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What are the most common process safety management risk assessment methods?

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Process safety management (PSM) is a systematic approach to prevent or minimize the consequences of hazardous events in industrial facilities. PSM involves identifying, evaluating, and controlling the risks associated with the processing, handling, and storage of hazardous materials. One of the essential elements of PSM is risk assessment, which is the process of estimating the likelihood and severity of potential incidents and their impacts on people, environment, and assets. Risk assessment methods can vary depending on the nature, complexity, and stage of the process, but some of the most common ones are:

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Debola A.

Energy Leader | Hydrocarbon & Low Carbon Energy

1 Hazard and operability study (HAZOP)

HAZOP is a structured and systematic technique that uses a set of guidewords (such as no, more, less, as well as, part of, etc.) to examine the deviations from the intended design or operation of a process and their causes and consequences. HAZOP is usually performed by a multidisciplinary team that includes process engineers, operators, safety specialists, and others. HAZOP is best suited for complex and novel processes that have not been fully tested or operated before.

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2 What-if analysis

What-if analysis is a simpler and less formal technique that uses brainstorming and open-ended questions (such as what if, how, why, etc.) to identify possible hazards and failures in a process and their effects and safeguards. What-if analysis can be performed by a small group of knowledgeable and experienced personnel who are familiar with the process. What-if analysis is more flexible and adaptable than HAZOP, but it can also be less comprehensive and consistent.

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Nike Amiaka
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Apart from its application in process plants, What-If Analysis can also be used in a range of applications such as railway, highways, airports, electrical installation, renewable energy, construction, and in non-technical areas such as facilitating a business continuing workshops or strategy workshop. It can also be applied to the whole life cycle phase of a project.

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3 Failure mode and effects analysis (FMEA)

FMEA is a bottom-up technique that focuses on the individual components or functions of a process and analyzes how they can fail, why they can fail, and what are the consequences and detection methods of their failure. FMEA assigns a numerical rating to each failure mode based on its severity, occurrence, and detectability, and calculates a risk priority number (RPN) to prioritize the corrective actions. FMEA is useful for evaluating the reliability and maintainability of a process, but it can also be time-consuming and tedious.

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4 Fault tree analysis (FTA)

FTA is a top-down technique that uses logic diagrams and symbols to represent the causal relationships between a specific undesired event (such as fire, explosion, spill, etc.) and the basic events or faults that can lead to it. FTA can quantify the probability of the top event by using mathematical formulas and data from historical records or experiments. FTA can provide a clear and visual representation of the fault scenarios and their interactions, but it can also be complex and demanding.

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5 Layer of protection analysis (LOPA)

LOPA is a semi-quantitative technique that combines the qualitative aspects of HAZOP or what-if analysis with the quantitative aspects of FTA or FMEA. LOPA evaluates the frequency and severity of a hazardous scenario and compares it with the existing or proposed layers of protection (such as alarms, relief valves, emergency shutdown systems, etc.) that can prevent or mitigate it. LOPA can determine the adequacy or gap of the protection layers and recommend the necessary improvements or changes. LOPA is a pragmatic and efficient technique, but it can also be subjective and dependent on the assumptions and data used.

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6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Debola A.

Energy Leader | Hydrocarbon & Low Carbon Energy
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The way I think about the various methods is like a toolbox: different tools for different problems. Often engineers can default to the method they are most familiar with and try to apply it to an issue. Step back and ask yourself: Is this the right tool for this scenario? Is there a more suitable tool? Can I ask for help from peers/others? Pick the right tool and you are more likely to get a clearer view of the risks, and what actions you need to take to manage them effectively.

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What are the most common process safety management risk assessment methods?

1

2

3

4

5

6

1 Hazard and operability study (HAZOP)

2 What-if analysis

3 Failure mode and effects analysis (FMEA)

4 Fault tree analysis (FTA)

5 Layer of protection analysis (LOPA)

6 Here’s what else to consider

Industrial Engineering

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What are the most common process safety management risk assessment methods?

1

2

3

4

5

6

1 Hazard and operability study (HAZOP)

2 What-if analysis

3 Failure mode and effects analysis (FMEA)

4 Fault tree analysis (FTA)

5 Layer of protection analysis (LOPA)

6 Here’s what else to consider

Industrial Engineering

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