Certified HAZOP Leader Advanced Process Hazard Analysis (PHA) Methods & Leadership (HAZOP, What-if, FMEA)

Introduction

Old approaches to safe design in the process industry relied on the application of codes of practice and the design was usually based upon experience from specialists and operators in the industry.  Such methods were able only to take into account the problems and accidents that had already happened.  With the introduction of new technologies, unconventional design, complex plants, and short operating experience, a proper PHA study is now a mandatory tool to identify potential hazards and operability problems.

PHA is a systematic multidisciplinary team study intended to identify and analyze the significance of potential process hazards and make initial recommendations for eliminating hazards, for reducing the consequences of potential accidents, and for improving general facility safety. PHA methods are used for new plants as well as for modifications to an existing design. The methods have been developed primarily for the process industry and have been applied on a great scale in the Oil and Gas sector.  However, the PHA techniques are now applied with success for other industries such as offshore construction, power and water projects, space and military industries, and environmental studies.

This program is designed to provide the participants with the knowledge and group leadership skills to lead teams in effective Process Hazards Analysis (PHA) studies.  The program is based on OSHA 29CFR Part 1910 Process Safety Management (PSM) regulations and was developed using instruction techniques and audio-visual materials specifically designed for engineers and supervisors. There is a focus on developing a practical understanding of what it takes to plan and lead a successful study and on practicing new skills.  Participants will be provided with comprehensive training and resource materials.

Objectives

• Apply the methodology of the PHA review techniques in general and the HAZOP technique in particular based on the International Standard IEC 61882 and identify the role of the independent chairman and the HAZOP team
• Determine the minimum Engineering Documents and drawings required to complete a satisfactory HAZOP report and illustrate the structure and content of such a Report
• Apply the HAZOP tool to process design of existing or new facilities including interface, start-up, and commissioning of a plant
• Assess the risk level/criticality associated with control loop/equipment failure and practice the major techniques for hazard identification
• List the responsibilities involved in the PHA leadership and the skills necessary for leading PHA studies
• Practice the various PHA techniques including What-If, HAZOP, and FMEA using real-life cases and use commercial software as useful tools in the facilitation of Process Hazards Analysis

Training Methodology

This is an interactive course. There will be open question and answer sessions, regular group exercises and activities, videos, case studies, and presentations on best practice. Participants will have the opportunity to share with the facilitator and other participants on what works well and not so well for them, as well as work on issues from their own organizations. The online course is conducted online using MS-Teams/ClickMeeting.

Who Should Attend?

This program provides an overview of all significant aspects and considerations of PHA for those who are involved in the management, engineering (design, process, chemical, facilities, instrumentation and control), operations and safety of process operations. Engineers, safety/environment personnel, plant operators, area managers, projects and maintenance personnel will benefit from the practical approach presented in this program.

Course Outline

DAY 1: Introduction to Risk Assessment

• Programme introduction: delegate and tutor introductions; programme objectives
• The concepts of hazards, risk and risk assessment
• Methods for risk evaluation
• Integrating risk assessment within Risk Management
• Qualitative, Semi-Quantitative and Quantitative Risk Assessment methodologies
• Feedback and review of Day 1

DAY 2: Risk Assessment Techniques: HAZOP

• Introduction to hazards identification and analysis techniques
• Techniques for hazard identification and analysis - HAZOP
• Where and when to use HAZOP and the requirements for a successful HAZOP study
• Team composition for HAZOP studies
• Guide words and process variables used for HAZOP studies
• Syndicate exercise - application of HAZOP to relevant processes
• Report back and review of Day 2

DAY 3: HAZOP Applications in the Process Industry

• HAZOP team leader/facilitator requirements
• HAZOP Team conduct
• Information required to allow successful HAZOP studies
• A case study where each delegate has the opportunity to facilitate a HAZOP meeting- Hydrocarbon transfer system
• Review of commercial software used for HAZOP and Management of Change ‘MOC’
• Report back and review of Day 3

DAY 4: Consequence Analysis

• The theory behind the fire, explosion and toxic dispersion modelling utilized in Quantitative Risk Assessments
• Types of fires and their effects on people and equipment
• Types of explosions and their effects on people and equipment
• Review of software available for consequence calculations
• Report back and review of Day 4

DAY 5: HAZOP and Human Factors

• Introduction to Human Error Classification
• Task Analysis
• Task-based HAZOP
• Integrating Human Factors into Process-based HAZOP
• HAZOP Reporting and report composition
• Report back on day 5 and discussion
• Programme review and the way ahead