HAZOP Technique and HAZOP Team Leader - 5 Days

Course Outline:

Day 1 (HAZOP Technique)

09:00  1.1 Welcome & Introduction                                                       

• Delegates self-introduction
• Course outline
• Workshop arrangements
• Remembering Trevor Kletz (video)

09:30  1.2 Introduction to Process Safety

• Historical incidents
• Causes of accidents
• Occupational safety vs. process safety

10:00  1.3 HAZOP Essentials

• Deviations, parameters and guidewords
• Simple exercise to identify flow deviations
• Introduction to causes and consequences

10:40  15 mins Break

10:55  Exercise 1:Domestic shower

Individual working to introduce different parameters (flow, temperature and pressure)

11:20  1.4 HAZOP Methodology

• Examples of process deviations
• Different operating modes
• Identifying causes, consequences, safeguards
• Double jeopardy and common mode failure

12:15  1.5 Recording and Reporting

Clarity of wording, numbering system, cross-referencing actions

12:30  Lunch

13:30  Exercise 2:Process HAZOP – Gasoline Storage Tank (tutored)

Tutored exercise to show the methodical approach to finding deviations

14:25  Exercise 3:Process HAZOP – Transfer pipeline

Using flow guidewords and illustrating how the HAZOP findings are recorded.

15:25  15 minsBreak

15:40  1.6 Node Selection

Examples which show the application of noding guidance in practice

16:00  Exercise 4: Node selection example

Individual working to mark up a P&ID with node boundaries

16:40  Kahoot Quiz

16:50  Day 1 learned outcomes

Day 2 (HAZOP Technique)

09:00  Exercise 5: Process HAZOP – Fuel gas heater

Group working to use all the main process parameters

10:30  15 mins Break

10:45  Exercise 6: Procedure HAZOP – Draining reactor feed vessel

Group working on how to manage HAZOP with incomplete operating procedure

11:30  2.1 Types of HAZOP

• Sequence of HAZOP studies in a project
• Batch HAZOP
• Procedure HAZOP

12:30  Lunch

13:30  Exercise 7: Hot Water Boiler

Group working on a procedure HAZOP for starting a boiler.

14:30  2.2 Roles of HAZOP Participants

• Facilitator
• Secretary
• Operations Representative
• Process Design Engineer
• Independent Engineer
• Instrument and Control Engineer

15:00  15 mins Break

• 15:15 3 Other Hazard Identification TechniquesHazard Identification (HAZID)
• Simultaneous Operations (SIMOPS)
• BowTie Analysis
• Failure Mode and Effects Analysis (FMEA)
• Layers of Protection Analysis (LOPA)

16:40  Day 2 learned outcomes

16:50  Kahoot Quiz

17:00   End of Day 2

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Preparation for Syndicate Exercise no. 8 – Glycol Regeneration Plant

Note:     Participants will be asked to read and understand the instructions for the ‘complex’ HAZOP syndicate exercise : allow approximately one hour.

 Day 3 (HAZOP Technique)

Introduction to Process HAZOP Syndicate Exercise

Delegates will undertake a HAZOP study of a more ‘complex’ process – gas dehydration and glycol regeneration. Trainer leads the first node for 20 minutes.

09:00  Process HAZOP Exercise – 1^stNode by tutor

09:30  Process HAZOP Exercise     1^stNode – in Groups

10:15  Feedback on 1^stNode

10:45  15 mins Break

11:00  Process HAZOP Exercise – 2^ndnode

12:15  Feedback on 2^ndNode

12:30  Lunch

13:30  Process HAZOP Exercise – 3^rdnode

15:00  Feedback on 3rd Node

15:15  15 mins Break

15:30  Process HAZOP Exercise – 4th node

16:45  Feedback on 4th Node

17:00  End of Day 3

 Day 4 (Team Leader)

09:00  Course Outline

09:15  4.1Risk Management

• Risk perception
• Key terminology
• Major accident hazard
• Risk management process
• Societal and individual risk
• Use of risk ranking
• Risk assessment methods
• ALARP principle
• Risk reduction and ‘hierarchy of controls’ (video)
• Inherent safety (video)

10:15  15 mins Break

10:30  Exercise 9: BP Texas City explosion

This videocase study illustrates failures of people, procedures and design.  Participants are invited to complete a questionnaire to identify the main causes and relevant safeguards which would have minimized the risk of explosion.

11:10  4.2Planning the Study

• Scope & Timing
• Working arrangements, estimating duration, venue
• Managing documentation
• Preparing Terms of Reference
• Team selection

12:00  4.3 Raising and Closing Actions

• Raising and resolving actions
• Action tracking
• HAZOP report format

12:30  Lunch

13:30  4.4 SIL & LOPA

• Layers of protection
• Safety integrity level (SIL)
• Mechanical protection
• Layers of protection analysis (LOPA)
  • LOPA case study : storage tank overfilling

14:20  4.5 Human Factors

• Types and causes of human error
• Human error probabilities
• Barriers to adopting human factors
• Ways to reduce human error
• How to incorporate HF into HAZOP studies
• Examples of HF application

14:50  Case Study: Road tanker offloading

Video,questionnaire and discussion

15:20  15 mins Break

15:35  4.6 Managing the Team

• Team leader’s role
• Authority of team leader
• Starting the meeting
• Team leader attributes

16:00  4.7 Meeting Leadership Skills

• Facilitation skills (video)
• Handling different personalities
• Desirable team behavior
• Success factors
• Avoiding pitfalls

16:40  Day 4 : learned outcomes

16:50  Kahoot quiz

17:00   Endof Day 4

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Day 5 (Team Leader)

09:00  5.1 Reliability of Protection Systems

• Reliability vs. availability
• Probability of failure on demand
• Redundancy and diversity
• Common mode failure
• Voting logic
• Failure data sources

09:40  5.2 Operability

• Causes of maloperation,
• Role of operator in HAZOP
• Maintenance hazards.
• Non-standard operations

10:00  5.3 Special Cases

• Interface HAZOP
• Managing post-HAZOP changes
• Management of Change (video)
• Re-validation HAZOP
• Delta HAZOP

10:30  15 mins Break

10:45  5.4 HAZOP Masterclass

The tutor’s career experience of leading HAZOP studies will be distilled into approx. 28 key lessons.

11:45  Exercise : HAZOP Leadership

Group members take turns to act as team leader in 40 minute sessions based on unused nodes from Exercise no. 8, with the tutor acting as the process engineer.  The tutor will observe and score their performance against set criteria advised in advance, such as

• Defining the node
• Capturing all relevant deviations
• Quality of recording
• Engagement of all team members
• Time management
• Control of discussion

12:30  Lunch

13:30  Exercise : HAZOP Leadership, continued

15:00  15 mins Break

15:15  Exercise  : HAZOP Leadership, continued

16:30  Day 5 : learned outcomes

16:40  Review of course content with reference to the Course Notes

16:55   Group photo

17:00  End of Day 5

Duration:5 Days

Cost:£1995 + Vat

HAZOP Team Leader Training Course