Process Safety Management

Process Hazard Analysis

Prevent fires, explosions, and the release of hazardous chemicals

Prevent fires, explosions, and the release of hazardous chemicals

Process HAzard Analysis Saves Lives

Process Hazard Analysis (PHA) reduces the risk of catastrophic events like fire, explosions, and the release of toxic chemicals and hazardous waste. An integral part of Process Safety Management programs, PHAs provide a regimented framework for assessing the hazards associated with an industrial process and the handling of toxic substances.

PHAs usually include a variety of components, including mechanical integrity of equipment, inspection and testing, addressing human element hazards, training programs, and dust hazard analysis.

Managing Risks in Hazardous Environments

In 1984, a pesticide plant in Bhopal, India released almost 40 tons of toxic chemicals into the atmosphere. This accident led to thousands of fatalities, hundreds of injuries and decades of health, environmental and financial challenges. Tragic incidents like this show the criticality of Process Hazard Analysis and why regulatory bodies have developed strict safety standards to reduce these risks. Safety standards include OSHA 1910.119 Process Safety Management of Highly Hazardous Chemicals, NFPA 652 “Standard for the Fundamentals of Combustible Dust” and the EPA’s Risk Management Plan rule. 


An effective PHA requires a systematic approach to evaluating an entire process including: 

  • Process design
  • Process technology
  • Operational and maintenance activities and procedures
  • Non-routine activities and procedures
  • Emergency preparedness plans and procedures
  • Training programs

TÜV SÜD Global Risk Consultants believes that a PHA and Process Safety Management Program should provide more than a response to regulatory needs. Of course, we will make sure you are compliant, but we will also be an essential contributor to an organization’s overall effectiveness.

TÜV SÜD GRC can assist you with the various types of process safety management services, such as:

  • Process safety transformation and performance improvement
  • Process safety program element development and support
  • HAZOP, What-If, Fault Tree, etc.
  • Process Safety Auditing
  • Dust Hazard Analysis (DHA)

TÜV SÜD GRC can help you stay up-to-date, compliant with these regulations and better manage your business.

FAQs: Process HAzard analysis


  • What is Process Hazard Analysis (PHA)?

    Process Hazard Analysis provides a regimented framework for assessing hazards associated with industrial processes and the handling of hazardous chemicals and toxic substances. PHAs aim to reduce the risk of catastrophic events like fire, explosions, or the release of toxic chemicals.

  • When should a Process Hazard Analysis be conducted?

    Organizations should do a thorough risk assessment of their processes every five years or if you have added new procedures or equipment. The Process Hazard Analysis should assess each stage of your operation – from startup to shut down.

  • What are the stages of a Process Hazard Analysis?

    A PHA has many stages including the assessment of process design, process technology, operational and maintenance activities and procedures, non-routine activities and procedures, emergency preparedness plans and procedures, and training programs.

  • How do you perform a PHA?

    Finding an experienced risk engineering partner like TÜV SÜD Global Risk Consultants is the best way to ensure regulatory compliance and a thorough analysis of all your process risks.

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Process Safety

Process Safety

Combine management and engineering efforts to mitigate accidents involving hazardous materials

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