Process Safety Management and HAZOP/LOPA Corporate Training
Lead HAZOP and LOPA studies with confidence, in live instructor-led labs built around real process scenarios.
Edstellar, a corporate training company, delivers corporate training that helps your team master process safety management through HAZOP and LOPA practice. Employees facilitate hazard studies, analyze layers of protection, and set SIL targets through guided labs led by process safety practitioners. Each session is tuned to your industry, plant processes, and workflows.
Instructor-led group trainingVirtual / on-site / off-site10 languagesDelivered inEnglish, Spanish, Mandarin, German, Arabic, Portuguese, Hindi, French, Japanese, Italian100+ countriesWe have delivered inUnited States, United Kingdom, India, Canada, Germany, France, Netherlands, UAE, Saudi Arabia, Singapore, Australia, Japan, Brazil, South Africa and 90+ more countries
How we build a process-safety-driven team
The Edstellar PROCESS SAFETY Capability Model
Diagnose
We assess your team's current hazard-study skills and review a real process scenario to focus the program on your highest-risk units.
Standardize
Teams agree on HAZOP and LOPA conventions, from guideword usage to IPL validation rules, so every study is consistent and auditable.
Practice
Learners facilitate HAZOP sessions and build LOPA worksheets in guided labs, with an instructor coaching each analysis step.
Measure
Instructors review each team's hazard studies against clear, measured criteria for depth, rigor, and documentation quality.
Scale
Your team leaves with reusable study templates and facilitation habits they can apply to every process unit and change review.
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Program Overview: What is Process Safety Management and HAZOP/LOPA?
Process Safety Management & HAZOP/LOPA is an instructor-led program for process engineers, safety engineers, and operations teams on high-hazard processes. It teaches your team to plan, facilitate, and document HAZOP studies and layer of protection analyses. Participants work real process scenarios, apply guidewords to nodes, evaluate independent protection layers, and define risk targets a facility can defend in front of regulators and auditors.
The program runs over 24 instructor-led hours across seven modules, moving from PSM frameworks into intensive, hands-on study work. Participants learn to chair HAZOP sessions, record credible causes and safeguards, and build LOPA worksheets with independent protection layers and conditional modifiers. Instructors coach the connection from study outcomes to safety instrumented systems and SIL targets, correcting worksheet discipline as it is built. The program closes with the Full HAZOP/LOPA Study capstone on a process unit.
Too many HAZOP studies become checkbox exercises: rushed sessions, vague causes, safeguards credited that are not truly independent, and documentation no auditor could reconstruct. When a study cannot withstand regulatory review, the risk it missed stays in the plant. This program teaches teams to facilitate rigorous studies and produce worksheets that hold up under scrutiny.
For the capstone, each team delivers a complete, review-ready HAZOP and LOPA package for a process unit: node-by-node HAZOP worksheets with guideword deviations, credible causes, and recorded safeguards; LOPA worksheets with independent protection layers, conditional modifiers, and justified SIL targets; and a summary linking study outcomes to safety instrumented system requirements. Instructors audit the package the way a regulator would, probing for credited-but-not-independent layers. Teams leave with a study template and the facilitation discipline to repeat it on every unit they own.
The program moves from process safety fundamentals into intensive, hands-on study work. Your team learns to chair HAZOP sessions, record credible causes and safeguards, build LOPA worksheets with conditional modifiers, and connect study outcomes to safety instrumented systems. By the final capstone, participants deliver a complete, review-ready HAZOP and LOPA package for a process unit.
What's Included in this Workshop for Your Enterprise Teams
- 1
Process safety frameworks
PSM elements, regulatory expectations, and safety lifecycle context.
- 2
Hazard identification
HAZID, What-If, and checklist techniques for screening process units.
- 3
HAZOP facilitation
Nodes, guidewords, deviations, and recording credible scenarios.
- 4
LOPA worksheets
Initiating events, IPLs, conditional modifiers, and risk targets.
- 5
Protection layers
BPCS, alarms, relief systems, and safety instrumented functions.
- 6
Capstone study
A complete HAZOP and LOPA package on a process unit.
- Instructor-led delivery across virtual, onsite, and hybrid
- Guided labs in every module with instructor coaching
- Capstone study package, reviewed with your team
- Flexible scheduling around your calendar
- HAZOP and LOPA templates and study guides included
- Group size and batches set along with you
Build your team's skills. Anywhere in the world.
Real-world use cases
from day one
Instructor-led training
for your teams
Delivered globally
in 100+ countries
Enterprise Training Solutions Customized for Your Company
One partner for instructor-led corporate training, delivered the way your teams work.
Request a Training Quote- Customized Training Delivery
- Scale Your Training: Small to Large Teams
- In-person Onsite, Live Virtual or Hybrid Training Modes
- Plan from 2000+ Industry-ready Training Programs
- Hands-On Labs on Live Infrastructure, Led by Industry Experts
Process Safety Management and HAZOP/LOPA Course Topics and Program Outline
Seven instructor-led modules take your team from process safety fundamentals to a complete, review-ready HAZOP and LOPA study package.
Built by Edstellar with process safety engineers who lead HAZOP and LOPA studies in operating plants
Built by process safety practitioners who chair HAZOP studies and build LOPA worksheets in operating plants, shaped around your stack and use cases.
We review your team's current hazard-study skills and profile a real process scenario to focus every lab on your highest-risk units.
Instructor-led sessions teach PSM frameworks, hazard identification, and the theory behind HAZOP and LOPA with live demonstrations.
Teams facilitate HAZOP sessions and build LOPA worksheets in guided labs, with an instructor coaching every analysis step.
Your team delivers a complete, review-ready HAZOP and LOPA study package for a real process unit in the capstone.
Every study you build targets your own process units, so the program pays off before it ends.
Delivered as
Instructor-led over 24 hours with guided labs in every module and a capstone study package reviewed with your team.
Intro lab: map the PSM elements to your own facility's procedures and identify gaps.
learna)Process safety vs occupational safety
b)The 20 PSM elements and their interfaces
c)Safety lifecycle and risk reduction targets
d)Regulatory landscape for high-hazard industries
e)Major accident case studies and lessons
Intro lab: run a What-If screening on a sample unit and rank scenarios on a risk matrix.
learna)HAZID study method and facilitation basics
b)What-If analysis for process units
c)Checklist and relative ranking techniques
d)Risk matrices and tolerability criteria
e)Selecting nodes and defining study scope
Practice lab: facilitate a live HAZOP on two nodes of a sample process while the instructor coaches recording discipline.
practicea)HAZOP team roles and chairing discipline
b)Node selection on P&IDs
c)Guideword and parameter deviation matrices
d)Recording causes, consequences, and safeguards
e)Ranking risk and agreeing recommendations
Practice lab: complete a LOPA worksheet for a loss-of-containment scenario and defend your IPL credits.
practicea)Initiating events and frequency data
b)Independent protection layers and validation rules
c)Conditional modifiers and enabling conditions
d)Calculating mitigated event frequency
e)Setting and documenting SIL targets
Practice lab: map study recommendations to protection layers and challenge weak IPL claims.
practicea)Layers of protection concept and architecture
b)BPCS, alarms, and operator intervention claims
c)Relief systems and passive protection
d)Safety instrumented functions and proof testing
e)Common-cause and dependent failure pitfalls
Practice lab: screen a plant modification through MOC and draft the pre-startup review checklist.
applya)MOC screening and risk review triggers
b)Pre-startup safety review checklists
c)Incident investigation and root-cause methods
d)Feeding lessons back into hazard studies
e)Action tracking and closure discipline
Capstone lab: produce a complete HAZOP and LOPA package for a process unit, reviewed with your team.
applya)Study planning and node breakdown
b)Facilitated HAZOP session on the capstone unit
c)LOPA worksheets for top scenarios
d)Recommendation register with owners and dates
e)Instructor review and study quality sign-off
Customize this program tailored to your team?
Tell us your training needs: what your team already works with, the level they’re at, and the topics you want them to focus on. We’ll adjust the modules, duration and hands-on labs, and send you a customized outline for your group.
Key Skills and Outcomes Your Team Will Gain
Seven outcome areas your team practices in guided labs, from study facilitation to SIL target setting.
Facilitate HAZOP studies
Chair structured HAZOP sessions, keep guideword discipline, and record credible cause-consequence pairs on live P&IDs.
Build LOPA worksheets
Quantify initiating events, credit independent protection layers, and calculate mitigated event frequencies.
Set and defend SIL targets
Derive safety integrity levels from LOPA results and document targets that survive internal and external review.
Screen and scope studies
Use HAZID, What-If, and risk matrices to select nodes and size studies to the hazard.
Evaluate protection layers
Challenge IPL claims, spot common-cause weaknesses, and connect study findings to instrumented functions.
Run MOC and pre-startup reviews
Screen plant changes for process safety risk and build disciplined pre-startup checklists.
Document study packages
Produce recommendation registers with owners and dates, plus investigation feedback loops that improve future studies.
Teams that Benefit from this Process Safety Management and HAZOP/LOPA Group Training
Built for the teams that own hazard studies and the safeguards they recommend. The content adapts to role and experience, so each cohort practices the study workflows it owns in its own plant.
Run defensible HAZOP and LOPA studies
Your process safety engineers chair studies, build worksheets, and own the recommendation register through the capstone.
Workflow friction
- Studies drift without facilitation rigor
- IPL claims get double-counted
- Recommendations stall without owners
How the program helps
- Sharper guideword and node discipline
- LOPA worksheets that survive audit
- Recommendation tracking that closes loops
Practice use cases
- HAZOP facilitation drills
- LOPA worksheet labs
- SIL target setting
Connect studies to operating reality
Operators and shift teams validate causes and safeguards against how the plant actually runs, day and night.
Workflow friction
- Studies miss real operating modes
- Changes bypass safety review
- Alarms credited without evidence
How the program helps
- Realistic cause and safeguard input
- MOC screening that reflects operations
- Pre-startup checks operators trust
Practice use cases
- MOC screening labs
- PSSR checklist builds
- Alarm claim reviews
Design safeguards studies can credit
Process and instrument engineers link study recommendations to BPCS, SIS, and relief designs they own.
Workflow friction
- Instrumented functions under-specified
- Common-cause failures overlooked
- Design changes skip review
How the program helps
- SIS designs tied to SIL targets
- Relief and passive protection review
- Change packages study-ready
Practice use cases
- SIS design reviews
- Protection layer mapping
- Change package labs
Govern the risk picture confidently
EHS and plant leaders learn to read study quality, challenge assumptions, and hold teams to closure discipline.
Workflow friction
- Thin studies get signed off
- Risk targets stay undocumented
- Incidents repeat without learning
How the program helps
- Quality checks on study packages
- Risk tolerability decisions made clear
- Investigation lessons fed back
Practice use cases
- Study quality reviews
- Risk decision labs
- Investigation feedback
Cohorts are shaped around your plant processes, so each team practices on scenarios from its own units.
Prerequisites: This program benefits process engineers, safety engineers, operators, and EHS professionals who work around high-hazard processes. Familiarity with P&IDs and basic process operations helps but is not required; the first modules build the foundation. No prior HAZOP or LOPA experience is needed, and the content adapts to each cohort's plant processes and industry context.
Process engineer to study leader
Progression maps each skill to the module phase where it is taught and the depth your team reaches by the capstone.
A learning path that grows with process safety careers, from study basics to confident, audit-ready practice.
Mixed cohort, or several teams at once?
We can tailor the training to different teams, roles, and experience levels within the same program.
Certificate of Training Completion.
On successful completion, employees receive an Edstellar course completion certificate, recognizing their commitment to ongoing learning and professional development. It validates the skills they have built and motivates them to keep growing and contribute to organizational success.
Earned, not attended. Awarded on completion of all hands-on labs and the capstone project.
Training Delivery Modes: Virtual, Onsite and Hybrid
Instructor-led sessions with guided labs throughout, delivered your way across onsite, virtual, and hybrid formats.
Hybrid Training
Instructor-led sessions mix onsite and virtual delivery with guided labs throughout. Teams facilitate HAZOP sessions and build LOPA worksheets while the instructor coaches each analysis step. Hybrid keeps scheduling flexible without losing live interaction.
- Live instruction across onsite and virtual sessions
- Guided labs with instructor coaching and study reviews
- Real process scenarios from your industry
- Capstone study package reviewed with your team
Onsite Training
Onsite sessions put the instructor in your plant with your P&IDs and procedures. Teams practice facilitation and worksheet building face to face, using scenarios from your own units. Onsite keeps the focus on your highest-risk processes.
- Instructor at your plant or office
- Labs built around your own process units
- Face-to-face facilitation practice
- Immediate feedback on study discipline
Live Virtual Training
Live virtual sessions deliver the same instructor-led labs through interactive online workshops. Teams share screens for HAZOP recording and LOPA worksheets while the instructor reviews each analysis. Virtual keeps distributed teams in the same study room.
- Live online instructor-led labs
- Shared study templates and worksheets
- Breakout practice on process scenarios
- Digital capstone review sessions
Need a training format that works for your team?
Full days, half days across weeks, or split by module. Tell us the delivery window and we schedule the cohort around it.
Learn from industry experts.
Every session is led by a practitioner who has run monitoring for models in production, not a generalist working from slides.
Marlikynti
Machine Learning Trainer in Bengaluru, India
12+ years of Experience
Vishnu
ISO 45001 / ISO 9001:2015 Trainer in Kollam
14+ years of Experience
Chihab
Workplace Safety Trainer in El Oued
6+ years of Experience
Suyash
HSE (Health, Safety & Environment) Trainer in Greater Noida
8+ years of Experience
Sachin
ISO Trainer in Hyderabad
11+ years of Experience
Rahul
LA ISO 9001 Trainer in Bengaluru
8+ years of Experience
Adesina
ISO 9001:2015 Lead Auditor Trainer in Port Harcourt
12+ years of Experience
Trainers are matched to your stack and delivery window at scheduling. We confirm your assigned trainer, with a full profile, before the program is booked.
Frequently Asked Questions
Share your team size, plant locations, and preferred dates through the group quote form, and a training advisor will respond within one business day with pricing.
Yes. A short discovery call with a training advisor aligns the agenda, labs, and capstone unit with your process safety goals.
Yes. The program runs fully live virtual with the same instructor-led labs, or onsite, or as a hybrid mix across your sites.
Yes. Onsite delivery lets the instructor use your P&IDs, procedures, and process units directly in the labs.
The program runs 24 instructor-led hours, typically scheduled across flexible session blocks that fit your operations.
Question not answered here?
Put it in the request. A training specialist answers it directly, within one business day.
Where this Training Fits in Your Team's learning path.
Process safety management comes second, after hazard assessment. Your team needs general risk skills before running HAZOP and LOPA studies on major hazards. The path then moves to safety instrumented systems and ends with human and organisational performance in high-hazard work.
Why Choose Edstellar as Your Process Safety Management and HAZOP/LOPA Corporate Training Provider
Edstellar pairs process safety practitioners with your team for instructor-led labs that produce review-ready study work, shaped around your plant and your highest-risk units.
EXPERT TRAINERS
YEARS DELIVERING
ORGANIZATIONS TRAINED
CERTIFIED
Tailored
Agendas, labs, and the capstone study are shaped around your plant processes, industry, and highest-risk units.
Proven Methodology
A study arc that moves from fundamentals to facilitated HAZOP sessions and audited LOPA worksheets, step by step.
Practice-Based Learning
Every module includes guided labs where teams facilitate studies and build worksheets with instructor coaching.
Expert Trainers
Process safety engineers who chair HAZOP studies and build LOPA worksheets in operating plants lead your sessions.
Global Scale
Consistent study standards and delivery quality across every site, shift, and cohort your program reaches.
Measurable Outcomes
Study quality reviews, worksheet criteria, and a reviewed capstone package prove the skills your team gained.
Also from Edstellar
Talent assessments
Psychometric, behavioral, leadership and 360-degree assessment.
→Training needs analysis
Needs analysis, gap identification, and a training roadmap.
→L&D consulting
Learning strategy, content, technology and ROI measurement.
→OD consulting
Org design, succession planning and cultural change.
→Managed training services
Training outsourcing, vendor management, logistics and administration.
→Coaching solutions
Executive and manager coaching that keeps skills in use.
Start an RFP shaped to your needs.
Answer three quick questions about team size, scope, and how often you need the program run, then send the request from the last step. Everything you choose travels with it, so you only fill this in once.
How many team members need training?
Process Safety Management & HAZOP/LOPA Training Packages & Pricing
Where L&D holds an annual budget, license packages price the whole year at once instead of raising a purchase order per workshop. Hours and licenses are pooled across teams, programs and locations, so unused capacity is not stranded in one department.
Starter
120
trainee licenses64 hours of group training
Tailored for SMBs
Growth
320
trainee licenses160 hours of group training
Ideal for growing SMBs
Enterprise
800
trainee licenses400 hours of group training
Designed for large corporations
Custom
Unlimited
trainee licensesDuration set by the rollout
Multi-region and multi-year
Training Packages & Pricing
Choose the training format that works for your team. Pricing is customized based on your requirements, cohort size, and delivery needs.
Request Process Safety Management and HAZOP/LOPA Training for Your Team
Tell us about your team, your plant processes, and the hazard studies you run. A training advisor will shape the agenda, labs, and delivery format around your goals.