Introduction

This course provides a comprehensive overview of Process Safety Management principles and practices for preventing major accidents in oil, gas, petrochemical, and process industries. It focuses on identifying and managing process hazards, assessing risks, maintaining asset integrity, managing operational changes, and developing effective emergency and incident-management systems. The course combines practical techniques, industry examples, and case studies to strengthen participants’ ability to manage process safety throughout the asset lifecycle.

Course Objectives

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

• Understand the fundamental principles and elements of Process Safety Management.
• Identify major process hazards and assess associated risks.
• Apply HAZID, HAZOP, LOPA, FMEA, and other risk-analysis techniques.
• Develop effective Management of Change (MOC) and Mechanical Integrity programs.
• Understand Safety Instrumented Systems (SIS) and Safety Integrity Levels (SIL).
• Improve Permit to Work, safe isolation, and operational safety practices.
• Investigate incidents and identify root causes.
• Develop effective emergency preparedness and response strategies.
• Establish process safety KPIs and performance-monitoring systems.
• Apply PSM principles through practical case studies and workshops.

Who Should Attend

• Process Safety Engineers
• HSE and Safety Professionals
• Process and Production Engineers
• Operations and Maintenance Engineers
• Facilities and Asset Integrity Engineers
• Project and Engineering Managers
• Risk and Reliability Engineers
• Plant and Operations Managers
• Technical and Engineering Supervisors
• Professionals involved in HAZOP, risk assessment, and process safety management

Course Outline

Day 1 – Process Safety Fundamentals

1. Process Safety Principles and Major Accident Hazards
2. Process Safety Management Systems
3. Hazard Identification and Risk Assessment
4. Process Safety Culture and Leadership
5. Process Safety Performance Indicators

Day 2 – Hazard Identification & Risk Analysis

1. HAZID and HAZOP Studies
2. What-If, Checklist and FMEA Techniques
3. Layer of Protection Analysis (LOPA)
4. Risk Assessment and Risk Matrices
5. Safety Instrumented Systems and SIL

Day 3 – Process Safety Management Elements

1. Process Safety Information (PSI)
2. Operating Procedures and Safe Work Practices
3. Management of Change (MOC)
4. Mechanical Integrity and Asset Integrity
5. Training, Competency and Contractor Management

Day 4 – Emergency & Incident Management

1. Emergency Preparedness and Response
2. Fire, Explosion and Toxic Release Prevention
3. Incident Investigation and Root Cause Analysis
4. Permit to Work and Safe Isolation
5. Emergency Drills and Crisis Management

Day 5 – Process Safety Assurance & Risk Reduction

1. Process Safety Auditing and Compliance
2. Process Safety KPIs and Performance Monitoring
3. ALARP and Risk Reduction Strategies
4. Bow-Tie Analysis and Major Accident Prevention
5. Integrated PSM Case Study and Workshop