At TAPI, advancing health from the core doesn’t only apply to the products we manufacture, it also shapes how we operate. Safety is a fundamental ingredient in our processes, and continuously improving how we identify and manage risk is key to that mission. As part of our evolving Process Safety Management (PSM) program, we recently delivered an in-depth training series focused on the new global guideline for Hazard and Operability Studies (HAZOP).
This new HAZOP procedure—GDE-05-513.01—is a critical tool to strengthen risk awareness, hazard identification, and cross-functional alignment. The training was designed not only to reinforce the new methodology, but also to embed it effectively across TAPI’s operational, technical, and safety communities.
A Tiered Training for Targeted Impact
The program was structured into two distinct training paths to meet the needs of different stakeholder groups:
- Core 2-Day Training (8 hours each day): This deep-dive track was delivered to EHS managers and specialists, HAZOP facilitators, process safety managers, and project engineers—those responsible for initiating, leading, and guiding HAZOPs in high-impact scenarios. The sessions covered all elements of the updated procedure, including facilitation techniques, risk ranking using TAPI’s proprietary matrix, and documentation best practices.
- 3-Hour Awareness Session: Aimed at regular HAZOP participants from our sites, including MS&T, operations, maintenance, and instrumentation teams. This session introduced the methodology, roles and expectations, and the rationale behind the updated approach, ensuring stronger participation and understanding during future studies.
Both sessions focused on creating a consistent, compliant, and collaborative risk review culture across TAPI.
What’s New in the HAZOP Standard
HAZOP is a structured team-based method to systematically evaluate deviations from intended process conditions and identify risks before they materialize. The new standard outlines a detailed, step-by-step methodology that brings several enhancements to our previous approach:
1. Stronger Team Composition & Roles
The updated guideline defines clear competency-based roles for each participant, including the HAZOP Facilitator, Scribe, Process and Instrumentation Engineers, EHS professionals, Operators, MS&T specialists, and even vendor representatives. The training emphasized how each of these voices brings critical insights to ensure a comprehensive evaluation.
2. Defined Risk Assessment Criteria
Participants were trained on TAPI’s risk matrix methodology, which combines likelihood and severity to generate a quantifiable risk score. The matrix includes specific thresholds for “Acceptable,” “Tolerable (ALARP),” and “Unacceptable” risks, helping teams prioritize follow-up actions and investments.
3. Barriers, Safeguards, and the ALARP Principle
The new training also clarified how to assess the validity of safeguards, known as barriers. To be considered valid, a barrier must be effective, independent, and auditable. For example, operator actions can only be considered safeguards under strict timing and training conditions. Additionally, the ALARP (As Low As Reasonably Practicable) concept was explored in detail for medium-risk scenarios—providing a defensible framework for when additional controls may no longer be justified.
4. Documentation and Closeout
An important part of the new guideline is ensuring clear, traceable documentation. Participants were guided through the new HAZOP Worksheet template, which captures deviations, causes, consequences, safeguards, and recommendations. The follow-up process—including assigning action owners, using tracking tools, and reporting progress to site leadership—was also emphasized.
Online Access via Process Safety (PS) Academy
To support long-term learning and implementation, the content from this training will soon be available as digital learning modules on the PS Academy platform. This enables easy access for onboarding new team members, refreshing knowledge, and fostering a consistent global safety culture.
Why It Matters
A well-executed HAZOP doesn’t just meet compliance—it actively prevents incidents. It is one of the most powerful tools we have to protect people, products, and the planet. By investing in deeper training and applying a standardized global methodology, we’re reinforcing our commitment to excellence in every facet of operations.
At TAPI, safety is a shared responsibility. This training equips our teams to uphold that responsibility, bringing science, rigor, and teamwork to the forefront of every process.
