Course Overview
This 2-day training program provides an in-depth understanding of hazard identification techniques across industries, focusing on process safety risk management.

Course Objectives
By the end of this course, participants will:
• Understand the importance of hazard identification in risk prevention.
• Learn key hazard identification techniques and when to apply them.
• Be able to select the appropriate technique based on the project lifecycle.
• Gain insight into new and emerging hazard identification approaches.

Course Content

Module 1: Fundamentals of Process Hazards and Risks
• Introduction to process hazard identification
• Key definitions: hazards, risks, and safety barriers
• Learning from historical industrial disasters
• Case Studies: Buncefield & CAPECO accidents
• Regulatory frameworks and industry standards

Module 2: Essential Hazard Identification Techniques
• What-If Analysis (SWIFT): Scenario-based risk assessment
• Checklists: Systematic hazard identification
• Brainstorming Techniques: Group-based risk evaluation
• Strengths, weaknesses, and applications of each technique

Module 3: Inherently Safer Design (ISD) & Risk Elimination
• Introduction to ISD principles
• Design modifications to eliminate or reduce hazards
• Case Study: CSB/Bayer plant explosion analysis
• Bow-Tie Diagrams: Visualizing risk pathways and control measures

Module 4: Chemical Reaction Hazards & Runaway Reactions
• Understanding runaway reactions and their causes
• Strategies for preventing and managing chemical hazards
• Case Study: CSB Synthron explosion video analysis

Module 5: Advanced Hazard Identification (HAZID) Techniques
• Introduction to HAZID methodology
• Reaction Exercise: Identifying risks in a simulated process

Module 6: Hazard and Operability Study (HAZOP)
• HAZOP methodology: Systematic deviation analysis
• Managing creeping changes in operations
• Delta HAZOP: Identifying risks from small process modifications

Module 7: Batch Process HAZOP & Its Unique Challenges
• Key differences between batch and continuous processes
• Case Study: CSB T2 Laboratories explosion analysis
• Hands-on HAZOP workshop: Group exercise

Module 8: Failure Modes, Effects, and Criticality Analysis (FMECA)
• Understanding FMECA methodology
• Case Study: Challenger disaster – Lessons from failure analysis
• System-Theoretic Process Analysis (STAMP/STPA) techniques

Module 9: Layers of Protection Analysis (LOPA)
• Understanding safety layers and barriers
• Integrating LOPA with other hazard assessment techniques
• Case Study Demonstration