Guidelines for Process Hazard Analysis (PHA) Revalidations, Second Edition

Cover 1 Title Page 5 Copyright 6 Table of Contents 7 List of Tables 11 List of Figures 11 Acronyms and Abbreviations 12 Glossary and Nomenclature 14 Acknowledgments 16 Preface 18 Dedication 19 Introduction 21 Objective of this Book 21 Scope of this Book 21 How to Use This Guidelines Book 22 1 OVERVIEW OF THE PHA REVALIDATION PROCESS 25 1.1 What is a PHA and What is a PHA Intended to Accomplish? 26 1.2 Overview of Typical PHA Activities 28 1.2.1 PHA Core Methodology 28 1.2.2 PHA Complementary Analyses 30 1.3 General Risk Assessment Principles 32 1.3.1 Risk and Risk Toler 32 1.3.2 Supplemental Risk Assessments 33 1.4 PHA Revalidation Objectives 35 1.5 PHA Revalidation Concept 38 1.6 PHA Revalidation Cycle 40 1.7 The Role of a PHA Revalidation Procedure 43 1.8 Relationship of RBPS Pillars to a PHA Revalidation 45 2 PHA REVALIDATION REQUIREMENTS 47 2.1 External Legal/Regulatory Requirements 47 2.1.1 General Obligations 49 2.1.2 Specific RAGAGEPs 50 2.2 Internal Company Policy Requirements 52 2.2.1 Compliance-Driven Policies 53 2.2.2 EHS-Driven Policies 53 2.2.3 Value-Driven Policies 54 2.3 Internal Company Drivers That Impact Revalidation 55 2.4 Principles for Successful Definition of Revalidation Requirements 57 3 EVALUATING THE PRIOR PHA 59 3.1 Prior PHA Essential Criteria 62 3.1.1 Prior PHA Methodology Used 62 3.1.2 Prior PHA Inputs 64 3.1.3 Prior PHA Scope 67 3.1.4 Drawing Essential Criteria Conclusions 70 3.2 Prior PHA Quality and Completeness 72 3.2.1 Application of Analysis Method(s) 73 3.2.2 Level of Detail and Accuracy of the Core Analysis 74 3.2.3 Logic Errors and Inconsistencies in the Analysis 80 3.2.4 Failure to Document Hazards 82 3.2.5 Improper Application of Risk Tolerance 83 3.2.6 Drawing Quality and Completeness Conclusions 84 3.3 Prior PHA Topics for Additional Evaluation 85 3.3.1 Status of Prior PHA Recommendations 85 3.3.2 Complementary Analyses and Supplemental Risk Assessments 86 3.3.3 Opportunity to Learn and Capture Information 86 3.3.4 Continuous Improvement 87 3.3.5 PHA Documentation Software Changes 87 3.3.6 Time Since the Previous Redo 87 3.4 Principles for Successful Prior PHA Evaluation 88 4 EVALUATING OPERATING EXPERIENCE SINCE THE PRIOR PHA 91 4.1 Operating Experience Influence on Revalidation 92 4.2 Types of Operating Experience That Should Be Considered 92 4.2.1 MOC and PSSR Records 93 4.2.2 Incident Reports 99 4.2.3 Routine Maintenance Records 101 4.2.4 Audit Results 102 4.2.5 Organizational Changes Not Addressed by MOCs 103 4.2.6 Metrics and Overall Performance 106 4.3 How Operating Experience Affects the Revalidation 107 4.4 Principles for Successful Operating Experience Evaluation 109 5 SELECTING AN APPROPRIATE PHA REVALIDATION APPROACH 113 5.1 Revalidation Approaches 114 5.1.1 Update 114 5.1.2 Redo 116 5.1.3 Combining Update and Redo in a Revalidation 118 5.2 Selecting the Revalidation Options 121 5.2.1 Have the Requirements Changed Significantly? 122 5.2.2 Is the Prior PHA Deficient or Unacceptable? 124 5.2.3 Are There Too Many Changes or Significant Revelations in Operating Experience? 125 5.3 Principles for Successful Revalidation Approach Selection 127 6 PREPARING FOR PHA REVALIDATION MEETINGS 129 6.1 Planning the Revalidation Meetings 130 6.1.1 Establishing the Revalidation Scope 130 6.1.2 Selecting Team Members 132 6.1.3 Estimating Schedule, Time, and Resources 134 6.2 Identifying and Collecting Information 137 6.2.1 Determining Information Requirements 137 6.2.2 Distributing Information 141 6.3 Reviewing and Preparing Information 141 6.3.1 Prior PHA Reports and Related Documentation 141 6.3.2 Prior PHA Recommendation Resolution Status 142 6.3.3 MOC and PSSR Records 144 6.3.4 Audit Results 150 6.3.5 Incident Reports 150 6.3.6 Current Piping and Instrument Diagrams 151 6.3.7 Current Operating Procedures 151 6.3.8 Special Considerations for Complementary Analyses and Supplemental Risk Assessments 152 6.4 Principles for Successful Revalidation Preparation 153 7 CONDUCTING PHA REVALIDATION MEETINGS 155 7.1 Applying Analysis Methodologies 155 7.1.1 Revalidation of the Core Analysis 156 7.1.2 Revalidation of Complementary Analyses 158 7.1.3 Revalidation of Supplemental Risk Assessments 161 7.2 Facilitating Effective Revalidation Meetings 163 7.2.1 Team Composition 163 7.2.2 Meeting Kickoff 164 7.2.3 Meeting Productivity 167 7.3 Revalidation Meeting Conclusion 173 7.4 Principles for Successful Revalidation Meetings 175 8 DOCUMENTING AND FOLLOWING UP ON A PHA REVALIDATION 179 8.1 Documentation Approaches 180 8.2 Report and Its Contents 184 8.3 Recommendations and Follow-Up 185 8.4 Records Retention and Distribution 187 8.5 Principles for Successful Documentation and Follow-Up 189 REFERENCES 191 APPENDICES 195 APPENDIX A Essential Criteria Checklist 195 APPENDIX B PHA Quality and Completeness Checklist 199 APPENDIX C Example Change Summary Worksheet 205 APPENDIX D Checklist of Process, Facility, and Human Factors Changes 207 APPENDIX E Example Facility Siting Checklists 211 APPENDIX F Example Human Factors Checklists 223 APPENDIX G Example External Events Checklist 233 INDEX 239 EULA 243 "This book is derived from the experience of many companies in the chemical and hydrocarbon processing industries, and presents demonstrated, concise, and common sense approaches for a resource-effective revalidation of process hazard analyses (PHAs). It includes flowcharts, checklists, and worksheets that provide invaluable assistance to the revalidation process. The new edition, now as a guideline, provides a complete and thorough update of the first book and will provide much needed and requested guidance on PHA Revalidations including evaluating Prior PHA Studies, Identifying an Appropriate Revalidation Methodology, Preparing and Conducting the Revalidation Study Sessions, and Documenting the Revalidation Study"-- Provided by publisher