Hazard Analysis &
Risk Management

This course provides a specialized, industry-focused introduction to Process Hazard Analysis (PHA) using Failure Modes and Effects Analysis (FMEA) and Layers of Protection Analysis (LOPA) for ammunition and explosives (AE) manufacturing operations. Participants will learn how to systematically evaluate energetic material processes—such as mixing, pressing, filling, assembly, and testing—through structured identification of failure modes, credible initiation mechanisms, and potential propagation pathways. Emphasis is placed on explosive-specific hazard recognition using tailored FMEA guide words enabling practitioners to identify unique energetic risks not addressed by generic chemical-processing approaches. The course integrates practical methodologies for quantifying risk to meet the evolving expectation for data-driven hazard analyses to meet regulatory compliance requirements.

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Building on the FMEA outputs, the LOPA module demonstrates how to translate identified hazards into semi-quantitative risk assessments suitable for high-hazard energetic operations. Participants learn to evaluate initiating event frequency, consequence severity (with attention to overpressure, fragmentation, thermal effects, and mass-detonation potential), and the effectiveness of independent protection layers such as grounding/bonding systems, remote operations, process interlocks, engineering controls, and procedural safeguards.

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Attendees will complete hands-on workshops involving real-world scenarios, preparing them to develop defensible, high-quality PHAs that reduce catastrophic incident potential in explosive environments.