Course Overview

Process Hazard Analysis is the backbone of process safety in industrial and refining operations — but the formal methodology (HAZOP, What-If, checklist reviews) is usually written for engineers, and non-technical staff often sit through PHA sessions without really understanding what's being decided or why it matters to them. This course strips PHA down to its practical essentials for supervisors, coordinators, operators, project staff, and other non-engineering roles who need to participate in, support, or act on PHA findings — without needing an engineering degree to follow along.

Audience: Site supervisors, project coordinators, HSE staff, operations/maintenance personnel, and other non-engineering roles who interact with PHA studies, action items, or recommendations.


Learning Outcomes

By the end of this course, learners will be able to:

1. Explain what a Process Hazard Analysis is and why it's legally and operationally required in high-hazard facilities.
2. Identify the common PHA methodologies (HAZOP, What-If, Checklist, FMEA) at a conceptual level, without needing to lead one.
3. Recognize key PHA terminology (deviation, node, guide word, cause, consequence, safeguard, recommendation) well enough to follow a study.
4. Describe their own role and responsibilities before, during, and after a PHA — including as a team member, subject matter contributor, or action-item owner.
5. Interpret a PHA worksheet/report and understand what findings and recommendations mean in practice.
6. Track and close out PHA action items correctly, including documentation expectations.
7. Understand how PHA connects to other process safety elements (MOC, incident investigation, permit-to-work).

Course Outline
Module 1: Why Process Hazard Analysis Matters
* What PHA is and the risks it's designed to catch
* Real-world consequences of skipped or poor-quality PHAs (brief case examples)
* Regulatory context (OSHA PSM 1910.119 / equivalent regional regulations)
Module 2: Core Concepts and Terminology
* Hazard vs. risk vs. consequence
* Deviations, causes, and safeguards
* Layers of protection (a plain-language intro)
Module 3: PHA Methodologies at a Glance
* HAZOP: nodes, guide words, and how a session flows
* What-If and Checklist reviews
* Choosing a method (why it matters, even if you're not choosing it)
Module 4: Your Role in the PHA Process
* Being an effective team member/contributor (operators, supervisors bring frontline knowledge)
* What to expect in a PHA session — and how to prepare
* Common mistakes non-engineers make (over-qualifying answers, staying silent, assuming "someone else" knows)
Module 5: Reading PHA Outputs
* Anatomy of a PHA worksheet
* Understanding risk ranking/matrices
* What a "recommendation" actually obligates you to do
Module 6: Action Item Ownership and Close-Out
* Assigning, tracking, and closing recommendations
* Documentation and audit-readiness
* Escalation when an item can't be closed on time
Module 7: PHA in the Bigger Picture
* Links to Management of Change (MOC), incident investigation, and permit-to-work
* Revalidation cycles (why PHAs get redone every 5 years)