Links. Index terms. American Institute of Chemical Engineers (AIChE) ix xi

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Lynette Mosley
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1 113 A American Institute of Chemical Engineers (AIChE) ix xi B Basic documentation, revalidation study 65 See also Revalidation study documentation C Center for Chemical Process Safety (CCPS) ix xi Center for Chemical Process Safety (CCPS) Workshop 3 Change identification 43 documented and controlled change 44 MOC and PSSR review PHA and incident investigation recommendations 46 P&ID comparison 46 procedure reviews 46 overview 43 types of change, summary table 45 undocumented and uncontrolled change 47 incident investigation reports 49 maintenance records 48 personnel interviews 47 PSM program audits 49 purchase specifications 49 worksheet for Checklist Analysis facility and process modification checklist 87 facility and stationary source siting checklist 93 human factors 103 PHA methods 7 prior PHA study 75 Clean Air Act Amendments of D Distribution information requirements revalidation study documentation 68 Documentation. See also Revalidation study documentation MOC and PSSR, information review and analysis 29 PHA criteria 36

2 114 E Environmental Protection Agency (EPA) 20 federal regulatory requirements 69 PHA criteria records retention 68 revalidation rationale 11 Essential criteria checklist, prior PHA study 75 Evergreen documentation, revalidation study 65 See also Revalidation study documentation External factors, revalidation methodology selection 55 F Facility and process modification checklist 87 Facility and stationary source siting checklist 93 Facility siting, revalidation study sessions 61 Failure Mode and Effects Analysis (FMEA), PHA methods 8 Fault Tree Analysis (FTA), PHA methods 8 Federal regulatory requirements 69 See also Environmental Protection Agency (EPA); Occupational Safety and Health Administration (OSHA) Follow-up recommendation revalidation study documentation 67 H Hazard and Operability Study (HAZOP) PHA criteria 34 PHA methods 8 Human factors checklist for 103 revalidation study sessions 61 I Incident reports change identification information review and analysis 30 Information requirements 23 determination of distribution 24 27

3 115 Information review and analysis 27 incident and near-miss reports 30 MOC and PSSR documentation 29 operating procedures 31 piping and instrument diagrams 31 prior recommendations 28 prior reports 27 PSM system audit 30 Internal factors, revalidation methodology selection 55 Interviews, personnel, change identification 47 M Maintenance records, change identification 48 Management of Change (MOC) change identification Information review and analysis 29 Methodology. See also Revalidation methodology prior Process Hazard Analysis (PHA) 36 Process Hazard Analysis (PHA) 6 N Near-miss reports, information review and analysis 30 O Occupational Safety and Health Administration (OSHA) 20 federal regulatory requirements 69 PHA criteria records retention 68 revalidation rationale 11 Operating experience, revalidation methodology selection 56 Operating procedures, information review and analysis 31 P Personnel interviews, change identification 47 Piping and instrument diagrams (P&IDs) change identification 46 information review and analysis 31

4 116 Pre-Startup Safety Report (PSSR) change identification Information review and analysis 29 Prior Process Hazard Analysis (PHA) study evaluation 33 See also Change identification; Process Hazard Analysis (PHA); Revalidation change identification 43 criteria 34 conclusions 37 documentation 36 essential criteria checklist 75 methodology 36 rigor 35 team make-up 36 current operations 39 overview 33 problems 39 quality and completeness revalidation methodology selection 56 Prior recommendations, information review and analysis 28 Prior reports, information review and analysis 27 Process Hazard Analysis (PHA). See also Prior Process Hazard Analysis (PHA) study evaluation; Revalidation goals of 5 methodology review 6 team composition 9 updates to 1 Process Safety Management (PSM) system audit change identification 49 information review and analysis 30 Productivity, revalidation study sessions 60 Purchase specifications, change identification 49

5 117 R Records retention, revalidation study documentation 68 Redo, revalidation methodology 53 Regulatory requirements. See also Environmental Protection Agency (EPA); Occupational Safety and Health Administration (OSHA) federal 69 revalidation rationale 12 Retrofit, revalidation methodology 52 Revalidation 11 See also Change identification; Prior Process Hazard Analysis (PHA) study evaluation; Process Hazard Analysis (PHA) concept of 13 logic flowchart for 21 objective of 13 procedures for 16 rationale for 11 schedule for 14 Revalidation methodology 51 See also Methodology options in 51 redo 53 retrofit, update and revalidate 52 update and revalidate 51 selection criteria 55 study sessions application 60 Revalidation study documentation 65 approaches to 65 contents of report 67 follow-up recommendation 67 records retention and distribution 68 Revalidation study preparations 19 information requirements 23 determination of distribution information review and analysis 27 incident and near-miss reports 30 MOC and PSSR documentation 29 operating procedures 31

6 118 Revalidation study preparations (Cont.) piping and instrument diagrams 31 prior recommendations 28 prior reports 27 PSM system audit 30 preplanning 19 scheduling 22 scope 19 team selection 20 Revalidation study sessions 59 methodology application 60 special topics 60 facility siting 61 human factors 61 productivity 60 wrap-up discussions 62 team training 59 S Schedule revalidation 14 study preplanning 22 Scope of revalidation, study preplanning 19 T Team composition PHA criteria 36 Process Hazard Analysis (PHA) 9 Team interviews, change identification 48 Team selection, study preplanning 20 Team training, revalidation study sessions 59 W What-If Analysis, PHA methods 7 What-If/Checklist Analysis, PHA methods 7 Worksheet, change identification Wrap-up discussions, revalidation study sessions 62

Best Practices for PHA Revalidations

Best Practices for PHA Revalidations GCPS2018 William G. Bridges Process Improvement Institute Inc. (PII) wbridges@piii.com Revonda Tew Process Improvement Institute Inc. (PII) rtew@piii.com Matías A. Massello Process Improvement Institute