Process Hazard Analysis Training Service | in Dammam - Riyadh - Jeddah - Makkah

1. Introduction to Process Hazard Analysis

• Process safety management overview per OSHA 29 CFR 1910.119 including (14 elements, covered processes, threshold quantities, employer responsibilities)

• PHA regulatory requirements per 1910.119(e) including (appropriate methodology, team composition, frequency revalidation every 5 years, documentation)

• Major accident prevention including (Bhopal, Flixborough, Texas City, Deepwater Horizon, lessons learned, industry impact)

• Process hazards including (reactivity, toxicity, flammability, explosivity, pressure, temperature, corrosivity)

• PHA objectives including (hazard identification, consequence evaluation, safeguard assessment, risk reduction, compliance demonstration)

• PHA team requirements per OSHA including (process expertise, engineering knowledge, operating experience, team leader, facilitator competency)

• PHA lifecycle including (preparation, execution, documentation, recommendation resolution, revalidation, management of change integration)

2. Process Safety Information Foundation

2.1 Chemical and Process Information

• Chemical hazards per 1910.119(d)(1) including (toxicity data, permissible exposure limits, physical data, reactivity data, corrosivity, thermal and chemical stability)

• Safety Data Sheets (SDS) review including (hazard identification, composition, first aid, handling, exposure controls, physical properties, stability)

• Process chemistry including (intended reactions, side reactions, exothermic versus endothermic, heat of reaction, runaway reaction potential)

• Materials of construction including (compatibility, corrosion allowances, temperature limits, pressure ratings, material degradation)

2.2 Technology and Equipment Information

• Process flow diagrams (PFD) per 1910.119(d)(2) including (major equipment, flow paths, design basis, process conditions)

• Piping and instrumentation diagrams (P&ID) including (equipment details, instrumentation, interlocks, alarms, relief devices, control systems)

• Equipment design specifications including (pressure vessels, heat exchangers, reactors, columns, pumps, compressors, design codes ASME)

• Electrical area classification including (Class I, Division 1/2, Zone 0/1/2, ignition sources, equipment suitability)

2.3 Process Limits and Operating Envelope

• Safe operating limits per 1910.119(d)(3) including (temperatures, pressures, flows, levels, compositions, maximum inventory)

• Consequence of deviation including (overpressure, overtemperature, loss of cooling, contamination, wrong material, off-spec product)

• Process capability and reliability including (design margins, operating windows, equipment limitations, utility dependencies)

• Critical process parameters including (safety instrumented functions, interlock setpoints, relief device settings, critical alarms)

3. PHA Methodology Selection and Overview

• PHA methodology selection criteria including (process complexity, hazard severity, facility lifecycle stage, resources, regulatory requirements)

• Qualitative versus quantitative methods including (descriptive risk, numerical probability, consequence modeling, risk matrices)

• Common PHA methodologies including (HAZOP, What-If, What-If/Checklist, FMEA, Fault Tree Analysis, Bow-Tie, LOPA)

• Methodology applicability including (continuous processes HAZOP, batch processes What-If, equipment FMEA, specific scenarios FTA)

• PHA scope definition including (process boundaries, included systems, excluded systems, study nodes, documentation basis)

• Study preparation including (information gathering, P&ID review, team scheduling, training, administrative setup)

4. HAZOP Study Methodology

4.1 HAZOP Fundamentals

• Hazard and Operability Study (HAZOP) principles including (systematic examination, creative thinking, deviation analysis, consequence evaluation)

• HAZOP elements including (guide words, parameters, deviations, causes, consequences, safeguards, recommendations)

• Guide words per IEC 61882 including (NO, MORE, LESS, AS WELL AS, PART OF, REVERSE, OTHER THAN)

• Parameters including (flow, pressure, temperature, level, composition, time, viscosity, phase)

4.2 HAZOP Execution Process

• Node selection including (logical sections, major equipment, operating modes, batch steps, manageable scope)

• Deviation generation including (applying guide words to parameters, meaningful combinations, No Flow, High Pressure, Low Temperature)

• Cause identification including (equipment failure, human error, external events, utility loss, process upset, maintenance error)

• Consequence evaluation including (safety impact, environmental release, asset damage, business interruption, severity ranking)

4.3 HAZOP Documentation and Recommendations

• Safeguard assessment including (engineered controls, administrative controls, detection systems, mitigation, emergency response)

• Risk evaluation including (qualitative risk matrix, likelihood and consequence, existing safeguards credit, residual risk)

• Recommendation development including (eliminate hazard, reduce likelihood, reduce consequence, improve safeguards, procedural changes)

• HAZOP worksheet documentation including (node, deviation, causes, consequences, safeguards, risk, recommendations, action owners)

5. What-If and What-If/Checklist Analysis

5.1 What-If Analysis

• What-If methodology including (brainstorming approach, creative thinking, experience-based, question formulation)

• Question development including (equipment failures, operating errors, external events, utility losses, what if pump fails, what if valve leaks)

• Scenario evaluation including (consequence identification, safeguard review, likelihood assessment, risk determination)

• What-If advantages including (flexibility, creativity, experienced team leverage, applicable to any process)

5.2 Checklist Analysis

• Checklist methodology including (compliance verification, code requirements, industry standards, lessons learned, best practices)

• Checklist development including (regulatory requirements, company standards, industry guidelines, past incidents, subject-specific)

• Checklist categories including (design criteria, operating procedures, maintenance, emergency response, process safety information)

• Combined What-If/Checklist including (brainstorming plus systematic verification, comprehensive coverage, structured creativity)

5.3 Application and Documentation

• Study scope and preparation including (process section definition, information review, team briefing, question/checklist preparation)

• Facilitation techniques including (open discussion, all voices heard, documentation in real-time, parking lot for scope issues)

• Documentation format including (questions/checklist items, answers/findings, consequences, recommendations, responsible parties, due dates)

• Follow-up requirements including (action tracking, completion verification, effectiveness review, outstanding item escalation)

6. Failure Modes and Effects Analysis (FMEA)

• FMEA methodology per SAE J1739 including (bottom-up approach, component-level analysis, failure mode identification, effects evaluation)

• FMEA components including (item/function, failure mode, failure cause, local effects, system effects, detection methods)

• Severity, Occurrence, Detection (SOD) ranking including (1-10 scales, severity of consequence, occurrence frequency, detection capability)

• Risk Priority Number (RPN) calculation including (Severity x Occurrence x Detection, prioritization, threshold criteria, high RPN focus)

• Process FMEA application including (equipment failures, instrument failures, control system failures, utility failures)

• FMEA documentation including (FMEA worksheet, RPN ranking, recommended actions, revised RPN after improvements)

• FMEA advantages including (systematic equipment review, quantified prioritization, continuous improvement focus, reliability engineering integration)

7. Layer of Protection Analysis (LOPA)

7.1 LOPA Fundamentals

• LOPA methodology per CCPS including (semi-quantitative, scenario-based, initiating event plus consequences, independent protection layers)

• LOPA objectives including (risk quantification, safeguard credit, risk tolerance verification, Safety Instrumented System SIS design basis)

• LOPA process including (scenario definition, consequence severity, initiating event frequency, enabling event/condition, independent protection layers)

• Risk tolerance criteria including (tolerable risk, risk target, frequency-consequence relationship, ALARP region)

7.2 LOPA Components and Evaluation

• Initiating event frequency including (equipment failure rates, human error probability, external event frequency, industry databases OREDA)

• Consequence severity including (fatality, major injury, community impact, environmental damage, asset loss, categorization)

• Independent Protection Layer (IPL) including (effectiveness, independence, reliability, specificity, auditable, management systems)

• IPL credit values including (Basic Process Control System BPCS 10x, alarms 10x, SIS 10x-1000x, relief devices 10x-100x, physical protection)

7.3 LOPA Application and SIS Requirements

• Mitigated event frequency calculation including (initiating frequency x enabling x IPL probability of failure on demand)

• Risk gap identification including (mitigated frequency versus tolerable risk, additional risk reduction needed, SIS allocation)

• Safety Integrity Level (SIL) determination per IEC 61511 including (SIL 1, SIL 2, SIL 3, risk reduction factor, PFD requirements)

• LOPA limitations including (single scenario, independence assumptions, common cause, human factors, low frequency events)

8. Bow-Tie Analysis and Barrier Management

• Bow-Tie methodology including (hazard, top event, threats, consequences, preventive barriers, mitigative barriers, visual representation)

• Hazard identification including (energetic material, pressure, toxicity, flammability, gravity, kinetic energy)

• Top event definition including (loss of containment, fire, explosion, toxic release, runaway reaction)

• Threat analysis including (pathways to top event, equipment failure, human error, external events, degradation)

• Preventive barriers including (elimination, substitution, engineering controls, administrative controls, detection and intervention)

• Mitigative barriers including (passive protection, active protection, emergency response, evacuation, medical treatment)

• Barrier performance standards including (availability, reliability, effectiveness, independence, survivability, auditability)

• Degradation factors and controls including (escalation factors, conditions reducing effectiveness, management systems maintaining barriers)

9. Risk Assessment and Safeguard Evaluation

9.1 Consequence Analysis

• Consequence modeling including (release scenarios, dispersion modeling, fire modeling, explosion overpressure, toxic exposure)

• Severity categories including (fatality, permanent disability, temporary disability, first aid, near miss, asset damage levels)

• Impact zones including (affected personnel, public exposure, environmental receptors, property damage radius)

• Worst-case versus alternative scenarios per EPA RMP including (maximum release, typical meteorology, passive versus active mitigation)

9.2 Likelihood Assessment

• Frequency categories including (frequent, probable, occasional, remote, improbable, numerical ranges)

• Failure rate data sources including (equipment databases OREDA, IEEE, industry experience, manufacturer data, plant-specific)

• Human error probability including (human reliability analysis, performance shaping factors, error rates THERP, HEART)

• Common cause failure including (shared equipment, common utilities, external events, dependent failures, beta factor)

9.3 Risk Matrix and Decision-Making

• Risk matrix structure including (likelihood axis, consequence axis, risk levels high/medium/low, color coding)

• Risk tolerability including (unacceptable region, ALARP As Low As Reasonably Practicable, broadly acceptable, risk criteria)

• Safeguard hierarchy including (inherently safer design, passive safeguards, active safeguards, procedural safeguards)

• Cost-benefit considerations including (risk reduction versus cost, gross disproportion, reasonable practicability, optimization)

10. PHA Documentation and Recommendation Management

10.1 PHA Report Preparation

• Report components per OSHA 1910.119(e)(4) including (hazards identified, team, methodology, findings, recommendations, dated)

• Executive summary including (scope, methodology, key findings, high-priority recommendations, risk profile, completion status)

• Detailed findings including (node/scenario descriptions, deviations/questions, consequences, safeguards, risk assessment, recommendations)

• Supporting information including (P&IDs marked up, team roster, meeting schedule, reference documents, data sources)

10.2 Recommendation Tracking and Resolution

• Recommendation prioritization including (risk-based ranking, safety-critical items, compliance-driven, resource requirements, timeline)

• Action item assignment including (responsibility, description, completion date, resources, interim measures if needed)

• Tracking system including (database, status updates, aging reports, escalation triggers, completion verification)

• Resolution verification including (implementation confirmation, effectiveness evaluation, documentation, sign-off, PHA update)

10.3 PHA Revalidation and Updates

• Revalidation requirements per OSHA including (at least every 5 years, document update, certify timeliness, resolve recommendations)

• Update triggers including (major modifications, incidents, near-misses, process changes, regulatory changes, technology advances)

• Management of Change (MOC) integration per 1910.119(l) including (PHA review prior to change, hazard evaluation, safeguard verification)

• Continuous improvement including (lessons learned integration, methodology refinement, team skill development, process safety culture)

11. PHA Team Participation and Facilitation

11.1 Effective Team Participation

• Team member roles including (process engineer, operations, maintenance, safety professional, facilitator/scribe, technical specialists)

• Active participation including (question asking, idea sharing, challenge assumptions, diverse perspectives, constructive dialogue)

• Team dynamics including (psychological safety, equal participation, time management, staying focused, parking lot use)

• Technical contribution including (process knowledge, operating experience, maintenance insights, engineering expertise, regulatory awareness)

11.2 PHA Facilitation Skills

• Facilitator responsibilities including (methodology application, team guidance, time management, conflict resolution, documentation quality)

• Study preparation including (scope definition, information gathering, P&ID review, team briefing, logistics arrangement)

• Session management including (agenda adherence, participation balance, technical discussion guidance, decision-making support, breaks)

• Documentation oversight including (real-time recording, accuracy verification, action clarity, worksheet completeness, report quality)

11.3 Common PHA Challenges

• Scope creep including (boundary control, parking lot use, future study identification, realistic completion targets)

• Team fatigue including (session duration 4-6 hours maximum, breaks every 90 minutes, multi-day pacing, mental energy)

• Groupthink and bias including (challenge conventional wisdom, devil's advocate, fresh perspectives, independent thinking)

• Resource constraints including (team availability, information completeness, budget limitations, schedule pressures, prioritization)