Hazard Identification and Operability Studies (HAZOP): A Systematic Approach to Process Safety and Risk Management

Hazard Identification and Operability Studies (HAZOP) is a structured and systematic technique widely used in process industries to identify potential hazards and operational issues in industrial processes. This course provides participants with a comprehensive understanding of the HAZOP methodology, its application, and its role in ensuring process safety and operational efficiency. Through lectures, practical exercises, case studies, and interactive discussions, participants will gain hands-on experience in conducting HAZOP studies and interpreting their results effectively.

Audience

This course is intended for:

Process engineers and safety professionals
HAZOP team leaders and facilitators
Plant operators and maintenance personnel
HSE (Health, Safety, and Environment) managers
Project engineers and design engineers
Anyone involved in process safety, risk management, or operational improvement

Course objectives

By the end of this course, participants will be able to:

Understand the principles, purpose, and benefits of HAZOP studies.
Identify deviations from design intent using guide words and parameters.
Conduct a HAZOP study systematically and document findings accurately.
Interpret HAZOP results to recommend corrective actions and improve process safety.
Comply with international standards and best practices for HAZOP implementation.
Facilitate or participate effectively in HAZOP teams.

Course contents

Day–1: Introduction to HAZOP and Fundamentals

Pretest to assess participants’ baseline understanding of HAZOP principles
Overview of HAZOP: History, purpose, applications, and its role in process safety.
Regulatory frameworks and industry standards (IEC 61882, OSHA PSM).
Key concepts: Guide words, process parameters, and deviations.
Group activity on identifying deviations using guide words and process parameters.

Day–2: Conducting a HAZOP Study

Step-by-step methodology for conducting a HAZOP study.
Roles and responsibilities of HAZOP team members.
Preparing for HAZOP: Data collection, PFDs, and P&IDs.
Documenting findings: HAZOP worksheets and reports.
Hands-on tutorial: on completing a HAZOP worksheet and analyzing a real-world HAZOP report.

Day–3: Advanced HAZOP Techniques and Tools

Advanced guide words for addressing complex systems and multi-stream processes.
Software tools for HAZOP (PHA-Pro, HAZOP Manager).
Integrating HAZOP with other risk assessment techniques (HAZID, FMEA).
Practical exercise using software for HAZOP studies and comparing manual vs. software-based approaches.
Quiz on advanced HAZOP techniques and tools.

Day–4: Interpreting Results and Implementing Recommendations

Analyzing HAZOP findings and prioritizing recommendations.
Developing action plans for risk mitigation.
Effective communication of HAZOP results to stakeholders.
Group discussion on prioritizing recommendations based on severity and likelihood.
Case study on tracking HAZOP recommendation implementation in a refinery.

Day–5: Best Practices and Final Assessment

Common pitfalls and challenges in HAZOP studies.
Best practices for effective HAZOP facilitation.
Review of key concepts and emerging trends in HAZOP (AI, digitalization).
Final written assessment covering all course topics.
Post-course feedback session and posttest evaluation of learning outcomes.

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