Process Hazard Analysis

The process hazard analysis is a thorough, orderly, systematic approach for identifying, evaluating, and controlling the hazards of processes involvin

The process hazard analysis is a thorough, orderly, systematic approach for identifying, evaluating, and controlling the hazards of processes involving highly hazardous chemicals. The employer must perform an initial process hazard analysis (hazard evaluation) on all processes covered by this standard. The process hazard analysis methodology selected must be appropriate to the complexity of the process and must identify, evaluate, and control the hazards involved in the process.

The Process Hazard Analysis Step

First, employers must determine and document the priority order for conducting process hazard analyses based on a rationale that includes such considerations as the extent of the process hazards, the number of potentially affected employees, the age of the process, and the operating history of the process. All initial process hazard analyses should be conducted as soon as possible, but at a minimum, the employer must complete no fewer than 25 percent by May 26, 1994; 50 percent by May 26, 1995; 75 percent by May 26, 1996; and all initial process hazard analyses by May 26, 1997. Where there is only one process in a workplace, the analysis must be completed by May 26, 1994.

Process hazard analyses completed after May 26, 1987, that meet the requirements of the PSM standard are acceptable as initial process hazard analyses. All process hazard analyses must be updated and revalidated, based on their completion date, at least every five years.

A Process Hazard Analysis (PHA) is essential to promote the safety and well-being of the people and facilities involved in your industrial processes, as well as to protect the environment. Our PHA services are comprehensive, encompassing the full suite of methodologies and are implemented by experts in the field. With their experience to guide you in assembling a PHA team, choosing the right format and leading you through the four basic PHA steps, you can improve your safety status and reduce risk. Ensure a successful PHA by learning more about how to prepare for the process and maximize your benefits.

Process Hazard Analyses (PHAs) comprise a wide range of methods and require a certain level of preparation. We have assembled a selection of typical questions and answers to assist you in getting ready for the process, knowing what to expect and deciding on the right approach for you.

What are the step for preparation for a PHA?

1. Determine the scope and scope limitations
2. Gather process safety information, including sample testing as needed
3. Establish team composition, including a team leader who is “knowledgeable in the specific PHA methodology being used” (OSHA).
4. Provide the team with PSI several days prior to the first meeting,
5. Schedule the meetings for not more than four hours per day, such as two hours before and after lunch.

What are the step for preparation for a PHA?

1. Checklists
2. What-If
3. What-If/Checklist
4. Hazard and Operability Analysis (HAZOP), based on ”nodes” in the P&I diagrams, or steps in the operating procedure
5. Failure Modes and Effects Analysis
6. Fault Tree Analysis [FTA]

What are the criteria for selecting a PHA Method?

1. Inherent hazards of materials
2. Status of the process (development, design, or in operation)
3. System complexity
4. Availability of a previous analysis
5. Applicability of good codes, standards, and RAGAGEP to the scope
6. Availability of excellent site/corporate experience, such that a well-organized What-If will likely extract all process safety issues

Do not apply a more-complex method such as HAZOP to a well-defined system that is “covered” by good codes and standards such as a flammable liquid tank farm. Do not apply a more complex and effort-intense method such as a FTA or a QRA unless there is a critical decision that has to be made concerning the safety of a process. [/content] [content title="Leader Qualification"] What are the must have qualifications of a PHA team Leader

1. Expertise and experience in PHA methodology
2. Excellent understanding of the science of hazardous materials and the consequences of releases (could be brought to the team by a subject matter expert)
3. Good understanding of “unit operations” and the uses and functions of typical process equipment
4. Good people skills to manage the team and develop consensus
5. Good organizational skills to organize and document the effort

What make PHA great?

1. Appropriate methodology
2. Correct application of the methodology
3. Appropriate team composition including subject matter experts as needed
4. Excellent documentation that includes why a specific method is appropriate
5. Executive summary that summarizes why the operation is safe and what major opportunities for improvement exist
6. Good team participation
7. Well defined recommendations
8. Site follow-up with documentation of recommendation closure, with attachment to the PHA report

A PHA specialists are experienced in the full suite of process hazard analysis methods, including checklists, what-if checklists, Hazard and Operability Studies (HAZOP), Failure Mode and Effect Analysis (FMEA), Fault Tree Analysis (FTA), Layers of Protection Analysis (LOPA) and more. As each PHA method has pros and cons as well as varying scope and application, consulting with one of our experts before making a choice contributes significantly to the overall success of your PHA.

Whatever PHA methodology is chosen, the first phase of the analysis is dedicated to gathering all the applicable safety information about the materials handled, the chemical process and conditions, the control methods employed, and the equipment and systems use. The applicable safety information relevant to the targeted process are gleaned from Safety Data Sheets (SDS’s), laboratory testing, design manuals, operating procedures, and equipment manufacturers/suppliers.

Next, a team is assembled under the guidance of an experienced, knowledgeable leader which includes members with diverse experience and expertise to examine the process in search of inherent hazards and operating risks such as fire, explosion, and the release of materials or energy. During the PHA exercise for each hazard identified the team examines the existing safeguards that prevent or mitigate the undesired consequences in addition to proposing new measures should they be required.

The final critical aspect of the PHA effort is to provide adequate documentation of the analysis, its findings and recommendations. A risk management plan must follow the PHA in order to ensure that effective follow-up and closure occurs.

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• Process Hazard Analysis - Managing Risk
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• 2. DOE Hanbook Chemical Process Hazards Analysis
• 3. Engineering Position Paper Process Hazard Analysis
• 4. Introduction to Process Safety for Undergraduates and Engineers