Process Hazard Analysis (PHA) Review and Update Checklist

PHAs are required to be revalidated every 5 years under OSHA PSM. This checklist guides systematic PHA revalidation review to ensure all process hazards are current, action items are closed, and safeguards remain adequate.

  • Industry: Oil & Gas / Energy
  • Frequency: Every 5 Years (OSHA PSM Requirement) / Triggered by MOC
  • Estimated Time: 60-90 minutes
  • Role: Process Safety Engineer / HSE Manager
  • Total Items: 31
  • Compliance: OSHA 29 CFR 1910.119(e) - Process Hazard Analysis, EPA 40 CFR Part 68 - Risk Management Program (RMP), AIChE CCPS Guidelines for Hazard Evaluation Procedures, API RP 14C - Analysis, Design, Installation, and Testing of Safety Systems

PHA Schedule and Currency

Verify PHA revalidation is current.

  • PHA revalidated within past 5 years per OSHA 1910.119(e)(6)?
  • PHA triggered by any Management of Change (MOC) since last revalidation?
  • PHA scope covers entire covered process per OSHA PSM 29 CFR 1910.119?
  • PHA team includes qualified personnel with process knowledge and PHA experience?
  • P&IDs reviewed and confirmed current before PHA study?

Hazard Identification Quality

Assess quality of hazard identification.

  • All credible process deviations systematically evaluated?
  • Human factors and procedural errors considered?
  • Start-up, shutdown, and abnormal conditions included in scope?
  • External hazards (natural disasters, external fires, vehicle impact) considered?
  • Catastrophic release scenarios with potential for multiple fatalities identified?

Safeguard Adequacy

Verify safeguards are adequate for identified risks.

  • Independent Protection Layers (IPLs) confirmed independent of initiating causes?
  • Safety Instrumented Systems (SIS) designed and tested to required SIL per IEC 61511?
  • All credited safeguards included in mechanical integrity maintenance program?
  • Residual risk acceptable per facility risk criteria after safeguards credited?
  • Pressure relief devices sized and tested per API 520/521?

PHA Action Item Tracking

Review PHA action item status.

  • All PHA recommendations tracked in action management system?
  • No overdue critical (risk reduction required) recommendations?
  • Any rejected recommendations documented with risk justification?
  • PHA action item closure rate meeting target (typically >80%)?
  • Closed action items verified effective in reducing identified risk?

PHA Documentation

Verify PHA documentation is complete.

  • PHA study report complete with methodology, team, and findings documented?
  • Process flow diagrams and P&IDs attached to PHA report?
  • PHA documentation retained for life of the process per OSHA 1910.119(o)(2)?
  • Incident and near-miss history reviewed in PHA team session?
  • PHA findings communicated to employees working in covered process?

EPA Risk Management Program (RMP)

Verify RMP compliance for applicable facilities.

  • RMP Program 3 requirements applicable for covered processes?
  • Worst-case release scenario and alternative release scenarios updated in RMP?
  • RMP filed with EPA and current with most recent update within 5 years?
  • Local emergency response coordination per RMP Section 68.96 maintained?
  • Complete PHA revalidation report prepared and distributed to management?
  • Next 5-year PHA revalidation date scheduled?

Related Oil Gas Energy Checklists

Related Process Safety Checklists

Why Use This Process Hazard Analysis (PHA) Review and Update Checklist?

This process hazard analysis (pha) review and update checklist helps oil & gas / energy teams maintain compliance and operational excellence. Designed for process safety engineer / hse manager professionals, this checklist covers 31 critical inspection points across 6 sections. Recommended frequency: every 5 years (osha psm requirement) / triggered by moc.

Ensures compliance with OSHA 29 CFR 1910.119(e) - Process Hazard Analysis, EPA 40 CFR Part 68 - Risk Management Program (RMP), AIChE CCPS Guidelines for Hazard Evaluation Procedures, API RP 14C - Analysis, Design, Installation, and Testing of Safety Systems. Regulatory-aligned for audit readiness and inspection documentation.

Frequently Asked Questions

What does the Process Hazard Analysis (PHA) Review and Update Checklist cover?

This checklist covers 31 inspection items across 6 sections: PHA Schedule and Currency, Hazard Identification Quality, Safeguard Adequacy, PHA Action Item Tracking, PHA Documentation, EPA Risk Management Program (RMP). It is designed for oil & gas / energy operations and compliance.

How often should this checklist be completed?

This checklist should be completed every 5 years (osha psm requirement) / triggered by moc. Each completion takes approximately 60-90 minutes.

Who should use this Process Hazard Analysis (PHA) Review and Update Checklist?

This checklist is designed for Process Safety Engineer / HSE Manager professionals in the oil & gas / energy industry. It can be used for self-assessments, team audits, and regulatory compliance documentation.

Can I download this checklist as a PDF?

Yes, this checklist is available as a free PDF download. You can also use it digitally in the POPProbe mobile app for real-time data capture, photo documentation, and automatic reporting.

Browse More Checklists