(65a) Adapting PHA Facilitation Techniques in Response to a Shortage of Skilled Facilitators

Keywords: American Institute of Chemical Engineers (AIChE), Center for Chemical Process Safety (CCPS), Hazard and Operability Study (HAZOP), Layer of Protection Analysis (LOPA), Occupational Safety and Health Administration (OSHA), Process Hazard Analysis (PHA), Process Safety Management (PSM).

Abstract

Process Hazard Analysis (PHA) is a cornerstone of risk management in the upstream, midstream, downstream, and chemical industries. Traditionally, PHAs are facilitated by highly skilled and experienced individuals whose expertise ensures that potential risks are adequately identified, assessed, and mitigated. However, the industry currently faces a significant shortage of these adept facilitators, prompting a re-evaluation of standard PHA facilitation techniques.

This paper advances the case for modifying traditional PHA facilitation techniques to address the shortfall in expert facilitators, ensuring continued efficacy in risk management practices.

More specifically, this paper will explore the following:

1. Recruiting the next generation of PHA facilitators: Academia and industry are simply not generating adequate talent pools to meet the PHA facilitation service demand. Recruiting techniques are often singularly focused on skillset; however, more effective and creative techniques are available to bolster the thinning ranks of PHA facilitators.
2. Leveraging technology: Given the scarcity of seasoned facilitators, there is a pressing need to capitalize on technology. Advanced AI and machine learning tools can assist in preliminary hazard identification, providing a solid base upon which less experienced facilitators can build.
3. Training and development acceleration: Investing in rapid yet comprehensive training programs can hasten the development of competent facilitators. Modular courses, on-the-job training, and mentorship programs can all be integrated to bolster the skill sets of budding facilitators.
4. Standardization and templates: To assist less experienced facilitators, the development of standardized procedures and templates can provide a consistent foundation. While customization will still be required based on unique company procedures and protocols, these tools can streamline the facilitation process.
5. Feedback and continuous improvement: Given the shift in facilitation techniques, it is imperative to establish a strong feedback mechanism. Regular reviews and post-PHA evaluations can identify areas of improvement, ensuring that the modified techniques continue to be refined over time. These reviews can incorporate communication packages during management review meetings to afford PHA recommendation review as well as PHA quality assurance.

The shortage of skilled PHA facilitators presents a unique challenge to the industry, but it also offers an opportunity to innovate and adapt. By integrating technology, accelerating training, standardizing processes, and emphasizing feedback, it is possible to maintain rigorous PHA standards even in the face of facilitator scarcity.

The target audience for this paper is anyone whose responsibilities include (1) leading within an organization required to comply with OSHA 1910.119, (2) establishing effective PHA guidance documents, and (3) participating on PHA teams to identify, assess, and manage process safety hazards.