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 Process Safety Culture accredited by ASSP CEU 1.2