A beginners guide to HAZOP studies
$2000.00
A Beginner’s Guide to HAZOP Studies: 5-Day Comprehensive Training Course
Course Overview
This intensive 5-day HAZOP training for beginners provides comprehensive knowledge of Hazard and Operability (HAZOP) study methodology, facilitation techniques, and practical application. Designed for engineers, operators, safety professionals, and anyone new to process safety analysis, this course develops competency in conducting effective HAZOP studies.
Target Audience: Process engineers, chemical engineers, plant operators, safety professionals, project engineers, maintenance supervisors, quality assurance personnel, and anyone involved in process safety management with little or no HAZOP experience.
Course Objectives:
Understand HAZOP methodology and principles
Learn systematic hazard identification techniques
Master HAZOP facilitation and team leadership
Apply guide words and parameters effectively
Document findings and recommendations properly
Develop actionable safety improvements
Day 1: HAZOP Fundamentals and Process Safety Basics
Morning Session: Introduction to Process Safety
Understanding Process Safety Management
Foundation of process safety concepts:
Process Safety Overview:
Process safety versus personal safety
Major accident prevention focus
Historical catastrophic incidents: Bhopal, Piper Alpha, Texas City
Consequences: fatalities, environmental damage, economic losses
Regulatory drivers: OSHA PSM, EPA RMP, Seveso Directive
Industry commitment to safety
Process Hazards:
Chemical reactivity and instability
Flammability and explosions
Toxicity and exposure risks
High pressure and temperature
Corrosive and reactive materials
Energy release potential
Layers of Protection:
Inherently safer design principles
Engineering controls and safety systems
Administrative controls and procedures
Personal protective equipment
Emergency response planning
Defense-in-depth philosophy
Afternoon Session: Introduction to HAZOP
What is HAZOP?
Understanding HAZOP methodology:
HAZOP Definition:
Hazard and Operability Study
Systematic team-based examination
Structured brainstorming technique
Identifying process hazards and operability problems
Design stage and existing plant application
International standard: IEC 61882
HAZOP History and Development:
Developed by ICI in 1960s
Evolution and refinement over decades
Global adoption across industries
Integration with risk management
Modern variations and adaptations
When to Conduct HAZOP:
New plant design: conceptual, detailed design
Plant modifications and expansions
Process changes and upgrades
Periodic revalidation (5-10 years)
After incidents or near-misses
Regulatory compliance requirements
HAZOP Benefits:
Systematic hazard identification
Improved process understanding
Enhanced safety and reliability
Reduced incidents and losses
Regulatory compliance
Team knowledge sharing
HAZOP Limitations:
Time and resource intensive
Requires experienced facilitation
Quality depends on team expertise
Cannot identify all hazards
Focuses on single-point deviations
Doesn’t quantify risks directly
Day 2: HAZOP Methodology and Preparation
Morning Session: HAZOP Study Process
The HAZOP Procedure
Understanding step-by-step methodology:
HAZOP Study Steps:
Define study scope and objectives
Select and brief the HAZOP team
Collect and review documentation
Divide process into nodes
Apply guide words systematically
Identify causes and consequences
Evaluate existing safeguards
Develop recommendations
Document and follow up
Study Scope Definition:
Boundaries of the study
Inclusions and exclusions
Interfaces with other systems
Study objectives and depth
Time and resource constraints
Success criteria definition
Node Selection:
Logical process sections
Equipment groups: reactors, columns, vessels
Manageable complexity: 2-4 hours per node
Node boundaries at control points
Consideration of interfaces
Documentation of node divisions
Documentation Requirements:
Process Flow Diagrams (PFDs)
Piping and Instrumentation Diagrams (P&IDs)
Process descriptions and operating procedures
Material Safety Data Sheets (MSDS/SDS)
Equipment specifications
Design basis and philosophy
Afternoon Session: Guide Words and Parameters
HAZOP Language
Mastering guide words and parameters:
Standard Guide Words:
NO/NOT/NONE: complete negation
MORE/HIGHER: quantitative increase
LESS/LOWER: quantitative decrease
AS WELL AS: qualitative increase
PART OF: qualitative decrease
REVERSE: logical opposite
OTHER THAN: complete substitution
Process Parameters:
FLOW: rate, direction, composition
PRESSURE: too high, too low
TEMPERATURE: hot, cold, fluctuations
LEVEL: overfill, empty, interface
COMPOSITION: purity, contaminants, ratios
TIME: too fast, too slow, sequence
MIXING: inadequate, excessive, segregation
Deviation Examples:
NO FLOW: blocked line, pump failure
MORE PRESSURE: relief valve failure, thermal expansion
LESS TEMPERATURE: cooling failure, wrong material
REVERSE FLOW: backflow, check valve failure
OTHER THAN COMPOSITION: wrong material charged
MORE LEVEL: overflow, instrumentation failure
Applying Guide Words:
Systematic application to each parameter
Meaningful deviations only
Creative thinking encouraged
Consider credible scenarios
Document “no credible cause” decisions
Balance thoroughness with efficiency
Day 3: Causes, Consequences, and Safeguards
Morning Session: Identifying Causes
What Can Go Wrong?
Understanding deviation causes:
Types of Causes:
Equipment failures: pumps, valves, instruments
Human errors: operational mistakes, maintenance
External events: utility failures, weather
Process upsets: reaction runaways, fouling
Design deficiencies: inadequate capacity
Instrument and control failures
Brainstorming Techniques:
Open team discussion
Building on ideas
No criticism during generation
Encourage diverse perspectives
Recording all suggestions
Combining similar causes
Credible versus Incredible:
Distinguishing plausible scenarios
Probability considerations (general)
Industry experience and history
Judgment versus detailed analysis
Multiple simultaneous failures
Documentation of assumptions
Afternoon Session: Consequences and Safeguards
What Happens and What Prevents It?
Analyzing impacts and protections:
Consequence Analysis:
Safety impacts: injuries, fatalities
Environmental releases: air, water, soil
Asset damage: equipment, production
Business interruption losses
Regulatory violations
Reputation and community impact
Severity Assessment:
Qualitative severity ranking
Minor, moderate, major, catastrophic
Personnel exposure potential
Environmental sensitivity
Economic impact estimation
Simple ranking sufficient for HAZOP
Existing Safeguards:
Engineering controls: relief valves, interlocks
Alarms and operator response
Automatic shutdown systems
Physical barriers and containment
Administrative controls: procedures, training
Emergency response capabilities
Evaluating Adequacy:
Are safeguards sufficient?
Independence and reliability
Single point failures
Human factor dependencies
Testing and maintenance verification
Recommendations for improvements
Day 4: Recommendations and Documentation
Morning Session: Developing Recommendations
Making Improvements
Creating actionable recommendations:
Types of Recommendations:
Additional safeguards: instruments, interlocks
Design changes: equipment, piping
Procedure improvements: operating, maintenance
Further analysis: detailed studies, calculations
Training and competency
Inspection and testing programs
Recommendation Quality:
Specific and actionable
Assigned to responsible party
Target completion dates
Prioritization: high, medium, low
Cost-benefit considerations
Implementation verification
SMART Recommendations:
Specific: clear action described
Measurable: verifiable completion
Achievable: practical and feasible
Relevant: addresses the hazard
Time-bound: completion deadline
Common Recommendation Types:
Install high-level alarm
Add pressure relief capacity
Revise operating procedure
Conduct detailed SIL assessment
Provide operator training
Implement inspection program
Afternoon Session: HAZOP Documentation
Recording the Study
Mastering documentation practices:
HAZOP Report Structure:
Executive summary
Introduction and scope
Study methodology
Team composition
Process description
Node-by-node findings
Recommendations summary
Action tracking
Recording During Study:
Scribe role and responsibilities
Real-time documentation software
Capturing all discussions
Clarity and completeness
Review with team during sessions
Parking lot for off-topic items
HAZOP Worksheets:
Node identification
Guide word and parameter
Deviation description
Causes identified
Consequences evaluated
Existing safeguards listed
Recommendations documented
Action assignments
Follow-Up and Tracking:
Action item register
Responsibility assignment
Progress monitoring
Completion verification
Management review
Closure documentation
Day 5: Team Dynamics and Practical Application
Morning Session: HAZOP Team and Facilitation
Leading Effective Studies
Understanding team dynamics:
HAZOP Team Composition:
HAZOP Leader/Facilitator: methodology expert
Process engineer: design knowledge
Operations representative: practical experience
Maintenance engineer: equipment expertise
Instrumentation/control specialist
Safety professional: regulations, standards
Scribe: documentation
Facilitator Role:
Leading the team through methodology
Maintaining focus and pace
Encouraging participation
Managing conflicts and personalities
Keeping on schedule
Ensuring quality and completeness
Team Member Responsibilities:
Active participation
Sharing knowledge and experience
Challenging assumptions constructively
Supporting facilitator
Respecting diverse views
Maintaining confidentiality
Effective Facilitation Techniques:
Establishing ground rules
Managing dominant personalities
Drawing out quiet participants
Parking lot for off-topic items
Time management strategies
Maintaining energy and focus
Dealing with difficult situations
Afternoon Session: Practical HAZOP Exercise
Hands-On Application
Conducting practice HAZOP study:
Exercise Overview:
Simple process example provided
P&ID and process description
Divided into small groups
Each group conducts mini-HAZOP
Focus on 2-3 nodes
2-3 hours working time
Process Example:
Storage and transfer system
Pumping and heat exchange
Realistic but simplified
Multiple deviation opportunities
Practice applying guide words
Identifying meaningful scenarios
Group Work:
Self-organizing teams
Rotating facilitator role
Applying systematic methodology
Completing HAZOP worksheets
Developing recommendations
Preparing presentation
Presentations and Feedback:
Each group presents findings
Comparison of approaches
Discussion of different perspectives
Facilitator feedback and coaching
Lessons learned sharing
Best practice identification
Wrap-Up and Next Steps:
Review of key learning points
Resources for continued learning
Industry standards and references
Software tools for HAZOP
Professional development pathways
Certification opportunities
Post-course support
Course Deliverables
Participants Receive:
Comprehensive HAZOP training manual
Guide word and parameter reference cards
HAZOP worksheet templates
Facilitation checklists and tools
Case study examples
Industry standards excerpts (IEC 61882)
Certificate of completion
Access to online resources
Interactive Components:
Video examples of HAZOP sessions
Real case study discussions
Hands-on practice exercise
Group facilitation practice
Peer feedback and coaching
Q&A with experienced practitioners
Why This Training Is Essential
Key Benefits:
Build foundational HAZOP competency
Understand systematic hazard identification
Contribute effectively to HAZOP teams
Improve process safety performance
Meet regulatory training requirements
Develop career skills in process safety
Network with safety professionals
Career Development:
Entry point to process safety field
Foundation for advanced studies
Pathway to HAZOP leader certification
Valued skill across industries
Professional credential enhancement
ROI:
Prevent incidents and losses
Improve plant safety and reliability
Regulatory compliance
Reduced insurance costs
Enhanced safety culture
Organizational capability building
Keywords: HAZOP training, hazard and operability study, process safety management, HAZOP methodology, guide words, process hazard analysis, HAZOP facilitation, safety engineering, risk assessment, IEC 61882, OSHA PSM, process safety training, beginner HAZOP course
