by Carolyn Bott and the scribe team A Process Hazard Analysis (PHA) will prove to be the cornerstone of Process Safety Management (PSM) at any operating facility with the correct tools and the right leaders. Although there are many variables concerning PHAs, the process can be simplified and impactful results can be attained. In this blog, we delve into the five essential components that constitute an efficient and effective PHA. Clear and well-defined scope that is relevant to the system being analyzed Systematic and structured approach Multidisciplinary team of subject matter experts who can identify and evaluate potential hazards from different perspectives Use of appropriate techniques and tools to evaluate and prioritize risks Periodic reviews and updates. PHA Scope A well-defined scope for a PHA is critical to identify potential safety and environmental hazards in a facility. Having a clear and defined scope: Sets the boundaries of the analysis -This assures all necessary elements are included and relevant risks are identified and assessed Enables the PHA team to focus on specific areas of concern and analyze them in detail - This reduces the potential for error and minimizes both the time and resources needed Ensures that all stakeholders are aware of the objectives and outcomes of the PHA Standard for Approaching PHAs Different companies may have their own specific PHA standards, specific to their operations and the risks involved. These standards typically outline essential measures to perform a thorough PHA, including: Qualifications and training required for team members Selection of appropriate methodologies Level of detail required in the analysis Documentation requirements for the study Frequency of review Ongoing monitoring requirements ensuring the safety and efficiency of operating processes Adherence to these standards is typically required by regulatory bodies and industry best practices. A standard can ensure all relevant factors are considered and a thorough analysis is conducted. Following a standard also facilitates communication and collaboration among stakeholders, enhances consistent decision-making across sites, and promotes continuous improvement in a site’s process safety. PHA Team An effective PHA team is composed of individuals with diverse expertise, including engineers, operators, maintenance personnel, and safety professionals. The team: Shall have expertise in engineering and process operations Shall include at least one employee who has experience and knowledge specific to the process being evaluated One member of the team must be knowledgeable in the specific process hazard analysis methodology being used Must be able to work collaboratively to identify hazards, evaluate risks, and develop appropriate risk management strategies Effective communication and teamwork are vital for a successful and efficient PHA. The proficiency of the PHA leader or facilitator has a substantial impact on the team and the outcome of the PHA. A facilitator leans on their own risk management experience and is responsible for guiding the team through the identification and evaluation of all credible process hazards. The leader continuously assesses the team’s dynamic and intervenes when necessary to ensure the group remains on task to complete the PHA efficiently with impactful results. A company can utilize in house experts or hire a third party to shepherd their PHA needs– Process Safety Consulting Techniques and Tools Methodologies The methodology selected must be appropriate to the complexity of the process and site standards. One or more of the following methods, as appropriate, may be used to determine and evaluate the hazards of the process being analyzed: What-if Checklist What-if Checklist Hazard and operability study (HAZOP) Failure mode and effects analysis (FMEA) Fault tree analysis An appropriate equivalent methodology For more info on choosing a risk assessment methodology, check out our webinar that examines the advantages and limitations of various methodologies: Choosing a Risk Assessment Methodology Tools Computer-based systems are used to document PHA discussions in an organized manner and provide consistency throughout the analysis. Examples of PHA documenting software include: Sphera® PHA-Pro® PrimaTech PHAWORKS RA® aeShield® aeFacilitator® Using appropriate software eases the execution of risk studies. Review Cycle All PHAs must be updated and revalidated every five years. The periodic review should reflect any changes in the process or surrounding environment that may impact safety. An alternate approach to managing PHA updates is to incorporate them into the study file as changes occur. This method is often called an Evergreen PHA or Continuous PHA Revalidation. An efficient and effective PHA can enhance the safety of processes, reduce the risk of accidents and incidents, improve compliance with regulations and standards, and ultimately support the organization's goals and objectives. Ensuring these five (5) components are in place can help companies have an efficient PHA to identify and mitigate risks before they become safety incidents.

By Ken O'Malley As aeSolutions celebrates its 25th year in business, it’s natural to wonder what the next 25 years will bring. And while there’s no crystal ball to predict how new technologies, for example, will change the way we solve client problems, the one thing I know is that our success will be grounded in the same people-first mindset that got us to where we are today. Here's what I mean. The way in which aeSolutions emphasizes employee retention and development makes me very proud. We have many long-tenured employees who could work anywhere, yet they choose aeSolutions as their professional home. For a company of our size, it’s rare to employ a full-time talent development specialist whose role is to create and improve employee development opportunities. While that represents a sizeable yet important investment to make our employees a top priority, we can point to more than two decades of proof that if we treat our employees well, our clients reap the benefit. The “Next 25” Technologies I was recently asked what I see as potential game-changing technologies that we can expect to impact the future of work, to which I responded that Artificial Intelligence (AI) will live near the top of that list for solving our most complex challenges, especially where large amounts of empirical data are available. The pace at which AI has advanced over the past year is staggering. Even more surprising is how accessible it has become to everyone. It has opened up new problem-solving opportunities and possibilities that we once thought were unimaginable. As industrial engineers and consultants, our work centers on designing and implementing solutions to complex challenges – something that AI will only get better at. At the same time, this advanced level of “machine thinking” will raise the potential for workers to contribute at a higher level which has always been the impact of new technology. This creates opportunities for people to grow and develop, something I think we should all be excited and optimistic about. I do believe advanced technologies will put some roles at risk, at least as these roles are being executed today, as these new systems get better and better at diagnosing complex problems. My optimism, however, comes from believing that humans will continue to maintain essential roles that require creativity, empathy, critical thinking, and ethical decision-making. Collaboration between humans and technology results in improved productivity and new opportunities; there’s no reason to think this latest technology revolution will be any different. Governmental and Market Factors Much of what we do here at aeSolutions is either directly or indirectly impacted by governmental policy, particularly as it relates to the regulated industries that we serve, such as the energy sector. Governmental decisions will continue to impact investments in new energy sectors, the green economy, and large-scale infrastructure programs. These are poised to create huge opportunities for companies like ours, provided we remain agile enough to adapt to these up-and-coming economic opportunities. On an international level, deglobalization without increasing production costs and a smaller workforce will both drive up the need for automation. Regardless, I’m confident we’ll continue to redefine ourselves in ways that allow us to deliver the most value to our existing clients and new ones. Staying Laser Focused For aeSolutions, putting the client at the center of our business, maintaining an efficient and lean operation to drive costs down, and focusing intently on clients’ needs and business objectives will shape the next two decades. Operationally speaking, being able to transition clients from our front-end consulting services to our back-end engineering and automation teams with high quality and predictability will be key to executing larger, more complex projects, ultimately bringing real, lasting value to our clients on a larger scale. We will continue to support our team members to help them reach their full potential as employees and as people. For clients, working hard to serve as their guides while always having a keen interest in their overall success, not just the success of their projects, is how we do business. With the leadership team we have in place and the exciting vision we have for the future, we are poised to take our employees, our clients, and our business to the next level.

In the evolving world of chemical processing, companies face a formidable challenge as they strive to keep pace with ever-evolving industry demands, develop novel formulations and deliver innovative products to market. Meeting customer needs often requires adjustments to production processes, including new plants, facility expansions and equipment upgrades. The successful execution of such projects hinges upon comprehensive planning, particularly when it comes to evaluating process safety risks. Complex assessments, such as studies of overpressure relief devices, facility sitings and process safety procedure development, are crucial elements in this process. However, plant operators are primarily experts in running chemical plant operations, not project planning. To shed light on this critical aspect, Chemical Processing recently spoke with Chris Neff, senior vice president of project development for aeSolutions. In this discussion, Neff delves into the intricacies of the project-planning process and outlines methods for chemical manufacturers to integrate safety seamlessly into their projects. "I think one of the biggest challenges is the belief that process safety is a cost rather than an integral part of the operation." The full interview is available on chemicalprocessing.com as well as an audio podcast:

Fire and Gas Products 20 years of delivering FM Approved industrial PLC Fire & Gas products ​ The aeSolutions FM Approved family of Fire & Gas safety systems ensures compliance with the latest NFPA 72 standards and FM 3010 standard for fire alarm signaling systems to meet all of OSHA’s requirements. ​ FM Approved to be in ​compliance with FM Approval's Combustible Gas Standard 6320, Toxic Gas Detection standard 6340, and ANSI/ISA 12.13.01 Performance Requirements for Combustible Gas Detectors standard. ​ FGS 1400 MK II is FM Approved for combination system I/O this allows the end user to control HVAC, process ESD, SIS safety functions, and other non fire processes from the fire panel. The FGS 1400 MK II is listed for Fire Command Center and proprietary Supervising Station functions. Are you Compliant? ​ With aeSolutions on your team, you can rest assured that your Fire and Gas System is designed to the latest FM Approve d Fir e and Gas standards utilizing our first-hand industry experience. Product Benefits: ​ • Scalability provides you with customization options • Listed for use with a wide variety of end devices for maximum flexibility • Customized functionality and listings available • Industrial PLC platform for plant-wide integration • Options for both SIL capable and non-SIL capable • FM-Listed for Fire & Gas detection and suppression to satisfy regulations • Industrial grade hardware for increased reliability in plant applications • Factory training available to enable end users to maintain their systems FGS 1400 MK II Industrial designed system, SIL 3-capable logic solver, scalable to large I/O count. Download datasheet ​ ​ FGS 1300 FM-approved for lower I/O count applications. Class I Division 2 area classification status. Download datasheet ​ ​ ​ PS 1 400 20 / 50 / 100 / 150 Power supplies that meet NFPA 72 requirements. The power you need, when you need it. Download datasheet : PS 1400 20A - PS 1400 50A - PS 1400 100A ​ ​ PS 1400-20-DIV2 Battery set FM-listed for Class I Div 2 areas. Rugged and reliable. Download datasheet Understanding Flammable Mist Explosion Hazards aeSolutions Announces Major Update to its FGS 1400 Fire & Gas Product Featured Design, fabrication, commissioning ​ aeSolutions can Partner with Siemens to provide a turnkey system from philosophy, fabrication, FAT, field installation of equipment, and SAT.

Engineering Company Integrating Process Safety, Automation & Fired Equipment Success Stories +25 Years Strong +40 Certified Experts +2000 Clients Served +600 Projects per Year Improving industry by guiding our clients to increasingly resilient operations and safer communities. How We Can Help Our Story Our Services Alarm Management Machinery Safety Migrations and Upgrades Process Safety Fired Equipment Project Management Combustible & Toxic Gas SIS Engineering Feature Stories 5 Facets of an Efficient Process Hazard Analysis (PHA) People First. People Always. Race-Ready Project Development Gives Chemical Plants an Edge - Chemical Processing A Look Back at 25 Years of Learning and Growing Process Safety Consulting: Enhancing Management Systems and Regulatory Compliance aeSolutions Making a Difference Client Success Built With Trusted Expertise aeSolutions is an engineering consulting and systems integration company that provides industrial process safety and automation products and services. We specialize in helping industrial clients achieve their site’s risk management and operational excellence goals. Process Safety As a supplier of complete process safety management (PSM) solutions, we pride ourselves on providing engineers from industry with design, maintenance, operating, and process safety backgrounds. Our specialists understand how plants operate because they have actually worked in covered processes and facilities. Alarm Managem ent Our clients recognize the relationship between the process safety performance of their facilities and the implementation of effective alarm management techniques and alarm philosophy. Our alarm management services help clients improve the performance of their alarm systems and increase the situational awareness of their operators. Machinery Safety Clients who operate and maintain machinery and robotics list safety is a top priority. We help manufacturing facilities achieve safe machine operation through risk assessments, application of the hierarchy of control, and sensible safeguard design. Our scalable programs address client’s specific needs and the machinery lifecycle to provide tailored solutions aligned with international and United States’ standards. DCS/PLC Migrations and Upgrades aeSolutions can provide the system integration methodology, technical services, and resources to accomplish the objectives of your automation project. We work with you from project inception to final commissioning through a proven project delivery model integrating diverse hardware, software, and services from multiple vendors and stakeholders into a unified, integrated system. Safety Instrumen ted Systems aeSolutions has a unique process to design and implement ISA84/IEC 61511-compliant safety instrumented systems (SIS). We integrate our knowledge and experience in PHA/LOPA along with control system hardware and field instrumentation to ensure that Safety Instrumented Functions (SIFs) are clearly defined. We define, design, and document the safety functions to meet your safety and online reliability requirements for 61511 and regulatory compliance. Fired Equipment From up-front engineering to end-user compliance testing, aeSolutions has helped clients create and maintain safe, efficient fired equipment and associated processes. With our extensive engineering knowledge of the National Fire Protection Agency (NFPA) and other regulations, aeSolutions is uniquely qualified to advise on virtually all combustion-related codes and other hazard assessments. Combustible & Toxic Gas The aeSolutions Fire and Combustible & Toxic Gas Detection team deliver a unique blend of experience in philosophy, technology selection, and geographic/scenario-based modeling. Beginning with a Gas Detection Philosophy development or review and update, we design a system that is fit for purpose, cost-effective, and has a defined basis that can be updated as the plant evolves.

Fire and Toxic & Combustible Gas - Detailed Engineering aeSolutions utilizes first-hand industry experience to design clients' Fire and Gas Systems to the latest FM Approved standards. Our system design services include developing wiring plans, functional test plans, factory acceptance and site acceptance test plans and facilitation(FAT/SAT Plans). During the Factory Acceptance Testing (FAT) we confirm that all aspects of the control system are in full compliance with the final design documentation. Field Design Deliverables ​ Written Narrative Riser Diagram Floor Plan Layout Sequence of Operation ​ ​ Manufacturer’s Published Instructions Battery Calculations Voltage Drop Calculations Detailed Design Deliverables Detector Final Placement End Device Selection I/O Assignment Panel Design Architecture Block Diagram Cable Schedule / Cable Block Diagrams ​ ​​ Installation Details for End Devices Engineering and Design calculations Completion Test Forms HMI screen requirements ​ Installation Support Fire & Gas Pr oducts ​ NRTL Approved Fire Panels NRTL Approved Power Supplies NRTL Approved Proprietary Supervisor Stations Ensure toxic gas detection ​ Fire & Gas Lifecycle Services Ongoing Maintenance Training - to Operate, Maintain, and More Contact Us