Guidelines for Revalidating a Process Hazard Analysis

ISBN-13: 9781119643609 / Angielski / Twarda / 2022 / 240 str.

Center for Chemical Process Safety (CCPS)

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List of Tables ixList of Figures ixAcronyms and Abbreviations xGlossary and Nomenclature xiiAcknowledgments xivPreface xviDedication xviiIntroduction xixObjective of this Book xixScope of this Book xixHow to Use This Guidelines Book xx1 OVERVIEW OF THE PHA REVALIDATION PROCESS 11.1 What is a PHA and What is a PHA Intended to Accomplish? 21.2 Overview of Typical PHA Activities 41.2.1 PHA Core Methodology 41.2.2 PHA Complementary Analyses 61.3 General Risk Assessment Principles 81.3.1 Risk and Risk Tolerance 81.3.2 Supplemental Risk Assessments 91.4 PHA Revalidation Objectives 111.5 PHA Revalidation Concept 141.6 PHA Revalidation Cycle 161.7 The Role of a PHA Revalidation Procedure 191.8 Relationship of RBPS Pillars to a PHA Revalidation 212 PHA REVALIDATION REQUIREMENTS 232.1 External Legal/Regulatory Requirements 232.1.1 General Obligations 252.1.2 Specific RAGAGEPs 262.2 Internal Company Policy Requirements 282.2.1 Compliance-Driven Policies 29vi Guidelines for Revalidating a Process Hazard Analysis2.2.2 EHS-Driven Policies 292.2.3 Value-Driven Policies 302.3 Internal Company Drivers That Impact Revalidation 312.4 Principles for Successful Definition of Revalidation Requirements 333 EVALUATING THE PRIOR PHA 353.1 Prior PHA Essential Criteria 383.1.1 Prior PHA Methodology Used 383.1.2 Prior PHA Inputs 403.1.3 Prior PHA Scope 433.1.4 Drawing Essential Criteria Conclusions 463.2 Prior PHA Quality and Completeness 483.2.1 Application of Analysis Method(s) 493.2.2 Level of Detail and Accuracy of the Core Analysis 503.2.3 Logic Errors and Inconsistencies in the Analysis 563.2.4 Failure to Document Hazards 583.2.5 Improper Application of Risk Tolerance 593.2.6 Drawing Quality and Completeness Conclusions 603.3 Prior PHA Topics for Additional Evaluation 613.3.1 Status of Prior PHA Recommendations 613.3.2 Complementary Analyses and Supplemental RiskAssessments 623.3.3 Opportunity to Learn and Capture Information 623.3.4 Continuous Improvement 633.3.5 PHA Documentation Software Changes 633.3.6 Time Since the Previous Redo 633.4 Principles for Successful Prior PHA Evaluation 644 EVALUATING OPERATING EXPERIENCE SINCE THE PRIOR PHA 674.1 Operating Experience Influence on Revalidation 684.2 Types of Operating Experience That Should Be Considered 684.2.1 MOC and PSSR Records 694.2.2 Incident Reports 754.2.3 Routine Maintenance Records 774.2.4 Audit Results 784.2.5 Organizational Changes Not Addressed by MOCs 79Contents vii4.2.6 Metrics and Overall Performance 824.3 How Operating Experience Affects the Revalidation 834.4 Principles for Successful Operating Experience Evaluation 855 SELECTING AN APPROPRIATE PHA REVALIDATION APPROACH 895.1 Revalidation Approaches 905.1.1 Update 905.1.2 Redo 925.1.3 Combining Update and Redo in a Revalidation 945.2 Selecting the Revalidation Options 975.2.1 Have the Requirements Changed Significantly? 985.2.2 Is the Prior PHA Deficient or Unacceptable? 1005.2.3 Are There Too Many Changes or Significant Revelations inOperating Experience? 1015.3 Principles for Successful Revalidation Approach Selection 1036 PREPARING FOR PHA REVALIDATION MEETINGS 1056.1 Planning the Revalidation Meetings 1066.1.1 Establishing the Revalidation Scope 1066.1.2 Selecting Team Members 1086.1.3 Estimating Schedule, Time, and Resources 1106.2 Identifying and Collecting Information 1136.2.1 Determining Information Requirements 1136.2.2 Distributing Information 1176.3 Reviewing and Preparing Information 1176.3.1 Prior PHA Reports and Related Documentation 1176.3.2 Prior PHA Recommendation Resolution Status 1186.3.3 MOC and PSSR Records 1206.3.4 Audit Results 1266.3.5 Incident Reports 1266.3.6 Current Piping and Instrument Diagrams 1276.3.7 Current Operating Procedures 1276.3.8 Special Considerations for Complementary Analyses andSupplemental Risk Assessments 1286.4 Principles for Successful Revalidation Preparation 129viii Guidelines for Revalidating a Process Hazard Analysis7 CONDUCTING PHA REVALIDATION MEETINGS 1317.1 Applying Analysis Methodologies 1317.1.1 Revalidation of the Core Analysis 1327.1.2 Revalidation of Complementary Analyses 1347.1.3 Revalidation of Supplemental Risk Assessments 1377.2 Facilitating Effective Revalidation Meetings 1397.2.1 Team Composition 1397.2.2 Meeting Kickoff 1407.2.3 Meeting Productivity 1437.3 Revalidation Meeting Conclusion 1497.4 Principles for Successful Revalidation Meetings 1518 DOCUMENTING AND FOLLOWING UP ON A PHA REVALIDATION 1558.1 Documentation Approaches 1568.2 Report and Its Contents 1608.3 Recommendations and Follow-Up 1618.4 Records Retention and Distribution 1638.5 Principles for Successful Documentation and Follow-Up 165REFERENCES 167APPENDICES 171APPENDIX A Essential Criteria Checklist 171APPENDIX B PHA Quality and Completeness Checklist 175APPENDIX C Example Change Summary Worksheet 181APPENDIX D Checklist of Process, Facility, and Human Factors Changes 183APPENDIX E Example Facility Siting Checklists 187APPENDIX F Example Human Factors Checklists 199APPENDIX G Example External Events Checklist 209INDEX 215

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The Center for Chemical Process Safety (CCPS) has been the global leader in developing and disseminating information on process safety management and technology since 1985. It has published over 100 books in its process safety guidelines and process safety concepts series and created over 30 training modules through its Safety in Chemical Engineering Education series.