HSEQT

PHA

Developed By: Ali Ahmad

Date: 22rd June 2024

© Fatimafert Ltd.
PROCESS HAZARDS ANALYSIS
WHAT IS RISK?

• Probability of an
event that may
impact
Risk = Possibility of a loss or &
or injury
• Consequence of an
event when it
impacts

Risk = Probability x Consequence

PHA (PROCESS HAZARD ANALYSIS)

To identify, evaluate, and develop methods to control significant hazards associated with
processes

PHA conducting process

1- Planning
2-Conducting
3- Documenting
4- Follow-up.
LOWERING THE RISK THRU MULTIPLE PROTECTION LAYERS

Inherently Safer Design High

Frequency
It designs hazards out of the process instead Med
of relying on controls Inherently Safer Low
Design
V Low

Consequence Consequence
Inspections & Tests

Hazard
Procedures and
Training
RISK ASSESSMENT & PROCESS HAZARD ANALYSIS
• PHA is a methodical approach used to examine :
✓ Each new “or”
✓ Existing facility
• To assure that hazards of "catastrophic and major" Safety or Environmental
Consequences are :
✓ Identified and
✓ Adequately controlled to an acceptable risk level
• Seek a multi-disciplined consensus on hazard control
• Results are used for:
✓ Follow-up
✓ Emergency Planning and
✓ Training
RISK ASSESSMENT & PROCESS HAZARD ANALYSIS

• New process and facilities (several reviews during different stages of development)
✓ Screening in early development stage
✓ Design review at design completion
✓ Final project safety report—before start-up
✓ Baseline PHA—within one year after any start-up changes existing facilities and ideally within 2-3
month

• Cyclic PHA analyses—frequency depends on hazards(A review of the baseline and subsequent
PHAs conducted at regular intervals)

• Revalidation of previous review at least every five years

• Process changes Incident Investigation Mothballing and/or dismantling of process facilities

• Sub HSE (P) Chairman is responsible to select the PHA team

STAGES OF PHAS IN A PROJECT
PHA Stages
Developmental / Basic Design Review
for a New Pre-Authorization Base Line PHA
Data (Detailed)
Project

Experimental / basic Design review of

10 to 40 % Design
data stage, proposed the process and
Stage of information Design has
process & equipment serves as the
Project available. Project is become firm
are in conceptual foundation for
not authorized yet
stage cyclic PHAs
Evaluate risks of the
Appropriate time to Focus on P&IDs & A “checkpoint”
process being
conduct a detailed stage where all HSE
Intent of PHA developed & guide
comprehensive PHA equipment design hazard analysis
toward an inherently
to identify hazards drawings efforts are checked
safer process.

To ensure that Focuses on the

Why a particular
appropriate hazard design being Design &
Intent / hazardous operation
control features are developed & on operating
Direction of or material is being
included in the the design experience review
Questions used and why not
design & project decisions to be of the process.
other
estimate made
PHA FREQUENCY AND REVALIDATION REQUIREMENTS

• Cyclic PHA frequency for an existing facility

Process Frequency (Years)
HHP 5
LHO 10

A revalidation PHA must be considered in following cases:

• The previous PHA no longer meets the needs or requirements of the
program.
• There are significant opportunities to improve the PHA.
• For new facilities with significant changes during start-up that could affect
process safety, a revalidation of the baseline PHA shall be done within one
year of start-up.
GENERAL INFORMATION

Factor considered in the frequency of PHAs for Lower Hazard Operations (LHO) is
1- Industry-wide practices
2- Number of process safety incidents
3- Risk involved

4 hours to 1 day recommended duration for a typical field tour conducted by the PHA team
Engineering Controls:
Systems or interlocks involving physical components operating without human intervention
Risk level I and II only:
Quantitative risk analysis be conducted in addition to the qualitative risk analysis
 PSM-5
RISK ASSESSMENT & PROCESS HAZARD ANALYSIS

• Both qualitative and quantitative

• Use alone or in combination, depending on individual PHA
• May require expert consultant or analyst
• Qualitative techniques
✓ What If (PHA technique is foundational and should be used in the first review of almost any
process)
✓ Hazard and Operability Study (HAZOP)
✓ Failure Mode and Effect Analysis (FMEA)
✓ Fault Tree Analysis (FTA) (Both event identification and frequency
PHA TEAM MEMBERS
Full Time Members
• PHA team leader (qualified in PHA technique or methodology and leadership.).
• Operations Engineer Concerned
• Process Engineer
• Project Engineer
• Boardman and Area Operator(s) Concerned
• Maintenance Engineer
• Safety Engineer (Only in case the PHA leader is a non-Safety Resource)
Part Time Members (As per requirement)
• Inspection Engineer
• E&I Engineer
• Machinery Engineer
REVIEWS
The Team Reviews:
• MSDS for the substances in the process.
• Operating conditions and safe limits.
• Operating procedures / instructions.
• Consequences of operating outside the limits.
• Piping and instrument diagrams (P&IDs).
• Equipment design basis. (Specification sheets of vessels, pumps & piping classification)
• Management of change documents since prior PHA review. (Process / Design Specification)
• Serious incident reports since prior review.
• Previous PHAs.
• If serious deficiencies exist in the PSI package, the PHA team must stop work, report to the site leadership and request
for the information to be updated and PHA dates to be revised.
• Human Factors.
• Facility Siting. (To understand the risks posed to occupants of buildings by process-related events)
• Field Tours (Walk-through inspection of the area under review to familiarize the team with the process and equipment
layout)
EVALUATIONS
• EHSE-Chairman is responsible for the development and approval of the annual PHA Matrix
• The Team Evaluates:

▪ The possible harmful effects of each event versus

▪ The current protection and
▪ Decides on whether additional protection is needed

• For each hazardous event identified, the PHA team shall document:
▪ Consequence (C1 – C4)
▪ Frequency rating (F1 – F4) and
▪ A risk level (1 – IV)

By means of Risk Assessment Chart / Matrix…

Consequence Analysis:
Developing potential scenarios of hazardous events and evaluating their impacts
QUALITATIVE RISK ASSESSMENT PROTOCOL
Type of Event / impact C-1 C-2 C-3 C-4
Public safety and health No injury or Minor injury of Injury or moderate Death or irreversible
health effects reversible health health effects. Liability health effects. Liability
effects for injury + damages for injury + damages
$500 M - $ 1 MM more than $ 1 MM.
Employee safety and No injury or Minor injury or Multiple MTC injuries; One or more fatalities or
health health effects reversible health 1-2 RW C / LWCs or irreversible health
effects moderate health effects. effects.
Categor y Typical Descripti on Appr oximate corresponding
quantitati ve frequenc y (per
year)
F-1 Extre me ly Not realistically expected to occur < 10 -4
unlikely (or re mote)
F-2 Very unlike ly Not expected to occur, but not incredible 10 -3 to 10 -4

F-3 Unlikely Unlikely to occur in the plant’s lifetime, but 10 -2 to 10 -3

could occur in one of number of similar

plants
F-4 Likely May occur at least once in the life time of the > 10 -2
installation
Frequency category F-4 IV II I I
 F-3 IV III II I
 F-2 IV IV III II
Increasing likelihood F-1 IV IV IV III
C-1 C-2 C-3 C-4
Increasing severity
Consequence Category
RECOMMENDATION APPROVALS
• Final Recommendations have to be reviewed by the Sub-HSE(P)
• Any recommendation to be waived off or another solution to be proposed will have to be
reviewed by the Site Executive HSE Committee
• Executive HSE Committee will assign high risk recommendations on immediate basis.
• Changes in target dates will only be reviewed thru Executive HSE Committee
• Management response on recommendations will be documented
• A PHA action/recommendation closure mechanism should be in place and to be stewarded
in Executive HSE Committee.
• 0ne month is the minimum timeline required for completing a procedural job
recommendation
• The PHA team must list recommendations using clear and concise wording, avoiding
specific design solutions.
• Recommendations from a PHA should be tracked and stewarded until their completion
through the SMIS system.
RISK ASSESSMENT & PROCESS HAZARD ANALYSIS
When to conduct a PHA

Planning and Preparing to Conduct a PHA

Define PHA Charter and Scope

Team Preparation

PHA Activity Team Responsibilities

Flow Start PHA Activities

Hazards Identification

Process Hazard Review

Human Factors, Facility Siting and Inherently Safer Processes

Develop PHA Recommendations

PHA Report and Presentation to Management

Recommendations Follow-up, Tracking, Monthly Stewardship

Closing Recommendations
QUESTIONS