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Article history:
Received 22 April 2014
Received in revised form
24 October 2014
Accepted 29 November 2014
Available online 2 December 2014
Process hazard analysis (PHA) is a cornerstone of process safety management programs. The quality of
the PHA performed directly affects the level of risk tolerated for a process. The lower the quality of a PHA,
the more likely higher risk will be tolerated. There are few requirements for PHA team members in the
U.S. Occupational Safety and Health Administration's process safety management regulations. More
detailed requirements for participation in a PHA are desirable.
A competency management program should be used to ensure PHA practitioners and teams are
appropriately qualied. Criteria for selecting PHA team leaders, or facilitators, and other team members
are key to such a program and are described in this paper. The criteria cover both technical and personal
attributes. Application of the criteria is described and team performance metrics, which can be used to
correlate performance with the assessment of competency to validate the criteria and methods used, are
discussed.
Owing to the importance of the role played by team leaders, certication of their competency is
desirable. Criteria for certication are described and their application is discussed.
2014 Elsevier Ltd. All rights reserved.
Keywords:
Process hazard analysis
Process safety management
PHA quality
PHA team qualications
PHA certication
1. Introduction
Process hazard analysis (PHA) is used to identify hazard scenarios that can have adverse impacts on such receptors as people,
property and the environment so that a determination can be
made as to whether or not the level of risk posed by a process is
tolerable (CCPS, 2008; Baybutt, 2013a). If not, recommendations
can be made for appropriate risk reduction measures. PHA is a
foundation element of process safety management (PSM) programs. PHA studies are conducted by teams of people. Consequently, they are subject to various possible human failures
inuenced by human factors (Baybutt, 2003; Baybutt, 2013b). In
particular, the qualications, experience, and personal characteristics of participants play a critical role in the quality of PHA
studies. Teams with members who are poorly qualied, possess
inadequate experience, or have undesirable personal characteristics will produce poor quality studies in which scenarios may be
missed or described inadequately, and scenario risks may be estimated incorrectly. Such PHA faults can lead to higher risk being
accepted than should be tolerated. Consequently, individuals who
* Corresponding author.
E-mail address: paulb@primatech.com.
http://dx.doi.org/10.1016/j.jlp.2014.11.023
0950-4230/ 2014 Elsevier Ltd. All rights reserved.
152
The PHA shall be performed by a team with expertise in engineering and process operations.
The team shall include at least one employee who has experience and knowledge specic to the process being evaluated.
One member of the team must be knowledgeable in the specic
process hazard analysis methodology being used.
Clearly, these are minimal requirements and more detailed requirements are desirable owing to the critical role that people play
in PHA.
In the preamble to the PSM standard, OSHA states (OSHA, 1992):
In order to conduct an effective, comprehensive PHA, it is
imperative that the analysis be performed by competent persons, knowledgeable in engineering and process operations.
Those persons be familiar with the process being evaluated.
A team approach is the best because no one person will possess
all of the knowledge and experience necessary to perform an
effective PHA and when more than one person is performing the
analysis, different disciplines, opinions, and perspectives will be
represented and additional knowledge and expertise will be
contributed to the analysis.
Some companies include an individual on the team who does
not have any prior experience with the particular process being
analyzed to help insure that a fresh view of the process is integrated into the analysis.
Employees and other experts may be brought onto the team on a
temporary basis to contribute their specialized knowledge.
Responsibilities
Competency requirements
Team composition
Selection criteria for teams and team members
Development of competencies
Assessment of competency
Documentation of competency
Maintaining competency
Reassessing competency
Monitoring competency
Dening and using performance metrics
Certication of practitioners
Continuous improvement
Each topic is now described.
Qualifications
Training
Experience
Skills
Behavior
Attitudes
Knowledge and
understanding
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Other personnel
Competency
Performance standards
Acceptable performance
4.1. Responsibilities
Company management is responsible for the selection of
team leaders and ensuring that they are appropriately qualied.
Usually, the manager responsible for a PHA study, or the team
leader assigned to a study, selects the other team members. They
should advise each other and jointly approve the other team
members.
May be representatives from vendors of self-contained processes, such as skid-mounted units, and licensed technology; contractors who perform activities such as maintenance; the design
company responsible for a new process; or the engineering company that will construct a new process. They provide information
on equipment design, maintenance, operation, etc. that may not be
known by company personnel.
Interpreter
PHA studies may be conducted by teams who are unable to
communicate in a common language or cannot do so well enough
to perform the study properly. Thus, the role of an interpreter is to
enable team members to communicate effectively.
Site coordinator
Acts as a liaison between the team and the process facility. Helps
to ensure that adequate facilities, such as a meeting room, are
provided and that other team needs are met. Not a participating
member of the PHA team.
4.4. Selection criteria for teams and team members
Different types of team members require different types of
competencies, although there is some overlap in requirements.
Overall team or group competency is also important. Therefore,
selection criteria are needed for both individual team members and
teams. Each type of team member should be selected based on
technical qualications and personal characteristics, or attributes,
that are appropriate for each type of team member. It is useful to
dene both critical and recommended attributes because ideal
team members are unlikely to be found in the real world.
4.4.1. Team selection
This section provides some suggested overall criteria that should
be met by PHA teams. PHA teams necessarily must be multidisciplinary. Team members are needed who together can
Table 1
Typical core and specialty PHA team members.
Core team members
Design engineer
Instrumentation/electrical
engineer
Mechanical engineer
Programmer
Process engineer
Operator (cover inside and outside activities).
More than one may be needed
Maintenance technician or engineer. More than
one may be needed
Controls engineer
Safety engineer
Inspection/materials
engineer
Research scientist/chemist
Environmental engineer/
regulatory specialist
Quality assurance/quality
control specialist
Human factors specialist
Industrial hygienist
Industrial engineer
Emergency responder
Note: There can be some overlap between core and specialty team members.
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Table 2
Suggested technical disciplines for a PHA team.
Design engineering
- Knowledge of how the process is intended to operate
- Knowledge of applicable standards, codes, specications and regulations
Process engineering
- Understanding of the process science and technology
- Ability to judge the adequacy of existing safeguards
Process controls engineer
- Knowledge of the process instrumentation, controls, alarms and interlocks
Operations and maintenance
- Hands on operating and maintenance experience
- Knowledge of how the process responds to upsets
Safety engineering
- Knowledge of process hazards, safety systems, relevant company policies
Other
- Specialty technical areas
- PHA facilitation and recording
- Quality control
- Etc.
Table 3
Positive attributes for PHA team leaders.
Technical
Critical
Technical education
Formal training in PHA and leadership/
facilitation skills
Knowledge of and expertise in the PHA
method to be used
Knowledge of regulatory, industry and
company requirements for PHA
Understands processes and their
operation quickly
Reads engineering drawings and
understands other process
documentation easily
Motivational/interpersonal skills
Communications skills
Personal
Impartial in the evaluation
Organized
Seeks consensus
High stamina
Able to focus on multiple items
simultaneously
Respected by the team
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156
Table 5
Positive attributes for scribes.
Table 8
Negative attributes for PHA team members.
Technical
Personal
Critical
Technically-oriented
Table 6
Negative attributes for scribes.
Table 7
Positive attributes for PHA team members.
Technical
Critical
Knowledge of and expertise in some
aspect of the process
Work with the process to be studied
Knowledge of codes, standards,
regulations and other requirements
that apply to their area of expertise
Able to read engineering drawings and
understand other process
documentation
Personal
Creative
Good memory
Willing to participate
Unfortunately, there is no way of knowing if all credible scenarios have been identied in a study. Some people may argue that
the occurrence of an actual incident that is not identied in a PHA
study is an indicator that the study was not performed as well as
possible. However, catastrophic incidents, which are the type of
most concern in PHA, occur infrequently and not often enough to
Talkative
Over-enthusiastic
Argumentative
Sarcastic
Dominant
Arrogant
Skeptical
Wants to control the
study
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5. Conclusions
Academic qualications
A technical degree in a relevant discipline, or equivalent, will
demonstrate that the individual has the needed intellectual capacity and basic technical knowledge. Independent conrmation
that the individual has earned the claimed qualications is
essential.
Experience
Relevant on-the-job work experience provides a background
and knowledge that is useful for a team leader. Conrmation of the
claimed work experience by peers and/or supervisors should be
required.
Facilitation skills
For higher certication levels, feedback on the performance of
the team leader in managing the team should be sought from team
members. Team members providing feedback should owe no allegiance or obligation to the team leader to help ensure objectivity in
the feedback provided.
Work products
For higher certication levels, examples of PHA studies facilitated by the individual can be utilized to demonstrate competency.
Expert PHA practitioners should review the work products against
the PHA guidelines that were used to produce them to determine
their validity.
Training
Team leaders should have successfully completed appropriate
training courses recently.
Professional references
References should attest to the academic qualications, experience, work products and professional ethics of the individual.
Examination
158
References
Baybutt, P., 2003. On the ability of process hazard analysis to identify accidents.
Process Saf. Prog. 22 (3), 191e194.
Baybutt, P., 2007. Competence management (Chapter 29). Human Factors
Methods for Improving Performance in the Process Industries. American
Institute of Chemical Engineers/Center for Chemical Process Safety, New
York, New York.
Baybutt, P., 2013a. Analytical methods in process safety management and system
safety engineering e process hazards analysis. In: Haight, J.M. (Ed.), Handbook
of Loss Prevention Engineering. Wiley-VCH.
Baybutt, P., 2013b. The role of people and human factors in performing process
hazard analysis and layers of protection analysis. J. Loss Prev. Process Ind. 26,
1352e1365.
CCPS, 2008. Guidelines for Hazard Evaluation Procedures, third ed., Center for
Chemical Process Safety/American Institute of Chemical Engineers.
OSHA, 1992. Process Safety Management of Highly Hazardous Chemicals, 29 CFR
Part 1910.119, U.S. Department of Labor, Occupational Safety and Health
Administration.
OSHA, 1994. Publication 3133, Process Safety Management Guidelines for
Compliance.
OSHA, 2001. November 19. Letter to Mr. Robert Summers. The Norac Company Inc.