Course description

The HAZOP (Hazard and Operability) Study is one of the most widely used methodologies for identifying potential hazards and operational problems in industrial processes. Originally developed by ICI in the 1960s, HAZOP has become an international standard for risk assessment and process safety in industries such as oil and gas, petrochemical, pharmaceuticals, and power generation. This five-day intensive course is designed to train engineers, safety officers, operations personnel, and managers in the practical and theoretical aspects of conducting HAZOP studies effectively.
The course is structured to provide both a strong foundation and hands-on experience in HAZOP facilitation. It will guide participants through the philosophy, principles, and detailed procedures of HAZOP. Key objectives include understanding system design, identifying risk scenarios, analyzing deviations in process parameters, evaluating the potential consequences, and recommending effective safeguards.
One of the primary goals of HAZOP is to proactively improve systems and processes by identifying potential deviations before they result in accidents or failures. Participants will learn how HAZOP reduces risks to people, equipment, and the environment, and how it contributes to efficient, productive, and compliant operations. Real-life examples and case studies will be used to reinforce key learning points, ensuring that participants gain the ability to apply HAZOP techniques across various industries.
The course emphasizes the importance of collaboration and team dynamics. HAZOP is a team-based activity that brings together experts from different disciplines, such as design, operations, maintenance, and safety. Through structured brainstorming sessions using P&IDs (Piping and Instrumentation Diagrams), operating procedures, equipment design specifications, and material safety data sheets (MSDS), the team identifies possible deviations in operational parameters such as pressure, flow, temperature, and vibration.
Participants will receive detailed training on using guide words and parameters to systematically review each part of a process. For each potential deviation, the team evaluates the causes, consequences, existing safeguards, and recommends improvements if necessary. Trainees will learn to document findings effectively using standardized templates and software tools.
The course also addresses regulatory requirements and industry best practices. By the end of the program, participants will be able to contribute meaningfully to HAZOP teams, lead small studies, and integrate HAZOP findings into operational risk management systems.
Another major advantage of the HAZOP approach is that it facilitates team building and increases awareness among all parties involved in process operations. Through guided workshops and group exercises, the course encourages collaboration, improves communication across departments, and promotes a culture of safety and continuous improvement.

Audience

This training course is specifically designed for 

  • Process Engineers
  • Safety and HSE Engineers
  • Operations and Maintenance Engineers
  • Project Managers
  • Risk Assessment Professionals
  • Plant Managers
  • Auditors and Inspectors
  • Technical Consultants

Prerequisites

  • Basic understanding of industrial operations
  • Familiarity with process flow diagrams (PFDs) and piping and instrumentation diagrams (P&IDs)
  • General knowledge of process safety principles is beneficial but not required

 

Course content

Introduction to HAZOP and Risk Management Concepts
Welcome and course overview
Introduction to process safety and risk management
History and evolution of HAZOP
Objectives and scope of HAZOP studies
Regulatory context and standards (e.g., OSHA, IEC, ISO)
Types of hazards in process industries
Team composition and roles
Interactive group activity: Hazard recognition exercise
Understanding Process Information and HAZOP Methodology
Detailed review of P&IDs and process flow diagrams
Introduction to operating procedures and design specifications
Characteristics of hazardous materials (flammable, explosive, toxic)
Overview of equipment used in process plants
HAZOP guide words and parameters (flow, pressure, temperature, vibration)
Case study: Reviewing a P&ID for a pump system
Workshop: Identifying deviations using guide words
Conducting a HAZOP Study
HAZOP methodology step-by-step
Preparing for a HAZOP session
Node selection and segmentation of systems
Brainstorming techniques and use of checklists
Analysis of deviations: causes, consequences, safeguards
Documentation and reporting standards
Case study simulation: HAZOP session on a gas processing unit
Role-playing exercise: Team-based HAZOP discussion
HAZOP Implementation and Improvement of Operational Systems
Implementation of HAZOP findings and recommendations
Linking HAZOP to safety instrumented systems (SIS) and layers of protection (LOPA)
Addressing human factors and procedural deficiencies
Aligning HAZOP with incident investigation and root cause analysis
Enhancing productivity and efficiency through procedural improvements
Team building and cross-functional collaboration in HAZOP studies
Group activity: Process improvement brainstorming
Advanced Topics, Reporting, and Review
Advanced HAZOP applications: batch processes, utilities, storage
Software tools and digital platforms for HAZOP documentation
Integrating HAZOP with broader risk management systems (e.g., Bowtie analysis, FMEA)
Review of key learnings and group discussion
Final workshop: Conducting a mini-HAZOP from start to finish
Q&A and feedback session
Course assessment and certification

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