Custom Courses Health, Safety and Environment (HSE)

Introduction to HAZOP Training

SAQA US AATICD-0052 | NQF 5 | Credits 10 | Duration 5 Days
From $913 per delegate

Description

This course provides a comprehensive introduction to Hazard and Operability (HAZOP) studies, a systematic methodology for identifying and evaluating potential hazards and operability issues in industrial processes. Participants will learn the principles, techniques, and application of HAZOP, enabling them to contribute effectively to process safety management and risk assessment.

Learning Outcomes

  • Apply the HAZOP methodology to systematically identify hazards and operability problems in a process.
  • Analyze process diagrams and operating procedures to determine deviations from design intent.
  • Evaluate the consequences and likelihood of identified hazards using qualitative risk assessment techniques.
  • Design effective recommendations to mitigate identified risks and improve process safety.
  • Implement HAZOP study findings into safety management systems and operational procedures.
  • Demonstrate effective teamwork and communication skills during HAZOP review sessions.

Target Audience

This course is designed for engineers, safety professionals, operations and maintenance personnel, and anyone involved in process design, operation, or management who needs to understand and apply HAZOP techniques.

Prerequisites

None — open enrollment

Course Outline

Day 1: Introduction to HAZOP and Process Safety

Objectives:
• Understand the purpose and importance of HAZOP in process safety.
• Identify the historical incidents that led to the development of HAZOP.
• Define key terms and concepts used in HAZOP.
• Recognize the role of HAZOP in risk management and regulatory compliance.

Topics:
• Overview of process safety and major accident hazards.
• History and evolution of HAZOP.
• Definitions: hazard, risk, consequence, likelihood, and risk matrix.
• Introduction to risk assessment methodologies (qualitative vs. quantitative).
• Regulatory framework: OHSA, Major Hazard Installation regulations, and international standards (IEC 61882).
• HAZOP as a team-based, systematic approach.
• Overview of the HAZOP process: preparation, examination, documentation, and follow-up.

Day 2: HAZOP Methodology and Team Dynamics

Objectives:
• Describe the HAZOP methodology step-by-step.
• Explain the use of guide words and parameters in identifying deviations.
• Understand the roles and responsibilities of HAZOP team members.
• Develop effective questioning and brainstorming techniques for HAZOP sessions.

Topics:
• Detailed steps of a HAZOP study: defining scope, selecting nodes, and using P&IDs.
• Guide words (NO, MORE, LESS, REVERSE, etc.) and process parameters (flow, pressure, temperature, etc.).
• Generating deviations and identifying credible causes.
• Evaluating consequences and existing safeguards.
• Risk ranking and decision-making.
• Team composition: leader, scribe, and discipline experts.
• Facilitation skills and managing group dynamics.
• Common pitfalls and how to avoid them.

Day 3: Conducting a HAZOP – Preparation and Execution

Objectives:
• Prepare a HAZOP study plan, including defining scope and selecting nodes.
• Use P&IDs and process descriptions to identify relevant nodes.
• Conduct a HAZOP session using guide words and parameters.
• Document findings accurately and completely.

Topics:
• Pre-HAZOP activities: gathering documentation, defining scope, and selecting team.
• Node selection and identification of design intent.
• Applying guide words systematically to each node.
• Recording deviations, causes, consequences, and safeguards.
• Using risk matrices for ranking.
• Handling complex scenarios: multiple deviations, human factors, and emergency operations.
• Documentation standards and report generation.
• Practical exercise: Conducting a HAZOP on a simple process.

Day 4: Advanced HAZOP Techniques and Integration with Other Studies

Objectives:
• Apply advanced HAZOP techniques for complex systems.
• Integrate HAZOP with other risk assessment methods (e.g., LOPA, QRA).
• Address human factors and operational procedures in HAZOP.
• Understand the use of software tools for HAZOP documentation.

Topics:
• Advanced guide words and deviations (e.g., 'other than', 'early', 'late').
• HAZOP for batch processes, procedures, and computer-controlled systems.
• Layer of Protection Analysis (LOPA) and its relationship to HAZOP.
• Incorporating human factors and ergonomics.
• HAZOP in the context of management of change (MOC).
• Software tools for HAZOP: features and benefits.
• Case studies: HAZOP of a chemical reactor, a pipeline, and a storage facility.
• Best practices for documenting recommendations and follow-up.

Day 5: HAZOP in Practice – Case Studies, Reporting, and Continuous Improvement

Objectives:
• Analyze real-world HAZOP case studies to identify lessons learned.
• Prepare a comprehensive HAZOP report and action plan.
• Understand the importance of follow-up and verification of recommendations.
• Apply continuous improvement principles to HAZOP processes.

Topics:
• Review of real incident investigations that highlight HAZOP failures.
• Case studies: HAZOP applied to a refinery unit, a pharmaceutical plant, and a water treatment facility.
• Writing effective recommendations and assigning actions.
• Management of change and revalidation of HAZOP studies.
• Auditing HAZOP quality and effectiveness.
• Integrating HAZOP into the overall safety management system.
• Final group exercise: Presenting a HAZOP report.
• Course review and assessment.

Practicals

16 hours of practicals To be conducted online or on-campus or in-house
Overview

The practicals provide hands-on experience in conducting HAZOP studies, from preparation to documentation. Learners will work in teams to perform HAZOP on realistic process scenarios, applying guide words and parameters, and producing reports. This reinforces the theoretical knowledge and develops facilitation and teamwork skills.

Practical Activities
  • Practical 1: HAZOP Preparation and Node Selection — Learners are given a P&ID of a simple process (e.g., a heat exchanger system) and must identify nodes, define design intent, and prepare a HAZOP worksheet. (4h)
  • Practical 2: Conducting a HAZOP Session — In teams, learners conduct a HAZOP on a selected node using guide words and parameters. They will brainstorm deviations, causes, consequences, and safeguards, and record findings. (6h)
  • Practical 3: Risk Ranking and Report Writing — Teams use a risk matrix to rank findings from the HAZOP session, then produce a HAZOP report with recommendations and action items. (4h)
  • Practical 4: Advanced HAZOP Scenario (Batch Process) — Learners apply advanced HAZOP techniques to a batch reactor process, including procedural deviations and human factors. (2h)

Summatives

Each delegate is assessed continuously throughout the course via daily exercises, scored practical assignments, and a final summative test at the end.

Practical Assignments — 30%

Practical assignments are observed and scored against a rubric during the practical sessions. Each delegate's practical mark is averaged into a single 100% score and contributes 30% to the final total.

Daily Exercises — 20%

Every training day ends with a multiple-choice exercise scored out of 100%. The scores from each daily exercise are averaged across the duration of the course to produce a Daily Average mark, which contributes 20% to the final total.

Final Test — 50%

On the last day a final summative test is written. It is a multiple-choice paper with multiple-answer questions: each question may have more than one correct option, and a single wrong selection on a question marks the entire question wrong — no partial credit. The final test is scored out of 100% and contributes 50% to the overall mark.

Final Total
Component Out of Weight
Practical Assignments (rubric-scored) 100% 30%
Daily Average (multiple choice) 100% 20%
Final Test (multi-answer multiple choice) 100% 50%
Final Total 100%

All marks are recorded on the AATICD LMS and visible to each learner under their account.

Certificate

Certificate of Completion

Awarded to delegates who achieve an overall mark of 50% or higher on the Final Total (Practicals 30% + Daily Average 20% + Final Test 50%).

How it works
  • Certificates are auto-generated on the AATICD LMS as soon as the marks pass the 50% threshold.
  • Each certificate is a branded PDF with the delegate's name, the course title, the unit standard ID, NQF level, credits, and the date of issue.
  • You can download or print your certificate from your LMS dashboard at any time after issue — there's no reissue fee and no expiry date.
  • If you scored under 50% you can sit the final test again at the next scheduled session at no extra cost.
Where to find it

Sign in to the LMS, open your dashboard, and your certificates appear under My Certificates. Each entry has a View / Download button and a print option.

Training Discounts

Group discounts apply automatically — the more delegates you enrol, the greater the saving. Discounts are calculated at 3% per 5 delegates, scaling up to 40% off for 100+ delegates.

Delegates Discount
5 3% off
10 6% off
15 9% off
20 12% off
25 15% off
30 18% off
50 30% off
75 40% off
100 40% off

3% discount per 5 delegates, up to 40% off for 100+ delegates. Contact us for a custom group quote.

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Training Discounts
Delegates Discount
5 3% off
10 6% off
15 9% off
20 12% off
25 15% off
30 18% off
50 30% off
75 40% off
100 40% off

3% off per 5 delegates, up to 40% for 100+

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