Process Hazard Analysis (HAZOP/PHA) – Awareness
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At Burraq Consulting, our “Process Hazard Analysis (HAZOP/PHA) – Awareness” training course provides an in-depth understanding of the tools, methods, and responsibilities related to hazard identification and operability studies in high-risk industries. Whether you are an operator, engineer, supervisor, or HSE professional, this course equips you with the foundational knowledge to participate in or support HAZOP and PHA processes.
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Course Overview
Industrial accidents have caused some of the most devastating human and environmental losses in history. From Bhopal to Texas City, one theme remains common: failure in identifying and mitigating process hazards.
To prevent such failures from recurring, Process Hazard Analysis (PHA)—particularly the HAZOP (Hazard and Operability Study) method—is a globally recognized framework for identifying, assessing, and controlling process-related risks.
At Burraq Consulting, our “Process Hazard Analysis (HAZOP/PHA) – Awareness” training course offers an in-depth understanding of the tools, methods, and responsibilities associated with hazard identification and operability studies in high-risk industries. Whether you are an operator, engineer, supervisor, or HSE professional, this course equips you with the foundational knowledge to participate in or support HAZOP and PHA processes.
What is Process Hazard Analysis (PHA)?
Process Hazard Analysis (PHA) is a structured approach used to identify potential hazards associated with industrial processes involving chemicals, high energy, or pressure. PHA ensures that all possible risks are evaluated to protect people, assets, the environment, and business continuity.
What is HAZOP?
A Hazard and Operability Study (HAZOP) is a systematic method for examining a process or operation to identify deviations from design intent that may lead to hazards or operational issues. It is one of the most widely used PHA methods, particularly in chemical, oil & gas, and manufacturing industries.
Who Should Attend?
This training is ideal for:
- Engineers (Process, Mechanical, Instrumentation, Electrical)
- HSE Professionals and Safety Officers
- Plant Managers and Supervisors
- Chemical Operators and Technicians
- QA/QC Inspectors
- Project Engineers and Designers
- Risk Analysts and Internal Auditors
- Industrial Maintenance Teams
Understand Process Safety to Prevent Industrial Catastrophes
Whether you're looking to train 1 individual or 100, Burraq Consulting will provide a professional, structured, and rewarding training experience.
Get a Quote0304 5144 000Detailed Course Content: Module-Wise Breakdown
Module 1: Introduction to Process Safety
- What is process safety and why it matters?
- Historical accidents and lessons learned (Bhopal, BP Texas, Flixborough)
- Difference between occupational and process safety
- Role of engineering controls, procedures, and behavior
- The lifecycle of process safety management
Module 2: What is Process Hazard Analysis (PHA)?
- Definitions and objectives of PHA
- Key stages: Identification, Analysis, Evaluation, Control
- Regulatory standards: OSHA 1910.119, API RP 750, ISO 31000
- When is PHA required? Design, operation, change management
- Stakeholders involved in the PHA process
Module 3: Overview of PHA Techniques
- HAZOP (Hazard and Operability Study)
- What-If Analysis
- Checklist Analysis
- Failure Mode and Effects Analysis (FMEA)
- Fault Tree Analysis (FTA)
- Layers of Protection Analysis (LOPA)
- Bowtie Analysis
Each method is briefly explained with use-cases.
Module 4: Introduction to HAZOP (Hazard and Operability Study)
- Origins and evolution of HAZOP
- Applicability to continuous and batch processes
- The concept of “design intent” and deviation
- Guidewords and parameters: Flow, Pressure, Temperature, Level, etc.
- Process nodes and how they are selected
Module 5: HAZOP Terminology and Guidewords
- Common guidewords: No, More, Less, As Well As, Reverse, Other Than
- Parameters: Flow, Pressure, Temperature, Composition, Level
- Combining guidewords + parameters to identify deviations
- Examples: “No Flow,” “High Pressure,” “Reverse Flow,” etc.
- Consequences and causes of deviations
Module 6: HAZOP Team Structure and Roles
- HAZOP Leader / Facilitator
- Scribe / Secretary
- Process Engineers
- Operators and Maintenance Staff
- Instrumentation and Control Experts
- Safety Officers and HSE representatives
- External consultants and designers (if required)
Module 7: Conducting a HAZOP Session
- Pre-study preparations: P&ID, PFD, SOPs, Process Description
- Node selection and team briefing
- Applying guidewords systematically
- Recording deviations, causes, consequences, safeguards, and actions
- Maintaining neutrality and encouraging participation
- Managing conflicts or disagreements
- Post-session review and report writing
Module 8: Risk Assessment and Recommendations
- Risk Matrix: Severity vs. Likelihood
- Prioritizing hazards based on risk score
- Types of recommendations: design, procedural, administrative
- Risk control hierarchy: Elimination to PPE
- Assigning responsibility and tracking implementation
Module 9: Documentation & Regulatory Compliance
- HAZOP worksheets and templates
- Action tracking and closure
- Audit and review cycles
- Integration with MOC (Management of Change)
- Compliance with OSHA PSM, SEVESO, NEPRA/OGRA safety rules
- Regulatory inspections and enforcement actions
Module 10: Challenges and Limitations of HAZOP
- Time-consuming and resource-intensive
- Dependence on experience of team
- May overlook external or non-process hazards
- Misinterpretation or poor documentation
- Need for periodic revalidation
Learning Outcomes
After completing the course, participants will:
✅ Understand the foundational purpose and scope of PHA and HAZOP
✅ Recognize hazards and operability risks in chemical/process operations
✅ Learn to use guidewords to identify process deviations
✅ Be capable of participating meaningfully in HAZOP studies
✅ Contribute to safer designs, procedures, and operations
✅ Support internal compliance and third-party audits
Training Methodology
We use engaging and effective adult learning techniques including:
- Real-life incident analysis and video case studies
- Interactive group discussions
- Hazard brainstorming exercises
- Walkthrough of sample HAZOP sessions
- Team-based activities and risk scoring
- Post-session quiz and knowledge check
Benefits to Your Organization
- Enhanced operational safety and reliability
- Improved compliance with local and international laws
- Early identification of failure scenarios
- Reduction in incidents, downtime, and emergency events
- Better design reviews and change management
- Development of safety-conscious work culture
Industries That Must Use HAZOP/PHA
This course is especially relevant for:
- Oil & Gas (Upstream, Midstream, Downstream)
- Fertilizer and Chemical Manufacturing Plants
- Pharmaceutical Manufacturing
- Food & Beverage Processing Units
- Petrochemical and Power Plants
- Water Treatment & Utilities
- Paint, Pesticide, Cement and Explosives Industry
Course Duration
- 1 Day (8 Hours)
- Awareness Level
- No prerequisite knowledge required
- Certificate of Participation issued by Burraq Consulting
Post-Training Resources
Participants will receive:
- Course handouts and HAZOP worksheet templates
- HAZOP checklist for preliminary use
- Risk matrix examples
- Sample HAZOP report
- Participation certificate from Burraq Consulting
Why Choose Burraq Consulting?
With deep expertise in process safety and industrial training, Burraq Consulting has become a trusted partner for Pakistani industries in high-risk sectors. Our trainers have decades of experience working with local and international standards and ensure that every session is practical, industry-relevant, and engaging.
We offer:
✅ Real-world examples from Pakistani industry
✅ Bilingual delivery in Urdu and English
✅ In-house customized training
✅ Post-training support for safety teams
✅ Templates, tools, and expert advisory
At Burraq Consulting, we believe safety is more than compliance—it’s a mindset. Our safety training programs are:
✅ Delivered by experienced health & safety professionals
✅ Aligned with local and international best practices
✅ Customizable to your company’s operations and risks
✅ Affordable and highly engaging
✅ Trusted by companies across Pakistan for over a decade
Training Options
- 📍 Available Nationwide – Lahore | Karachi | Islamabad | Faisalabad | Multan
- 🖥️ Virtual Classrooms – For remote teams or home learners
- 🏭 Customized On-Site Sessions – Based on your equipment & procedures
- 💼 Corporate Packages Available – For 10+ participants