Course Overview

This 2-day training program provides an in-depth understanding of hazard identification techniques across industries, focusing on process safety risk management.

Course Objectives

By the end of this course, participants will:

• Understand the importance of hazard identification in risk prevention.
• Learn key hazard identification techniques and when to apply them.
• Be able to select the appropriate technique based on the project lifecycle.
• Gain insight into new and emerging hazard identification approaches.

Who Should Attend?

This course is designed for:

• Process safety engineers & process engineers
• Plant/process operators
• Professionals involved in design, commissioning, decommissioning, installation, and modification of industrial plants
• Construction, nuclear, and oil & gas industry representatives

Course Content

Module 1: Fundamentals of Process Hazards and Risks
Introduction to process hazard identification
Key definitions: hazards, risks, and safety barriers
Learning from historical industrial disasters
Case Studies: Buncefield & CAPECO accidents
Regulatory frameworks and industry standards

Module 2: Essential Hazard Identification Techniques
What-If Analysis (SWIFT): Scenario-based risk assessment
Checklists: Systematic hazard identification
Brainstorming Techniques: Group-based risk evaluation
Strengths, weaknesses, and applications of each technique

Module 3: Inherently Safer Design (ISD) & Risk Elimination
Introduction to ISD principles
Design modifications to eliminate or reduce hazards
Case Study: CSB/Bayer plant explosion analysis
Bow-Tie Diagrams: Visualizing risk pathways and control measures

Module 4: Chemical Reaction Hazards & Runaway Reactions
Understanding runaway reactions and their causes
Strategies for preventing and managing chemical hazards
Case Study: CSB Synthron explosion video analysis

Module 5: Advanced Hazard Identification (HAZID) Techniques
Introduction to HAZID methodology
Reaction Exercise: Identifying risks in a simulated process

Module 6: Hazard and Operability Study (HAZOP)
HAZOP methodology: Systematic deviation analysis
Managing creeping changes in operations
Delta HAZOP: Identifying risks from small process modifications

Module 7: Batch Process HAZOP & Its Unique Challenges
Key differences between batch and continuous processes
Case Study: CSB T2 Laboratories explosion analysis
Hands-on HAZOP workshop: Group exercise

Module 8: Failure Modes, Effects, and Criticality Analysis (FMECA)
Understanding FMECA methodology
Case Study: Challenger disaster – Lessons from failure analysis
System-Theoretic Process Analysis (STAMP/STPA) techniques

Module 9: Layers of Protection Analysis (LOPA)
Understanding safety layers and barriers
Integrating LOPA with other hazard assessment techniques
Case Study Demonstration

Course Methodology

The learning methodology uses a mixture of presentations, discussion, case studies, video content and interactive exercises to transform participant knowledge into hands-on practice in a safe environment.

Certification:

All attendees who successfully complete the training will be awarded a Certificate of Completion, acknowledging their knowledge in Managing Major Emergencies accredited by ASSP CEU 1.2