Incorporating Inherently Safer Design Practices into Process Hazard Analysis

Abstract

Inherently safer design concepts are particularly useful for risk reduction and are highly recognized and recommended by safety professionals as a first choice in process design practices. These concepts can be easily applied, particularly in the design phase of a process, and may have very powerful benefits at relatively low cost. In the practice of engineering new or modified processes, however, these concepts are often not incorporated in a structured manner. Without knowledge or insight of these concepts, engineers may be retaining unnecessary risk or employing less reliable and more expensive alternatives to reducing risk. Due to regulatory requirements to conduct Process Hazard Analyses, such as OSHA's Process Safety Management standard (29 CFR 1910.119) and EPA's Risk Management Planning regulation (40 CFR Part 68), Process Hazard Analysis reviews are being conducted more than ever. There is a requirement in these regulations to establish and maintain a baseline risk understanding by retroactively evaluating existing processes. With all of this effort being expended, a major opportunity to improve process safety of U.S. businesses may be lost if teams are not well informed and prepared for the job. The paper will explore these issues, and recommended ways to incorporate concepts into process hazard analysis. Key concepts of inherently safer design will be outlined. These methods can then be adopted by industry as part of a process hazard analysis, and can benefit them by reducing risk more effectively and easily.