PHA Risk Assessments for Carbon Capture Projects in Oil and Gas

As the oil and gas industry continues to evolve toward a lower-carbon future, carbon capture and storage (CCS) has emerged as a key strategy for reducing emissions. However, while CCS technologies present an opportunity to mitigate environmental impact, they also introduce new operational risks that must be properly managed. At RskLess, we have conducted numerous risk assessments for CCS projects, leveraging our expertise in Process Hazards Analysis (PHA) to ensure that these systems are as safe and reliable as any other hazardous process in the industry.

Why Risk Assessments Are Essential for Carbon Capture Projects

CCS involves the capture, transportation, and storage of carbon dioxide (CO2), a process that presents significant safety and operational challenges. CO2 is an asphyxiant, can create high-pressure conditions, and presents unique risks when handled at scale. Without rigorous risk assessments, facility owners may overlook potential hazards, leading to operational failures, regulatory non-compliance, or even catastrophic events.

One of the best ways to systematically identify and mitigate these risks is through Process Hazards Analysis (PHA), a core component of Process Safety Management (PSM) best practices. By applying well-established methodologies such as Hazard and Operability Studies (HAZOP) and Layer of Protection Analysis (LOPA), we ensure that CCS projects maintain the same level of safety scrutiny as any other high-risk industrial process.

Applying PHA to Carbon Capture Projects

PHA is a structured approach to identifying and evaluating potential hazards in a process. When applied to CCS projects, a PHA typically addresses:

Capture Process Risks: Identifying potential hazards in amine-based absorption, membrane separation, or other CO2 capture technologies, including chemical reactivity, thermal runaway, and equipment failures.

Compression and Transportation Hazards: Assessing the risks associated with handling CO2 at high pressures, potential pipeline integrity issues, and transportation safety concerns.

Storage and Injection Challenges: Evaluating subsurface risks such as unintended migration of CO2, well integrity failures, and potential seismic activity.

By following a structured PHA approach, operators can proactively identify scenarios that could lead to process upsets, leaks, or equipment failures. More importantly, they can implement layers of protection to mitigate these risks, such as pressure relief systems, real-time monitoring, and emergency response plans.

CCS Safety: Not That Different from Other Hazardous Processes

One of the most common misconceptions about CCS is that it requires an entirely new safety paradigm. In reality, many of the same principles that govern process safety in refining, petrochemical, and natural gas processing apply directly to carbon capture. This is why best practices like PSM and PHA remain just as relevant in CCS as they are in traditional oil and gas operations.

Regulatory bodies, such as the Occupational Safety and Health Administration (OSHA) and the Environmental Protection Agency (EPA), already require stringent risk management for hazardous processes. By applying PHA to CCS projects, companies ensure compliance with these regulations while also safeguarding their workforce, assets, and surrounding communities.

Putting it in Action

As CCS adoption grows in the oil and gas sector, prioritizing safety through thorough risk assessments will be critical to its success. At RskLess, we have performed PHAs for multiple CCS projects and have seen firsthand how this systematic approach enhances process safety and reliability. Companies that integrate PHA into their CCS initiatives not only minimize risks but also reinforce their commitment to best-in-class safety and environmental stewardship.

If your organization is planning a CCS project, don’t overlook the importance of a rigorous risk assessment. Contact us to learn how our expertise in PHA can help ensure the safety and success of your carbon capture initiatives.