Process Safety Professional
Process Safety Professional
Process Safety Professional
Course Overview
Process Safety
Preventing Loss of Containment and Major Accident Hazards
Good lost-time injury rates have hidden catastrophic process risk at Texas City, Piper Alpha and Bhopal, and the lesson still applies across Gulf refining, petrochemical and gas operations. This course builds capability in hazard analysis, protection layers, integrity management, change control and process safety indicators that actually predict major accident risk.
What You Will Learn
The main objectives of the course are:
- Define process safety and low-frequency, high-consequence risk.
- Distinguish process safety from occupational safety metrics.
- Analyze fires, explosions, toxic releases and escalation.
- Apply lessons from Flixborough, Bhopal and Piper Alpha.
- Implement OSHA PSM, Seveso III and CCPS frameworks.
- Scope and document process hazard analyses.
- Facilitate HAZOP studies using guide words.
- Perform layers of protection analysis and risk gaps.
- Model consequences and interpret F-N curves.
- Operate management of change and pre-startup reviews.
- Manage mechanical integrity and SIL verification.
- Track API 754 indicators and lead the management system.
Who Should Enroll
This certificate is designed for process safety engineers, operations and process engineers, plant and technical managers, HSE leads in oil, gas and petrochemicals, maintenance and integrity engineers, control and instrumentation specialists, PHA facilitators, and risk consultants serving process industries.
Skills You Will Build
- Process Hazard Analysis
- HAZOP Facilitation
- Layers Of Protection Analysis
- Consequence Modelling
- Management Of Change
- Mechanical Integrity
- Safety Instrumented Systems
- Permit And Safe Work Practices
- Process Safety Metrics
- Incident Investigation
- Major Accident Hazard Awareness
- Loss Of Containment Prevention
- Regulatory Framework Application
- Semi-Quantitative Risk Analysis
- Risk-Based Inspection
- SIL Verification
- Emergency Preparedness
- Process Safety Culture
- Barrier Management
- Management System Assurance
Course Outline – Process Safety
Module 1: Introduction to Process Safety Management
- What Process Safety Means
- Low-Frequency, High-Consequence Risk
- The Business and Human Case for Process Safety
- Key Terminology and the Language of Loss Prevention
Module 2: Process Safety vs Occupational Safety
- Two Different Kinds of Risk
- Why Good Lost-Time Rates Hide Process Hazards
- The Texas City Lesson
- Aligning Both Disciplines in One Organization
Module 3: Major Accident Hazards
- Fires, Explosions and Toxic Releases
- Loss of Containment as the Root Event
- Vapour Cloud Explosions and BLEVEs
- Domino and Escalation Effects
Module 4: The Evolution of Process Safety: Learning From Catastrophe
- Flixborough and the Birth of Modern Process Safety
- Seveso and the European Regulatory Response
- Bhopal: The Deadliest Industrial Disaster
- Piper Alpha and the Safety Case Regime
Module 5: Process Safety Frameworks
- OSHA PSM: The Fourteen Elements
- EPA Risk Management Program
- Seveso III and the Safety Report
- CCPS Risk Based Process Safety
Module 6: Process Hazard Analysis (PHA)
- The Purpose and Scope of PHA
- Selecting a Methodology: What-If, Checklist, FMEA
- Node Selection and Team Composition
- Documenting and Tracking PHA Recommendations
Module 7: HAZOP Studies
- The HAZOP Philosophy
- Guide Words, Parameters and Deviations
- Running an Effective HAZOP Session
- Recording Causes, Consequences and Safeguards
Module 8: Layers of Protection Analysis (LOPA)
- From Qualitative to Semi-Quantitative Risk
- Independent Protection Layers and IPL Criteria
- Initiating Event and Failure Frequencies
- Calculating Mitigated Risk and Risk Gaps
Module 9: Quantitative Risk Assessment and Consequence Modeling
- When Qualitative Methods Are Not Enough
- Consequence and Dispersion Modeling
- Frequency Analysis and Fault/Event Trees
- Individual and Societal Risk: F-N Curves
Module 10: Management of Change (MOC)
- Why Change Is a Leading Cause of Incidents
- Defining Change: Replacement-in-Kind vs Modification
- The MOC Review and Approval Workflow
- Pre-Startup Safety Review
Learn at your convenience
*Note: These are self-paced courses, allowing learners to study independently at their own pace.
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