By the end of the training, participants will be able to:

·         Recognize the role of HAZOP & LOPA in lifecycle risk management.

·         Apply advanced HAZOP methodology on complex processes and systems.

·         Identify deviations, hazards, causes, and consequences with improved rigor.

·         Evaluate independent protection layers (IPLs) and their performance.

·         Perform detailed LOPA calculations and risk rankings.

·         Integrate HAZOP and LOPA into SIL determination and process safety programs.

·         Use best practices for documentation, facilitation, and follow-up actions.

·         Avoid common pitfalls and improve study quality and consistency.

·       Professionals working in chemical, petrochemical, oil & gas, pharmaceutical and other process industries.

• In addition this course is suitable for professional development programs in process plants, engineering companies, and safety organizations

Detailed 5-Day Course Outline

Day 1 – Foundations & Advanced HAZOP Concepts

Module 1: Introduction to Process Safety & Risk Analysis

·         Risk management hierarchy in process plants

·         Relationship between HAZOP, LOPA, QRA, SIL, and PHA

·         Regulatory & industry standards (OSHA PSM, CCPS, IEC 61511)

Module 2: HAZOP Methodology – Deep Dive

·         HAZID vs HAZOP vs What-If vs FMEA

·         Key components: nodes, deviations, parameters, causes, consequences

·         Guide words and advanced interpretation

·         Identifying high-quality causes and consequences

Module 3: Preparing for an Effective HAZOP

·         Data collection & documentation requirements

·         Defining nodes and boundaries

·         Managing complex process systems

·         Team composition & leadership roles

Practical Session

·         Reviewing P&IDs / PFDs for HHA (Harmful Hazard Analysis)

·         Node selection workshop

Day 2 – Advanced HAZOP Execution & Facilitation

Module 4: Facilitating an Effective HAZOP

·         Leadership techniques for HAZOP facilitators

·         Managing team dynamics and avoiding bias

·         Best-practice recording & documentation

·         Common mistakes in HAZOP and how to avoid them

Module 5: Advanced HAZOP Studies

·         Use of conditional modifiers

·         Human factors considerations

·         Integrating alarms and operator responses

·         Techniques for high-hazard operations & batch processes

Practical Session

·         Full HAZOP case study (multidisciplinary team exercise)

·         Live facilitation and documentation practice

Day 3 – Introduction to LOPA & Linking with HAZOP

Module 6: LOPA Fundamentals

·         When and why LOPA is used

·         Relationship between HAZOP and LOPA

·         Risk tolerance criteria (company-specific, CCPS)

·         Frequency and consequence modelling basics

Module 7: Independent Protection Layers (IPLs)

·         Definition, criteria, and performance

·         IPL dependencies and failure modes

·         Typical IPLs (relief systems, SIS, alarms, procedures, interlocks)

·         PFDavg (Probability of Failure on Demand) fundamentals

Module 8: Triggering LOPA from HAZOP

·         Determining HAZOP scenarios that require LOPA

·         Selecting initiating events

·         Data sources (generic failure rates, historic data, industry databases)

Practical Session

·         Converting HAZOP scenarios into LOPA candidates

·         Initiating event frequency assignment workshop

Day 4 – Advanced LOPA Calculations & SIL Determination

Module 9: Quantitative LOPA Analysis

·         Calculating risk reduction factors (RRFs)

·         PFD values for IPLs and safeguards

·         Consequence severity mapping

·         Accounting for uncertainty & conditional modifiers

Module 10: SIL Determination & SIS Lifecycles

·         Understanding Safety Integrity Levels (SIL 1–3)

·         Linking LOPA to IEC 61511 lifecycle

·         Combining LOPA with SIL allocation and verification

·         Instrumented safety functions (SIFs)

Module 11: Risk Decision-Making & Recommendations

·         Interpreting LOPA results

·         ALARP principles and cost-benefit considerations

·         Developing actionable recommendations

Practical Session

·         Full LOPA calculation exercise

·         SIL determination scenario

Day 5 – Integrated Case Studies, Review, and Best Practices

Module 12: Combined HAZOP–LOPA Workshop

·         End-to-end case study (process plant system)

·         Identify deviations → run HAZOP → trigger LOPA → calculate risk → derive SIL

·         Documenting findings & recommendations

Module 13: Software Tools & Digital HAZOP/LOPA

·         Overview of common software (PHA-Pro, PHAWorks, BowTieXP, exSILentia)

·         Best practices for digital documentation

Module 14: Enhancing Study Quality & Organizational Learning

·         Quality assurance & peer review

·         Managing large studies across multi-unit plants

·         Tracking recommendations & action closure

·         Continuous improvement using previous HAZOP/LOPA data

Module 15: Course Review & Assessment

·         Final assessment (written + practical)

·         Summary of lessons learned

·         Certificates and closing session

BTS attendance certificate will be issued to all attendees completing minimum of 80% of the total course duration.

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