UNIT 2

Preliminary Hazard Analysis

Dr. Basavaraj R J
Department of Chemical Engineering
RV College of Engineering
Introduction

is PHA?
What
Introductio
Application
PHA
n
scope
PHA
procedure

Hazard
checklist

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 What is preliminary hazard
analysis?
Introduction
What
Preliminary hazard analysis (PHA) is a semi-quantitative
is PHA? analysis that is performed to:
Application
PHA
PHA procedure
scope
Hazard checklist 1. Identify all potential hazards and accidental events
that may lead to an accident
2. Rank the identified accidental events according
to their severity
3. Identify required hazard controls and follow-up
actions
Several variants of PHA are used, and sometimes under
different names like

❑ Rapid Risk Ranking

❑ Hazard identification (HAZID)

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 What can PHA be used
for?
Introduction
1. As an initial risk study in an early stage of a project
What (e.g., of a new plant/Industry).
is PHA?
Application Accidents are mainly caused by release of energy. The PHA
PHA
PHA procedure identifies where energy may be released and which
scope
accidental events that may occur, and gives a rough
estimate of the severity of each accidental event. The PHA
results are used to (i) compare main concepts, to
(ii) focus on important risk issues, and as (iii) input to more
detailed
2. As an initial step of a detailed risk analysis of a
risk analyses.
system concept or an existing system.
The purpose of the PHA is then to identify those accidental
events that should be subject to a further, and more detailed
risk analysis.

3. As a complete risk analysis of a rather simple

system. Whether or not a PHA will be a sufficient analysis
depends both on the complexity of the system and the
objectives of the analysis.
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 PHA
scope
Introduction
What
The PHA shall
is PHA? consider:
Application
PHA
PHA procedure ❑ Hazardous components
scope
❑ Safety related interfaces between various system
elements, including software
❑ Environmental constraints including operating
environments
❑ Operating, test, maintenance, built-in-tests,
diagnostics, and emergency procedures
❑ Facilities, real property installed equipment,
support equipment, and training
❑ Safety related equipment, safeguards, and possible
alternate approaches
❑ Malfunctions to the system, subsystems, or software

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Introduction

PHA procedure
PHA Main Steps
Prerequisites
Hazard
identificatio
n
Frequency
Severity
Frequencyclasses
classes
Risk ranking P H A procedure/Methodology
Pros and cons
Review

Hazard checklist

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 PHA Main Steps

Introduction
1. PHA prerequisites
PHA procedure
PHA
2. Hazard identification
Main Steps 3. Consequence and frequency
Prerequisites
Hazard estimation
identificatio
n
4. Risk ranking and follow-up
Frequency actions
Severity classes
Frequency classes
Risk ranking
Pros and cons
Hazard checklist
Review

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 PHA prerequisites

Introduction
1. Establish PHA team
PHA procedure
2. Define and describe the system to be
PHA analyzed
(a) System boundaries (which parts should be
Main Steps
Prerequisites included and which should not)
Hazard
identificatio (b) System description; including layout
n drawings, process flow diagrams, block
Frequency
Severity classes
diagrams, and so on
Frequency classes (c) Use and storage of energy and hazardous
Risk ranking materials in the system
Pros and cons
Hazard checklist
Review
(d) Operational and environmental conditions
to be considered
(e) Systems for detection and control of
hazards and accidental events, emergency
systems, and mitigation actions

3. Collect risk information from previous and similar

systems (e.g., from accident data bases)

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 PHA team

Introduction
A typical PHA team may
PHA procedure
PHA
consist of:
Main Steps
Prerequisites
❑ A team leader (facilitator) with competence and
Hazard experience in the method to be used
identificatio
n ❑ A secretary who will report the results
Frequency
❑ Team members (2-6 persons) who can provide
Severity classes
Frequency classes necessary knowledge and experience on the
Risk ranking
Pros and cons system being analyzed
Hazard checklist
Review

How many team members who should participate will

depend on the complexity of the system and also of the
objectives of the analysis. Some team members may
participate only in parts of the analysis.

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 System functions

Introduction
As part of the system familiarization it is important to
PHA procedure
PHA
consider:
Main Steps
Prerequisites
❑ What is the system dependent upon (inputs)?
❑ What activities are performed by the system
(functions)?
❑ What services does the system provide (output)?

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 System breakdown

Introduction
To be able to identify all hazards and events, it is often
PHA procedure
PHA
necessary to split the system into manageable parts, for
Main Steps example, into three categories
Prerequisites

❑ System parts (e.g., process units)

❑ Activities
❑ Exposed to risk (who, what are
exposed?)

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 Selection of PHA worksheet

Introduction
The results of the PHA are usually reported by using a
PHA procedure
PHA
PHA worksheet (or, a computer program). A typical
Main Steps PHA worksheet is shown below. Some analyses may
Prerequisites
require other columns, but these are the most common.

Analys
Syste Operating t:
m: mode: Date:
Accidental Probabl Contingencies/
Ref. Hazard Prob. Sev. Comments
event e Preventive
(what, where, causes actions
when)

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 Preliminary Hazard
List
• Equipment-Related Hazards
• Operator-Related Hazards
• Failure Mode and Effect Analysis
worksheet
• HAZOP worksheet

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 Preliminary Hazard List (PHL)
Equipment-Related Hazards
Project/System: Prepared Date:
by:
Hazardous Hazard Causes Conseque Recommen
Event Category nces dations
Condition or Identify the Identify the The failure Suggested
state hazard potential effect actions to
that has the based on the causes for on people, be taken to
potential energy each hazard property, reduce haz-
to cause an type, such as business, ards, such as
injury or production, conduct
property electrical, environment, a job safety
damage mechanical, etc. analysis
chemical, (jSA), provide
etc. required
PPE, training,
etc.

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 Preliminary Hazard List (PHL)
Operator-Related Hazards
Project/System: Prepared Date:
by:
Hazardous Hazard Causes Conseque Recommen
Event Category nces dations
Condition or Identify the Identify the The failure Suggested
state hazard potential effect actions to
that has the based on the causes for on people, be taken to
potential energy each hazard property, reduce haz-
to cause an type, such as business, ards, such as
injury or production, conduct
property electrical, environment, a job safety
damage mechanical, etc. analysis
chemical, (jSA), provide
etc. required
PPE, training,
etc.

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 FMEA Worksheet
Potential Failure Mode, Effects, and Criticality Analysis
System Name: Air Severity Ranking Table (FMEA)
Occurance Rating Table Detection Ranking Table
Nibbler 5 Catastrophic: A failure 5 A high probability of 1Very high probability that
results in death and/or major occurrence the failure will be
losses and cost 4 A moderate probability detected
Date: of occurrence
4 Critical: A failure results in a 2High probability that the
serious injury or property 3 An occasional failure will be
Prepared By: damage probability of occurrence detected
3 Major: A failure results in 2 A remote probability of 3Moderate probability that
minor injury to personnel occurrence the failure will be
Start Date: and/or property damage 1Minor: A failure results in detected
2 Minor: A failure results in minor system failure 4Low probability that the
minor system damage but but does not cause failure will be
does not cause injury injury to property damage detected
1 Negligible: Near miss 5Very low probability that
without injury, property the failure will be
damage, or delay detected

S O D
Responsible E C E
S O D R R
Part Part Failure Recommende Individual/ V C T
Consequence E Potential Causes C E P P
Name & Function Mode d Actions Party & Due Action
s V C T N N
Number Date Results

1-

2-

3-
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 HAZOP
Insert Provide a Guide
Worksheet
Use a Provid Provide Curren Provide Who is
node/ paramet word, guide e the effects t solutions responsi
subsyst er, such such as word possibl here, such control to ble for
em as high, and a e as injury, s eliminate completi
temperat low, paramet cause property or reduce ng this
ure, more, er, such s damage, the risk task?
pressure, less, no, as more downtime,
volume, etc. pressure etc.
time, etc.
Make
There
sure
could be
to
more
investig
than
ate all
one
possible
paramet
guide
er for
words
each
for each
subsyste
paramet
m.
er.

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Preliminary Hazard Analysis CASE STUDY

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Preliminary Hazard Analysis CASE STUDY

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20
 Fault Tree Analysis
• A fault tree is a diagram that displays the logical
interrelationship between the basic causes of the hazard.
• Fault tree analysis can be simple or complex depending
on the system. Complex analysis involves the use of
Boolean algebra to represent various failure states.
• Detailed review of a specific undesirable event
• Top-down effort
• Normally reserved for critical failures or mishaps
• May be qualitative or quantitative

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 Steps in FTA

• The first stage is to select the hazard or top

event that is to be analysed.
• The tree is structured so that the hazard
appears at the top. It is then necessary to
work downwards, firstly by identifying causes
that directly contribute to this hazard.
• When all the causes and sub-causes have
been identified, the next stage is to construct
the fault tree.

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 Fault Tree
A fault tree is constructed by defining a top event and then defining the
cause events and the logical relations between these cause events

This is based on:

- Equipment failure rates
- Design and operational error rates
- Human errors
- Analysis of design safety systems and their intended function

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 Fault Tree EVENT SYMBOLS
Event symbols are used for primary events and intermediate
events. Primary events are not further developed on the fault
tree. Intermediate events are found at the output of a gate.
The event symbols are shown below:

The primary event symbols are typically used as follows:

•Basic event – failure or error in a system component or element (example: switch
stuck in open position)
•External event – normally expected to occur (not of itself a fault)
•Undeveloped event – an event about which insufficient information is available, or
which is of no consequence
•Conditioning event – conditions that restrict or affect logic gates (example: mode of
operation in effect)
•An intermediate event gate can be used immediately above a primary event to
provide more room to type the event description.

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 Fault Tree GATE SYMBOLS

Gate symbols describe the relationship between input

and output events.
The symbols are derived from Boolean logic symbols:

The gates work as follows:

•OR gate – the output occurs if any input occurs.
•AND gate – the output occurs only if all inputs occur
•Exclusive OR gate – the output occurs if exactly one input occurs.
•Priority AND gate – the output occurs if the inputs occur in a specific sequence
specified by a conditioning event.
•Inhibit gate – the output occurs if the input occurs under an enabling condition
specified by a conditioning event.

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Fault Tree construction: Reaction in the reactor system

Feed : Reactants

SV1 – Safety Valve 1

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FTA

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Fault Tree: For Pressurised
reactor system
Process vessel
over pressured

PSV- Process Safety valve

AND

Pressure rises PSV does not relieve

AND OR

Process Control fails Set point too

pressure high Fouling inlet or high
rises outlet
PSV too PSV stuck closed
small

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Fault Tree: Car Start

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 ETA: Event Tree Analysis
Event
Event tree
tree analysis
analysis(ETA)
(ETA) isis aa forward,
forward, bottom
bottom up,
up, logical
logical modeling
modeling technique
technique
for
for both
both success
success and
and failure
failure that
that explores
explores responses
responses through
through aa single
single initiating
initiating
event
event and
and lays
lays aa path
path for
for assessing
assessing probabilities
probabilities of
of the
the outcomes
outcomes and
and overall
overall
system
systemanalysis.
analysis.
Event
Event tree:
tree: traces
traces possible
possible events
events from
from loss
loss of
of operations
operations for
for
reactor
reactoroperation.
operation.

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 EVENT TREE
• Used to determine the likelihood of potential consequences after
the hazard has been realised

• It starts with a particular event and then defines the possible

consequences which could occur

• Each branching point on the tree represents a controlling point,

incorporating the likelihood of success or failure, leading to
specific scenarios
• Such scenarios could be:
• Fire
• Explosion
• Toxic gas cloud
• Information can then used to estimate the frequency of the outcome
for each scenario

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 Fault Tree

• Fault Tree Diagram are logic diagram that shows the

state of an entire system in a relationship of the
conditions of its elements.

• Fault Tree Diagram are used to analyze the probability

of functional system failures and safety accidents.

• An FTD visualize a model of the processes within a

system that can lead to the unlikely event.

• A fault tree diagrams are created using standard logic

symbols . The basic elements in a fault tree diagram are
gates and events.

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