course | Process Hazard Analysis (PHA) and HAZOP

Introduction to Process Hazard Analysis (PHA)

• Overview of process safety and regulatory drivers
• Introduction to PHA: Purpose and benefits
• Relationship between PHA, risk assessment, and functional safety
• Overview of IEC 61508 and IEC 61511 requirements
• Lifecycle of safety instrumented systems
• Group Activity: Map PHA steps to IEC 61511 lifecycle

Fundamentals of Hazard and Risk
 

• Definitions: Hazard, risk, exposure, consequence, likelihood
• Risk assessment principles
• ALARP concept and safety tolerability
• Risk control hierarchy and layers of protection
• Introduction to other PHA techniques (e.g., What-if, FMEA, LOPA)
• Exercise: Apply risk reduction concepts to real-life scenarios

HAZOP – Overview and History

• Origins and development of HAZOP
• Types of processes suitable for HAZOP
• Objectives and limitations of HAZOP
• Role of HAZOP in overall PHA strategy
• Case examples: Real-world incidents where HAZOP could have helped

Core Elements of a HAZOP Study

• Process description and P&ID review
• Node identification and parameter selection
• Guidewords and their application
• Typical deviations and process consequences
• Risk identification and control suggestions
• Workshop: Practice identifying deviations using guidewords

Structured Methodology of HAZOP

• Step-by-step HAZOP procedure
• Documentation templates and standard forms
• Team roles and responsibilities
• Recording findings, causes, consequences, safeguards, and actions
• Role of the facilitator and scribe
• Mock HAZOP Session (Part 1): Node review and deviation identification

Risk Ranking and Risk Matrices

• Purpose and structure of risk matrices
• Severity and likelihood scoring
• Risk class definitions
• Prioritizing actions and recommendations
• Example matrix development and customization
• Exercise: Apply risk ranking to sample HAZOP scenarios

Special Considerations for Batch Processes

• Differences between batch and continuous processes
• HAZOP challenges in non-steady-state operations
• Phased operation HAZOP techniques (start-up, charging, reaction, shutdown)
• Use of sequential function charts (SFC) in batch HAZOP
• Case Study Review: HAZOP for a batch reactor system

Preparing for a HAZOP Workshop

• Pre-workshop data collection and team selection
• Review of PFDs, P&IDs, cause & effect charts, operating procedures
• Software tools for HAZOP documentation (e.g., PHA-Pro, HAZOP Manager)
• Scheduling and organizing the sessions
• Communicating expectations to team members
• Checklist Activity: Preparing a HAZOP kick-off packet

Practical Application and HAZOP Simulation

Mock HAZOP Session (Part 2):

• Full walkthrough using case-based P&ID
• Team roles simulated
• Guidewords applied, deviations analyzed, and risks ranked

• Discussion and feedback on HAZOP performance
• Common mistakes and how to avoid them
• Final Project.