A Case Study on KOC Approach for PHA Revalidation of Existing Gathering Centre

A hazard is an inherent physical or chemical characteristic that has the potential to do harm (to people, property, or the environment). A hazard evaluation study is an organized effort to identify and analyze the significance of hazardous situations associated with a process or activity.

There are number of reasons such as changes in Process or Equipment, in on-site or off-site occupancy patterns and Gaps and Deficiencies in Prior PHA. In addition, new knowledge is now available to better understand the hazards potential and control, safeguard previously credited in the PHA have been removed / compromised or discredited, and Actual incidents have revealed scenarios not previously identified in the PHA. Positively, process changes have actually removed hazards from the process, prior PHA did not take proper credit for some risk reduction measures and new risks reduction measures have been added, which clearly reduced the original risk.

Objective:

The primary objective of a PHA revalidation is to produce an updated PHA that adequately identifies, evaluates, and proposes controls for the hazards of the process, as they are currently understood.

Methodology:

KOC has established KOC.PS.017 - Process Hazard Analysis (PHA) Revalidation Procedure to determine an appropriate approach for the revalidation (Redoing vs. Update and Revalidate), conducting revalidation in timely manner, establish responsibilities and confirming that the PHA is accurately reflects the hazards of the current process.

The revalidation process build upon the still pertinent portions of the prior PHA. Corrections are made and new content is added to the PHA as required (i.e., the PHA is Updated), and the results are documented to serve as the new PHA (i.e., the PHA is Revalidated).

KOC appointed well known third party consultant for onsite PHA revalidation and below are stages for PHA revalidation.

Team Selection

Selecting the Appropriate PHA Revalidation Approach

• Update and Revalidate.
• Retrofit, Update, and Revalidate
• Redo Review and Analyze Information Review of Operating Experience
• Evaluating of PHA Quality and Completeness
• PHA Revalidation Information Requirements

• Changes Review
• Review Previous Incidents
• Review the Status / Resolution of Previous PHA Recommendations
• Update Human Factors
• Update the Facility Siting Analysis
• Address Hazards Associated with Non-Routine Operating Modes
• Address Compliance of PHA with Regulatory Requirements Documentation of PHA Revalidation Recommendation Follow - up
• PHA Report Contents
• Wrap-Up Discussions

Results

Type of studies carried out and number of new recommendations will be discussed for Gathering Center 24.

Conclusion:

Continuous improvement in the control of newly introduced process safety risks.

Ensured the effective close out of pending actions raised during previous process hazard analysis.

Addresses all four pillars of Risk Based Process Safety.

Considerable time saving in comparison to Redo PHA.

Improvement in employee engagement.