HAZOP & LOPA Process Safety Course

Lesson 1 • Hazard Identification Concepts

Covers the nature of process hazards and their sources in chemical and energy systems. Builds vocabulary needed for structured hazard identification methods.

Lesson 2 • Regulatory and Standards Framework

Surveys functional requirements from major process safety standards and regulations. Positions HAZOP and LOPA as tools for meeting regulatory risk reduction obligations.

Lesson 3 • Risk Assessment Principles

Explains qualitative and semi-quantitative risk concepts including likelihood and consequence. Prepares students to apply risk matrices in later study sessions.

Lesson 4 • Accident Causation and Bow-Tie Model

Presents accident causation theory and the bow-tie barrier model as conceptual scaffolding. Directly supports understanding of safeguard evaluation in HAZOP and LOPA.

Lesson 1 • Process Hazard Documentation Review

Guides students through material safety data, operating procedures, and design basis documents. Establishes the document set required before a HAZOP study begins.

Lesson 2 • Instrumentation and Control Systems

Explains measurement, control, and alarm functions relevant to process safety. Students learn how control failures generate HAZOP deviations.

Lesson 3 • Process Flow and Mass Balance Basics

Covers process flow diagrams and steady-state mass and energy balance concepts. Enables students to recognize abnormal conditions as deviations from design intent.

Lesson 1 • Node Definition and Study Boundaries

Explains how to divide a process into nodes and define study boundaries on P&IDs. Proper node selection controls study quality and completeness.

Lesson 2 • HAZOP Study Planning and Scheduling

Covers scope definition, resource estimation, and session scheduling for a HAZOP study. Students produce a realistic study plan as a practical deliverable.

Lesson 3 • HAZOP Origins and Objectives

Traces the development of HAZOP and its role in systematic hazard identification. Clarifies what HAZOP does and does not accomplish within a risk management programme.

Lesson 4 • Guide Words and Deviations

Defines the standard guide word set and how deviations are formed by combining guide words with process parameters. This is the analytical engine of every HAZOP session.

Lesson 1 • Systematic Deviation Analysis

Guides the step-by-step process of applying guide words to each node parameter. Students practice identifying causes, consequences, and safeguards for each deviation.

Lesson 2 • HAZOP Documentation and Worksheets

Covers standard HAZOP worksheet structure, field definitions, and documentation quality. Complete, accurate records are essential for regulatory review and revalidation.

Lesson 3 • Opening and Orienting the Team

Covers session kickoff, P&ID walkthrough, and establishing team ground rules. A well-oriented team reaches consensus faster and produces higher-quality findings.

Lesson 4 • Risk Ranking HAZOP Findings

Applies qualitative risk matrices to rank each scenario by severity and likelihood. Risk ranking prioritises which findings require action recommendations.

Lesson 1 • HAZOP of Continuous Processes

Demonstrates HAZOP application to steady-state continuous flow systems such as reactors and distillation. Emphasises flow, pressure, temperature, and composition deviations.

Lesson 2 • HAZOP of Utility and Offsite Systems

Extends HAZOP to steam, cooling water, nitrogen, and flare systems that support process units. Utility failures are common initiating events in process hazard scenarios.

Lesson 3 • HAZOP of Procedures and Human Factors

Introduces procedure-based HAZOP and human error as a deviation source. Connects human factors analysis to safeguard reliability in LOPA.

Lesson 1 • Initiating Event Frequency Data

Presents industry-standard initiating event frequency values for equipment failures and human errors. Students learn to select and justify frequency data for LOPA calculations.

Lesson 2 • Risk Tolerance Criteria in LOPA

Covers how organisations establish tolerable risk frequency targets for safety, environmental, and asset consequences. Criteria selection drives all LOPA risk reduction decisions.

Lesson 3 • LOPA Calculation Overview

Introduces the LOPA frequency calculation sequence from initiating event to mitigated consequence frequency. Students perform a simple end-to-end calculation before detailed IPL study.

Lesson 4 • LOPA Scenario Structure

Defines the components of a LOPA scenario: initiating event, enabling conditions, conditional modifiers, and consequence. Each component contributes to the scenario frequency calculation.

Lesson 1 • Passive and Active IPL Types

Categorises IPLs as passive, active, or human and assigns typical probability of failure on demand values. Students apply standard PFD values to LOPA calculations.

Lesson 2 • LOPA Documentation and Scenario Records

Covers LOPA worksheet structure, assumption documentation, and traceability to HAZOP findings. Proper records support SIS design, audit, and revalidation activities.

Lesson 3 • IPL Definition and Independence Criteria

Defines what qualifies as an independent protection layer and the four IPL criteria. Strict application of independence prevents double-counting of risk reduction credit.

Lesson 4 • Safety Instrumented Systems as IPLs

Explains how safety instrumented systems qualify as IPLs and how SIL relates to PFD. Connects LOPA output to SIS design requirements.

Lesson 1 • Continuous Improvement of Risk Records

Addresses how to maintain living PHA records that reflect current process and risk knowledge. Accurate living records support operational decisions and regulatory inspections.

Lesson 2 • Action Item Tracking and Close-Out

Establishes a system for tracking HAZOP and LOPA recommendations through to verified closure. Unresolved actions represent unmitigated risk and regulatory non-compliance.

Lesson 3 • Periodic Revalidation of PHA Studies

Covers regulatory and best-practice requirements for periodic HAZOP and LOPA revalidation. Students plan a revalidation study using prior records and accumulated MOC history.

Lesson 4 • Management of Change and PHA Triggers

Defines when process changes require HAZOP or LOPA reanalysis and how to scope the review. MOC integration prevents new hazards from entering service without assessment.