Hazard Identification and Risk Analysis

Most asset failures are avoidable when risks are systematically identified and managed. After years of working with industrial facilities, I've found that effective risk management requires mastering five complementary frameworks: 1) HAZOP/HAZID: The foundation of process safety • HAZID provides early, broad-brush hazard identification • HAZOP deliversa systematic analysis of process deviations • Digital transformation now allows these assessments to feed directly into maintenance systems 2) FMEA (Failure Modes and Effects Analysis) • The comprehensive failure analysis framework • Now enhanced through digital twins that can simulate thousands of potential scenarios • Predictive models identify vulnerabilities that would be impossible to spot manually 3) CRA (Corrosion Risk Assessment) • Specialized analysis for material degradation mechanisms • Modern distributed sensing networks detect moisture ingress and corrosion in real-time • Early detection means addressing issues months before traditional methods would find them 4) RBI (Risk-Based Inspection) • The intelligence layer that optimizes inspection resources • AI algorithms now continuously recalculate priorities as conditions change • No more relying on outdated static schedules or calendar-based inspections 5) IOW (Integrity Operating Windows) • Defines the safe operational limits for process variables • Real-time monitoring ensures operations stay within these boundaries • Automatic alerts when parameters approach critical thresholds The power comes from integration. One refinery I worked with linked all five frameworks through a unified digital platform. Their system automatically flags when operating conditions might trigger corrosion mechanisms identified in their CRA, then updates inspection priorities in real-time. Is your organization still managing these as separate activities, or have you begun integrating them into a cohesive digital risk management strategy? *** P.S.: Looking for more in-depth industrial insights? Follow me for more on Industry 4.0, Predictive Maintenance, and the future of Corrosion Monitoring.

Compiling a Hazard and Harms List (HHL) at the beginning of medical device development is a simple technique to improve all risk management activities for that product (or family of products). Have you ever been in an audit trying to explain to the auditor why the severity of a particular harm is rated differently in one risk document versus another? The obvious explanation is that two different teams performed the risk analyses in the two documents but that won’t satisfy the auditor (and it shouldn’t satisfy your company either). Risk management is too important to let everyone decide for themselves what harms are possible and the severity of each harm. Risk management needs a standardized approach based on clinical expertise. Instead of ad hoc definitions of severity of harm in each risk analysis, start your risk management activities by compiling an authoritative list of all hazardous situations and harms associated with the intended use of the medical device. This is typically a table with a column for hazardous situations, for the corresponding harms, and for the severity of each harm. The table is carefully reviewed and finalized with the Chief Medical Officer (or other clinical expert). Then the HHL serves as the foundation for all types of risk assessment for the product (System Hazard Analysis, Design FMEA, Usability Risk Analysis, etc.). Note that there are multiple possible formats for an HHL and multiple names (AKA “Master Harms List”, “Hazards List”). The important point is to have a single, authoritative list that will form the basis for all risk assessments for a particular medical device.

Hydrogen Production Plants Safety Studies: HAZID, HAZOP, QRA, LOPA, SIL and FEME 🟦 1) Green hydrogen production is set to increase rapidly, posing a significant challenge for the industry. Large-scale industrial water electrolysis plants use hydrogen and oxygen within the same equipment, separated by a membrane or diaphragm. Ensuring process safety is essential. In this post, I've summarized the safety study required for your green hydrogen project. 🟦 2) HAZID HAZID (Hazard Identification study) is a qualitative technique for identifying a process's main hazards. It involves using a block diagram or process flow diagram (PFD), which is used in the early stages of the design process. 🟦 3) HAZOP HAZOP (Hazard & Operability analysis) is a method to identify process hazards by analyzing deviations from normal conditions at the P&ID level. It focuses on equipment function loss and human error. Key elements of HAZOP sessions are: - Deviation - Cause of the deviation - Consequence of the deviation - Installed safeguards 🟦 4) Bow tie The bow tie method visually presents hazard scenarios, including the chain of events and barriers to prevent or mitigate scenarios. It is useful for internal and external communication of scenarios. 🟦 5) Risk matrix A risk matrix is used to assess the tolerability of a scenario based on the frequency and severity of undesired events. Likelihood is measured in frequencies per year, while consequences are defined by HSE impact and economic losses. The risk matrix determines the risk level. 🟦 6) Quantitative Risk Analysis (QRA)  QRA is a method for calculating safety contours by considering the combination of fatalities and frequency. It involves determining the frequency of fatalities using tools like Fault Tree Analysis (FTA) and Event Tree Analysis (ETA). The consequence itself is determined using other tools, and all barriers that have an effect reduce the evaluated risk. 🟦 7) Level of Protection Analysis (LOPA) A small team further analyzes a subset of the most hazardous scenarios identified during a HAZOP, assessing the frequency and severity of the consequence. The basic principle of LOPA is that every safeguard may fail, so the consequence of the non-protected scenario cannot be eliminated. 🟦 8) Safety Integrity Level (SIL) SIL assessments are used to assign risk deduction factors to instrumental safeguards. The requirements for safety instrumented systems are given in IEC61508 and 61511. Four SIL levels are specified, with SIL 4 having a risk deduction factor of 10,000 to 100,000 and SIL 1 having a factor of 10 to 100. 🟦 9) Failure Mode and Effect Analysis (FMEA) FMEA focuses on equipment part failure and frequency to determine maintenance strategies. The accuracy of risk assessment depends on data quality. Source: See attached image. This post is based on my knowledge and is for educational purposes only.  👇 What other hydrogen safety study do you conduct? #hydrogen #Process #Safety

HAZOP (Hazard and Operability Study) and HAZID (Hazard Identification) are both systematic risk assessment methodologies, but they differ in their focus, scope, and application. Here's a breakdown of their differences: 1. Purpose and Focus - HAZOP : Primarily focuses on identifying potential deviations from the design intent of a process and their consequences. It assesses possible hazards and operability issues in a process or system. - HAZID : Focuses on identifying hazards in a broader sense, typically at the early stages of a project, without diving deeply into process deviations. It helps to flag major hazards and set up necessary safety measures. 2. Scope and Timing - HAZOP : Conducted during the design phase and often revisited in the operational phase, typically at the detailed design or operational stage. It’s more specific and detailed. - HAZID : Usually conducted at the concept or preliminary design phase of a project. It’s a higher-level assessment aimed at recognizing general hazards early in the project lifecycle. 3. Approach - HAZOP : Uses guide words like "No," "More," "Less," "As well as," etc., to systematically analyze deviations in each part of a process. - HAZID : Employs checklists or brainstorming sessions to identify various hazard types, such as chemical, environmental, and physical, without a strict focus on deviations. 4. Team Composition - HAZOP : Requires a multidisciplinary team, including process engineers, safety specialists, and operations personnel, to analyze the finer details of the process. - HAZID : Often involves a broader group, possibly including project managers, environmental specialists, and safety engineers, to capture a wide range of potential hazards early on. 5. Outcome - HAZOP : Results in a detailed analysis of process deviations, operability issues, and recommended corrective actions or design modifications. - HAZID : Results in a preliminary list of potential hazards, hazard ranking, and initial recommendations for risk management, which may lead to further detailed assessments like HAZOP. In short, HAZOP is a more detailed, focused study conducted later in the design phase to evaluate operability and specific deviations, while HAZID is broader, conducted earlier, and meant to identify general hazards across a project. #processsafety #Hsemanagers#Hseoman #quality #operations

⚠️ What is Risk Assessment? ⚠️ Risk Assessment is the process of identifying hazards, evaluating the risks, and taking appropriate actions to minimize or eliminate potential harm to people, assets, or operations. It helps answer: What could go wrong? 🔥💥⚡ How likely is it to happen? 📊 What would be the impact? 🚑🏢 What controls are in place or needed? 🛡️ 🛠️ Steps to Create a Risk Assessment 🧩 Step 1: Identify Hazards 🔌 Electrical faults 🔥 Fire sources (kitchens, flammable storage) 🧱 Falling objects (scaffoldings, ceiling tiles) 🚿 Water leaks/slips 🦺 Unsafe work practices by staff or contractors 📋 Step 2: Determine Who Might Be Harmed 👷♂️ Staff & Technicians 🧑💼 Tenants or Visitors 🚚 Contractors or Vendors 📉 Step 3: Evaluate the Risks Assess the likelihood and severity: Likelihood (Low/Medium/High) Severity (Minor/Moderate/Major) Use a Risk Matrix to prioritize actions. 🛡️ Step 4: Control Measures Apply the hierarchy of control: 🚫 Eliminate hazard (e.g., remove faulty equipment) 🔁 Substitute with safer alternative 🔐 Engineering controls (guards, barriers) 📋 Admin controls (SOPs, signage) 🦺 PPE (helmets, gloves, goggles) 📝 Step 5: Record & Review Document all risks, controls, and responsibilities Review regularly or when: New equipment is installed A workplace incident occurs Layout or operations change 🏗️ How to Implement Risk Assessment On-Site (As an FM) ✅ 1. Conduct Site Walkthroughs Regular inspections to spot new hazards Involve technical team and safety officer ✅ 2. Create a Risk Register Maintain a centralized record of all risks, controls, and status Use Excel, CAFM, or safety management software ✅ 3. Assign Responsibility Clearly state who is responsible for managing each risk Train technicians & contractors on safety protocols ✅ 4. Share the Assessment Conduct toolbox talks and induction trainings Place safety signage and instructions on-site ✅ 5. Monitor & Audit Review controls are working (alarms, extinguishers, emergency exits) Conduct mock drills (fire, electrical fault, gas leak) ✅ 6. Comply with Standards Follow OSHA, ISO 45001, local civil defense, and insurance guidelines 📌 Summary: Why Risk Assessment Matters Benefit & Impact 🧠 Proactive safety culture - Prevents accidents before they happen 📋 Legal & insurance compliance - Meets statutory and policy requirements 📉 Reduced downtime - Avoids equipment damage and business loss 🛠️ Efficient operations - Staff work confidently and safely

𝗥𝗲𝗰𝗼𝗴𝗻𝗶𝘇𝗶𝗻𝗴 𝗣𝗿𝗼𝗰𝗲𝘀𝘀 𝗛𝗮𝘇𝗮𝗿𝗱𝘀 𝗮𝗻𝗱 𝗟𝗮𝘁𝗲𝗻𝘁 𝗖𝗼𝗻𝗱𝗶𝘁𝗶𝗼𝗻𝘀 Field visits, or walkabouts, are a common tool used by leaders at all levels to engage the workforce and demonstrate that OE is a core value. These visits have typically been used to observe behaviors that impact personal safety performance. While these visits also provide an opportunity for leaders to demonstrate their commitment to process safety risk mitigation, process hazards and the latent conditions that can potentially lead to serious process incidents are much more difficult to recognize. Finding these potential issues takes a different focus and level of rigor when visiting field operations. Latent conditions can be defined as existing conditions that may lie unrecognized until combined with another upset condition (latent condition or active error) to result in an incident. Latent conditions could be the managerial influences and social pressures that make up the culture (“the way we do things around here”), which may affect the design of equipment or systems, and may stem from insufficient supervisory oversight. They tend to be hidden until uncovered by an incident, possibly due to several latent conditions combining in an unforeseen way. The goal should be to identify these latent conditions before they can escalate into a potential process safety incident. To do this, we need to change the way we look at hazards when we go out into the field. We still have to look for hazards and behaviors that can impact personal safety, but we must broaden our search for potential process safety incidents. The Hazard Identification Tool is great for helping identify hazards that can lead to potential immediate and certain safety consequences. However, it is harder to use on those potential future and uncertain scenarios.  Generally, there are four areas of focus to help identify potential loss of containment scenarios during a field walk.  1. Identify the potential source of a loss of containment event.  2. Identify latent conditions that could allow loss of containment events to escalate into more severe process safety consequences – fire, explosion, toxic impact, etc.  3. Review the stewardship of our safeguards (both preventive and mitigative) – are they still effective?  4. Identify non-process safety hazards that could be a cultural indicator and relate to process safety as an Operational Discipline issue.   ... #LatentConditions #ProcessSafety #ProcessHazards #HAZOP #HAZID #LOPA #SIL #QRA

🔶 Comprehensive Risk Assessment: A Strategic Pillar of Workplace Safety 🔶 In today’s complex and dynamic work environments — especially within high-risk industries such as oil & gas, construction, manufacturing, and logistics — risk assessment is not merely a regulatory requirement, but a strategic imperative for ensuring operational continuity and safeguarding human life. 🧠 What is Risk Assessment? Risk Assessment is a structured and proactive approach aimed at identifying, evaluating, and mitigating potential hazards in the workplace. It enables organizations to make informed decisions that minimize exposure to danger and ensure compliance with occupational health and safety (OHS) standards. 🎯 Core Objectives: Prevent accidents and occupational injuries before they occur. Protect assets and reduce downtime due to safety-related incidents. Enhance worker wellbeing and job satisfaction by creating safer work environments. Reinforce safety culture at all organizational levels. 🔄 The Risk Assessment Process: Hazard Identification Spot all potential sources of harm — mechanical, chemical, physical, or procedural. Risk Analysis & Evaluation Assess the likelihood and impact of each hazard, prioritizing based on severity. Implementation of Control Measures Apply the hierarchy of controls: Eliminate the hazard (preferred) Substitute with less hazardous alternatives Engineering and administrative controls Use of Personal Protective Equipment (PPE) Monitoring, Review, and Continuous Improvement Regularly update assessments to adapt to changing work conditions, technologies, or processes. 👥 Responsibility & Engagement While risk assessment is led by HSE professionals, its success relies on collaboration across all levels of the organization — from executives to field workers. A shared sense of accountability ensures that risk controls are practical, effective, and sustainable. ⚠️ Common Risks Across Worksites: Falls from height Electrical and fire hazards Manual handling and ergonomic risks Chemical exposure Confined spaces and poor ventilation ✅ Conclusion: A well-executed risk assessment strategy is a cornerstone of sustainable operations. It’s about anticipating the unexpected, fostering a culture of vigilance, and making safety a core value — not just a policy. “A safe workplace is not a privilege. It is a right — and a responsibility.” #RiskAssessment #HSEExcellence #WorkplaceSafety #OperationalIntegrity #ZeroHarm #ProactiveSafety #OccupationalHealth #OilAndGasSafety #IndustrialRisk #SafetyLeadership #LinkedInProfessionals #ContinuousImprovement #PreventiveCulture

🚨 Unsafe Acts Without Risk Assessment: A Silent Killer at the Workplace 🚨 Every job comes with its own set of hazards. Yet, many accidents happen not because of the job itself — but due to unsafe acts and the absence of proper risk assessment. 😟 🔥 Whether it's working at heights without fall protection, handling chemicals without PPE, or bypassing Lockout Tagout (LOTO) systems, these actions may seem like shortcuts — but they often lead to serious injuries or fatalities. 📌 A comprehensive risk assessment is not just a checklist—it's a lifesaving tool. It helps you: ✅ Identify potential hazards ✅ Evaluate the level of risk ✅ Implement necessary controls ✅ Ensure legal compliance ✅ Foster a strong safety culture 🌐 🎯 Remember, the time you spend assessing risk could be the time that saves a life. Don’t rush. Don’t guess. Assess before you act. 🛠️ Safety isn't expensive — it's priceless. 🔍 "Stop and think" before you start any task. 🧠 Stay alert. Stay protected. Stay alive. Because at the end of the day, the goal is simple — EVERYONE GOES HOME SAFE. 🏠👷♂️👷♀️ #WorkplaceSafety #RiskAssessment #SafetyCulture #PPE #LOTO #SafeWork #HealthAndSafety #ZeroHarm #WorkAtHeight #HazardIdentification #SafetyAwareness #SafetyFirst #StopThinkAct #SafetyMatters #IncidentPrevention 🚧⚠️🦺