Introduction

Safety engineering is the systematic application of engineering principles, procedures, and technology to prevent accidents, minimize risks, and enhance safety in the workplace. This comprehensive course is designed to equip participants with essential knowledge and practical tools for applying safety engineering principles to design safe systems, mitigate hazards, and comply with safety regulations. Participants will learn risk-based methodologies, safety design techniques, and emerging technologies in safety engineering to create safer work environments.

Objectives

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

1. Understand Safety Engineering Fundamentals – Gain a clear understanding of core safety principles and methodologies.
2. Apply Risk Assessment Techniques – Use HAZOP, FMEA, and other methods for identifying and assessing hazards.
3. Design Safe Systems & Processes – Incorporate safety features in process design, equipment selection, and workplace layouts.
4. Implement Safety Control Measures – Design and implement engineering controls to reduce hazards.
5. Use Safety Analysis Tools & Software – Apply advanced tools for safety modeling, risk analysis, and failure prevention.
6. Understand Regulatory Requirements – Navigate local and international safety standards to ensure compliance.

Who Should Attend?

This course is ideal for:

• Safety Engineers responsible for designing and maintaining safe systems.
• HSE Managers & Professionals focused on safety engineering and risk mitigation.
• Process Engineers integrating safety in operational processes and designs.
• Risk & Compliance Officers managing safety standards and audits.
• Health and Safety Inspectors ensuring equipment and processes are up to safety standards.
• Corporate Executives developing and overseeing safety engineering strategies within their organizations.

Course Outline

Day 1: Introduction to Safety Engineering

• Session 1: Principles of Safety Engineering

  • What is Safety Engineering? Key concepts and historical development.
  • The role of Safety Engineering in workplace safety and risk management.
  • Safety culture and its impact on organizational safety.

• Session 2: Safety Systems and Safety Design

  • Designing safe systems, processes, and work environments.
  • Key principles of inherently safer design.
  • Case Study: Safety redesign of a chemical process to eliminate hazards.

• Session 3: Understanding Hazards and Risk

  • Types of hazards: physical, chemical, ergonomic, biological, and environmental.
  • Risk assessment methodologies: Quantitative vs. qualitative approaches.
  • Hands-on: Identifying hazards in a real-world manufacturing environment.

Day 2: Risk Assessment and Hazard Analysis

• Session 1: Hazard Identification Techniques

  • Common methods: HAZOP, FMEA, Fault Tree Analysis (FTA), and Failure Mode Effects Analysis (FMEA).
  • Risk Matrix: Assessing likelihood and severity of risks.
  • Hands-on: Performing a basic hazard identification exercise.

• Session 2: Safety Analysis Tools and Techniques

  • Introduction to safety modeling software and simulation tools.
  • Risk analysis tools: Bowtie analysis, Monte Carlo simulations, and more.
  • Hands-on: Using safety software to model and analyze a simple safety system.

• Session 3: Assessing and Managing Process Safety

  • Process safety management (PSM) systems and standards.
  • Safety instrumented systems (SIS) and their role in safety engineering.
  • Case Study: Assessing and managing risks in a high-risk manufacturing facility.

Day 3: Engineering Controls & Safety Measures

• Session 1: Hierarchy of Controls

  • Understanding and applying the Hierarchy of Controls: Elimination, Substitution, Engineering Controls, Administrative Controls, PPE.
  • Designing engineering controls for safety: ventilation, alarms, and machine safeguards.
  • Case Study: Engineering controls in a hazardous chemical plant.

• Session 2: Safety Equipment Selection & Maintenance

  • Key considerations in selecting and maintaining safety equipment (e.g., PPE, fire suppression systems, machine safeguards).
  • Preventive maintenance and its role in ensuring safety.
  • Hands-on: Evaluating safety equipment for effectiveness and compliance.

• Session 3: Implementing Safety Procedures

  • Developing and enforcing safety protocols and procedures for workplace operations.
  • Creating safe work practices and emergency response plans.
  • Hands-on: Developing a procedure for handling hazardous materials safely.

Day 4: Safety Engineering in Practice

• Session 1: Design of Safe Workplaces and Machinery

  • Ergonomics: Designing safe, comfortable workspaces to minimize strain and injury.
  • Machine safety: Guarding, emergency stops, and interlocks.
  • Hands-on: Designing a safe workstation based on ergonomic principles.

• Session 2: Safety during Construction and Maintenance

  • Construction safety principles for designing safe construction sites.
  • Managing risks during equipment maintenance, repair, and decommissioning.
  • Case Study: Engineering controls during the construction of a power plant.

• Session 3: Implementing Safety in Complex Systems

  • Designing safety systems for complex industries such as aerospace, energy, and chemical processing.
  • The role of reliability engineering in preventing failures.
  • Hands-on: Analyzing safety in a complex system (e.g., an oil refinery).

Day 5: Safety Regulations, Standards, and Future Trends

• Session 1: Regulatory Standards and Compliance

  • Navigating OSHA, ISO, and local safety regulations.
  • Applying safety engineering standards to meet legal and regulatory requirements.
  • Hands-on: Reviewing safety systems for compliance with ISO 45001 and other standards.

• Session 2: Emerging Trends in Safety Engineering

  • The role of AI, IoT, and Big Data in advancing safety engineering practices.
  • Introduction to digital twins and predictive maintenance for safety applications.
  • Case Study: How AI is transforming safety engineering in the automotive industry.

• Session 3: Final Project, Certification & Strategy Presentation

  • Group Project: Design a safe system for a real-world scenario using the principles learned.
  • Presentations and peer review of safety engineering designs.
  • Certification Ceremony & Networking: Acknowledging participants’ accomplishments and discussing career pathways.

Course Delivery Format:

✔ Expert-Led Training – Learn from industry professionals with hands-on experience in safety engineering.
✔ Interactive Workshops & Case Studies – Apply theory to real-world scenarios and learn from practical examples.
✔ Hands-On Exercises – Work with safety analysis tools, design simulations, and engineering solutions.
✔ Peer Collaboration – Develop solutions through group activities, discussions, and knowledge sharing.
✔ Certification & Career Advancement – Receive a recognized certification in Safety Engineering Principles to enhance your career in safety and risk management.