Development of an Integrated HIRA and Fault Tree Analysis Framework for Process Safety and Fire Mitigation in Photovoltaic Cell Manufacturing

Abstract

The transition towards sustainable, net-zero energy systems relies fundamentally on the mass production of solar photovoltaic (PV) modules. Driven by aggressive national targets and policy frameworks like the Production Linked Incentive (PLI) scheme, India is rapidly scaling its domestic PV manufacturing capacity from megawatt to multi-gigawatt scales. As these highly automated facilities expand, the operational footprints and associated industrial hazard densities have increased exponentially. This research paper systematically evaluates the complex process safety challenges inherent in modern PV cell fabrication, which closely mirrors the hazards of the semiconductor industry. By integrating qualitative Hazard Identification and Risk Assessment (HIRA) with quantitative reliability engineering tools—specifically Fault Tree Analysis (FTA) and Failure Mode and Effects Analysis (FMEA)—this study provides a high-resolution risk profile tailored to the unique Indian industrial environment characterized by high ambient temperatures and grid fluctuations. The analysis identifies the handling of pyrophoric Silane (SiH4) gas in the Plasma-Enhanced Chemical Vapor Deposition (PECVD) process and the use of highly toxic Hydrofluoric Acid (HF) as the most critical vulnerabilities. Through rigorous Boolean logic modeling and cut-set evaluation, the probability of catastrophic failures, such as confined-space gas explosions, is quantified. The paper culminates in the proposal of robust mitigation strategies, emphasizing Layer of Protection Analysis (LOPA), Safety Instrumented Systems (SIS), and automated fail-safe mechanisms to ensure the safe and sustainable scaling of India's solar manufacturing sector.