PROCESS HAZARD ANALYSIS (PHA) CHECKLIST

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--- PROCESS DESCRIPTION & SCOPE ---
[ ] Process Name
[ ] Process Description (Detailed)
[ ] Process Capacity (e.g., Units/Hour)
[ ] Raw Materials Used (List)
[ ] Process Flow Diagram (PFD) Description & Location
[ ] Process Flow Diagram (PFD) - Uploaded File
[ ] Equipment List & Key Operating Parameters
[ ] Process Phase (e.g., Mixing, Reaction, Drying) (Mixing, Reaction, Separation, Drying, Formulation, Packaging)
[ ] Boundaries of the Analyzed Process (Start & End Points)

--- HAZARD IDENTIFICATION ---
[ ] Describe the process flow and key equipment involved.
[ ] Identify raw materials used in the process. (Select all that apply) (Chemical A, Chemical B, Material C, Other (Specify in LONG_TEXT))
[ ] List any potential deviations from normal operating conditions (e.g., pressure, temperature, flow rate).
[ ] Identify potential energy sources present in the process. (Select all that apply) (Electrical, Thermal, Mechanical, Chemical (e.g., flammable, corrosive), Pressure)
[ ] Describe any known hazards associated with the chemicals used in the process (refer to SDS/MSDS).
[ ] Identify any potential ignition sources in the area. (e.g., open flames, sparks, hot surfaces)
[ ] Describe any potential release scenarios (e.g., spills, leaks, explosions).
[ ] Upload relevant process diagrams and layouts.

--- RISK ASSESSMENT (SEVERITY & PROBABILITY) ---
[ ] Severity Rating - What's the worst possible consequence? (Catastrophic (Loss of Life, Major Environmental Damage), Critical (Serious Injury, Significant Environmental Release), Moderate (Minor Injury, Limited Environmental Impact), Minor (First Aid, Minimal Environmental Impact))
[ ] Probability Rating - How likely is this consequence to occur? (Frequent (Expected to occur several times per year), Likely (Expected to occur once a year), Possible (Could occur sometime during the lifetime of the facility), Unlikely (Highly improbable to occur))
[ ] Severity Score (Assign a numerical value based on the severity rating)
[ ] Probability Score (Assign a numerical value based on the probability rating)
[ ] Justification for Severity Rating
[ ] Justification for Probability Rating
[ ] Risk Matrix Category (Based on Severity & Probability Scores) (High, Medium, Low)
[ ] Notes/Comments

--- EXISTING CONTROLS & SAFEGUARDS ---
[ ] Are safety interlocks present and functioning on critical equipment? (Yes, documented and tested annually, Yes, but testing is less frequent, No, Not Applicable)
[ ] Describe the existing alarm system and its response procedures.
[ ] What type of pressure relief devices are in place? (Spring-loaded relief valve, Rupture disk, Pilot-operated relief valve, Combination, None)
[ ] What is the frequency of inspections for critical safety devices?
[ ] Describe any Standard Operating Procedures (SOPs) related to this process.
[ ] Are lockout/tagout procedures in place and followed? (Yes, documented and enforced, Yes, but enforcement needs improvement, No, Not Applicable)
[ ] Which of the following Personal Protective Equipment (PPE) is required for this process? (Safety Glasses, Gloves, Respirator, Hearing Protection, Other (Specify))
[ ] Date of last inspection of fire suppression system.

--- RECOMMENDED RISK REDUCTION MEASURES ---
[ ] Detailed Description of Proposed Mitigation
[ ] Estimated Cost of Mitigation (USD)
[ ] Target Completion Date for Mitigation
[ ] Responsibility for Implementation (Engineering, Operations, Maintenance, Safety)
[ ] Relevant Departments to Notify (Production, Quality, Maintenance, Safety)
[ ] Rationale/Justification for Chosen Mitigation
[ ] Supporting Documentation (e.g., drawings, vendor specs)
[ ] Status of Mitigation (Not Started, In Progress, Completed, Deferred)

--- MANAGEMENT OF CHANGE (MOC) ---
[ ] Describe the proposed change to the process, equipment, or materials.
[ ] Justification for the change - Why is this change necessary?
[ ] Type of Change (Select one) (Equipment Modification, Process Modification, Material Substitution, Personnel Change, Procedure Modification, Other)
[ ] Estimated Cost of Change (USD)
[ ] Proposed Implementation Date
[ ] Potential Hazards Identified due to this change (Select all that apply) (Increased Risk of Fire, Increased Risk of Explosion, Increased Chemical Exposure, Equipment Failure, Process Instability, Personnel Safety Concerns, Environmental Impact, No Identified Hazards)
[ ] Reviewer Name
[ ] Reviewer Signature

--- TRAINING & COMPETENCY ---
[ ] List the core competencies required for personnel involved in this process. (Process Knowledge, Equipment Operation, Hazard Recognition, Emergency Procedures, Lockout/Tagout, Personal Protective Equipment (PPE))
[ ] Number of personnel trained on this process.
[ ] Date of last training session for this process.
[ ] Describe the content of the training program.
[ ] Training Method Used (Classroom, On-the-Job Training, Computer-Based Training, Simulated Training)
[ ] Upload copies of training records/certificates.
[ ] Verification of Competency Method (Written Exam, Practical Demonstration, Observation, Other)
[ ] Describe the method used to verify individual competency.

--- EMERGENCY RESPONSE & PROCEDURES ---
[ ] Describe the established emergency shutdown (ESD) procedure for the process.
[ ] Which emergency response teams are available and notified during an incident? (Fire Department, Medical Team, Spill Response Team, Security, Environmental Team, Other (Specify))
[ ] Estimated evacuation time to designated assembly areas (in minutes).
[ ] Describe the communication methods used to alert personnel during an emergency.
[ ] Are emergency drills conducted regularly? (Yes, No, Not Applicable)
[ ] Date of last emergency response drill.
[ ] Summary of findings and corrective actions from the last emergency response drill.
[ ] Are emergency procedures posted in accessible locations? (Yes, No, Partially)
[ ] Attach a copy of the emergency response plan.

--- REVIEW & DOCUMENTATION ---
[ ] PHA Completion Date
[ ] PHA Revision Number
[ ] Summary of PHA Findings & Conclusions
[ ] PHA Report File
[ ] PHA Review Status (Not Reviewed, Reviewed, Approved)
[ ] Reviewer Name
[ ] Next PHA Review Date
[ ] PHA Lead Signature

--- COMPLIANCE & REGULATORY REQUIREMENTS ---
[ ] Applicable OSHA Standards? (29 CFR 1910.119 (Process Safety Management), 29 CFR 1910.120 (Hazard Communication), Other (Specify in LONG_TEXT), Not Applicable)
[ ] Relevant EPA Regulations? (Clean Air Act, Clean Water Act, Resource Conservation and Recovery Act (RCRA), Emergency Planning and Community Right-to-Know Act (EPCRA), None Applicable)
[ ] Documentation of Permit Requirements (e.g., Air Permits, Wastewater Permits)
[ ] Last PHA Review/Update Date (per Regulatory Requirements)
[ ] Frequency of PHA Review (as per regulation or company policy)
[ ] State-Specific Regulations? (Yes (Specify in LONG_TEXT), No)
[ ] Upload Copies of Relevant Permits

--- END OF TEMPLATE ---
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