Washington Administrative Code › Title 296 - Labor and Industries, Department of › Chapter 296-67 - Safety standards for process safety management of highly hazardous chemicals › Part B › Section 296-67-323 - Hazard analyses

Current through Register Vol. 24-14, July 15, 2024
(1)
				Process hazard analysis (PHA).
(a) The
				employer must perform and document an effective PHA appropriate to the
				complexity of each process, in order to identify, evaluate, and control hazards
				associated with each process. All initial PHAs for processes not previously
				covered by WAC
				296-67-017 must be completed
				within three years of the effective date of Part B of this chapter. PHAs
				performed in accordance with the requirements of WAC
				296-67-017 must satisfy the
				initial PHA requirements of Part B of this chapter. All modes of operation
				pursuant to WAC
				296-67-327 Operating procedures,
				must be covered by the PHA.
(b) The
				employer must determine and document the priority order for performing PHAs
				based on the complexity, severity, and extent of process hazards, the number of
				potentially affected employees, the age of the process and the process
				operating history. The employer must use at least one of the following
				methodologies:
(i) What-if;
(ii) Checklist;
(iii) What-if/checklist;
(iv) Hazard and operability study
				(HAZOP);
(v) Failure mode and
				effects analysis (FMEA);
(vi) Fault
				tree analysis; or
(vii) Other PHA
				methods recognized by engineering organizations or governmental
				agencies.
(c) The PHA
				must address:
(i) The hazards of the
				process;
(ii) Previous publicly
				documented process safety incidents in the petroleum refinery and petrochemical
				industry sectors that are relevant to the process;
(iii) DMR reports that are applicable to the
				process;
(iv) HCA reports that are
				applicable to the process;
(v)
				Potential consequences of failures of process equipment;
(vi) Facility siting, including the placement
				of processes, equipment, buildings, employee occupancies and work stations, in
				order to effectively protect employees from process safety hazards;
(vii) Human factors;
(viii) A qualitative evaluation of the types,
				severity and likelihood of possible incidents that could result from a failure
				of the process or of process equipment;
(ix) The potential effects of external
				events, including seismic events, if applicable;
(x) The findings of incident investigations
				relevant to the process;
(xi) A
				review of applicable management of change (MOC) documents completed since the
				last PHA; and
(xii) Engineering and
				administrative controls associated with the process.
(d) The PHA must be performed by a team with
				expertise in engineering and process operations, and must include at least one
				refinery operating employee who currently works in or provides training about
				the process, and who has experience and knowledge specific to the process being
				evaluated. The team must also include one member with expertise in the specific
				PHA methodology being used. As necessary, the team must consult with
				individuals with expertise in damage mechanisms, process chemistry, safeguard
				protection analysis, and control systems.
(e) The team must document its findings and
				recommendations in a PHA report, which must be available to affected employees
				whose work assignments are in the petroleum refinery and who may be affected by
				the findings and recommendations.
(f) The PHA report must include:
(i) The methodologies, analyses and factors
				considered by the PHA team;
(ii)
				The findings of the PHA team; and
(iii) The PHA team's recommendations,
				including additional safeguards to address any deficiencies identified by the
				SPA.
(g) At least every
				five years, the written PHA must be updated and revalidated in accordance with
				the requirements of this section to ensure that the PHA is consistent with the
				current process.