(32cg) Key to a Good Hazard Analysis – Do Your Homework!

Process Hazard Analysis (PHA) is a systematic method for identification and analysis of hazards associated with industrial, municipal, and other potentially dangerous processes. The structured methodology for this analysis involves detailed examination of process safety information (PSI) related to a process, splitting of complex systems into manageable sub-system(s) or nodes, and conducting a facilitated brainstorming session with relevant stakeholders. Hazards and their consequences are risk ranked and documented, sufficiency of existing safeguards is assessed, and recommendations to effectively improve personnel and process safety are recorded. However, lack of Process Safety Information (PSI) may complicate the preparation and execution of a PHA or DHA (Dust Hazard Analysis). This may result in failure to identify important hazards, significant impact to project schedule, more constraints on the project budget, and last but not the least, reduced credibility.

Comprehensive homework in advance of a PHA is the cornerstone of a successful and acceptable deliverable. The foremost and crucial step is to zero-in on the type of study (HAZOP, HAZID, What-if, or other), agree on a scope and collect all relevant PSI related to the study's scope. Documents including, but not limited to Safety Data Sheets, General Arrangement, Combustible Dust screening and explosion test data (such as K_st, P_max, Minimum Ignition Temperature, Minimum Explosible Concentration, and others), Piping and Instrumentation Diagrams (P&IDs), Process Narrative, Interlocks and Alarms list and an overview of applicable codes and standards are essential for understanding the system behavior, defining nodes, and evaluating deviations from intended operation. In certain situations, it may be necessary to do preliminary work to persuade the client that dust is a potential risk that needs to be addressed.

With insufficient information and preparation, the facilitator may base their understanding on assumptions, consult with a subject matter expert, use rules of thumb, or may find it prudent to postpone the session, instead of redoing the analysis. Recently developed open-source AI (Artificial Intelligence) tools can assist in the preparation. Examples include faster document analysis for generating high level descriptions, analyzing drawings for recognizing potential hazards, and producing preliminary recommendations (Don't you wish we had it before!). The facilitator can compile this information to establish a baseline for the session, and then collaborate with participants to uncover additional scenarios and augment the analysis. This presentation will include illustrations of using AI for homework, demonstrate the financial implications of choosing the incorrect approach and inadequate preparation, using historical project data.

A thorough groundwork can build a solid framework for brainstorming with a multidisciplinary team and optimize the team's efforts towards the more critical aspects of a hazard analysis.