Identifying and Controlling Hazards
Course 101
Safety Certified Supervisor Series

MODULE FOUR: ANALYZING THE WORKPLACE

Process Hazard Analysis

What Is a "Process" for the purpose of this analysis? A process can be defined as any series of actions or operations that convert raw material into a product. The process can terminate in a finished product ready for consumption or in a product that is the raw material for subsequent processes.

A process hazard analysis is a detailed study of a process to identify every possible hazard to employees. Every element of the process must be studied. Each action of every piece of equipment, each substance present, and every move made by an employee must be assumed initially to pose a hazard to employees. Process hazard analysis then is applied to show that the element either:

• Poses no hazard,
• Poses a hazard that is controlled in every foreseeable circumstance, or
• Poses an uncontrolled hazard.

Often the process hazard analysis will concentrate on the specialized equipment used in the process. The equipment may be used to:

• Move materials;
• Apply mechanical forces to change materials;
• Apply special forms or concentrations of energy to materials (e.g., ionizing radiation, magnetic or electric fields, and lasers);
• Mix materials; or
• Bring and hold materials together and contain them, under either ambient or special conditions, for chemical or biological reactions, etc.

The best time for an employer to conduct a process hazard analysis is when the process is first being designed, before equipment is selected. This review, in turn, will assist you in choosing process equipment for its effective, efficient, and safe operation. Be sure to consider the equipment's capacity for confining the process within predetermined safe limits. The type, number, and location of detectors you select for monitoring the process should ensure not only productive operation, but also safe operation. Remember to take into account any substance or mixture of substances that could present fire or explosion hazards.

When you have selected your equipment, the information from the process hazard analysis will help you to develop an appropriate inspection and maintenance schedule.

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