An overview of process hazard evaluation techniques

Since the 1985 release of methyl isocyanate in Bhopal, India, which killed thousands, the chemical industry has begun to use process hazard analysis techniques more widely to protect the public from catastrophic chemical releases. These techniques can provide a systematic method for evaluating a system design to ensure that it operates as intended, help identify process areas that may result in the release of a hazardous chemical, and help suggest modifications to improve process safety. Eight different techniques are discussed, with some simple examples of how they might be applied. These techniques include checklists, "what if" analysis, safety audits and reviews, preliminary hazard analysis (PHA), failure modes and effect analysis (FMEA), fault tree analysis (FTA), event tree analysis (ETA), and hazard and operability studies (HAZOP). The techniques vary in sophistication and scope, and no single one will always be the best. These techniques can also provide the industrial hygienist with the tools needed to protect both workers and the community from both major and small-scale chemical releases. A typical industrial hygiene evaluation of a facility would normally include air sampling. If the air sampling does detect a specific hazardous substance, the source will probably be a routine or continuous emission. However, air sampling will not be able to identify or predict the location of a nonroutine emission reliably. By incorporating these techniques with typical evaluations, however, industrial hygienists can proactively help reduce the hazards to the workers they serve.