Introduction
As we know, process safety engineers are the backbones in industries like hydrogen production, oil and gas, chemical manufacturing, and carbon capture & storage, where even minor incidents can lead to significant harm. These professionals are responsible for identifying potential hazards, evaluating risks, and implementing measures to prevent incidents. With growing complexity and stricter regulations, proficiency in specialized process safety software tools has become more important than ever.
Modern software tools simplify hazard identification (HAZID), risk assessments, simulations, and compliance management. However, selecting the right software and mastering it can be challenging without guidance.
In this article, you’ll learn about four essential process safety software tools—PHA-Pro, PHAST, SAFETI, FLACS, and BowTieXP—that every process safety engineer, risk management professional, or HAZID study engineer should become familiar with.
The above-mentioned software can help you with,
- Simulating hazard consequences (fire, explosion, toxic) – SAFETI, PHAST, FLACS
- Workshop discussion findings – PHA-Pro
- Summarise hazard barriers and threats – BowTieXP
We’ll explore their functionalities, practical uses, and how mastering them can significantly enhance your career.
Understanding Process Safety and the Importance of Specialized Software
Process safety engineering involves preventing and mitigating incidents related to hazardous materials, equipment failures, and human errors in industrial settings. Unlike general safety practices, process safety specifically addresses risks associated with chemical reactions, pressure build-ups, toxic releases, explosions, and fires.
In high-hazard sectors such as hydrogen energy or chemical plants, even small oversights in safety analysis can lead to incidents resulting in serious injuries, environmental harm, regulatory fines, or financial losses. To minimize these risks, process safety engineers rely on specialized software tools for performing detailed hazard assessments, consequence modeling, scenario simulations, and maintaining compliance with industry standards.
By using these specialized process safety software tools, engineers can confidently ensure safer operations and regulatory compliance in their industries.
The 4 Must-Know Process Safety Software Tools
1. PHA-Pro (Hazard Analysis)
PHA-Pro, (developed by Sphera) is among the most widely used software tools for conducting structured Process Hazard Analysis (PHA) and HAZOP studies. Designed specifically for safety engineers, it helps systematically identify, document, and manage process hazards.
Key Functionalities of PHA-Pro,
- HAZOP Facilitation
PHA-Pro guides engineers through structured Hazard and Operability Studies, helping identify potential process deviations, their causes, consequences, and safeguards systematically.
- Layer of Protection Analysis (LOPA)
The tool simplifies the documentation of protective layers, making it easy to evaluate whether adequate safeguards exist to minimize identified risks.
Recommendation Tracking and Reporting
PHA-Pro organizes and tracks recommendations arising from hazard assessments, ensuring timely follow-ups, compliance, and resolution.
Practical Applications
PHA-Pro is ideal in industries such as oil & gas, hydrogen plants, chemical manufacturing, and carbon capture facilities, where understanding and documenting risks is mandatory. For example, during design or operational modifications, engineers can quickly identify hazards related to changes, document safety requirements, and track their completion systematically.
Training Recommendations
To master PHA-Pro, it’s beneficial to participate in structured webinars, hands-on workshops, or online certification courses provided by specialized process safety and hazop training platforms. These courses provide practical examples and enable engineers to effectively use the tool in real-world situations.
2. PHAST & SAFETI (Consequence Modeling and Risk Assessment)
PHAST
PHAST (Process Hazard Analysis Software Tool), developed by DNV GL, is widely recognized for consequence modeling of hazardous chemical releases, fires, explosions, and toxic gas dispersion. PHAST supports accurate and detailed Quantitative Risk Assessments (QRA) that help engineers predict potential outcomes of hazardous scenarios and plan preventive measures.
Core Capabilities of PHAST
Gas Dispersion Modeling – Accurately models toxic or flammable gas dispersion, predicting concentration levels and impact zones.
Fire and Explosion Analysis – Simulates scenarios like jet fires, pool fires, vapor cloud explosions (VCE), and BLEVE (Boiling Liquid Expanding Vapor Explosion), helping engineers assess fire and explosion risks comprehensively.
Quantitative Risk Assessment (QRA) – Quantifies risk using detailed data-driven assessments, supporting informed decision-making for facility siting, design, and emergency planning.
Importance of Compliance and Incident Prevention
Industries dealing with hazardous materials regularly utilize PHAST to demonstrate compliance with industry standards such as OSHA PSM, EPA RMP, and regional safety regulations. Engineers use PHAST modeling to predict and minimize potential impacts, aiding in emergency preparedness and risk reduction efforts.
SAFETI
SAFETI is also from DNV using for risk assessment, enables quantitative risk analysis (QRA) by modeling consequence effects (discharge, dispersion, pool evaporation, fire, explosion, toxicity) and probabilistic risk (frequencies, ignition, wind roses, population impact).
Core features of SAFETI,
- Enables Quantitative Risk Analysis (QRA)
- Models consequence effects: discharge, dispersion, pool evaporation, fire, explosion, and toxicity
- Analyses probabilistic risks: event frequencies, ignition probabilities, wind rose data, and population impacts
- Supports risk-based design by identifying highest-risk contributors
- Offers Occupied Buildings Risk Assessment, including 3D explosions, building vulnerability, and overpressure/thermal curves
- Provides Multi-Component modeling for accurate two-phase mixture behavior.
- Facilitates cost-benefit and sensitivity analyses
Training Resources
Beginners should participate in industry-specific webinars and training sessions offered by experienced process safety professionals. These practical sessions help engineers efficiently learn PHAST/SAFETI software and apply it effectively in their organizations.
3. BowTieXP (Summarise Hazard Barriers and Threats)
BowTieXP, developed by CGE Risk (a DNV company), is advanced software designed for visual risk management. It simplifies complex hazard scenarios into intuitive bowtie diagrams, clearly identifying threats, consequences, and control measures. Widely adopted across industries, it enhances barrier management, compliance assurance, and effective communication of risk strategies and responsibilities.
Core Capabilities of BowTieXP
- Bowtie Diagram Creation – Enables simple visualisation of complex risk scenarios using intuitive bow‑tie diagrams—showing hazards, threats, barriers, top events and consequences.
- Barrier Analysis & Management – Link barriers to effectiveness, type and ownership; identify degraded or missing barriers and track accountability using customizable color coding
- Spreadsheet Integration (BowTieXL) – Exposes case data in Excel-like spreadsheets, supports calculations (e.g. aggregated barrier effectiveness, cost, ALARP assessments), and feeds results back into diagrams
- AuditXP & IncidentXP Add‑Ons – AuditXP lets you generate barrier‑quality questionnaires; IncidentXP links incident analyses to bowties to monitor real‑world barrier performance and trends
- Enterprise Risk Management (Enterprise version) – Centralises bowties, audits, incidents and dashboards across organisation; risk‑overview widgets and hierarchical roll-up reporting enhance oversight.
Importance of Compliance and Risk Communication
BowTieXP is widely used to visualise Safety Management Systems and meet regulatory expectations, enabling clear communication of risks and control measures across teams and stakeholders. It supports accountability, audits and safety case preparation across industries.
Recommended Training
Structured certification programs and expert-led webinars specifically focused on Barrier Risk Management using BowTie are recommended. Participating in these training sessions will help engineers gain the expertise needed to apply these simulation tools effectively.
4. FLACS / AERMOD (CFD and Dispersion Modeling Tools)
FLACS (Flame Acceleration Simulator) and AERMOD are advanced modeling software tools designed for predicting consequences associated with explosions, fires, and toxic gas dispersion scenarios.
FLACS – CFD Explosion and Fire Modeling
FLACS (developed by GEXCON) is typically used for fire/explosion risk assessment studies or as part of QRA. It uses Computational Fluid Dynamics (CFD) to simulate realistic explosion and fire scenarios in complex industrial environments. Engineers can model scenarios like vapor cloud explosions and confined-space fires to understand potential impacts and design effective mitigation strategies. It has a capacity of modelling 1800 chemical components.
AERMOD – Air Dispersion Modeling
AERMOD (by Lakes Software) is widely used for modeling the dispersion of pollutants or toxic gases into the atmosphere. Engineers utilize AERMOD to predict how accidental chemical releases might affect surrounding areas, aiding in emergency response planning and regulatory compliance.
Importance of these tools in Safety Planning
Industries such as chemical production, hydrogen plants, carbon capture facilities, and oil & gas operations rely on FLACS and AERMOD to perform critical facility-siting assessments, predict explosion impacts, and manage community risks related to toxic gas releases.
Training Opportunities
Engineers can enhance their skills through dedicated webinars or certification training programs that offer hands-on experience with FLACS and AERMOD, ensuring effective utilization in real-life situations.
How to Master These Process Safety Software Tools?
Effectively mastering these process safety software tools requires a structured approach:
- Structured Webinars: Attend interactive webinars delivered by industry experts for practical demonstrtions.
- Certification Courses: Enroll in certified courses that provide recognized credentials.
- Hands-on Practice: Engage regularly in practical sessions or projects to build confidence and expertise.
SOG Academy provides tailored training programs, expert-led webinars, and customized learning paths suitable for beginners and advanced safety professionals alike, helping engineers confidently use these essential software tools.
Conclusion and Next Steps
Mastering process safety software tools like PHA-Pro, PHAST, SAFETI, BowTieXP and FLACS/AERMOD greatly enhances your ability to identify, evaluate, and mitigate risks in hazardous industries. Continuous learning and developing expertise in these tools supports your professional growth and help ensure safer operational environments.
Ready to take your skills to the next level? Explore our specialized process safety training programs and webinars designed specifically for process safety engineers and risk management professionals.
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