Lion Safety Consulting supported the Zabrze Combined Heat and Power Plant modernisation project by leading a structured HAZOP and LOPA for systems related to biomass and RDF handling.

The project concerned the modernization of the existing CHP plant infrastructure, focused on the change of fuel structure and integration of new biomass and RDF handling systems with the existing power generation assets. The reviewed scope included systems associated with fuel reception, unloading, storage, transport, preparation and feeding, together with related auxiliary systems, safeguards, control functions and interfaces with the boiler and existing CHP plant installations.

The HAZOP session was carried out in a hybrid format, with the on-site part conducted at the ILF office in Warsaw and selected participants joining remotely via Microsoft Teams. The study was attended by representatives of ILF, Fortum and relevant system suppliers, which allowed the team to review the design from engineering, operational and vendor-specific perspectives.

Lion Safety Consulting’s scope included independent facilitation of the HAZOP workshop, systematic identification of deviations, causes and consequences, review of existing and proposed safeguards, and assessment of selected scenarios using LOPA-based reasoning where applicable.

Particular attention was paid to hazards related to combustible solid fuels, dust generation, potential explosive atmospheres, fire and self-heating risks, material blockage and accumulation, ignition source control, fire detection and mitigation, and the safe integration of new systems with existing CHP infrastructure.

The study supported the project team in identifying process safety risks, validating the adequacy of safeguards and defining recommendations for further design development and risk reduction.