Process Hazard Analysis (PHA) Leader Training Using the HAZOP, FMEA, What-if, and Checklist Techniques (Course 8)

Recommended prerequisites: Students should have attended Course 1 or Course 2 unless student has equivalent experience. Course graduates will be capable of organizing, leading, and documenting PHAs of processes or for changes to processes (MOC risk review). Only those who will be leading and/or scribing PHAs or administering the PHA (risk review) program should attend. Courses 9, 10, and 11 are highly recommended after this course.

The risk review techniques most popular for initial PHAs of entire units or of large projects, MOC reviews, and PHA revalidations are hazard and operability (HAZOP) analysis and what-if/checklist. Both of these techniques facilitate systematic, imaginative searches for process hazards and potential operational difficulties. In this course, you will also learn how to use the failure mode and effects analysis (FMEA) method and you will learn how to use checklists of hazards to supplement your brainstorming analyses. You will learn the best situations and circumstances to use each technique. You will lead and participate in several analyses to familiarize yourself with each technique.

One complete course-day focuses on human factors issues and how to analyze for human errors that can occur in step-by-step procedures; this is the most important part of any risk review. You will learn the original form of the HAZOP and what-if/checklist techniques so you can effectively analyze procedures (startup, shutdown, normal batch operation, emergency operation, etc.) for the hazards of not performing a step as specified.

This course has a 15:1 or lower student-to-instructor ratio for necessary coaching needed during the many workshops.

This course is taught by expert PHA leaders who, collectively, have been and currently are involved in hundreds of PHAs.

Typical Course Candidates

Process engineer or project engineer
Operations supervisor
PSM coordinator
E, H, & S Managers & Engineers

What You Will Learn

How to perform a PHA to meet PSM requirements for initial PHAs and management of change analyses including these critical elements:
- Preparing for the PHA
- Scoping the PHA
- Collecting information
- Selecting the team
- Leading a meeting
- Documenting results
How to analyze operating procedures for critical accident scenarios
How and when to apply HAZOP, FMEA, and/or what-if/checklist analyses methods to any process system in any industry such as chemical, petroleum, pulp and paper, explosives, mining, iron and steel, pharmaceuticals, and consumer products
Experience via realistic workshops

Take Home:

A CD containing a copy of hazard evaluation software and manual (license not included; demo works for 15 days; a license can be obtained from separately)
Blank PHA analysis forms, generic PHA report, and a spreadsheet for estimating the labor and time requirements for doing a PHA
Electronic (PDF) copy of course notebook
A copy of the course notes and problem solutions
A Certificate of Completion
2.7/3.1 CEUs and 2.7/3.1 COCs

Course Outline

Day 1 (8:00 a.m. to 5:00 p.m.)

Introduction
- Learning objectives
- Overview of process safety management
- Risk assessment concepts
- Overview of PHA requirements
Overview of risk review methods
- Methods and their usefulness over the life cycle of a process
- Making risk judgments
- Human factors concepts and how to address human factors during hazard
evaluations
Preparing for the hazard evaluation (risk review or PHA)
- Scoping the analysis
- Choosing technique and level of detail and sections
- Choosing the team members
- Logistics and procedures for pre-meeting, meeting, and post-meeting tasks
What-if/checklist technique
- Workshop: Example What-if (instructor-led)
- Workshop: What-if/checklist review of a continuous process

Day 2 (8:00 a.m. to 5:00 p.m.)

HAZOP technique
- Workshop: Example HAZOP (instructor-led)
- Workshop: HAZOP review of a continuous process
Analysis documentation, results, and follow-up
- Workshop: HAZOP review of a continuous process (continued)

Day 3 (8:00 a.m. to 5:00 p.m.)

- Workshop: HAZOP review of a continuous process
(continued)

HAZOP/what-if techniques for analyzing procedures and batch processes
- Workshop: Example HAZOP of a procedure (instructor-led)
- Workshop: HAZOP/what-if reviews of batch processes and
procedures

Day 4 (8:00 a.m. to 5:00 p.m.)

Workshop: HAZOP/what-if reviews of batch processes and procedures (continued)
Failure Mode Effect Analysis (FMEA)
- Workshop: FMEA of a critical auxiliary system
Checklist analysis as supplements to brainstorming methods
- Workshop: Using Checklists after brainstorming methods
Workshop: Estimating the schedule and labor required to perform a PHA
Certification exam (optional)

Day 5 (8:00 a.m. to 2:00 p.m.)
(optional Software Training – Does NOT include a license to the software; the license must be purchased separately)

Hazard Evaluation Software - functions and features
Workshop: Using software to prepare for and document hazard evaluations/risk reviews

More Information

Instructor(s):

Bill Bridges is a primary instructor for this course. He has trained more than 3000 PHA (HAZOP/What-if) leaders over the past 16 years of teaching this topic. And he has led over 100 unit-wide PHAs. He co-authored the definitive textbook on this topic by AIChE, Guidelines for Hazard Evaluation Procedures, 2nd edition, 1991. To find our more about this course or to check into having this course taught at your site; contact Mr. Bridges at 1.865.675.3458 or by e-mail at wbridges@p-i-i-i.com.

Revonda Tew is a primary instructor for this course. She has many years of PSM implementation experience, led many PHAs, and has PHA teaching and coaching experience. Feel free to contact Mrs. Tew at rtew@p-i-i-i.com.

Jeff Woody is a co-instructor for this course. He has many years of PSM and safety implementation experience, led and participated in many hazard evaluations in DOE settings (Design Safety Analysis [DSA], PDSA, etc.), and has PHA teaching and coaching experience.

Schedule:

>> See the Calendar of Publicly Offered Training.

This course can also be taught (either as-is or customized) at your site. Please contact PII for details about having our training provided at your site.

Pricing for Public Offerings (per student):

$1,695.00 USD for 4-day version, in USA
$1,995.00 USD for 5-day version, in USA

$2995.00 USD for 5-day version, in Dubai, UAE

Registration Information:

>> Click here to register for this course.