Introduction

Process Safety Management (PSM) is an essential discipline aimed at preventing the release of hazardous chemicals that could cause serious accidents, injuries, or environmental harm. This 5-day Process Safety Management (PSM) Training Course is designed to provide participants with a comprehensive understanding of PSM principles, regulatory requirements, and best practices for managing process safety risks. The course includes hands-on exercises, case studies, and modern tools to ensure participants are equipped to manage process safety in high-risk industries effectively.

Course Objectives

By the end of the course, participants will:

1. Understand the key principles of Process Safety Management (PSM).
2. Learn the regulatory requirements for PSM (e.g., OSHA 29 CFR 1910.119, EPA RMP).
3. Be able to conduct hazard analyses and risk assessments to identify potential process hazards.
4. Gain knowledge of the process safety lifecycle, from design to operation.
5. Learn how to implement PSM elements such as process hazard analysis (PHA), operating procedures, and safety instrumented systems (SIS).
6. Develop the skills to manage and lead process safety initiatives within their organization.

Who Should Attend?

This course is ideal for:

• Process safety managers and engineers
• Health and safety officers
• Operations managers and team leads
• Risk management professionals
• Compliance officers
• Engineers in process industries (chemical, oil and gas, pharmaceuticals, etc.)
• Facility managers and safety coordinators

Day-by-Day Outline

Day 1: Introduction to Process Safety Management

• Overview of Process Safety Management
  • Definition, objectives, and significance of PSM
  • The difference between occupational safety and process safety
  • Importance of PSM in preventing catastrophic incidents
• Regulatory Requirements and Standards
  • OSHA Process Safety Management (PSM) standard (29 CFR 1910.119)
  • Environmental Protection Agency (EPA) Risk Management Program (RMP)
  • Industry-specific standards and guidelines (e.g., CCPS, NFPA, IEC61511)
• PSM Program Elements
  • Overview of the 14 elements of PSM: Process Safety Information, Process Hazard Analysis, Operating Procedures, and more
• Interactive Session:
  • Discussion on high-profile process safety incidents and lessons learned

Day 2: Hazard Analysis and Risk Assessment

• Process Hazard Analysis (PHA) Techniques
  • Overview of PHA methodologies: HAZOP, FMEA, FTA, What-If Analysis
  • Selecting the appropriate PHA method for specific processes
• Risk Assessment and Management
  • Understanding risk assessment principles (likelihood vs. consequence)
  • Identifying and evaluating process hazards
• Quantitative vs. Qualitative Risk Analysis
  • Tools and techniques for performing both types of risk analysis
• Workshop:
  • Conducting a hazard analysis for a simple process flow (HAZOP or What-If Analysis)

Day 3: Process Safety Design and Documentation

• Designing Safe Processes
  • Engineering controls and safety features for process design
  • Safety Instrumented Systems (SIS), Pressure Relief Systems, and Hazardous Material Containment
• Process Safety Information (PSI)
  • Creating and maintaining up-to-date documentation: Piping & Instrumentation Diagrams (P&ID), Process Flow Diagrams (PFD), and Material Safety Data Sheets (MSDS)
  • The role of PSI in hazard identification and risk management
• Operating Procedures and Safe Work Practices
  • Developing, implementing, and maintaining standard operating procedures (SOPs)
  • Lockout/Tagout (LOTO), hot work permits, and confined space entry procedures
• Case Study:
  • Reviewing a process safety incident and identifying deficiencies in design or documentation

Day 4: Managing Process Safety Risk

• Safety Culture and Leadership in PSM
  • Promoting a strong safety culture and leadership commitment to process safety
  • Integrating PSM into organizational safety management systems
• Process Safety Audits and Inspections
  • Conducting process safety audits and self-assessments
  • Techniques for effective inspections and ensuring compliance with PSM standards
• Incident Investigation and Root Cause Analysis
  • Investigating incidents using tools such as Root Cause Analysis (RCA) and Failure Mode and Effect Analysis (FMEA)
  • Developing corrective actions to prevent recurrence
• Emergency Response and Planning
  • Process-specific emergency response plans and preparedness
  • Coordination with local authorities and response teams
• Workshop:
  • Analyzing an incident and conducting a root cause analysis with a focus on process safety

Day 5: Continuous Improvement and Implementation

• Performance Monitoring and Metrics
  • Key performance indicators (KPIs) for process safety management
  • Using data and leading indicators to track performance
• Continuous Improvement in Process Safety
  • Implementing a continuous improvement cycle (Plan-Do-Check-Act) for process safety
  • Updating and improving PSM elements based on audit findings, near misses, and incident investigations
• Managing Change in Process Safety
  • Change management and the importance of reviewing PSM systems when processes change
  • Ensuring proper documentation and employee training during changes
• Final Project Presentation:
  • Participants present a process safety management plan for a specific workplace scenario or process
• Assessment and Certification:
  • Knowledge review, quiz, and practical demonstration of key PSM concepts
  • Certification in Process Safety Management (PSM)

Conclusion and Certification

• Summary of the key concepts covered during the course
• Open Q&A session for additional clarifications
• Certification ceremony and closing remarks