- Hazard Review Services: Process hazard analysis (PHA), hazard and operability (HAZOP) analysis, What-if analysis, failure more effect analysis, identification of safety integrity level (SIL) for safety instrumented systems (SIS), project risk reviews, etc.
PII staff have led more than 250 major PHAs/HAZOPs and revalidations and we co-authored the definitive textbook on these analyses and published many papers on the topic as well.
- Lead and document the PHA/hazard evaluations of each phase of a large project (such as a new process). It is never a good idea to let your equipment vendor, technology licensor, or construction contractor lead the PHAs for a new process (project); they have a conflicting interest to maintain budget and schedule. Also, they rarely have qualified (and probably none have expert) PHA leaders on staff. The industry best practice is to have someone from outside of the project team lead the PHA meetings. If you have a qualified leader within your plant, then it is ideal to use that person. If not, your only wise alternatives are (1) borrow a leader from somewhere else within your company (if possible) or (2) contract a leader who is both expert in PHAs and independent of the project team. PII has many expert PHA leaders (and scribes/secretaries) who can fill this role for you.
- Lead and document the PHA/hazard evaluations of existing (older) process. Again, if you have qualified leaders and scribes within your plant, then it is ideal to use those persons to lead and document the PHAs that must be done for your existing facilities. If not, you can (1) borrow a leader from somewhere else within your company or (2) contract a leader. PII has many expert PHA leaders (and scribes/secretaries) who can fill this role for you. Using a PHA leader from PII in this role is also an excellent way to show, by example, how PHAs should be led and documented, thereby providing further training to your staff in this important skill.
- Coach your PHA leaders through their first PHA. Over the 20 years that we have been training PHA leaders (both when we worked in chemical plants and since we’ve been a consultant), coaching has proven to be a critical factor in producing a good PHA leader. After a person completes PHA classroom training, they have indeed learned a lot. But, to become an efficient and thorough PHA leader requires considerable experience in leading actual PHAs. This learning period can be very costly to your company; costly both in time wasted during the PHA and costly in missed hazards. Thus, industry has found it is best if the new graduate learns from existing experts; this is the “coaching” portion of PHA leadership training. PII course instructors and our expert PHA leaders make excellent coaches. They can demonstrate how to prepare for PHA meetings, how to effectively lead the hazard review meetings, and how to document the results in a useable PHA report.
- Example: We have served in this role at many facilities where the PII coach worked with new graduates of PHA Leadership training. This is usually accomplished by letting the instructor choose the best leaders and scribes from recently completed classroom training. Although this approach as worked around the world, let me use a specific example from a country where doing PHAs/HAZOP is newer: In Saudi Arabia, this approach was successfully used at SHARQ (a large petrochemical and polyolefin production facility in Jubail) and at the Royal Commission of Yanbu (which operates the sea water supply for cooling, electrical utility, and natural gas utility for all industries in Yanbu). In each organization, we first had one week of classroom training. Then, the top 6 graduates were divided into 3 pairs (a leader and scribe made up each pair). The instructor then coached these three pairs of recent PHA course graduates as each pair prepared for and led their first PHA (using actual drawings, SOPs, and team members from their companies). This coaching was accomplished while three separate PHAs/HAZOP meetings were in progress; the coaching took 2 weeks. Then, we provided a coach a few months later to review the draft report and meet with the team leaders and scribes (to help the leaders and scribes resolve any remaining weaknesses identified by the coach) This approach worked very well to produce good PHA results while also producing well trained PHA leaders. The result today is that these two organizations now have well trained PHAs leaders and no longer require outside assistance on PHAs. And, these skilled PHA leaders and scribes are able to pass on their experience to new leaders and scribes, thereby reducing the need to use outsiders as trainers.
- Follow this link to Hazard Review Services to find out more about how PII can help your company.
- SIF/SIL Determination
- SIF Specification
- SIF Design
- SIL Verification
- SIS Installation
- SIS Functional Checks
So, regardless of your needs in Safety, PSM, risk management, or process reliability, we have the expertise and staff to assist you. Feel free to contact us so that we can work with you to develop the best plan to meet your needs.