1. Practical application of risk assessment: Use of pHA
Jen Czak
PSM Lead
Phillips 66

2. Session Outline Terminology How to assess risk Gas station example
How Industry risk assessments are different
Questions
Closing

3. Terminology

4. PHA
Process Hazard Analysis – An organized and systematic assessment of potential hazards associated with the processing or handling of highly hazardous materials.
WAC
(1) The employer shall perform an initial process hazard analysis (hazard evaluation) on processes covered by this standard. The process hazard analysis shall be appropriate to the complexity of the process and shall identify, evaluate, and control the hazards involved in the process...

5. HAZARD
Source of potential damage or harm
Example – Icy surface

6. RISK Likelihood that any hazard will cause harm
Example – Potential for individual to be injured slipping on an icy surface

7. SAFEGUARD Something that protects people or the environment from harm
Example - Ice melt, sand, footwear traction devices, padding

8. RISK TOLERANCE How much risk you are willing to accept
Example – A person is walking across an icy surface covered with sand.
Is the risk for an injury from a fall acceptable?

9. How to Assess Risk

10. Need to consider equipment and human failures and external events
Risk is determined in two parts – potential consequence and likelihood
Consequence should be considered without safeguards
Yes No

11. Gas Station Example

13. Skin, mouth, nose, throat, and stomach irritant
Identify Hazards
Flammable liquid
Possible carcinogen
Skin, mouth, nose, throat, and stomach irritant
Environmental

14. Filling Vehicle with Gasoline
Cause – Credit card machine doesn’t work
Consequence – Time delay, can't fill car with gasoline
No hazardous consequences

15. Filling Vehicle with Gasoline
Cause – Select wrong grade of gasoline
Consequence – Increased cost, or potential engine damage over time.
No hazardous consequences

16. Filling Vehicle with Gasoline
Cause – Person holds trigger down while moving the nozzle to the car
Consequence – Release of gasoline, minor exposure
Safeguards –
Is the risk acceptable?

17. Filling Vehicle with Gasoline
Cause – Squeeze trigger to activate gasoline pump and set latch on nozzle (normal operation – no specific cause)
Consequences –
Gasoline vapors present near opening ignite and start a fire, person is burned
Person is exposed to gasoline vapors
Safeguards – Warning signs posted on pumps about precautions for potential ignition sources, nozzles are equipped with rubber boots/splash guards
Is the risk acceptable?

18. Safeguards

19. Small Group activity

20. Filling Vehicle with Gasoline
Cause – Pump shuts off or shutoff valve trips early while filling
Consequence – Time delay, can't fill car with gasoline
No hazardous consequences

21. Filling Vehicle with Gasoline
Cause – Low ambient temperature when filling up with gasoline
Consequence – Low temperatures cause person to wait in vehicle while gasoline is being pumped, static discharge occurs when person touches nozzle, gasoline vapors ignite and start a fire, person is burned
Safeguards – Warning signs posted on pumps about precautions for static electricity
Is the risk acceptable?

22. Filling Vehicle with Gasoline
Cause – High ambient temperature when filling up with gasoline
Consequence – Additional vapors present when refueling
Gasoline vapors present near opening ignite and start a fire, person is burned
Person is exposed to gasoline vapors
Safeguards – Warning signs posted on pumps about precautions for potential ignition sources, nozzles are equipped with rubber boots/splash guards
Is the risk acceptable?

23. Filling Vehicle with Gasoline
Cause – Raining when filling up with gasoline
Consequence – Potential for some moisture to get into gasoline tank causing engine damage
No hazardous consequences

24. Filling Vehicle with Gasoline
Cause – High wind when filling up with gasoline
Consequence – May be more difficult to complete task
No hazardous consequences

25. Filling Vehicle with Gasoline
Cause – Shutoff valve fails
Consequence – Gasoline tank is overfilled, release of gasoline, gasoline catches on fire, person is burned
Safeguards – Instructions on how to insert nozzle and warning signs about precautions for potential ignition sources posted on pumps
Is the risk acceptable?

26. Filling Vehicle with Gasoline
Cause – Person tops off gasoline tank after the shutoff valve has been activated
Consequence – Release of gasoline, minor exposure
Safeguards – Warning signs posted on pumps, nozzles are equipped with rubber boots/splash guards
Is the risk acceptable?

27. Filling Vehicle with Gasoline
Cause – Person drives off with nozzle still inserted into car
Consequence – Hose is ripped off injuring nearby person, release of gasoline, gasoline catches on fire resulting in additional injuries to other person and property damage
Safeguards – Breakaway valve installed on hoses, nozzle instructions posted at pumps, emergency pump shut-offs
Is the risk acceptable?

28. Filling Portable Container with Gasoline
Cause – Portable container filled inside vehicle or on bed of truck
Consequence – Static builds up while filling and ignites flammable vapors, fire starts, person is burned
Safeguards – Warning signs posted on pumps about portable container risks
Is the risk acceptable?

29. Filling Portable Container with Gasoline

30. Filling Portable Container with Gasoline
Cause – Shutoff valve fails when filling portable container
Consequence – Container is overfilled, person is exposed to gasoline
Safeguards – Warning signs posted on pumps about portable container risks
Is the risk acceptable?

31. How Industry Risk Assessments are Different

32. 1. Minimum experience level for team members
WAC
(4) The process hazard analysis shall be performed by a team with expertise in engineering and process operations, and the team shall include at least one employee who has experience and knowledge specific to the process being evaluated. Also, one member of the team must be knowledgeable in the specific process hazard analysis methodology being used.

33. 2. Defined risk matrix / risk tolerance

34. 3. Requirements for safeguard evaluation
Layer of Protection Analysis (LOPA)
Quantitative Risk Analysis (QRA)
Fault Tree Analysis (FTA)

35. Any Questions?

36. Closing