EPC-stage HAZOP Study for a Polystyrene Plant

We identified and provided solutions to potential hazards and operability and maintainability problems for a polystyrene plant in Egypt.


We were commissioned by a plastics company to conduct a HAZOP (Hazard and Operability) study for its polystyrene plant in Egypt, with the purpose to provide the suitable documentation to finalise the design in the Engineering, Procurement and Construction (EPC) stage.

The study aimed at providing the following services to the customer:


We facilitated a three week session with the representatives from client, EPC contractors and the project management company to study the plant design in a node by node basis. The session identified potential hazards and rated the consequences of the hazards. Recommendations aiming at remediating the hazards were also provided.


We provided the following deliverables to the customer:

  • Potential hazards, operability and maintainability problems were identified and recorded;
  • Mitigation measures were recommended for the detail design, addresses the all the identified problems;
  • High quality HAZOP reporting, which detailed a clear rationale for the actions and tracking methods.

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