Process Safety & Incident Investigation
HAZOP Leadership & Advanced Process Analysis
An advanced HAZOP programme for mid-to-senior process safety and engineering professionals responsible for leading, participating in or overseeing complex hazard identification and risk assessment. Going beyond conventional guideword analysis, participants apply advanced methodologies for identifying process hazards, evaluating risk assumptions, challenging the adequacy of existing safeguards and verifying risk reduction measures — integrating HAZOP findings with broader Process Safety Management (PSM) frameworks and organisational governance.
Industry focus: Petrochemical & Manufacturing Plants
Who Should Attend
Designed for these roles
- Engineering Directors accountable for process safety performance
- Technical Authorities overseeing hazard identification and risk assessment
- Process Safety Managers leading HAZOP, PHA and safeguard reviews
- Plant Managers and Senior Process Engineers responsible for operational risk decisions
Delivery formats
- Customised in-house training at your plant or office
- Public classroom delivery, subject to schedule
- Live online delivery where suitable
- Recommended group size: 8–20 participants
Problems Solved
What this course fixes
HAZOP studies that become guideword recitals instead of genuine hazard challenge
Safeguards accepted at face value without verifying independence or effectiveness
Weak recommendations that cannot be tracked to closure or defended at governance level
Human and organisational factors on process safety left unexamined in the study room
HAZOP findings disconnected from the wider PSM framework and decision-making
Learning Outcomes
What participants can do after the programme
Outcomes are written as tasks, not topics — so managers can verify capability back at work.
- Lead and challenge HAZOP sessions using advanced analysis methodologies beyond basic guidewords
- Evaluate risk assumptions and challenge the adequacy and effectiveness of existing safeguards
- Assess the influence of human factors and organisational issues on process safety
- Develop high-quality recommendations and strengthen action tracking and management
- Integrate HAZOP findings with PSM frameworks and organisational governance
- Apply advanced hazard identification practice to real-world operational challenges using major industrial incident case studies
Course Outline
Detailed programme content
Day 1 — Advanced HAZOP Methodology & Safeguard Challenge
- Beyond conventional guideword analysis: advanced hazard identification methodologies
- Evaluating risk assumptions and testing safeguard adequacy, independence and effectiveness
- Verifying risk reduction measures and ALARP reasoning in the study room
- Human factors and organisational influences on process safety
- Case study: major industrial incident — tracing the safeguards that failed
Day 2 — Leadership, PSM Integration & Organisational Governance
- Leading the team: facilitation, challenge culture and managing dominant voices
- Developing high-quality recommendations that survive management review
- Action tracking, closure verification and HAZOP quality assurance
- Integrating HAZOP outputs with PSM frameworks, MOC and organisational governance
- Workshop: apply advanced analysis to a live operational scenario and defend the findings
Trainer Profile
Delivered by Sathish Kumar
Senior Trainer — Reliability, Maintenance & Rotating Equipment
19 years industry experience
Sathish builds maintenance strategies that survive contact with a real budget. His workshops use participants' own failure history, so teams leave with a revised task list rather than a certificate alone.
Real project exposure
- RCM implementation across critical pumps and compressors at a combined-cycle power plant
- Root cause failure analysis on repeat bearing failures in a boiler feed pump train
- Spare parts and criticality review for a palm oil refinery group
Certifications
- CMRP — Certified Maintenance & Reliability Professional
- Vibration Analyst Category III (ISO 18436-2)
- RCM2 Practitioner
Trainer allocation is confirmed in your proposal. Substitute trainers hold equivalent certification and sector experience.
Next Step
Run this programme for your team
We will confirm available dates, trainer, duration and HRD Corp claimable investment — and adjust the outline to your equipment and standards at no extra cost.
No obligation. Proposals include HRD Corp claim guidance.
Related Training
Programmes teams often pair with this
Tripod Beta Practitioner — Bronze Level: Developing Competent Investigators Through the Tripod Beta Methodology
A structured programme in the Tripod Beta methodology for incident investigation — building tripod trees, testing barriers, identifying preconditions and underlying causes, and producing recommendations that change the organisation rather than the individual.
View courseASME Section VIII Div. 1 — Pressure Vessel Design, Fabrication & Inspection
A three-day, calculation-driven programme covering ASME Section VIII Division 1 from material selection and shell thickness through nozzle reinforcement, welded joint categories, hydrotest and nameplate — using real vessel drawings and Malaysian DOSH practice.
View courseAPI 510 Pressure Vessel Inspection & Integrity Management
Inspection planning, corrosion rate calculation, remaining life and repair decisions for in-service pressure vessels, taught with real thickness survey data.
View courseNext Step