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What Is a Process Hazard Analysis?

A Process Hazard Analysis (PHA) is a structured and systematic method for identifying and evaluating the hazards associated with industrial processes. It is a foundational requirement of OSHA’s Process Safety Management standard – 29 CFR 1910.119 and supports broader compliance with the EPA’s Risk Management Program (RMP).

PHAs are used to identify the potential for catastrophic events such as fires, explosions, and toxic releases—enabling organizations to understand the causes and reduce the likelihood and impact through engineered and administrative safeguards.

Expert-Led PHA Facilitation
Built for High-Hazard Industries

Smith & Burgess offers expert-led PHA services, supported by a diverse team of seasoned facilitators with backgrounds in refining, petrochemicals, energy, and specialty chemical sectors. Our team facilitates PHAs with a rigorous yet practical approach, helping your facility meet compliance standards, improve safety, and justify risk-based decision-making.

Whether your facility is undergoing a five-year PHA revalidation, expanding operations, implementing a management of change (MOC), or performing a baseline study, we deliver structured, audit-ready PHA studies that help teams identify hazards and mitigate risks.

We work collaboratively with your operations, engineering, leadership teams to ensure all findings and recommendations are practical, prioritized, and tailored to your risk tolerance.

Our PHA Methodology

Each PHA begins with a comprehensive review of your Process Safety Information (PSI), including process flow diagrams, piping and instrumentation diagrams (P&IDs), operating procedures, and prior incident data. We assemble a cross-functional team and apply the most appropriate method based on process complexity and phase.

  • Thorough pre-study planning and node selection
  • Application of proven techniques (e.g., HAZOP, What-If, LOPA)
  • Real-time documentation and risk ranking
  • Identification of independent protection layers
  • Development of actionable, prioritized recommendations

We also ensure that all assumptions and risk matrices are documented in a way that withstands internal and regulatory audits.

Proven Methodologies We Apply

HAZID
(Hazard Identification)

A qualitative method used early in the design phase or during conceptual studies to identify general hazards across systems, equipment, and environments.

What-If Analysis

A scenario-based brainstorming technique used to explore “what-if” deviations from expected process behavior and their potential consequences.

HAZOP
(Hazard and Operability Study)

A guideword-driven methodology that systematically reviews process nodes to identify deviations from design intent, their causes, consequences, and safeguards.

LOPA
(Layer of Protection Analysis)

A semi-quantitative technique that evaluates the effectiveness of protection layers and determines whether additional safeguards are necessary to achieve risk tolerance levels.

How PHAs Prevent Incidents and Ensure Compliance

PHAs are not only required by law–they are essential for protecting people, assets, and the environment.

A well-executed PHA will:

  • Identify credible causes of process-related incidents
  • Uncover gaps in existing protection layers and controls
  • Prioritize safety upgrades and operational investments
  • Provide regulatory documentation for OSHA and EPA audits
  • Enhance your facility's safety culture and training focus

Revalidations must be conducted at least every five years. In addition, PHAs should be updated whenever significant changes are made to processes, equipment, or control systems.

Partnering With Smith & Burgess for PHA Excellence

Smith & Burgess brings a depth of real-world experience, technical discipline, and client-centered flexibility that sets us apart.

  • Trusted Expertise: Decades of experience facilitating PHAs across oil & gas, refining, chemical, and manufacturing sectors
  • Audit-Ready Deliverables: Fully documented PHAs aligned with OSHA, RMP, and internal corporate standards
  • Proven Facilitation: Our facilitators ensure productive sessions, clear documentation, and achievable recommendations
  • Flexible Engagements: We support greenfield, brownfield, MOC-triggered studies, and five-year revalidations
  • Up-to-Date Practices: Active contributors to industry groups including CCPS, AIChE, and API subcommittees

Partner with PHA Experts You Can Trust

Request a consultation to discuss your next PHA or receive a tailored quote based on your facility’s specific needs.