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An overview of process hazard evaluation techniques.

M G Gressel1, J A Gideon

  • 1National Institute for Occupational Safety and Health, Division of Physical Sciences and Engineering, Cincinnati, OH 45226.

American Industrial Hygiene Association Journal
|April 1, 1991
PubMed
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Process hazard analysis techniques systematically evaluate chemical industry systems to prevent catastrophic releases. Industrial hygienists can use these methods to protect workers and communities from chemical hazards.

Area of Science:

  • Chemical Engineering
  • Industrial Safety
  • Risk Management

Background:

  • The 1985 Bhopal methyl isocyanate disaster highlighted the need for enhanced chemical safety.
  • The chemical industry widely adopted process hazard analysis (PHA) techniques post-Bhopal.
  • PHA methods systematically evaluate system designs to prevent hazardous chemical releases.

Purpose of the Study:

  • To discuss various process hazard analysis techniques for improving industrial safety.
  • To illustrate the application of these techniques with simple examples.
  • To highlight the role of PHA in protecting workers and communities from chemical releases.

Main Methods:

  • Discussion of eight distinct PHA techniques: checklists, "what if" analysis, safety audits, preliminary hazard analysis (PHA), failure modes and effect analysis (FMEA), fault tree analysis (FTA), event tree analysis (ETA), and hazard and operability studies (HAZOP).

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  • Examples of technique application are provided.
  • Integration of PHA with traditional industrial hygiene evaluations, such as air sampling.

    • Main Results:

    • PHA techniques offer systematic approaches to identify and mitigate process safety risks.
    • The discussed methods vary in complexity and applicability; no single technique is universally superior.
    • PHA complements air sampling by identifying potential sources of non-routine chemical emissions, which air sampling alone may not reliably detect.

    Conclusions:

    • Process hazard analysis techniques are crucial for preventing major industrial accidents and protecting public health.
    • Industrial hygienists can leverage PHA to proactively reduce chemical hazards for workers and the surrounding community.
    • A combination of PHA and traditional industrial hygiene practices provides comprehensive safety management.