What’s Missing? - Quality PHAs & Hazard Identification Programs

Hazard identification is of critical importance to any process safety or risk management program, as hazards must be identified before they can be eliminated, controlled, or the associated risks minimized and managed. Process Hazard Analysis (PHA) is used by the chemical process and other industries to identify hazards, with Hazard and Operability (HAZOP) studies an industry-favored technique considered to be the most thorough. Yet, hazards do sometimes go unidentified and this potentially can result in significant consequences and impacts. Following an incident, scrutiny is often first directed at the PHA…was the hazard identified and/or how was it addressed?

How can the chemical process industries have the best chance at identifying and mitigating the significant hazards? Current trends and problems in PHAs are identified, and guidance is given for developing quality PHAs and hazard identification programs. Topics addressed include development of overall programs; tools, techniques and associated expectations; leadership; teams; recording and documentation; technical information; timing and resources; mental-model mismatches in techniques and criteria; maintaining a sense of vulnerability; outside-of-the-box thinking; and the impacts of a positive process safety culture. Case studies are used to illustrate the variability in hazard identification results from the 3 page to the 300 page report, and highlight the impacts of lack of knowledge to arrogance.