Process Hazard Analysis Software: Compare the Top 5 (2025)

You need process hazard analysis software that fits your biogas or biomethane projects. The challenge is knowing which platform will actually work for your operations without wasting budget on tools that promise everything but deliver half measures. Some options are built for oil and gas giants with price tags to match. Others lack the depth you need for serious PHA studies. And many vendors make it nearly impossible to understand what you're buying until you sit through three sales calls.

This guide compares five PHA software platforms you can actually evaluate and use in 2025. We cover what each tool does well, where it falls short, how it handles HAZOP and LOPA studies, what deployment looks like, and what you'll pay. By the end, you'll know which platform matches your project size, regulatory requirements, and team capabilities.

1. PHAWorks RA Edition

PHAWorks RA Edition from Primatech gives you dedicated process hazard analysis software built on three decades of PHA expertise. The platform handles HAZOP, What-If, LOPA, FMEA, and other study methods in one application without forcing you to buy modules you won't use. You download the software to your Windows machine, and it runs locally with no cloud dependency or recurring subscription fees eating into your project budget.

Overview of PHAWorks RA Edition

The software structures your PHA studies through pre-built templates and customizable worksheets that match industry standards. You create nodes, define parameters, identify deviations, and document causes and consequences in a guided workflow. PHAWorks stores all your study data in a single database file that you can back up, share, and archive without vendor lock-in. The interface looks dated compared to modern web apps, but it's fast and responsive once you learn where everything lives.

Supported PHA methods and workflows

PHAWorks handles HAZOP studies with full guideword libraries and automatic parameter combinations. You can run What-If analyses, Checklist reviews, FMEA studies, and combined What-If/Checklist assessments in the same project file. The software calculates risk matrices and LOPA scenarios with configurable risk criteria, and you can define your own consequence categories and likelihood scales. Each study method gets its own worksheet format, so your team follows consistent documentation practices across different analysis types.

"The platform handles HAZOP, What-If, LOPA, FMEA, and other study methods in one application without forcing you to buy modules you won't use."

Fit for biogas and biomethane projects

PHAWorks works well for mid-sized biogas upgrading systems and biomethane injection facilities where you need structured PHA documentation for permitting and safety management. The software lets you define custom equipment types, process parameters, and hazard scenarios specific to anaerobic digestion and gas treatment. You won't find biogas-specific templates out of the box, but you can build and save your own for digesters, upgrading skids, and gas compression trains.

Collaboration, reporting and data management

The software supports multi-user editing through file sharing and network drives, though only one person can edit a study at a time. You export reports to Word, Excel, or PDF with full control over formatting and included sections. PHAWorks tracks action items, recommendations, and safeguards with status fields you can filter and sort. The reporting features are comprehensive but require manual formatting work to match your company templates.

Deployment model, training and pricing

PHAWorks installs on individual Windows PCs with perpetual licenses that you buy upfront. Primatech offers online training courses and consulting support at additional cost. You pay for the software once and own it forever, with optional annual maintenance for updates and technical support. Expect to budget time for training your team on the interface and study workflows before they can work independently.

2. Sphera PHA Pro

Sphera PHA Pro delivers enterprise-grade process hazard analysis software designed for companies managing complex process safety programs across multiple sites. The platform runs as a web-based application that your team accesses through standard browsers, eliminating local installation headaches and giving your PHA leaders real-time access to study data from anywhere. Sphera built this tool for large organizations with mature safety management systems, and it shows in the depth of features and integration capabilities.

Overview of Sphera PHA Pro

The software centralizes your PHA studies, risk assessments, and action tracking in one system tied to your equipment hierarchy and process inventory. You define your facility structure once, then reuse those definitions across multiple studies and revalidations. Sphera handles version control automatically, tracking every change to study worksheets, recommendations, and supporting documentation. Your team sees who made what changes and when, which matters during audits and management of change reviews.

Advanced analysis and what if scenario modeling

PHA Pro includes built-in what-if scenario tools that let you model process upsets, equipment failures, and operator errors without leaving the study worksheet. You can run consequence modeling for releases, fires, and explosions when you integrate with Sphera's separate risk modeling tools. The platform calculates risk rankings using your defined criteria and flags high-risk scenarios that need additional safeguards or deeper analysis.

"The software centralizes your PHA studies, risk assessments, and action tracking in one system tied to your equipment hierarchy and process inventory."

Strengths for large and high hazard facilities

Sphera PHA Pro fits best at multi-site operations with dedicated process safety teams and hundreds of operating units to manage. The software handles large HAZOP studies with 50-plus nodes and thousands of deviations without slowing down. You get robust safeguard libraries and scenario databases you can share across facilities to standardize your PHA approach. Smaller biogas projects won't need this level of capability and will pay for features they never use.

Integration with enterprise EHS and process safety

The platform connects to Sphera's broader operational risk suite, pulling data from incident management, compliance tracking, and audit systems. You link PHA recommendations directly to work orders in your maintenance system and track completion status without spreadsheets or email chains. Integration requires IT resources and planning, but it eliminates duplicate data entry across safety systems.

Implementation effort and pricing expectations

Expect a multi-month implementation with configuration, data migration, and user training before your team can run studies independently. Sphera prices PHA Pro on an annual subscription basis tied to user count and facility count, with separate fees for implementation services and ongoing support. Budget for costs that scale with company size, not project complexity.

3. Open-PHA by Kenexis

Open-PHA by Kenexis gives you free process hazard analysis software that runs on Windows, Mac, and Linux without licensing fees or subscription costs. This desktop application handles the core PHA study methods you need for biogas facilities without the enterprise complexity of commercial platforms. You download the software, install it locally, and start building your HAZOP or LOPA studies immediately.

Overview of Open PHA by Kenexis

The software provides structured worksheets for conducting PHA studies using industry-standard methodologies. Kenexis designed Open-PHA as a community tool for process safety professionals who need reliable documentation without vendor dependencies. Your study data stays in local files you control, and you can export results to standard formats for sharing with regulators or project stakeholders.

Core HAZOP and LOPA functionality

Open-PHA handles HAZOP studies with standard guideword tables and LOPA calculations with protection layer credits. You define nodes, parameters, and deviations in the HAZOP module, then document causes, consequences, and safeguards. The LOPA module calculates risk reduction based on independent protection layers you specify. Both study types generate reports you can customize for your documentation requirements.

Benefits and limits of a free desktop tool

You get zero software costs and no vendor lock-in, which matters for smaller projects with tight budgets. The interface works but lacks the polish and automation features of commercial platforms. Open-PHA handles one study at a time with basic reporting, so you won't find advanced analytics, risk dashboards, or enterprise integration capabilities here.

"You get zero software costs and no vendor lock-in, which matters for smaller projects with tight budgets."

Using Open PHA in smaller biogas projects

The software fits farm-scale digesters and small upgrading systems where you need documented PHA studies for permits but can't justify enterprise software costs. You can complete a basic HAZOP in days rather than weeks once your team learns the interface. Larger biomethane facilities with multiple process trains will outgrow Open-PHA quickly.

Support options and total cost of ownership

Kenexis provides community forums and basic documentation but no formal technical support or training services. Your total cost includes only the time your team spends learning the software and building your study templates. Budget for slower progress on your first few studies as your PHA leaders figure out the workflows.

4. SafetyCulture

SafetyCulture offers a mobile-first inspection and safety platform that you can adapt for process hazard analysis workflows. The software started as an inspection checklist tool and evolved into a broader operational safety solution with templates, asset management, and incident tracking. You access SafetyCulture through web browsers or mobile apps on iOS and Android, giving your field teams tools they can use during facility walkthroughs and equipment inspections.

Overview of SafetyCulture for process hazards

The platform provides customizable digital checklists that your team uses to document hazard identification, risk assessments, and safety observations. You can build templates that follow HAZOP or checklist-based PHA formats, capturing photos, equipment IDs, and hazard descriptions during facility reviews. SafetyCulture handles the inspection and documentation side of process safety but lacks dedicated study worksheets and guideword libraries found in specialized process hazard analysis software.

Using templates for inspections and PHA studies

SafetyCulture includes pre-built templates for safety audits and risk assessments that you modify for biogas facility inspections. Your team captures hazard information on tablets or phones, and the platform automatically generates reports with photos and GPS coordinates. Building a proper PHA study template requires significant customization work to match industry standards.

Mobile data capture and frontline engagement

The software excels at getting safety data from field workers who inspect digesters, upgrading equipment, and gas handling systems. You assign inspections to specific team members, set recurring schedules, and receive automatic notifications when issues are found. Your operators can flag hazards during daily rounds without returning to a desk.

When SafetyCulture is and is not enough for PHA

SafetyCulture works for ongoing hazard observations and basic risk assessments at smaller biogas facilities. The platform cannot handle complex HAZOP studies, LOPA calculations, or detailed safeguard analysis that regulators expect for larger biomethane projects.

"The platform cannot handle complex HAZOP studies, LOPA calculations, or detailed safeguard analysis that regulators expect for larger biomethane projects."

Plans, pricing and rollout considerations

SafetyCulture charges $24 per user per month with annual billing and offers a free tier for teams up to 10 users. You can deploy the software quickly with minimal IT involvement, and your team learns the interface in hours rather than days.

5. Intelex Process Hazard Analysis

Intelex delivers cloud-based process hazard analysis software as part of its broader environmental, health, and safety management suite. The platform targets regulated industries that need formal PHA programs integrated with incident management, audit tracking, and compliance workflows. You access Intelex through web browsers with role-based permissions that control who can create studies, approve recommendations, and view risk data across your organization.

Overview of Intelex process hazard analysis

The software structures your PHA studies through configurable workflow templates that match OSHA PSM and EPA RMP requirements. You document hazard scenarios, safeguards, and risk rankings in forms that connect to your equipment database and chemical inventory. Intelex tracks study status from planning through completion and revalidation, sending automatic reminders when studies need updates or recommendations are overdue. Your process safety team sees all active PHAs in one dashboard rather than hunting through shared drives and spreadsheets.

PHA workflows and automation features

Intelex automates study assignment, approval routing, and recommendation tracking using rules you configure during implementation. You set up automatic notifications for study leaders, technical reviewers, and management based on study stage and risk findings. The platform generates action items from PHA recommendations and routes them to responsible parties with due dates and escalation triggers. Your team spends less time on administrative tasks and more time on actual hazard analysis.

"The platform generates action items from PHA recommendations and routes them to responsible parties with due dates and escalation triggers."

Fit for regulated and multi site operations

Intelex fits multi-facility operations with centralized process safety management and formal compliance obligations. The software handles hundreds of studies across multiple locations with consistent templates and risk criteria. Companies with dedicated EHS staff and IT resources will use the integration and automation capabilities effectively. Smaller biogas projects with limited compliance requirements won't need this level of system complexity.

Data, integrations and analytics capabilities

The platform stores all PHA data in a central database you can query for risk reports, action status, and study completion metrics. Intelex connects to maintenance management systems, document control platforms, and incident tracking tools through APIs and pre-built connectors. You build custom dashboards that show risk trends, overdue recommendations, and study backlogs across your facilities.

Pricing model and how to budget for it

Intelex uses annual subscription pricing based on user count and module selection, with separate fees for implementation and training services. You pay for the full EHS platform even if you only use the PHA module. Implementation takes several months with configuration, data migration, and user training before your team can work independently.

Next steps

You now have a clear comparison of five process hazard analysis software options and understand which platform matches your project requirements and budget constraints. Your next move depends on your facility size, regulatory obligations, and internal team capabilities. Smaller biogas projects benefit from Open-PHA's zero-cost model or SafetyCulture's simple mobile interface for basic inspections and checklists. Mid-sized operations need PHAWorks' structured study workflows and perpetual licensing that eliminates recurring subscription costs. Large multi-site facilities justify Sphera or Intelex despite higher implementation costs and longer deployment timelines that require dedicated resources.

The software you choose must support your actual process hazards, not hypothetical ones. 99pt5's BioTreater™ system delivers guaranteed 99.5% BioMethane recovery and CO2e emission reduction with built-in safety features that simplify your PHA studies and reduce operational risks. Start by defining your specific PHA requirements and critical scenarios today, then request demos from vendors that match your project scale and compliance needs.