Mapping of Process Hazard Analyses in Swedish Process Industries and How the Work Can Be Improved

Abstract

This study aims to map how Swedish process industries use qualitative risk analyses, such as process hazard analyses (PHA), to assess risks. Beyond the Seveso legislation, which requires all facilities classified as upper tier to perform a safety report each fifth years, there are no Swedish legislation or regulations regarding how and when PHAs should be executed. Hence, Swedish process industries are allowed to perform their risk assessments in several ways. Based on this, the objective of this study is to map how Swedish process industries work with PHAs and identify potential improvements. The improvements were identified based on Swedish process industries’ thoughts and lessons learned from the Norwegian Oil and Gas (O&G) industry. The Norwegian O&G industry was used as a reference since it has been characterized by large disasters which have resulted in extensive resources spent on performing risk assessments. Semi-structured in-depth interviews of representatives from Swedish process industries and safety experts working within the Norwegian O&G industry formed the basis of the methodology. The study identifies preliminary hazard analysis, Hazard and Operability (HAZOP) study, and What-If as the most common PHA methods within the Swedish process industry. These analyses are mainly performed for modifications of existing facilities, for new designs, or as part of the Seveso safety report. The analyses intend to identify safety improvements of proposed or existing designs. The main lesson learned from the Norwegian O&G industry is described as working in a structured and synchronized way within the companies through all steps of the risk assessments.

Popular Abstract

How Swedish Process Industries Use Qualitative Risk Assessments and How the Work Can Be Improved

Performing risk analyses are central in many organisations, not least for process industries which are characterised by extensive risks. These risks can be analysed in a quantitative or qualitative way, depending on the purpose of the analysis. Qualitative risk assessments with focus on process risks can be referred to as Process Hazard Analyses (PHA). This study identifies preliminary hazard analysis, Hazard and Operability (HAZOP) study and What-If as the most common PHA methods among Swedish process industries. PHAs are used frequently within the Swedish process industry, however, working with PHAs in a standardised and synchronized way is identified as the main improvement. This includes not only how the analyses are executed, but how the PHA methods are chosen and how the results are handled.

All facilities with considerable amounts of hazardous substances, according to the Swedish Seveso legislation, are classified as upper tier facilities. These facilities must perform a safety report each fifth years including the main risk factors, risks for surroundings, and prevention and mitigation measures. However, which risk analysis methods that should be used for this is not given. In general, there are no legislation or regulations about how and when PHAs should be performed in Swedish process industries. Consequently, companies may analyse risks with varying extensiveness and quality, which could affect the reliability of the studies when comparing them on a national level. Therefore, this study aims to map how Swedish process industries work with PHAs and identify areas of improvement. Due to the long history of risk management within the Norwegian O&G industry, lessons learned from the industry were used as a reference in addition to the Swedish process industries’ own experiences.

By identifying which PHA methods are used, how and when they are used, as well as how the results are handled, it is possible to get an overview of the differences between Swedish process industries. These practical perspectives can be used as a basis for understanding how PHAs are used and thus provide input to national guidelines. In addition, by identifying possible improvements, Swedish process industries can get inspiration which may help them improve the risk management on their sites. To achieve this, nine representatives from Swedish process industries and three employees from one engineering company were interviewed. For the Norwegian O&G part of the study four consultants from ORS Consulting, with extensive experiences within the industry, were interviewed. These interviews were analysed and compared with other sources such as books, articles, standards, and guidelines to further investigate the accuracy.

Preliminary hazard analysis, HAZOP and What-If is the most common PHA methods within the Swedish process industry. These are used to achieve safe facilities by identifying safety improvements to the proposed or existing design, usually recorded as recommendations. Meeting legislative requirements is also regarded as reason for performing PHAs, however, it is considered secondary compared to companies’ own incentives. When certain PHA methods are used depends on the initiating factor of the analysis, the experiences within the company, required level of detail and time available. In general, PHAs are mainly used in connection to modifications of new or existing designs, or as part of intermittent analyses. As already described, working with PHAs in a standardised and synchronised way within all parts of risk assessments, is identified as the main improvement. This means that the companies should minimize the number of decisions made by personal judgements and increase the use of guidelines when performing PHAs. In addition, there is a need for national guidelines and standards which can work as support for the companies when developing their own guidelines. In this way, companies can work in a structured and synchronised way without being limited to certain requirements which are not adjusted to each facility.

• author: Bergström, Isabella
• supervisor: Johan Ingvarson
• organization: Risk Management and Safety Engineering (M.Sc.Eng.)
• course: VRSM01 20221
• year: 2022
• type: H2 - Master's Degree (Two Years)
• subject: Technology and Engineering
• keywords: Risk management, Qualitative risk assessment, PHA, Process safety, Seveso directive
• language: English
• id: 9092535
• date added to LUP: 2022-06-23 09:45:09
• date last changed: 2022-06-23 09:45:09