In high-hazard industries such as oil and gas, chemicals, and petrochemicals, managing risks to ensure the safety of workers, protect the environment, and maintain operational integrity is a top priority. The Process Safety, Health, and Environmental Review (PHSER) is a structured methodology designed to evaluate and verify that safety, health, and environmental risks are identified and controlled throughout a project’s lifecycle. By systematically reviewing processes, designs, and operations, PHSER ensures facilities operate safely and comply with stringent regulations. This article explores the principles, methodology, and practical applications of PHSER, with insights into how Cormat Group implements this approach to achieve safety and environmental excellence.

What is Process Safety, Health, and Environmental Review (PHSER)?

The Process Safety, Health, and Environmental Review (PHSER) is a formal, staged review process that assesses a project’s safety, health, and environmental performance at key milestones, from conceptual design to operation. It aims to identify potential hazards, evaluate risks, and ensure that appropriate controls are in place to prevent incidents like fires, explosions, or environmental spills. PHSER is typically conducted in multiple stages, aligning with project phases such as feasibility, design, construction, commissioning, and operation.

PHSER is a critical requirement in industries governed by regulations like the UK’s Control of Major Accident Hazards (COMAH), OSHA’s Process Safety Management (PSM) standard, or environmental permitting frameworks. For example, during the design of a chemical plant, a PHSER might identify gaps in fire protection systems, leading to the addition of sprinklers or fire-resistant materials. The goal is to reduce risks to As Low As Reasonably Practicable (ALARP), ensuring safety, health, and environmental protection throughout the project lifecycle.

Why is PHSER Important?

PHSER plays a vital role in high-hazard industries for several reasons:

• Preventing Major Incidents: By identifying hazards early, PHSER prevents catastrophic events like explosions or toxic releases, protecting workers and communities.
• Regulatory Compliance: Regulations like COMAH and PSM require staged safety reviews, with PHSER providing evidence of due diligence.
• Protecting Health: PHSER addresses occupational health risks, such as exposure to toxic substances, ensuring worker well-being.
• Environmental Protection: By evaluating environmental risks, PHSER prevents spills, emissions, or other impacts that could harm ecosystems.
• Asset Protection: Mitigating risks reduces equipment damage, minimizing costly downtime and repairs.
• Stakeholder Confidence: Cormat Group builds trust with employees, regulators, and communities by conducting thorough PHSERs, demonstrating a commitment to safety and sustainability.

A 2023 report by the Health and Safety Executive (HSE) found that facilities implementing staged PHSERs reduced major accident rates by 38%, highlighting the effectiveness of this proactive approach.

Key Components of PHSER

PHSER is built on several core elements that ensure a comprehensive review of safety, health, and environmental risks:

1. Hazard Identification

Identify potential hazards, including process risks (e.g., fires, explosions), health risks (e.g., chemical exposure), and environmental risks (e.g., spills or emissions).

2. Risk Assessment

Evaluate the likelihood and consequences of identified hazards, using qualitative or quantitative methods to prioritize risks.

3. Control Measures

Identify preventive controls (e.g., safety interlocks, operator training) and mitigative controls (e.g., fire suppression, spill containment) to reduce risks.

4. Compliance Verification

Ensure that designs, processes, and operations comply with relevant regulations, standards, and best practices, such as COMAH, PSM, or ISO 14001.

5. ALARP Demonstration

Demonstrate that risks are reduced to ALARP by balancing the cost of additional controls against the safety and environmental benefits achieved.

6. Action Tracking

Assign responsibilities and timelines for implementing control measures, ensuring accountability and follow-through.

7. Documentation

Create detailed PHSER reports, including hazard lists, risk assessments, control measures, and compliance evidence, to support audits and regulatory submissions.

PHSER Stages

PHSER is conducted in stages, each aligned with a project phase to ensure risks are managed throughout the lifecycle:

Stage 1: Concept and Feasibility

• Objective: Assess high-level risks during project planning.
• Activities: Conduct a HAZID to identify major hazards, review site selection, and evaluate environmental impacts.
• Outcome: Ensure the project concept aligns with safety and environmental goals.

Stage 2: Front-End Engineering Design (FEED)

• Objective: Verify that preliminary designs address identified risks.
• Activities: Review process flow diagrams (PFDs), conduct HAZOP studies, and assess safety system designs (e.g., fire and gas detection).
• Outcome: Confirm that designs incorporate necessary controls.

Stage 3: Detailed Design

• Objective: Ensure detailed designs meet safety, health, and environmental requirements.
• Activities: Review piping and instrumentation diagrams (P&IDs), verify equipment specifications, and assess compliance with standards like IEC 61508.
• Outcome: Validate that designs are safe and compliant before construction.

Stage 4: Construction and Commissioning

• Objective: Confirm that construction and commissioning adhere to design specifications.
• Activities: Inspect installations, test safety systems (e.g., emergency shutdowns), and verify PFP measures like fire-resistant coatings.
• Outcome: Ensure systems are installed and functional as designed.

Stage 5: Operation and Maintenance

• Objective: Verify that operational procedures and maintenance plans sustain safety and environmental performance.
• Activities: Review operating manuals, conduct training, and test Health, Safety, and Environment Critical Equipment and Systems (HSECES).
• Outcome: Ensure ongoing risk management during operations.

Stage 6: Decommissioning

• Objective: Assess risks during facility closure or repurposing.
• Activities: Evaluate dismantling procedures, manage residual hazards (e.g., chemical residues), and ensure environmental cleanup.
• Outcome: Confirm safe and environmentally responsible decommissioning.

Challenges in PHSER

PHSER faces several challenges:

• Complexity: Reviewing large or intricate facilities requires significant time and expertise. Breaking the review into stages helps.
• Data Limitations: Incomplete data on hazards or system performance can affect accuracy. Industry databases or testing can fill gaps.
• Stakeholder Alignment: Diverse teams may have conflicting priorities, requiring skilled facilitation to reach consensus.
• Dynamic Operations: Changes in processes or regulations demand ongoing PHSER updates.
• Regulatory Demands: Meeting standards like COMAH or PSM requires meticulous documentation and validation.

The Role of Technology in PHSER

Technology enhances the efficiency and accuracy of PHSER:

• Risk Assessment Software: Tools like PHA-Pro or BowTieXP streamline hazard identification and documentation.
• Modeling Tools: Software like PHAST or CFD simulates fire, explosion, or dispersion scenarios, informing risk assessments.
• Digital Twins: Virtual models test designs and controls during early project stages.
• Artificial Intelligence (AI): AI predicts risks based on historical data, improving PHSER outcomes.
• Asset Management Systems: Tools like SAP track control implementation and maintenance, ensuring compliance.

Cormat Group leverages these technologies to conduct precise and efficient PHSERs, ensuring robust risk management.

Conclusion

Process Safety, Health, and Environmental Review (PHSER) is a vital tool for managing risks across the lifecycle of high-hazard facilities. By identifying hazards, assessing risks, and implementing controls, PHSER prevents incidents, protects health, and safeguards the environment. Cormat Group demonstrates how a rigorous PHSER process drives safety and environmental excellence, ensuring compliance and resilience. Despite challenges like complexity and data limitations, technology, stakeholder collaboration, and staged reviews can overcome them. As industries evolve, PHSER will remain essential for building safer, more sustainable workplaces.