HAZOP Process Hazard Analysis (PHA) PPT.pdf

HAZOP training

1. Virtual Training Session
on “Process Hazard
Analysis (PHA)”

2. ➢Safety Moment, What Happened?
➢Hazard Identification
➢Risk Terminology
➢Overview of PHA
➢History of PHA
➢PHA & Risk Analysis
➢Safety Management Systems
➢Human factors in Facility Risk
➢PHA Teams
➢General PHA Procedure Flow Chart

3. The Worst Situation Ever!!
Bhopal Gas Tragedy
The Bhopal gas tragedy:
Toxic legacy - Bing video

4. The Big Dig Ceiling Collapse (2006)
Bing Videos

5. Let us understand with a situation and know how would
you respond to it!!!
AScenario….
•Youareoperatingacranewith
heavyloadonitandsuddenly
youreceiveanimportantcall
fromyourwifeandshetells
somethingwhichshocksyou
andsuddenlyyoudroptheload
whichleadstodestroyingthe
productandalsohitsother
workersonthesite??

6. Sensational Significance
•What is the cause of the accident?
•What is the consequence of the event?
•What can we do to prevent all those things
to happen in the first place?

7. What is a Hazard?
Source with a potential to causeharm
Does it have the
potential to cause
harm?
If the answer is yes,
then it is a hazard
People: Injury or
fatality
Environment:
negative impact
Asset: Property
damage

8. Hazard could in Different Forms Like!!

9. What are Physical Hazards?
Various Types
of Factors
which come in
Physical
Hazard!!

10. What Comes Under Ergonomics?
Musculoskeletal
disorders, hand
activity
level,lifting.

11. Chemicals Are Dangerous!!
YOU SHOULD BE
VERY CAREFULL
WITH THEM

12. Biological Hazards
THESE SINGS WILL HELP
YOU TO IDENTIFY

13. Psycho-Social Hazard
Examplesinclude
Work-relatedstress,whosecausalfactorsinclude
excessiveworkingtimeandoverwork,violence
fromoutsidetheorganization,bullying,whichmay
includeemotionalandverbalabuse,sexual
harassment,mobbing,burnout,discrimination,
exposuretounhealthyelementsduringmeetings
withbusinessassociates.
Psychological hazards
Those that are basically causing stress to a worker.
This kind of hazard troubles an individual very
much to an extent that his general well-being is
affected.

14. But How Do We Identify the Hazard?
Thehazardidentificationmethods
maybecategorizedas
•Comparativemethodsand
•Fundamentalmethods

15. •Thesemethodsare
basedonhazard
identificationby
comparing with
standards.
•Thevariousmethods
arechecklist,safety
audit,hazardindices
andpreliminaryhazard
analysis
•Four main methods in this
category are what-if
analysis, failure modes and
effects analysis (FMEA),
job safety analysis (JSA)
and hazard and operability
study (HAZOP)
Comparative Method Fundamental Method

16. Terminology
•Hazard:A potential source of harm,damage,or loss.(e.g.,flammable materials,falling
objects,exposure to chemicals)
•Risk:Thecombinationof thelikelihoodof a hazard occurring and theconsequencesof it
happening.(e.g.,the risk of a fire causing significant property damage)
•Severity:The extent of the damage or harm caused by a hazard.(e.g.,a minor injury
versus a fatality)
•Likelihood:The probability of a hazard occurring.(e.g.,a high likelihood of slips and falls
on a wet floor)
•Vulnerability:The susceptibility of people,property,or the environment to be harmed
by a hazard.

17. What is ?
Risk is a combination of likelihood of harm being done and
severity of that harm.
Risk= Likelihood X Severity
(Probability) (Consequence)

18. Example
What do you observe?
HAZARD
RISK

19. Risk Assessment Approaches
Qualitativeriskanalysisisasubjective
assessmentofrisksbasedontheir
qualities,characteristics,andsubjective
judgment.
Quantitative risk analysis involves a
more objective and numerical
assessment of risks. It attempts to assign
specific values or ranges to the likelihood
and impact of risks and uses
mathematical models for analysis.

20. ERGO BREAK

21. Risk Control
•It is also referred to as "hazard
control," and it is the step in the risk
management process where
techniques are put into place to
eliminate or lessen hazards that have
been identified.
•It involves responses to risk factors that
could result in an accident or other
negative outcome at work.

22. Overview of PHA
•Theapplicationofoneormoreanalyticalmethodstoidentifyandevaluate
processhazardsforthepurposeofdeterminingtheadequacyofneedforcontrol
measures.
•Itisusedtoanalysepotentialcausesandconsequencesoffires,explosions,
releasesoftoxicorflammablechemicals,andmajorspillsofhazardouschemicals.
•Itfocusesonequipment,instrumentation,utilities,routineandnon-routine
humanactions,andexternalfactorsthatmightimpactaprocess.

23. Before Starting
the PHA, what
should we
required?

24. PHA Requirements
•Block flow diagrams or P&ID (Piping
and instrumentation diagram)
•Process parameters limits
•Qualitative estimates of the
consequences of deviations

25. PHA Must Address …
•The hazardsof the process
•Identification of previous incidents with likely potential for
catastrophic consequences
•Engineering and administrative controls applicable to the hazards and
their interrelationships

26. 26/49
PHA Must Address … (cont’d)
•Consequences of failure of engineering and administrative controls,
especially those affecting employees
•Facility siting
•Human Factors
•The need to promptly resolve PHA findings and recommendations

27. PHA Technique
✓What-if,
✓Checklist,
✓Hazard and operability study (HAZOP),
✓Failure mode and effects analysis (FMEA),
✓Fault tree analysis, or
✓An appropriate equivalent methodology

28. Block
Diagram

29. P&ID

30. Let See History of PHA

32. Risk Analysis-PHA Technique

33. Checklists Technique
•This method uses established codes, standards and
well-understood hazardous operations as a checklist
against which to compare a process.
•A good checklist is dependent on the experience level
and knowledge of those who develop it.

34. What If
Technique
•Thisapproachusesamulti-skilledteamtocreate
andansweraseriesof“what-if”typequestions.
•Takeexampleofthecondensingsystemofa
distillationtower.
•Teammembersaskquestionssuchas:
“What-Ifthereishighpressureinthetower?”
“What-Iftheoperatorforgetstoopenthedrainvalve?”
“What-Ifthereisanexternalfireinthisarea?”

35. Failure Mode
and Effect
Analysis
(FMEA)
•Failure Modes and Effects Analysis (FMEA) is
a technique for determining the ways in
which equipment items and their internal
components can fail, and what the
consequences of such failures would be on
the overall system reliability and safety.
•A systematic study of the consequences of
failure (breakdown) of certain operational
hardware such as transmitters, controllers,
valves, pumps, etc.

36. HazardandOperabilityStudy(HAZOP):
•Astructured,systematicreviewthatidentifiesequipmentthatis
beingusedinawaythatitwasnotdesignedtobe,andwhich
mightcreatehazardsoroperationalproblems.
•HAZOPsareusuallyconductedbyamulti-skilledteamthatstudies
pipingandinstrumentdiagrams.Eachpipelineandvesselis
evaluatedforcertainlimitationsanddeviationsinflow,
temperature,pressure,etc.

37. Fault-Tree Analysis
•Thismethoddrawsapicture(model)that
showswhatundesirableoutcomesmight
resultfromaspecificinitiatingevent(for
example,apiperuptureinapiperack).
•Thismethodissometimesusedinaccident
investigationstodetermineprobablecause.

38. SAFETY MANAGEMENT SYSTEM (SMS)
•AnSMSisasystematicframeworkdesigned
toproactivelyidentify,assess,andmitigate
riskstoensureasafeworkenvironment.
•Itinvolvesfollowingspecificrulesand
procedurestomakesureeveryonestaysand
healthwhileworking.
•SMSshouldbe:Documented,Accessibleand
Comprehensible.
•Ensuringtheeffectivenessandcompliance
SMSshouldbealignwiththeinternational
standardslikeISO45001.

39. CONTD.
•Importance of SMS:
✓Improved Risk Management
✓Legal Compliance
✓Employee Engagement
✓Organizational Performance

40. CONTD.
•Key elements of the SMS:
•Policy
•Planning
•Implementing
•Assessing
•Management Review
SMS
Components
Safety Policy
Safety Risk
Management
Safety
Assurance
Safety
Promotion

41. CONTD.
4 COMPONENTS OF SMS
Safety Policy Safety Assurance Safety Risk
Management
Safety Protection
Establishes senior
management’s
commitment to
continually improve
safety, defines the
method, procedures,
and organizational
structure needed to
meet safety goals.
Evaluates the
continued
effectiveness of
implemented risk
control strategies,
supports the
identification of new
hazards.
Determines the need
for, and adequacy of,
new or revised risk
controls based on the
assessment of
acceptable risk.
Includes training,
communication, and
other actions to create
a positive safety
culture within all levels
of the workforce.

42. CONTD.
•SMS helps in:
•Hazard Identification
•Reporting
•Risk Management
•Performance Evaluation
•Quality Assurance

43. CONTD.
•Effective SMS:
•Management Leadership and Employee Involvement
•Worksite Analysis
•Hazard Prevention
•Training

44. CONTD.
•SMS should be able to cover:
•Define roles and responsibility
•Ensure adequate skills, information, tools and decision-making are
present in day to day and abnormal operations.
•Maintain awareness of hazards and risks
•Plan, implement, measure and evaluate MA controls and SMS
•Develop performance requirements
•Set targets for improvement of safety at the facility

45. Human factor in Facility Risk
•Human factors are conditions that affect an
employee’s interaction with their workplace,
equipment, work procedures, or even their
team.
•These conditions might arise from physical,
psychological, or social reasons, but ultimately,
they affect employees’ human abilities to
perform their work safely.

46. Example of Human factors

47. People
•Employee’s knowledge, abilities and limitations, and expectations will affect
how they interact with others around them.
•Their individual differences such as their age and culture, also matter. If
employees are stressed or distracted, these are predictors that safety
performance might be affected.

48. •The overarching organizational factors, such as
management systems, also play an essential role.
•Managerial policies and decisions about the job design as
well as how the information is communicated to the
employee, will also impact human factors.
•This means that safety professionals must consider things
such as work schedule, workload, task design, and
requirements, besides written and spoken communications
to convey instructions and data to employees.
Management

49. •Work environments also affect safety in the
workplace.
•The facilities, workstation configuration and
accessibility, as well as workplace controls, warning
systems, and other physical aspects that affect human
well-being such as noise, temperature, and heat
exposure all matter.
Work environments

50. •Experience can prevent significant accidents because this process occurs intuitively
and automatically and does not involve analytical, data-driven risk assessments.
•Each time the benefit is realized without a negative consequence, the behavior
becomes automatic. But injuries can also occur when experience becomes a habit,
influencing behavior.
•The act of doing in the workplace becomes careless when people think that the job
is safe.
Another reason why human factors can be challenging to minimize is that
risky behaviors are sometimes driven by experience.

51. •Human factors also result from employees’ lack of awareness of what is
happening in complex and dynamic operating environments.
•Safety systems and risk models often do not describe safety risks or
environmental change.

52. Organizations need to take a proportionate approach to human factors in risk
assessment based on their hazard and risk profile.
Human Factor in Risk Assessment
Key Principles in integrating Human Factors in Risk Assessment:
✓Through risk assessment, we have to identify those tasks which are safety critical or expose
people occupational health hazards
✓Ensure to have an understanding of how the tasks are carried out and the environment in which
they are performed. This may include walking and talking through the task where it is carried
out.
✓Involve the workforce in carrying out the assessment and the identification of appropriate
controls
✓The people carrying out the assessment should have an understanding of the different types of
failure and the factors that make them more or less likely to occur;

53. ✓Identify the human failures that could be made in the task which might lead to an accident of
incident and the performance influencing factors that make those failures more or less likely to
occur.
✓Identify appropriate control measures which prevent or mitigate the human failures identified;
✓Where possible we should aim to design out the potential for human failure and design for
recovery. This includes design of the plant, system, environment and task, taking into account
the needs and capabilities of users.
✓Checking if the control measures work. Regularly review risk assessment to see if any further
improvements can be made.
Key Principles in integrating Human Factors in Risk Assessment: (Continued……….)

54. PHA Teams
PHAs are generally team activities.
The team members should represent a cross-section of disciplines and
functions, typically including operations, engineering, maintenance,
and process design.
Having all the disciplines present helps ensure that all types of hazard
scenarios are discussed.
Furthermore, the interaction between team members helps uncover
those hazards that may be created due to communication difficulties
or misunderstandings between departments.

55. Team of PHA…..
i.Engineering principles
ii.Instrumentation
iii.Equipment design/set-up
iv.Research and Development
v.Maintenance
vi.Environmental, Health & Safety

56. General PHA Procedure

57. Step 1
Establish the
Goals and
Boundaries
Step 2
Select the
Most Effective
PHA
Techniques
Step 3
Collect Useful
Data for
Process Hazard
Analysis
Step 4
Conduct the
Process Hazard
Analysis
Step 5
Assess Risks
and
Consequences
Step 6
Create Risk
Mitigation
Steps
Step 7
Document All
of Your
Analysis
PHA Procedure

58. PHA Sequence
When a new process is being designed and
constructed, it is normal for different types of
PHA to be performed at each stage of the design.

59. Conceptual (theoretical )Design
•Conceptual Design PHA provides a
preliminary safety analysis
•What-If method is probably the
best method for this phase of the
PHA

60. PRELIMINARY DESIGN
•Once the basic process design is
complete
•What-If method works well at this stage
•What-If/Checklist method is also a good
choice at this stage.
•The What-If approach encourages broad-
range thinking, while the Checklist
questions provide a framework on which
to base the analysis

61. FINAL DESIGN
At the conclusion of the final design, a complete set of P&IDs will have been published.
Other documentation available to the PHA team will include electrical loop drawings,
MSDS, and draft operating manuals.
So, the final design PHA is usually a full HAZOP study.

62. PRE-
STARTUP
SAFETY
REVIEW
•The last process safety evaluation to be
carried out before the start-up.
•Pre-startup Safety Review PSSR is not a PHA.
•A PSSR is not a PHA instead it serves to
ensure that the plant was constructed as
required by the original design and that all
required changes (including those stemming
from the PHA) have either been
implemented or meet the original design
intent.

63. MANAGEMENT OF CHANGE (MOC)
Any significant proposed change to a plant that is already running or whose design has been
finalized, should be analyzed with a PHA as part of the Management of Change process.
What-If or a brief HAZOP is a good choice for the PHA.

64. DECOMMISSIONING /DEMOLITION
When a plant is decommissioned, it has two possible fates.
The first is that it will be simply mothballed in the hope that it can be renovated and restarted
at some unspecified time in the future when economic conditions call for such action.
The second possibility is that the plant will be torn down, and the site used for something else.
In either case, a PHA should be performed, with the What-If technique probably being the
preferred method.
If the plant is to be demolished, the checklist will focus on due diligence items

65. Examples of Process Hazard Analysis
•Example: Chemical Production:
•Forinstance,PHAdiscoveredapotentialriskassociatedwitha
particularreactionprocessinachemicalfactory.What-If
Analysisdiscoveredthattemperaturedifferencesbeyondaspecific
limitmightsetoffarunawayreaction,increasingthelikelihoodofan
explosion.Improvedtemperaturecontrolmethodsandalternative
safetysystemsweresuccessfullyputinplacetoreducethe
dangerandguaranteeemployeesafety.

67. Any Questions!!!!
Thank you
Trainer–MunishKumar([phone])