Process Hazard Analysis is a systematic and comprehensive approach used in process industries to identify, evaluate, and mitigate potential hazards associated with their operations. PHA is typically conducted during the early stages of the facility’s design, construction, or modification, and it aims to ensure the safety and integrity of the process.
If properly conducted, the risk relating to human health, process downtime, property damage, and product quality issues caused by equipment failures, human errors, or even external events can be reduced significantly.
Gexcon’s consultants have years of experience in performing Process Hazard Analysis and can assist you at all stages of your engineering and management control process from concept design, process development, facility safe operation, initial hazard evaluation to continued safe operability of your facility.
Once hazards are identified, a risk assessment is conducted to evaluate the severity, likelihood, and potential impact of each identified risk.
HAZID (Hazard Identification)
HAZID (Hazard Identification) is a risk analysis technique for early identification of hazards performed at the earliest possible stage of project development.
Through HAZID, Gexcon can help you identify potential hazards in your facility and reduce the likelihood and severity of credible events associated with those hazards that might have a catastrophic impact on your employees, business, and the environment. Identifying high-risk scenarios at an early stage of the project development can significantly reduce the cost of implementing measures suitable to reduce the risk to an acceptable level.
HAZOP (Hazard and Operability Studies)
A HAZOP (Hazard and Operability Study) is a structured form of Hazard Assessment which can form the first step of the Hazard and Risk Assessment Life Cycle. The purpose of the HAZOP study is to verify and test that the control and operation of your facility are robust and inherently safe so far as is reasonably practicable, by identifying credible deviations from normal operation, assessing their potential consequences and safeguards which are in place to mitigate the associated risk with these scenarios.
Through HAZOP, Gexcon can identify where there may be hazard or operability issues and make recommendations for potential measures to address these. In some instances, these recommendations may require the project team to design a suitable engineering solution.
CHAZOP (Control Systems HAZOP)
Unlike HAZOP, which looks at the entire facility, mechanical equipment and processes, CHAZOP (Control Systems Hazard and Operability Study) focuses on the potential hazards associated with the control system and individual failures of the processes.
Through CHAZOP, Gexcon can assist in identifying the hazards related to the operability of the control system and investigate the control system’s suitability.
FMEA (Failure Mode and Effects Analysis)
FMEA (Failure Mode and Effects Analysis) allows organisations to anticipate, identify and detect potential points of failure of design or manufacturing processes and analyse the effects of potential consequences occurring as a result of those failures.
FMEA encourages a systematic analysis of process flows and identifies weak points or areas for improvement. By evaluating failure modes and their effects, you can make necessary process modifications to enhance efficiency, reliability, and safety. This proactive approach also reduces the likelihood of unplanned downtime and associated expenses, such as equipment repairs, production loss, or regulatory fines.
BowTie Analysis
BowTie Diagrams are used to represent the relationship between potential causes, consequences and controls associated with undesired hazardous events, together with the barriers in place for preventing those from being realized. By mapping out the barriers on the diagram, organizations can assess the effectiveness of existing controls, identify any gaps or weaknesses, and develop strategies to strengthen the barriers.
The methodology is formed by the relationship between Hazards, Top Events, Threats and Consequences and is designed to provide a more functional overview to visualize credible paths from threats to high-consequence scenarios. It provides a clear and concise visual representation of the risks and potential consequences associated with process facilities, making it easier to understand and communicate the risk landscape.
The analysis promotes proactive risk management by emphasising preventive measures. By identifying potential threats and vulnerabilities, you can implement proactive controls to prevent incidents or minimize their impact. This approach helps reduce the likelihood of accidents, disruptions, and losses.
What-If?
What-If? is a workshop-based process hazard analysis form which investigates the potential consequences of foreseeable process upsets and the safeguards in place to mitigate the risk of these scenarios. The effectiveness of this hazard analysis method relies heavily on the experience of the workshop team to ensure that relevant foreseeable scenarios are captured.
What-If? methodology allows for brainstorming and exploration of potential scenarios, deviations, or conditions that could lead to hazardous situations. By asking “What if?” questions, organisations can uncover and identify previously unrecognised hazards, contributing to a more comprehensive understanding of risks. This methodology also promotes a safety-conscious culture within the organisation as it encourages employees at all levels to actively participate in hazard identification and risk assessment by encouraging them to think critically. This engagement fosters a proactive mindset and a shared responsibility for safety throughout the organisation.
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