability.

The next step involves estimating the effectiveness of existing safety measures in lowering the risk of a hazardous event to see if it’s within acceptable levels. It helps relevant personnel decide if the current protections are adequate or if additional measures are required.

• Ensure the risk criteria are clearly defined and consistently applied across all scenarios.
• Incorporate sensitivity analysis to determine which factors have the most significant impact on risk reduction and evaluate their uncertainty.
• Document the rationale for acceptability in detail to justify the need for additional or improved IPLs.

Step 5: Recommend and implement additional protection layers if needed.

There’s a possibility that the risk evaluated is unacceptable. In this case, organizations must implement new IPLs to achieve the necessary risk reduction. These may include new safety equipment, updated procedures, modifications to the process, or changes to the existing controls.

• Focus on the most effective and feasible measure that provides significant risk reduction.
• Engage stakeholders to ensure practical and sustainable implementation.
• Integrate the new layer of protection into the safety and operational system.