SA SAFETY

A short course on Process

Hazard Analysis (pha)
for Chemical Engineers

Process Hazard Analysis (PHA) provides a means of systematically reviewing the design and operation of a facility
to identify occurrence of hazardous events with potential consequences on people, property and production,
environment and reputation (a more new issue to be considered in a PHA). PHA studies can be conducted not
only on continuous and batch chemical processes, but also on storage, transportation and other operating,
manufacturing or support systems. This paper describes the main elements to be considered when conducting such
an analysis.

Keywords
Process Hazard Analysis

Juan A. Vílchez
Ph.D. Chemical Engineer. TIPs scientific and technical advisor
Estrella Blanco
M.S. Chemical Engineer. TIPs project manager

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 A short course on Process Hazard Analysis (PHA) for Chemical Engineers

INTRODUCTION on the best allocation of resources THE PHA TEAM

Process Hazard Analysis (PHA) provides to address the problems identified. A process hazard analyses is usually
a means of systematically reviewing Consequently, means must be performed by a team. The interaction
the design and operation of a facility provided for qualitatively estimating of the team members results in a
to identify occurrence of hazardous the severity and likelihood of each more thorough and complete review
events with potential consequences scenario identified during the study, than would be accomplished by each
on: in order to develop a risk estimate. individual working separately on the
PHA studies can be conducted same project. A team typically consists
• People. not only on continuous and batch of 5-7 individuals. One member is a
• Property and production. chemical processes, but also on person trained and knowledgeable
• Environment. storage, transportation and other in the PHA technique. The other
• Reputation (a more new issue to operating, manufacturing or support members are usually selected for
be considered in a PHA). systems. The following specific PHA their knowledge of the process and/
techniques are acceptable to OSHA or technical contribution to the team.
PHA studies are usually conducted and EPA under the PSM and RMP The team leader is responsible
by a team of individuals led by a regulations (OSHA 1990, EPA 1996): for study preparation, guiding and
person knowledgeable in the PHA managing the team, and supervising
technique (the PHA Leader, Team • Checklist. the study documentation and report
Leader, Facilitator o Director). When • What-if. generation. Team members provide
the team identifies possible hazard • What-if/Checklist. information about the system to the
scenarios and consequences for the • HAZOP (HAZard and OPerability team and identify hazard scenarios
facility, the team may then evaluate studies). under the direction of the team
whether existing safeguards are • FMEA (Failure Modes Effects leader. In general a technical secretary
adequate to protect against the Analysis). or scribe is employed to record results
scenario. Safeguards may be either in and prepare reports. Alternatively,
the form of hardware or administrative These techniques are also identified the team leader can assume this
procedures. In some cases, the team by the American Institute of Chemical responsibility in small PHA studies.
may make recommendations for Engineers(AIChE) as recognized There is no one perfect combination
corrective action, for further study to hazard analysis techniques for process of team members. However, since
determine an optimal solution, or for facilities such as chemical, petroleum the team members need to be
additional investigation to determine and petrochemical plants (CCPS 1985, knowledgeable of the process and
whether a problem exists that 1992 and 2008). its operation, at least some of the
warrants action. The team session are The application of similar specific team should come from the operating
registered in form of table/worksheet techniques are required by the facility. A typical team may consist of
by a technical secretary or scribe. European Commission (EC) major- the following members:
The primary objective of PHA is the accident directives (so-called Seveso
identification of hazard scenarios. directives I, II and III). 1. Team Leader or PHA Director.
The generation of recommendations New or updated techniques and 2 Secretary or Scribe.
or corrective actions, is a secondary variations, similar to those presented 3. Process/Engineering
objective (but also important). The above, can be used also used for representative.
PHA team should avoid delaying the hazard identification: 4. Operations representative
study sessions trying to engineer (essential member!).
solutions to every potential problem • FMEDA (Failure Modes Effects and 5. Safety representative.
identified. If a solution is not obvious, Diagnostic Analysis). 6. Maintenance/Inspection
note in the worksheet that a potential • HAZID (HAZard IDentification representative.
problem exists and recommend that study). 7. Instrumentation/Electrical
someone review it later for potential • SWIFT (Structured What-IF representative.
solutions. Technique).
Facility management may need The members 1 to 5 are essential
Important note: while PHA can provide a
more information to make decisions comprehensive and systematic analysis of the and should be present during all the
on what should be done. It is useful hazards in a facility, it cannot provide complete PHA meetings.
assurance that all hazards have been identified.
if a simple risk estimate can be Also, no analysis method can compensate for The actual composition of a specific
a team that lacks knowledge of the process or
assigned for each hazard scenario in operation under study, applicable codes and team will depend upon the objectives
standards, regulations and accepted industry
order to provide a basis for deciding safe design practices. of the study, the type of facility being

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Figure 1. Typical PHA worksheet

studied, and other considerations. any significant amount of time trying is to use 2 two column approach in
Other individuals may be used as to engineer a solution when a potential the worksheet: the scenario column
resources for the team and brought problem is uncovered. If a solution (hazard) and the consequence column
into only those meeting sessions to the problem is obvious, the team (damage).
where their particular knowledge is should document their recommended • List of safeguards or measures
needed. This approach keeps the core solution. If a solution is not obvious, available to protect against the
team to an efficient size. they should recommend that someone scenario.
follow up and resolve the problem • A risk ranking of each hazard
THE PHA SESSIONS outside the PHA study. Also, if there scenario based on severity, likelihood
A PHA team will require a number of is insufficient information available and/or risk, which may provide for
hours to complete a study for a typical at the time to decide if a potential more targeted analysis, planning and
process. The team will therefore problem exists, the team should note resource allocation. Risk ranking can
usually hold several meetings, or it, assign someone to collect additional be done in several ways:
working sessions, spread over several information, and continue with the
days to perform the study. Since study. The issue should be revisited - Unmitagated risk (not considering
PHA is tiring, the sessions are usually later by the team, when additional the effect of the safewards on the risk
scheduled for the morning when the information is available, to determine ranking).
team members are most fresh. The if a potential problem exists. - Mitigated risk (considering the
sessions are normally scheduled to effect of the safewards on the risk
last for periods of 4-6 effective hours. THE PHA WOKSHEET ranking).
Longer sessions or afternoon sessions PHA is intended to identify hazards.
tend to tire the members, reducing It is not intended to be a problem- • Recommended actions to improve
the effectiveness of the analysis and solving technique. The essential safety such as:
the quality of the study. results of a PHA study are recorded in
During each session, the PHA team a worksheet containing: - Recommendations for changes
records their work in a worksheet. The • Selected question, root cause or in design, procedures, etc. to correct
basic purpose of the PHA study is to failure origin of trouble. a problem where it is obvious to the
identify potential hazard scenarios. • A description of each hazard PHA team.
Therefore, the team should not spend scenario identified. The best way it - Recommendations for follow up

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 A short course on Process Hazard Analysis (PHA) for Chemical Engineers

where no conclusion was possible due DEFINING A STUDY - Toxic releases.

to lack of information. The first step in conducting a PHA is - Fires and explosions.
- Recommendations for additional to explicitly state the purpose, scope
study to determine if a situation and objectives of the study. They • Consequences to be considered:
actually represents a hazard of directly influence the content and
concern. emphasis of the study and the time - Public safety.
that will be required to complete the - Public property damage.
Typical columns in a PHA worksheet study. Also be sure that the expected - Employee safety.
are: results of the study are clear to - Liability.
those who have requested the study. - Loss of plant or equipment.
• Question/cause/failure (origin of Sometimes, management has a - Insurability.
trouble). perception of what the PHA study - Loss of production.
• Scenario (evolution to a hazardous will achieve which may be different - Environmental impact.
situation). from that of the team.
• Consequence (type and level of • Identify the major contributors to
damage). Purpose risk at the facility.
• Safeguard (to protect against The purpose of the study is the • Determine possible accident
scenario). underlying reason that the study was sequences for emergency planning.
• Mitigated Risk Ranking (considering requested. Examples are:
safeguards). SELECTING A TEAM
• A c t i o n s ( p r o p o s e d s a f e t y • Comply with regulations. PHA is a team process. It relies on
improvements in order to reduce the • M e e t c o m p a n y p o l i c y the principle that a team of people,
risk). requirements. working in a brainstorming session,
• Address facility sitting. will more thoroughly review the
SUCCESS FACTORS process than would be accomplished
Discussion by the team may also Scope by each person working individually.
reveal a lack of information or lead to It is also important to define the scope The PHA team should consist of
a question. The study leader should of the study. This includes specifying: persons with differing backgrounds
ensure that any such issues are to bring a variety of viewpoints to
resolved before the study is completed • Physical boundaries of the system the team. Previous PHA experience is
so that the final report contains only to be studied. desirable but not essential for team
warranted recommendations. There • M o d e s o f o p e r a t i o n t o b e members.
are several factors that can influence included. A PHA team usually consists of
the success of a PHA study. These • Whether domino effects (effects 5-7 people, although a smaller team
include: on and from adjacent systems) are to may be sufficient for a small facility.
be included. If the team is too large, the group
• Clearly understood statement • What external events are to be approach fails because too many
of the study purpose, scope and treated. people are trying to communicate
objectives. • Extent to which recommendations with one another and are inhibited
• Degree of preparation by the team f o r c o r re c t i v e a c t i o n s w i l l b e from working closely. If the group
leader. developed. is too small, it may lack the breadth
• Experience of the team leader in • Whether severity and likelihood of knowledge needed to help assure
leading PHAs. rankings will be used. completeness and the creativity
• E x p e r i e n c e a n d b re a d t h o f • Whether procedures will be generated by multiple interactions.
knowledge of the team. treated implicitly or explicitly. The team is led by a person who
• Accuracy of the process drawings should be knowledgeable and
and other reference information. Objectives experienced in the PHA technique
• A d e q u a c y o f t h e s t u d y Objectives are usually set by the being used. The team leader does not
documentation. person requesting the hazard analysis, necessarily need to know the process
• Adequacy of follow up activities but could be assisted by the PHA team being reviewed. Duties of the team
after the study is completed. Usually leader. The objectives provide a clear leader include:
a database o software tool is focus for the study. Examples are:
recommended for this follow up. • Preparation for the study (ensure
• Adequacy of meeting facilities. • Types of hazards to be treated: needed information is available,

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identify resources needed, plan study). in the PHA worksheet (using a word study as various experts, or technical
• Ensure participants understand processor, a spreadsheet or a specially specialists, are utilized on an as
the process and their roles. designed software product). It is also needed basis. Some specially designed
• Guide team members through the common for this software package to software products provide the
review. be used by the team leader. capability to record team participants
• P ro v i d e t e c h n i c a l i n p u t t o Other team members are selected by session.
supplement the team. based on the technical expertise and/ Team members provide information
• Manage the team. or operating experience they bring to about the process, brainstorm
• Supervise the recording of the the team. For example, a team may hazard scenarios, identify existing
meetings. include: safeguards, estimate severities and
• Ensure the PHA reports are likelihoods of hazard scenarios,
complete and accurate. • Design engineer. and identify any obvious initial
• Instrument design engineer. recommendations.
The team leader is usually assisted • Process engineer. It is also useful to have a designated
by a technical secretary, or scribe, • Chemist. local on-site coordinator when
whose responsibilities include: • Safety engineer. performing a PHA study in order to
• Maintenance engineer. provide a liaison between local facility
• Record the results of the PHA • Operations supervisor. management and the team, and to
team meetings. • Operator. help ensure adequate facilities are
• Prepare the meeting reports. provided for the team.
• Assist in the collection of needed Note that titles of job positions may
information. vary with facilities and companies. PREPARING FOR A STUDY
The actual composition of the team The amount of preparation needed for
The scribe is the individual who will depends on the particular study. a study will depend upon the size and
most likely use a software package The composition may also vary from complexity of the facility and whether
for registration of the meeting notes meeting to meeting within a PHA a continuous or batch process is to be

Figure 2. Typical PFD/P&ID before node selection

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 A short course on Process Hazard Analysis (PHA) for Chemical Engineers

studied. Study preparation involves instrument sequence control charts contain enough information for the
several phases: or descriptions, logic diagrams, cause- study. For these cases the principal
consequence matrices, plant manuals effort is to ensure they are accurate.
Obtaining needed information and equipment manufacturers’ This may entail walking the principal
The basic information needed will manuals may be needed. lines to compare the drawings with
usually consist of: Interlock definitions, logic diagrams the actual installation.
and cause-consequence matrices • For batch processes, however,
• Process description and process are vital information when a PHA is the preparative work is usually more
chemistry details. integrated in a SIS life cycle analysis extensive because the status of the
• O p e r a t i n g a n d e m e r g e n c y as defined in EIC 61511. In this case process must be described at each
procedures (from a process point of all SIF must appear in the safeguard step in the process. This information
view). column associated to the hazard can be obtained from operating
• Process Flow Diagrams (PFD’s). scenarios may require protection. instructions but it is not usually readily
• Piping and Instrument Diagrams Documents must be inspected to available. It may be useful to prepare
(P&ID’s). ensure they are appropriate, complete a display indicating the status of each
• Plot plan or layout. and accurate. Knowledge of the piece of equipment on a time basis.
• Material Safety Data Sheets process including its operation is also If operators are physically involved in
(MSDS). required. This is usually provided by the process (e.g. in charging vessels),
the team members. rather than simply controlling the
Information will also be needed process, their activities should be
on safeguards, instrumentation, Converting the information to a represented by means of flow charts
interlocks and controls. Other suitable form or a list of sequential or parallel tasks
documentation that may be • For continuous processes, the describing the recipe.
needed includes utility drawings, preparative work is minimal. The
mechanical drawings, isometrics and existing process flow sheets, P&ID’s Planning the study
equipment data sheets. Additionally, and other documentation usually • The team leader will usually

Figure 3. Typical PFD/P&ID after node selection

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plan the sequence of work prior to be used to estimate the relative risk. for the PHA team meetings. These
beginning the PHA study. This will help This allows prioritizing the scenarios methods are based on the number of
to ensure that the team approaches to more effectively address the nodes or systems in the process. For
the process and its operation recommendations that may arise. example, in the case of the HAZOP
systematically. The study plan is based • If a risk ranking of hazard scenarios technique, a rule of thumb is to
on how the process is operated: is used, levels and definitions should be allow approximately 2-3 hours/node.
established for severity, likelihood and These values represent 2-3 nodes/day
- For continuous processes the risk. These should be established prior according the PHA session periods
sequence of study is straightforward. to starting the team sessions and should recommended for to maintain the
The study team starts at the beginning be agreed upon by management. team fresh. In any case, experience
of the process and progressively works • In order to compare the potential with the PHA technique is usually
downstream. hazards in various areas of the facility, the best method of estimating the
- For batch processes, the sequence several statistical comparisons can be time. It should be noted that time
of study should follow the steps in the made using these severity, likelihood for study preparation, documenting
batch. and risk ranking estimates. The risk the study outside the study sessions,
presented by any area of the plant and follow up activities also needs to
• Planning the study sequence depends on the number and types of be estimated. A software tool greatly
usually includes the initial selection of hazards present, the number of ways reduces the documentation time
study nodes or systems/subsystems. they can be realized (causes), how required.
This information can be entered into a likely they are to occur (likelihood) Individual PHA team sessions
list prior to starting the study sessions and the extent and magnitude of should last no more than 4-6 net
or as the meetings are held: their consequences should they occur hours. The work is intensive and
(number of consequences considered the effec ti v enes s of the team
- The division of a process into important and their severities). diminishes rapidly as the length of
nodes may be made on the basis • It should be noted that these the session increases. Sessions are
the process conditions (P, T) between prioritization factors should only be best scheduled for the morning when
main valves, presence of main vessel, used to provide general guidance the participants will be most alert. For
isolation capabilities or some other on ranking risks, since there is large projects, the process may need
criterion. It is a good idea identify considerable subjectivity involved in to be broken into separate units and
each node on a P&ID using colour the performance of a PHA and in the each assigned to one of several teams
layout makers. estimation of severity and likelihood in order to accomplish the work in
values in particular. Moreover, the the desired time frame. The proposed
- The division of a process into severity and likelihood values provide schedule should be discussed and
systems and subsystems may be rankings rather than true numerical agreed upon with management and
made on the basis of area within the estimates, so the prioritization factors team members prior to beginning
facility, type of process, stage in the do not represent actual risk values. the study sessions. Management
operation, or some other criterion. • These prioritizations must be should be kept informed if significant
tempered by engineering judgment changes to the schedule become
• The precise breakdown depends and a careful check of the original necessary.
on the facility being studied; how worksheets to see if any unusual Adequate facilities should be
detailed a study is to be conducted; conditions exist that could distort the scheduled for the study sessions.
the purpose, scope and objectives of area groupings derived by statistical Ample room is required to spread out
the study; and the preferences of the means. drawings and other information. The
team members. • Additional insight into the risks meeting room should also be located
• The study plan should be discussed presented by each area of the plant is where interruptions are less likely to
with the study team before starting provides an indication of systems that occur.
the study. have a high proportion of high risk
hazard scenarios and consequently CARRYING OUT THE STUDY
Defining the risk ranking (optional) are potential candidates for further The team uses the chosen PHA
• The team may assess the likelihood analysis. technique to identify hazard scenarios.
of a hazard scenario occurring, and Different PHA techniques vary in how
the severity of its consequences, Arranging the Meetings they do this. Details are provided in
given that the scenario occurs. The There are a number of methods independent lectures for each specific
likelihood and severity levels can then for estimating the time required technique.

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 A short course on Process Hazard Analysis (PHA) for Chemical Engineers

Figure 5. Typical PHA meeting room layout Figure 6. PHA meeting

room (P&IDs on the
table, PHA worksheet
projected and
blackboard for notes)

When evaluating the possible

causes of a scenario, the PHA team
should keep in mind the three basic
types of causes:

• Equipment failure (includes

instrumentation failures). Figure 7.
• Human error. PHA meeting
• External events. room (with
P&IDs on wall)

A scenario is determined to be
realistic, and is therefore subject to identified, any existing safeguards to follow up and obtain additional
further review, if in the judgment of should be noted. If a risk ranking information. This person can then
the team, there are sufficient credible is being used, values of severity report back to the PHA team at
causes to believe it can occur. In and likelihood are estimated. It is a subsequent meeting. The team
determining whether seemingly low important that values are assigned can then assess whether or not a
probability events can occur, the consistently throughout the study. potential hazard exists and whether
relative probability of occurrence of If it is considered that a potentially a recommendation is needed. If the
the three basic types of causes should significant hazard exists, and the problem is a lack of knowledge on
be kept in mind. existing safeguards are not adequate the team’s part, other specialists may
T h e o rd e r o f p ro b a b i l i t y o f given the severity and/or likelihood be called in.
occurrence generally is: of the event, a recommendation for It is useful to track the progress of
corrective action may be made. An the study by marking on the P&ID
Human errors > Equipment failures >
External events assignment of responsibility should be those sections that have been studied.
made to an individual or department This can be done using a highlighter
But the order of frequency of for follow up on the recommendation. or by annotating the drawing. This
occurrence for instrumented processes Even though the team leader procedure helps ensure complete
with minimal human intervention prepares in advance for the study, in coverage.
generally is: many cases the team may not have
sufficient information, or knowledge, GENERATING REPORTS
Equipment failures > Human errors > to determine whether a significant Recording the results is a vital part
External events
hazard potentially exists. In these of a PHA study. It is impossible to
Once realistic hazard scenarios are cases, someone should be assigned record manually all that is said, yet it

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is important to document what the when combined with a computer • Ensuring the study meets the
team reviews and the background of data projection device. This allows purpose, scope, and objectives
any recommendations made. It is also the PHA team to view what is entered established at the beginning of the study.
important that the documentation in the worksheet as it is entered. • Ensuring the study is thorough,
allow for, and facilitate, following The team can provide immediate complete, and done correctly.
up any action items and information feedback thus minimizing the need • Ensuring the study is adequately
needs. The basic documentation for post-session review and editing documented and transmitted to the
produced to facilitate these needs of the worksheets. appropriate persons.
includes a PHA worksheet, some form A software tool also facilitates
of action items report, and a final the follow up activities by providing Often a study is perceived as being
study report. the ability to automatically generate “poor” because of misconceptions by
The PHA worksheet is the key to action items and information needs management as to the actual results
recording the essential information. It lists. of a PHA study. For this reason, it is
is completed by the scribe during the important to ensure that everyone
team sessions. The worksheets should RESPONSIBILITIES OF clearly understands the nature of the
represent a complete record of what THE TEAM LEADER PHA process and the expected results
the team considered during the study. The team leader is responsible for of the study. Other reasons for a
From the worksheets, the action items the overall satisfactory completion of “poor” study include:
and information needs are extracted. the study. The team leader’s role and
These are usually summarized in a responsibilities can be categorized by • Inadequate study time.
separate report. This facilitates follow the stage of the study as follows: • Inadequate documentation.
up on the items without having to • Inadequate team efforts.
search through the worksheets to find • Preparatory stage. • Incomplete study.
them. • Study stage. • Inadequate team guidance
A software tool facilitates the • Follow up stage. • Inadequate facilities.
documentation process by allowing • Inadequate follow up.
the worksheet to be completed on The team leader is responsible for:
a personal computer as the study DOCUMENTING THE STUDY
progresses. The use of a computer • Guiding the process. A study report should be prepared at
allows more information to be • Managing the team. the completion of the study. The report
documented than would be likely if • Recording the results of the study. should clearly explain to a reader the
the worksheets were completed by purpose, scope and objectives of the
hand. This is particularly important QUALITY CONTROL study, what was accomplished, and
when the report may be reviewed by OF A PHA STUDY any significant recommendations.
someone outside the team, such as Quality control of a PHA study involves The study session worksheets should
a regulatory authority. The use of a consideration of several items. These be included, possibly as an appendix
software tool is particularly effective include: item.

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Proper documentation of a PHA Study Results/Findings the complete contents of the study
study will address the following items: This section provides a summary worksheets.
discussion on the types of
• Documentation of the team hazard scenarios, safeguards and DOCUMENTING
sessions. recommendations identified. Also TEAM SESSIONS
• Follow up reports. provided is a summary of the results Documentation of the team sessions
• Study report. by risk ranking, if applicable, a should be completed in the form of
A typical study report may include description of how recommendations a worksheet. The worksheet should
the following sections: are categorized, a description of contain areas to record the part of the
the purpose and intent of the process being reviewed, information
Executive Summary recommendations, and a categorical describing the hazard scenario,
Ideally, the executive summary listing of study recommendations, if safeguards, the scenario severity and
provides brief overview of what, manageable. likelihood, and any recommendations.
when, where, why, who, how and A software tool facilitates the
findings, and is: Conclusions recording of the team sessions by the
This is an optional section. It use of an electronic worksheet.
• Targeted for management review. highlights the fact that all study
• Usually one to three pages in recommendations are preliminary FOLLOW UP ACTIONS
length. and will require further consideration The PHA study will generate action
• Best written after complete report before implementation. Planned items which can be classified as one
is drafted. follow up activities are sometimes of two basic types:
described.
Introduction to the executive • Information needs.
summary Appendixes • Recommendations.
The introduction for the executive A. Description of Hazard Analysis Study
summary includes a brief process Technique Information needs often happens
description describing how the A detailed description of the PHA during the team sessions, because
unit(s) studied fit into the overall site, technique used to complete the study insufficient information is available
lists the highly hazardous chemical must be provided. This is typically a to determine if a problem exists. In
included in the study and includes boilerplate description. such cases, rather than belabor the
a reference block flow diagram team when no resolution will result,
(BFD) or process flow diagram (PFD), B. Study Nodes or Systems/ the item should be documented as
if available. The introduction also Subsystems and Drawings a need for information. It should be
describes the contents of the report A listing and description of the study assigned to one of the team members
by presenting the title of each section nodes or systems/subsystems is to investigate and report back at a
of the report. provided. Also, a list of the process subsequent team meeting. Follow up
drawings used in the study is included. assignments should be documented
Purpose, scope and objectives Drawing references should include the in an information needs report (if
This section provides a summary drawing number, revision and date. necessary) and distributed promptly
discussion of both the scope Key equipment and lines should be to the assigned individuals. As the
and objectives of the study. this identified on the drawings. individuals report back on specific
is particularly important if the items, the revised status of these items
study analyzed only a portion of a C. Action Items should be documented. All follow up
process. The scope should identify An Action Items Report can be items should be resolved before the
the boundaries of the study and generated by the software in an study is completed. The team leader
critical interfaces to other systems. automatic way for inclusion in should ensure that information need
The objectives should specify the this appendix and it must provide action items are investigated and
hazards treated and the classes of a complete description of all resolved during the course of the
consequences considered. recommendations. study when the team is available to
review the item.
Study Approach D. Hazard Analysis Study Worksheets Recommendations are those items
This section provides a summary A Worksheet Report can be generated which may result in a change in the
discussion of how the study was also by a software tool for inclusion design and/or operation of the facility.
conducted. in this appendix and it contains These items may take time to complete

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and will therefore be documented in for following up on the action items.

the final report as open action items. A key aspect of this communication is
a complete study report. Since the PHA
PRIORITIZATION OF ACTIONS study may generate a large number of
The PHA study may result in a large worksheets, in which the important
number of action items. The number items are buried, a summary report is
of action items may be greater than necessary. The summary report should
the facility could reasonably be be able to stand alone, inform readers
expected to handle at one time. To of the purpose, scope and objectives
properly manage the action items, a of the study, describe what was
method of prioritization of the action accomplished, and identify the most
items is desirable to allow the facility significant findings. For completeness,
to focus its resources. Several schemes the worksheets may be included as an
are available to help prioritize the appendix item or as a supplemental
action items, including: report.
Assignments for follow up of
• Risk ranking: an estimate is made the PHA findings will most likely
of the likelihood of the event and be distributed among a number of
the severity if it were to occur. Risk is individuals and/or departments. The
a combination of the likelihood and most effective communication of
severity of an incident. A risk matrix, the results is one which comes from
with likelihood and severity as the axes, top management. The study team
is then used to determine the risk. should prepare a report for the top
• Simple prioritization: a scale management of the facility. The
(e.g. 1 to 5, A to E, etc.) is used to report should then be distributed
subjectively prioritize the action items. from management to the responsible
• Categorization: action items individuals/departments to highlight
are categorized as either safety or management’s commitment to
procedural items. Higher priority resolving any action items resulting
is given to the safety items. Sub- from the study.
categorization of the items in each
category may also be done, such MANAGEMENT OF CHANGE
as into hardware (equipment) and Resolution of the PHA study action
procedural items. Procedural items are items may result in proposed changes
considered no (or low) cost items and to the facility design and/or operation.
easily accomplished. The proposed changes should be
reviewed to ensure the resolution of
COMMUNICATING a problem does not introduce new
PHA RESULTS hazards. Often this can be done
The benefit of the PHA study may be quickly by an individual reviewing the
diminished if the results are poorly original PHA report and evaluating
communicated to those responsible potential effects of the proposed
change. At other times it may be
necessary to reconvene the PHA team
ACRONYMS to evaluate the potential effect of a
proposed change.
PHA: Process Hazard Analysis
OSHA: US Occupational Safety and Health Administration
EPA: US Environmental Protection Agency
PSM: Process Safety Management of highly hazardous chemicals (OSHA requirement) REFERENCES
RMP: Risk Management Plan (EPA requirement) 1. CCPS, “ Guidelines for Hazard Evaluation
Procedures with Worked Examples”, AIChE
HAZOP: HAZard And OPerability study (1992)
FMEA: Failure Mode and Effects Analysis study 2. CCPS, “ Guidelines for Hazard Evaluation
AIChE: American Institute of Chemical Engineers Procedures with Worked Examples”, AIChE
CCPS: Center for Chemical Process Safety (2008)
HAZID: HAZard IDentification study 3. IEC 61882:2001 Hazard and operability
studies (HAZOP studies) - Application guide

60 Industria Química Special Achema 2015