By the end of the training, participants will be able to:

• Recognize the role of HAZOP & LOPA in lifecycle risk management.
• Apply advanced HAZOP methodology on complex processes and systems.
• Identify deviations, hazards, causes, and consequences with improved rigor.
• Evaluate independent protection layers (IPLs) and their performance.
• Perform detailed LOPA calculations and risk rankings.
• Integrate HAZOP and LOPA into SIL determination and process safety programs.
• Use best practices for documentation, facilitation, and follow-up actions.
• Avoid common pitfalls and improve study quality and consistency.

• Professionals working in chemical, petrochemical, oil & gas, pharmaceutical and other process industries.
• In addition this course is suitable for professional development programs in process plants, engineering companies, and safety organizations

Day 1 – Foundations & Advanced HAZOP Concepts

Module 1: Introduction to Process Safety & Risk Analysis

• Risk management hierarchy in process plants
• Relationship between HAZOP, LOPA, QRA, SIL, and PHA
• Regulatory & industry standards (OSHA PSM, CCPS, IEC 61511)

Module 2: HAZOP Methodology – Deep Dive

• HAZID vs HAZOP vs What-If vs FMEA
• Key components: nodes, deviations, parameters, causes, consequences
• Guide words and advanced interpretation
• Identifying high-quality causes and consequences

Module 3: Preparing for an Effective HAZOP

• Data collection & documentation requirements
• Defining nodes and boundaries
• Managing complex process systems
• Team composition & leadership roles

Practical Session

• Reviewing P&IDs / PFDs for HHA (Harmful Hazard Analysis)
• Node selection workshop

 Day 2 – Advanced HAZOP Execution & Facilitation

Module 4: Facilitating an Effective HAZOP

• Leadership techniques for HAZOP facilitators
• Managing team dynamics and avoiding bias
• Best-practice recording & documentation
• Common mistakes in HAZOP and how to avoid them

Module 5: Advanced HAZOP Studies

• Use of conditional modifiers
• Human factors considerations
• Integrating alarms and operator responses
• Techniques for high-hazard operations & batch processes

Practical Session

• Full HAZOP case study (multidisciplinary team exercise)
• Live facilitation and documentation practice

Day 3 – Introduction to LOPA & Linking with HAZOP

Module 6: LOPA Fundamentals

• When and why LOPA is used
• Relationship between HAZOP and LOPA
• Risk tolerance criteria (company-specific, CCPS)
• Frequency and consequence modelling basics

Module 7: Independent Protection Layers (IPLs)

• Definition, criteria, and performance
• IPL dependencies and failure modes
• Typical IPLs (relief systems, SIS, alarms, procedures, interlocks)
• PFDavg (Probability of Failure on Demand) fundamentals

 Module 8: Triggering LOPA from HAZOP

• Determining HAZOP scenarios that require LOPA
• Selecting initiating events
• Data sources (generic failure rates, historic data, industry databases)

Practical Session

• Converting HAZOP scenarios into LOPA candidates
• Initiating event frequency assignment workshop

 Day 4 – Advanced LOPA Calculations & SIL Determination

Module 9: Quantitative LOPA Analysis

• Calculating risk reduction factors (RRFs)
• PFD values for IPLs and safeguards
• Consequence severity mapping
• Accounting for uncertainty & conditional modifiers

Module 10: SIL Determination & SIS Lifecycles

• Understanding Safety Integrity Levels (SIL 1–3)
• Linking LOPA to IEC 61511 lifecycle
• Combining LOPA with SIL allocation and verification
• Instrumented safety functions (SIFs)

Module 11: Risk Decision-Making & Recommendations

• Interpreting LOPA results
• ALARP principles and cost-benefit considerations
• Developing actionable recommendations

Practical Session

• Full LOPA calculation exercise
• SIL determination scenario

 Day 5 – Integrated Case Studies, Review, and Best Practices

Module 12: Combined HAZOP–LOPA Workshop

• End-to-end case study (process plant system)
• Identify deviations → run HAZOP → trigger LOPA → calculate risk → derive SIL
• Documenting findings & recommendations

 Module 13: Software Tools & Digital HAZOP/LOPA

• Overview of common software (PHA-Pro, PHAWorks, BowTieXP, exSILentia)
• Best practices for digital documentation

Module 14: Enhancing Study Quality & Organizational Learning

• Quality assurance & peer review
• Managing large studies across multi-unit plants
• Tracking recommendations & action closure
• Continuous improvement using previous HAZOP/LOPA data

Module 15: Course Review & Assessment

• Final assessment (written + practical)
• Summary of lessons learned
• Certificates and closing session

CDGA attendance certificate will be issued to all attendees completing a minimum of 80% of the total course duration