Need help with hazard reviews, HAZOPs, process hazard analyses (PHAs)? We can help. 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.
Process safety is all about controlling risk of failures and errors. Controlling risk is primarily about reducing human error. All elements of Risk-Based Process Safety (RBPS) and other alternative standards for process safety have many elements, and each of these in turn help to reduce the chance of human error or else limit its impact. One core element is the process hazard analysis (PHA). PHAs have been performed formally in gradually improving fashion for more than five decades. Methods such as Hazard and Operability (HAZOP) analysis, What-If Analysis, and failure mode effect analysis (FMEA) have been developed and honed during this time. PII offers various levels of training (e.g., leading, scribing, coaching) related to performance of hazard reviews, including:
- 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) due to 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 (while working in chemical plants and also as consultants), coaching has proven to be a critical factor in producing a good PHA leader. Completing PHA classroom training is the first step. However, 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, both in time wasted during the PHA and in missed hazards. Thus, based on industry experience, 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
Documentation efforts by PII for the above items include:
- Issuing the recommendations
- Cleaning up the PHA tables
- Updating the tables and documenting the resolutions during all project phases (if requested)
- Writing the final PHA report