Process Hazard Analysis – OVERVIEW

Day 1: Introduction to Process Hazard Analysis (PHA)

• What is PHA and Why It Matters?

• History of Process Safety and Major Industrial Incidents

• Regulatory Drivers: OSHA PSM, EPA RMP, API RP 750

• Key Elements of a PHA Program

• Hazard Identification vs Risk Assessment

• The Role of Maintenance in Process Safety

Day 2: PHA Techniques and Their Applications

• Overview of Common PHA Techniques:

  • HAZOP (Hazard and Operability Study)

  • What-If Analysis

  • FMEA (Failure Modes and Effects Analysis)

  • Checklist Analysis

• Selecting the Right PHA Method

• PHA Methodology Workshop: Maintenance-Focused Scenarios

• Team Roles and Responsibilities in PHA Studies

Day 3: Hazard Identification and Risk Evaluation

• Types of Hazards in Maintenance Work:

  • Mechanical Integrity Failures

  • Human Factors

  • Confined Spaces and Hot Work

• Risk Ranking and Risk Matrices

• Risk Reduction Hierarchy and ALARP Concept

• Hands-On Exercise: Identifying and Ranking Hazards in Maintenance Tasks

Day 4: Conducting and Documenting a PHA

• Preparing for a PHA Study

• Facilitating vs Participating in a PHA Session

• Documentation Standards and Reporting Requirements

• Integrating PHA Findings into Maintenance Plans

• Case Study: Maintenance-Related Incident Analysis and PHA Recommendations

Day 5: Applying PHA in Maintenance and Continuous Improvement

• Interfacing PHAs with Maintenance and Reliability Programs

• Using CMMS and Asset Management Systems to Implement PHA Actions

• Inspection and Maintenance of Safety-Critical Equipment

• PHA Revalidation and Continuous Improvement Practices

• Course Review and Action Planning