Course Overview
This comprehensive program provides engineers and safety professionals with essential knowledge and practical skills in process safety management, hazard evaluation, and risk mitigation for chemical, oil & gas, and manufacturing industries. Participants will learn systematic approaches to prevent catastrophic incidents through proven engineering and management practices.
Course Objectives
Upon completion, participants will be able to:
- Implement process safety management (PSM) systems per OSHA/EPA/CCPS standards
- Conduct hazard evaluations (HAZOP, LOPA, FMEA)
- Design safety instrumented systems (SIS) per IEC 61511
- Apply inherently safer design principles
- Develop mechanical integrity programs
- Lead incident investigations using root cause analysis
- Manage process safety compliance for regulatory requirements
Who Should Attend
This course is essential for:
- Process safety engineers
- Plant managers and supervisors
- Process design engineers
- Operations and maintenance personnel
- EHS professionals
- Risk management specialists
- PHA/HAZOP team leaders
Course Modules
Module 1: Fundamentals of Process Safety
- Process safety vs occupational safety
- Historical incidents and lessons learned
- Process safety lifecycle
- Regulatory frameworks (OSHA PSM, EPA RMP, SEVESO)
Module 2: Hazard Identification & Risk Assessment
- Hazard evaluation techniques (HAZID, What-If, Checklist)
- HAZOP methodology (IEC 61882)
- Layer of Protection Analysis (LOPA)
- Risk tolerance criteria
Module 3: Inherently Safer Design
- ISD principles (Minimize, Substitute, Moderate, Simplify)
- Process intensification
- Safety in process design
- Case studies of ISD applications
Module 4: Safety Instrumented Systems
- IEC 61511 safety lifecycle
- Safety Integrity Level (SIL) determination
- SIS design and implementation
- Verification and validation
Module 5: Process Safety Management
- 14 elements of PSM (OSHA 1910.119)
- Management of Change (MOC)
- Operating procedures and safe work practices
- Emergency planning and response
Module 6: Mechanical Integrity & Asset Management
- Equipment classification and inspection
- Preventive/predictive maintenance
- Quality assurance in repair work
- Fitness-for-service assessments
Module 7: Incident Investigation & Learning
- Root cause analysis methods
- Incident reporting and documentation
- Lessons learned systems
- Safety culture assessment
Module 8: Advanced Applications
- Human factors in process safety
- Alarm management (ISA 18.2)
- Process safety metrics and KPIs
- Management systems integration