Quick Overview
- 1#1: PHAWorks - Enables efficient performance and documentation of process hazard analyses like HAZOP, LOPA, and What-If studies.
- 2#2: BowTieXP - Visualizes risks using the bowtie methodology to identify, assess, and manage barriers against threats and consequences.
- 3#3: exSILentia - Supports full safety lifecycle management including SIL verification, PFD calculations, and prior use data.
- 4#4: Phast - Models discharge, dispersion, fires, explosions, and toxic effects from hazardous material releases.
- 5#5: Sphera PHA - Comprehensive platform for conducting, managing, and tracking process hazard analyses and risk assessments.
- 6#6: FLACS - Provides CFD simulations for gas dispersion, fire, and explosion risk in complex geometries.
- 7#7: Safeti - Performs quantitative risk assessments for major accident hazards in process facilities.
- 8#8: SuperChems - Analyzes reactive chemical systems, relief systems, and two-phase flow for process safety.
- 9#9: ITEM Toolkits - Supports HAZOP, FMEA, FMECA, fault tree, and event tree analyses for safety and reliability.
- 10#10: FaultTree+ - Builds and analyzes fault trees and reliability block diagrams for system safety assessment.
Tools were chosen based on rigorous evaluation of feature efficacy, technical precision, user experience, and practical value, ensuring alignment with the demands of modern process safety requiremen
Comparison Table
Process safety software is essential for mitigating risks in industrial environments, with popular tools including PHAWorks, BowTieXP, exSILentia, Phast, Sphera PHA, and more. This comparison table outlines key features, functionalities, and use cases to help readers evaluate options for their specific safety management requirements.
| # | Tool | Category | Overall | Features | Ease of Use | Value |
|---|---|---|---|---|---|---|
| 1 | PHAWorks Enables efficient performance and documentation of process hazard analyses like HAZOP, LOPA, and What-If studies. | specialized | 9.7/10 | 9.8/10 | 8.7/10 | 9.4/10 |
| 2 | BowTieXP Visualizes risks using the bowtie methodology to identify, assess, and manage barriers against threats and consequences. | specialized | 9.1/10 | 9.4/10 | 8.7/10 | 8.9/10 |
| 3 | exSILentia Supports full safety lifecycle management including SIL verification, PFD calculations, and prior use data. | specialized | 8.7/10 | 9.5/10 | 7.5/10 | 8.0/10 |
| 4 | Phast Models discharge, dispersion, fires, explosions, and toxic effects from hazardous material releases. | specialized | 8.7/10 | 9.4/10 | 7.1/10 | 8.0/10 |
| 5 | Sphera PHA Comprehensive platform for conducting, managing, and tracking process hazard analyses and risk assessments. | enterprise | 8.5/10 | 9.2/10 | 7.8/10 | 8.0/10 |
| 6 | FLACS Provides CFD simulations for gas dispersion, fire, and explosion risk in complex geometries. | specialized | 8.7/10 | 9.5/10 | 6.5/10 | 8.0/10 |
| 7 | Safeti Performs quantitative risk assessments for major accident hazards in process facilities. | specialized | 8.5/10 | 9.2/10 | 7.8/10 | 8.0/10 |
| 8 | SuperChems Analyzes reactive chemical systems, relief systems, and two-phase flow for process safety. | specialized | 8.2/10 | 9.1/10 | 7.4/10 | 8.0/10 |
| 9 | ITEM Toolkits Supports HAZOP, FMEA, FMECA, fault tree, and event tree analyses for safety and reliability. | specialized | 7.8/10 | 8.5/10 | 6.9/10 | 7.4/10 |
| 10 | FaultTree+ Builds and analyzes fault trees and reliability block diagrams for system safety assessment. | specialized | 7.6/10 | 8.4/10 | 6.9/10 | 7.2/10 |
Enables efficient performance and documentation of process hazard analyses like HAZOP, LOPA, and What-If studies.
Visualizes risks using the bowtie methodology to identify, assess, and manage barriers against threats and consequences.
Supports full safety lifecycle management including SIL verification, PFD calculations, and prior use data.
Models discharge, dispersion, fires, explosions, and toxic effects from hazardous material releases.
Comprehensive platform for conducting, managing, and tracking process hazard analyses and risk assessments.
Provides CFD simulations for gas dispersion, fire, and explosion risk in complex geometries.
Performs quantitative risk assessments for major accident hazards in process facilities.
Analyzes reactive chemical systems, relief systems, and two-phase flow for process safety.
Supports HAZOP, FMEA, FMECA, fault tree, and event tree analyses for safety and reliability.
Builds and analyzes fault trees and reliability block diagrams for system safety assessment.
PHAWorks
specializedEnables efficient performance and documentation of process hazard analyses like HAZOP, LOPA, and What-If studies.
PHA Data Manager for seamless centralization, querying, and reuse of PHA data across multiple studies and facilities
PHAWorks by Primatech is a premier Process Hazard Analysis (PHA) software suite designed for process safety management in high-risk industries like chemicals, oil & gas, and pharmaceuticals. It supports a wide range of methodologies including HAZOP, LOPA, What-If, FMEA, HAZID, and bow-tie analysis, enabling structured team-based hazard identification and risk assessment. The software provides advanced worksheet customization, data centralization via PHA Data Manager, and automated reporting for regulatory compliance such as OSHA PSM and IEC 61511.
Pros
- Comprehensive support for all major PHA methods with customizable worksheets
- Powerful PHA Data Manager for centralized data handling and reuse across studies
- Robust reporting, auditing, and integration capabilities for enterprise compliance
Cons
- Steep learning curve for non-expert users due to depth of features
- Primarily desktop (Windows-based) with limited native cloud or mobile access
- Enterprise-level pricing may be prohibitive for small teams
Best For
Large-scale process industry teams in oil & gas, chemicals, or pharma conducting frequent, complex PHAs for regulatory compliance.
Pricing
Quote-based enterprise licensing; perpetual licenses per user/seat start around $5,000-$10,000+ with annual maintenance fees.
BowTieXP
specializedVisualizes risks using the bowtie methodology to identify, assess, and manage barriers against threats and consequences.
Dynamic bowtie diagrams with real-time barrier effectiveness scoring and degradation modeling
BowTieXP is a specialized software solution from CGE Risk Management for conducting BowTie risk analysis, a visual method widely used in process safety to map threats, consequences, barriers, and controls around top events. It enables users to build interactive bowtie diagrams, perform quantitative risk assessments, track barrier performance, and generate compliance reports for safety cases. The tool is particularly valued in high-hazard industries for its ability to support barrier management and integrate with enterprise risk systems.
Pros
- Powerful interactive bowtie diagramming with escalation factors and barrier health indicators
- Robust quantitative analysis and auditing tools compliant with standards like IEC 61882
- Excellent reporting, export options, and integration with tools like Sphera or PHA-Pro
Cons
- Steep learning curve for advanced features and complex models
- Enterprise pricing can be prohibitive for small teams or startups
- Limited native mobile support and occasional performance lags with very large diagrams
Best For
Large organizations in oil & gas, chemicals, or petrochemicals seeking advanced visual barrier management and regulatory compliance.
Pricing
Enterprise licensing model; pricing upon request, typically starting at several thousand USD annually based on users and modules.
exSILentia
specializedSupports full safety lifecycle management including SIL verification, PFD calculations, and prior use data.
Seamless workflow integration from HAZOP/LOPA to automated SIL verification with linked failure data
exSILentia, developed by exida, is a comprehensive software suite for functional safety lifecycle management in process industries, focusing on Safety Instrumented Systems (SIS). It includes modules for PHA/HAZOP, LOPA, SIL selection, SIL verification, proof test coverage, and alarm management, ensuring compliance with IEC 61508/61511 standards. Widely used for risk assessment and safety integrity level calculations, it leverages certified failure rate databases like FMEDA data for accurate analysis.
Pros
- Extensive module integration for full safety lifecycle
- Reliable, certified component failure databases (e.g., phiMD)
- Detailed, audit-compliant reporting and documentation
Cons
- Steep learning curve for new users
- High cost for full suite access
- Interface feels dated compared to modern tools
Best For
Process safety engineers and consultants in oil & gas, chemicals, or pharma managing complex SIS designs under strict IEC 61511 compliance.
Pricing
Perpetual licenses start at $4,000-$15,000 per module; annual maintenance ~20% of license cost; custom quotes for enterprise.
Phast
specializedModels discharge, dispersion, fires, explosions, and toxic effects from hazardous material releases.
Unified Dispersion Model (UDM) that handles neutral, buoyant, dense gas, and passive dispersion regimes in a single, advanced framework.
Phast by DNV is an industry-leading process safety software suite for modeling the consequences of hazardous material releases, including atmospheric dispersion, pool evaporation, jet fires, pool fires, fireballs, and explosions. It enables quantitative risk assessment (QRA), safety case preparation, and compliance with regulations like COMAH and Seveso. Validated against extensive experimental data and real incidents, Phast is widely used in oil & gas, petrochemical, and chemical sectors for reliable hazard prediction.
Pros
- Exceptionally accurate models validated against real-world data
- Comprehensive scenario coverage including multi-phase releases and 3D explosions
- Seamless integration with DNV's Safeti for full QRA workflows
Cons
- Steep learning curve requiring specialized training
- High enterprise-level pricing
- Primarily Windows-based with limited cloud or mobile support
Best For
Process safety engineers and risk analysts in oil & gas or chemical plants needing precise consequence modeling for regulatory compliance.
Pricing
Enterprise licensing with perpetual or subscription models; typically $10,000–$25,000 per license annually plus maintenance, quoted on request.
Sphera PHA
enterpriseComprehensive platform for conducting, managing, and tracking process hazard analyses and risk assessments.
Built-in re-engineering engine that automates updates across PHA studies when process changes occur
Sphera PHA is a leading process hazard analysis (PHA) software solution tailored for high-risk industries like oil & gas, chemicals, and manufacturing. It supports a wide range of methodologies including HAZOP, LOPA, FMEA, HAZID, and What-If analyses, enabling structured team-based risk assessments. The platform facilitates detailed documentation, quantitative risk calculations, and seamless integration with Sphera's broader EHS and operational risk management suite for comprehensive process safety management.
Pros
- Comprehensive support for all major PHA methodologies with customizable worksheets
- Powerful reporting, visualization, and export capabilities including bowtie diagrams
- Strong integration with enterprise systems like SpheraCloud for end-to-end risk management
Cons
- Steep learning curve due to extensive customization options
- High implementation and licensing costs for smaller teams
- Limited native mobile support for field-based reviews
Best For
Large-scale process industry organizations requiring robust, scalable PHA tools with enterprise integrations.
Pricing
Enterprise quote-based pricing, typically starting at $20,000+ annually depending on users, modules, and deployment (cloud or on-premise).
FLACS
specializedProvides CFD simulations for gas dispersion, fire, and explosion risk in complex geometries.
Proprietary CFD solver optimized for deflagration-to-detonation transitions, unmatched in explosion prediction fidelity
FLACS, developed by Gexcon, is a specialized Computational Fluid Dynamics (CFD) software for modeling gas explosions, fires, and dispersion of hazardous materials in complex industrial geometries. It is widely used in process safety for Quantitative Risk Assessments (QRA), facility siting studies, and explosion protection design in oil & gas, petrochemical, and hydrogen sectors. The software excels in providing validated, high-fidelity simulations that predict overpressures, heat fluxes, and toxic exposures with industry-leading accuracy.
Pros
- Exceptional accuracy in explosion and fire modeling validated against large-scale tests
- Robust handling of complex 3D geometries and multiphase flows
- Integrated tools for QRA and risk visualization
Cons
- Steep learning curve requiring CFD expertise
- High computational demands needing powerful hardware
- Premium pricing limits accessibility for smaller firms
Best For
Process safety engineers in high-hazard industries like oil & gas needing precise CFD-based explosion risk simulations.
Pricing
Custom quotes required; perpetual licenses or annual subscriptions typically start at €20,000+ depending on modules, with additional costs for training and support.
Safeti
specializedPerforms quantitative risk assessments for major accident hazards in process facilities.
Unified environment for 3D consequence visualization and probabilistic risk mapping
Safeti by DNV is a sophisticated quantitative risk assessment (QRA) software tailored for process industries like oil & gas, petrochemicals, and chemicals. It models hazards such as jet fires, pool fires, explosions, and toxic dispersions, providing detailed consequence analysis and risk quantification for onshore and offshore facilities. The tool integrates probabilistic event trees and fault trees to support safety case development and regulatory compliance.
Pros
- Highly accurate multi-hazard consequence modeling
- Extensive material and equipment libraries
- Seamless integration with DNV's Synergi suite
Cons
- Steep learning curve for non-experts
- Resource-intensive for large-scale models
- Pricing opaque without direct inquiry
Best For
Large industrial operators in high-hazard sectors needing advanced QRA for safety justifications and ALARP demonstrations.
Pricing
Custom enterprise licensing; annual subscriptions start at $10,000+ depending on modules and users—contact DNV for quotes.
SuperChems
specializedAnalyzes reactive chemical systems, relief systems, and two-phase flow for process safety.
Advanced reactive hazard evaluation module that simulates adiabatic calorimeters and predicts onset temperatures, self-heat rates, and maximum temperatures/pressures for safe scale-up.
SuperChems by ioMosaic is a specialized process safety software designed for hazard evaluation and consequence analysis in chemical processes. It excels in modeling reactive chemical systems, relief system sizing using DIERS methodologies, and predicting outcomes of fires, explosions, toxic releases, and two-phase flows. The tool supports process hazard analysis (PHA), layer of protection analysis (LOPA), and compliance with standards like API 521 and NFPA.
Pros
- Comprehensive reactive chemistry modeling and runaway reaction prediction
- Robust relief valve and vent sizing capabilities with DIERS compliance
- Integrated consequence modeling for realistic hazard scenarios
Cons
- Steep learning curve due to complex interface and extensive options
- Windows-only desktop application with limited cloud integration
- High cost may deter smaller organizations
Best For
Process safety engineers in chemical, pharmaceutical, and petrochemical industries managing reactive systems and high-hazard processes.
Pricing
Custom quote-based; perpetual licenses start around $10,000-$20,000 per seat with annual maintenance fees of 20%.
ITEM Toolkits
specializedSupports HAZOP, FMEA, FMECA, fault tree, and event tree analyses for safety and reliability.
Integrated FaultTree+ module with advanced cut-set analysis and uncertainty propagation for precise safety integrity level (SIL) verification
ITEM Toolkits from Item Software is a comprehensive suite of Windows-based tools for reliability, availability, maintainability, and safety (RAMS) analysis tailored to process safety applications. It includes modules for fault tree analysis (FaultTree+), event tree analysis (EventTree+), HAZOP/LOPA studies (ITEM Risk), Markov modeling, and SIL verification, enabling quantitative risk assessment and compliance with standards like IEC 61508/61511. The software supports complex system modeling to identify critical failure modes and safety barriers in high-hazard industries such as oil & gas and chemicals.
Pros
- Extensive module library for fault trees, event trees, and SIL calculations
- Robust quantitative risk analysis with cut-set minimization and importance measures
- Long-standing industry use with proven accuracy for regulatory compliance
Cons
- Outdated graphical user interface feels clunky compared to modern competitors
- Limited cloud or web-based options; Windows-only deployment
- Steep learning curve for non-expert users due to technical depth
Best For
Experienced process safety engineers in oil & gas or chemical plants requiring in-depth RAMS and probabilistic risk assessments.
Pricing
Perpetual licenses start at ~$4,000-$15,000 per module depending on features; volume discounts and annual maintenance ~15-20% of license cost; custom quotes required.
FaultTree+
specializedBuilds and analyzes fault trees and reliability block diagrams for system safety assessment.
Phased mission analysis for modeling time-dependent system behaviors in safety-critical sequences
FaultTree+ from Isograph Software is a specialized tool for fault tree analysis (FTA), enabling the modeling of complex system failure scenarios to quantify risks in process safety applications. It supports coherent and non-coherent fault trees, minimal cut set generation, importance measures, and integration with event trees for comprehensive quantitative risk assessments (QRA). Widely used in industries like oil & gas and chemicals, it helps in safety integrity level (SIL) verification and HAZOP follow-up studies.
Pros
- Powerful fault tree editing with graphical interface and automated cut set analysis
- Supports advanced calculations like importance ranking and uncertainty analysis
- Robust export options including reports, diagrams, and data integration with Excel
Cons
- Steep learning curve for non-experts due to specialized terminology and setup
- Limited native integration with broader process simulation tools like Aspen or PHAST
- Windows-only, lacking modern cloud or mobile accessibility
Best For
Process safety engineers in high-hazard industries needing detailed fault tree analysis for regulatory compliance and risk quantification.
Pricing
Perpetual licenses start at around £4,500 ($5,800 USD), with annual maintenance at 20% of license cost; volume discounts available.
Conclusion
In the competitive landscape of process safety software, these tools stand out as leaders, each excelling in specific areas to support robust risk management. PHAWorks takes the top spot, renowned for its efficiency in conducting critical hazard analyses like HAZOP and LOPA, streamlining documentation and performance. BowTieXP follows, impressing with its intuitive bowtie methodology visualization for risk barriers, while exSILentia excels in full safety lifecycle management, from SIL verification to prior use data tracking. Teams can find strong solutions based on their priorities, with the top three offering standout value.
Start with PHAWorks, the top choice for effective, thorough hazard analysis, to enhance your process safety protocols and drive stronger operations.
Tools Reviewed
All tools were independently evaluated for this comparison