identify, evaluate, and control the hazards involved in the process. Employers
shall determine and document the priority order for conducting process hazard
analyses based on a rationale which includes such considerations as extent of
the process hazards, number of potentially affected employees, age of the
process, and operating history of the process. The process hazard analysis
shall be completed prior to process startup.
The employer shall use one or more of the following methodologies that are appropriate
to determine and evaluate the hazards of the process being analyzed.
Hazard and Operability Study (HAZOP);
Failure Mode and Effects Analysis (FMEA);
Fault Tree Analysis; or
(vii) An appropriate equivalent methodology.
The process hazard analysis shall address:
The hazards of the process;
The identification of any previous incident which had a likely potential for
catastrophic consequences in the workplace;
Engineering and administrative controls applicable to the hazards and
their interrelationships such as appropriate application of detection
methodologies to provide early warning of releases. (Acceptable detection
methods might include process monitoring and control instrumentation
with alarms, and detection hardware such as hydrocarbon sensors.);
Consequences of failure of engineering and administrative controls;
Human factors; and
A qualitative evaluation of a range of the possible safety and health effects
of failure of controls on employees in the workplace.