Improving Process Hazard Analysis (PHA) outcomes to better manage critical controls in mining industry: From PHA to verification in the field

Process safety management in the mining and metals industry is relatively new compared to other high‐hazard process industries such as oil and gas or chemicals. Practices are less mature and are developing, transferring from other industries, and using the International Council on Mining and Metals (ICMM) guidance to manage critical controls. This paper shares how Rio Tinto, a leading mining and metals company, has improved its critical controls management practices. Focus is put on how the company has improved the quality of its process hazard analyses (PHAs) and critical controls management activities through a series of actions. This covers clarification of the methodology used, development of training packages, revision of the methodology used to identify critical controls, development of a PHA facilitation approval process and a PHA facilitation approval committee, implementation of a training and coaching program for internal candidates, and development of assurance activities to monitor effectiveness of the process. These actions have resulted in very encouraging results in terms of overall quality of the PHAs, effectiveness of the PHA approval process to support the new methodologies introduced, and the development of internal facilitation capabilities.