Human error analysis, process hazard review

Several qualitative approaches can be used to identify hazardous reaction scenarios, including process hazard analysis, checklists, chemical interaction matrices, and an experience-based review. CCPS (1995a p. 176) describes nine hazard evaluation procedures that can be used to identify hazardous reaction scenarios-checklists, Dow fire and explosion indices, preliminary hazard analysis, what-if analysis, failure modes and effects analysis (FMEA), HAZOP study, fault tree analysis, human error analysis, and quantitative risk analysis. 

There are various types of analyses that are used for a process hazard analysis (PHA) of the equipment design and test procedures, including the effects of human error. Qualitative methods include checklists, What-If, and Hazard and Operability (HAZOP) studies. Quantitative methods include Event Trees, Fault Trees, and Failure Modes and Effect Analysis (FMEA). All of these methods require rigorous documentation and implementation to ensure that all potential safety problems are identified and the associated recommendations are addressed. The review should also consider what personal protective equipment (PPE) is needed to protect workers from injuries. 

To identify the potential hazards in your chemical processes, a process hazard analysis (PHA) must be conducted. The facility should set up a team to conduct facility investigations and evaluations on processes that might be dangerous. This hazard analysis team should focus on the location of each process area, the hazards of the process, the probable outcome if controls fail, and the possibility of human error. The prudent facility manager makes a careful review of the plant s historical record concerning previous incidents—those that caused or could have caused catastrophic results. When the analysis is completed and recommendations have been issued to management for resolving the safety issues identified, this document becomes a permanent plant record that should be updated every five years. 

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