Process Hazard Analysis


It is becoming more and more important for every company to evaluate the potential hazards associated with the process to control the risks properly.
With the services of Process Hazard Analysis, TOYO will provide an appropriate specialist to help the Client in identifying process hazards associated with materials used and/or with the operating conditions.
With this proactive evaluation of the process at an early stage of the project lifecycle, the Client will be able to make rational decisions on cost effective safety measures.
The output of this service can be used as a material for OHSAS 18001.


  • Implementing appropriate Analysis Methodology in a systematic way, TOYO can help the Client to identify potential hazards effectively.
  • In the course of analysis, the Client can also identify operability problems, if any.
  • The outcome of the services will be documented so that the implicit knowledge of process engineers and operators can be converted to explicit knowledge


1. Selection of appropriate Analysis Methodology

  • Best fit analytical methodology will be selected from HAZOP, PHA, What-If, FMEA, etc. consistent with the type and engineering phase of the facility to be analyzed.

2. Performing Analysis

  • TOYO will dispatch appropriate specialist to lead the hazard identification study by Client's team.
  • The hazard identification team shall consist of the Client's specialists such as process engineer, operation/production engineer, instrument engineer, safety engineer etc
  • TOYO will provide recommendations on countermeasures or necessary further detail study as a result of hazard identification examination

3. Summarize the Analysis Results

  • The outcome of the analysis will be documented identifying the potential causes, effects, and safeguards so that the scenarios and countermeasures are made clear.

Extensive Experiences

  • TOYO has extensive experience in performing hazard identification studies for Refining Plants, Petrochemical Plants, Fertilizer Plants, Power Plants, Batch Process Plants, etc.
  • TOYO has applied various types of analytical methodologies such as HAZOP, PHA, What-If, FMEA, FMECA, FTA, ETA, etc.

Example of Hazard Identification

Client's Requirement

Client wished to invest in cost-effective safety measures, recognizing clearly the potential hazards in the plant.

Example of Services

1. Selection of Methodology

  • HAZOP was chosen in view of timing of analysis and available documents.
  • HAZOP team was organized by Client's process, operation, instrument, and safety engineers.
  • TOYO dispatched HAZOP leader to perform HAZOP study.

2. Performing Analysis

  • At first, team confirmed HAZOP procedure according to the CCPS-AIChE(*) guideline.
  • Analyzed the process systematically, applying HAZOP guide words to the relevant parameters.
  • In the course of the HAZOP study, the team identified miscellaneous problems.

(*) Center for Chemical Process Safety-American Institute of Chemical Engineer

3. Summarize the Analysis Results

  • The analysis results were recorded in the worksheet

Benefits to Client

  • The Client identified hazard and operability problems in the plant clearly, and therefore established effective countermeasures. The Client recognized that HAZOP was effective for cost-effective decision making.
  • HAZOP records (worksheets) were effectively used for the revamping and modification, and also as educational materials for new employees and contractors