Course Overview
This intensive program provides comprehensive training in process hazard analysis, risk management, and regulatory compliance for oil & gas, chemical, and manufacturing industries. Participants will master HAZOP facilitation, LOPA implementation, and safety instrumented systems while learning to develop robust process safety management (PSM) systems.
Course Objectives
Upon completion, participants will be able to:
- Lead effective HAZOP studies per IEC 61882
- Implement Layer of Protection Analysis (LOPA)
- Design Safety Instrumented Systems (SIS) per IEC 61511
- Develop compliant PSM programs (OSHA 1910.119, EPA RMP)
- Apply bowtie methodology for risk visualization
- Conduct process hazard reviews (PHA, What-If, FMEA)
- Manage process safety compliance (CCPS, COMAH)
Who Should Attend
This course is essential for:
- Process safety engineers
- HAZOP leaders/facilitators
- PSM managers
- Operations managers
- Risk assessment specialists
- Plant engineers
- EHS professionals
Course Modules
Module 1: Process Safety Fundamentals
- Process safety vs occupational safety
- Major accident case studies (Bhopal, Texas City)
- Safety lifecycle (IEC 61511)
- PSM regulatory framework (OSHA, SEVESO, COMAH)
Module 2: Hazard Identification
- HAZOP methodology (IEC 61882)
- Guideword application
- Node selection strategies
- Documentation best practices
Module 3: Risk Assessment
- LOPA methodology
- Risk matrix development
- Safety Integrity Level (SIL) determination
- Independent Protection Layers (IPLs)
Module 4: Safety Instrumented Systems
- SIS architecture (IEC 61511)
- Sensor/valve reliability analysis
- Proof testing requirements
- Bypass management
Module 5: Process Safety Management
- 14 PSM elements (OSHA 1910.119)
- Mechanical integrity programs
- Management of Change (MOC)
- Compliance auditing
Module 6: Advanced Risk Visualization
- Bowtie methodology
- Fault tree/event tree analysis
- Human factors in process safety
- Alarm management (ISA 18.2)
Module 7: Practical Applications
- HAZOP facilitation workshop
- LOPA scenario development
- SIF verification exercises
- PSM audit simulation