Process Hazard Analysis Emphasizing Ammonia Refrigeration Systems

A PHA is required for facilities covered under OSHA’s Process Safety Management standard and EPA’s Risk Management Plan (RMP) rule. To be effective, the PHA team must be able to identify hazards, evaluate their significance, and develop recommendations to control or eliminate the hazards in and around ammonia refrigeration systems. In this course, you will have the opportunity to put the principles of PHA to work as you develop a mock PHA for a refrigerated facility.

• PSM coordinators
• Refrigeration operators
• Refrigeration design engineers
• Safety and environmental professionals with PSM and/or RMP responsibilities
• Others responsible for developing and implementing process safety management programs 

This course is part of the Process Safety Management Professional Certificate. Increase your knowledge and effectiveness at managing PSM/RMP programs for your ammonia refrigerated facility, while earning a recognized credential.

Day 1

Welcome
Douglas T. Reindl, PhD, PE, Professor, Engineering Professional Development, Director, Industrial Refrigeration Consortium (IRC), University of Wisconsin-Madison

Introduction to Process Hazard Analysis – Doug Reindl

• Hazards – what they are and how to identify them
• PHA regulatory requirements
• When and why should you conduct hazard evaluations or analyses?
• OSHA interpretations on PHAs

Preparing for a PHA

• How to define PHA objectives and scope
• Staffing
• Information requirements
• Strategies to effectively engage all PHA participants

Frederick T. Elder, PhD, PE, Adjunct Professor, University of Wisconsin-Madison, President, Frederick T. Elder and Associates

Critical Factors to Include in PHAs – Doug Reindl

• Human factors
• Facility siting
• Failure of engineering and administrative controls (safeguards)
• How to account for all operating scenarios

Workshop (Human Factors-Related)

P&IDs -Their Role in the PHA Process – Fred Elder

• Purpose of P&IDs
• Characteristics of effective P&IDs
• Role of P&IDs in the PHA process

Management of Change (MOC) – Doug Reindl

• How changes impact the process hazard analysis
• “Change” vs. “replacement in-kind”
• Types of changes that should trigger a PHA
• OSHA interpretations on MOCs that lead to PHAs

Day 2

Overview of PHA Methodologies – Doug Reindl

• What-if/Checklist
• Hazard and Operability Study/Analysis (HAZOP)
• Failure Mode and Effects Analysis (FMEA)
• Fault tree analysis
• Advantages, disadvantages, and limitations of each methodology
• Importance of matching the PHA methodology to the complexity of the process

How to Conduct a PHA Using the What-if/Checklist Methodology – Doug Reindl

• Identify PHA objectives, scope, and subsystems
• Gather required information as input to the process
• Develop and modify the What-if/Checklist
• Rank risks and how risk impacts requirements for recommendations
• Document the PHA process and findings
• Pitfalls
• Preview of What-if/Checklist workshop

What-if/Checklist Workshop

Given appropriate preliminary documentation (P&IDs, photos, etc.), you will work in groups to define PHA objectives and subsystems for analysis, review given information, modify the What-if/Checklist, and complete a first-cut of a hazard evaluation list. Representatives from each group will present their PHA objective(s) and What-if/Checklist modifications.

Site Visit-Engine Room Walk-thru

Day 3

What-if/Checklist Workshop – (Continues)
Each group conducts a mock PHA using their What-if/Checklist.

What-if/Checklist Workshop Closeout

Roundtable discussion of site visit and PHA using the What-if/Checklist methodology

PHA Revalidation – Doug Reindl

• Revalidation requirements
• Planning for revalidation
• Redo, update, revise and revalidate-what’s the difference?
• How to conduct and document the PHA revalidation

Action Required Following a PHA – Fred Elder

• Determine actionable recommendations
• Resolution of PHA action items
• Prioritization
• Management response
• Communication of findings

PHA Process Quality Improvement – Doug Reindl

• Post-mortem evaluation of a PHA session
• Strategies to achieve PHA process improvement

"Your courses are well thought out and planned to provide everything I expected. All speakers were very helpful and professional. Thank you."

"I came in clueless and I feel comfortable with the knowledge gained."

"Good class. I learned all I expected to."

"Great enlightening experience on PHAs, HAZOP, etc. Very informative material and an excellent, resourceful staff. Thanks."

"Excellent program!"

Frederick Elder

Dr. Elder received his bachelor’s degree from the University of Kansas, a master’s degree from Wichita State University, and a Ph.D from UW-Madison, all in Mechanical Engineering. He has extensive experience in safety including Process Safety Management and its application to ammonia refrigeration systems. He regularly serves as an instructor for the OSHA Training Institute. Dr. Elder is a registered professional engineer in the State of Wisconsin.

Douglas Reindl

Douglas Reindl, PhD, PE is a professor at the Department of Mechanical Engineering and a Program Director at the Office of Engineering Professional Development at the University of Wisconsin-Madison. He has extensive experience in mechanical systems – including industrial ammonia refrigeration systems. As the founding director of the Industrial Refrigeration Consortium, he works extensively to improve the safety, efficiency, reliability, and productivity of ammonia refrigeration infrastructure. Dr. Reindl received his BS in mechanical engineering technology from the Milwaukee School of Engineering, MS in mechanical engineering from UW–Madison, and PhD in mechanical engineering from UW–Madison. He is a registered professional engineer in the State of Wisconsin.