PROCESS SAFETY MANAGEMENT
Prevent. Protect. Perform – Mastering Process Safety for Sustainable Operations
Course Schedule
| Venue (InHouse) | Fees |
|---|---|
| At Your Organization Premises | Ask For The Quotation |
Course Introduction
This course delivers a robust understanding of Process Safety Management (PSM), focusing on the proactive identification, evaluation, and mitigation of risks associated with hazardous chemicals and complex industrial operations. Participants will explore OSHA’s 29 CFR 1910.119 standard, industry best practices, and globally accepted PSM frameworks to help build a culture of operational excellence and regulatory compliance.
Course Objectives
By the end of this training, participants will:
- Understand the 14 elements of OSHA’s Process Safety Management standard
- Identify process hazards and conduct effective risk assessments
- Learn techniques for mechanical integrity, change management, and incident investigation
- Build a compliant and practical PSM implementation roadmap
- Promote a strong process safety culture throughout the organization
Key Benefits of Attending
PSM failures can lead to catastrophic consequences. This course is essential for those responsible for chemical, oil & gas, manufacturing, and power plant safety. It prepares you to lead, manage, and sustain process safety systems that protect lives, assets, and reputation.
Intended Audience
- Process safety professionals and engineers
- EHS, HSE, and safety officers
- Plant managers, superintendents, and operations leaders
- Compliance managers and regulators
- Industrial maintenance and project engineers
Individual Benefits
- Deep understanding of regulatory and technical process safety frameworks
- Improved career prospects in high-hazard industries
- Hands-on skills for implementing PSM elements
- Preparedness for process safety audits and inspections
Organization Benefits
- Reduced potential for incidents, shutdowns, and regulatory fines
- Improved safety performance and employee morale
- Greater compliance with OSHA, API, CCPS, and other standards
- Improved risk governance and corporate sustainability
Instructional Methdology
- Interactive technical presentations
- Group workshops and simulations
- Incident case studies and video analysis
- Practice with tools like HAZOP, MOC, and LOPA
- Final project and knowledge check
Course Outline
DETAILED 5-DAY COURSE OUTLINE (CUSTOMIZABLE)
Training Hours: 7:30 AM – 3:30 PM
Daily Format: 3–4 Learning Modules
Coffee Breaks: 09:30 & 11:15 | Lunch Buffet: 01:00 – 02:00
Day 1: Fundamentals of PSM
- Module 1: Introduction to Process Safety Management (07:30 – 09:30)
- Module 2: OSHA’s 14 PSM Elements Overview (09:45 – 11:15)
- Module 3: Risk-Based Process Safety – CCPS Model (11:30 – 01:00)
- Module 4: Workshop – Process Hazard Mapping Exercise (02:00 – 03:30)
Day 2: Hazard Identification & Risk Analysis
- Module 1: Process Hazard Analysis (PHA) Tools: HAZOP, What-If, FMEA (07:30 – 09:30)
- Module 2: Layers of Protection and LOPA Introduction (09:45 – 11:15)
- Module 3: Facility Siting and Human Factors (11:30 – 01:00)
- Module 4: Case Study – Bhopal, Texas City, and BP Incidents (02:00 – 03:30)
Day 3: Operational Safety and Maintenance Integrity
- Module 1: Operating Procedures & Safe Work Practices (07:30 – 09:30)
- Module 2: Mechanical Integrity and Equipment Reliability (09:45 – 11:15)
- Module 3: Contractor Safety and Training Programs (11:30 – 01:00)
- Module 4: Workshop – Mechanical Integrity Checklist Review (02:00 – 03:30)
Day 4: PSM Controls and Change Management
- Module 1: Management of Change (MOC) Principles (07:30 – 09:30)
- Module 2: Emergency Planning and Response (09:45 – 11:15)
- Module 3: Incident Investigation and Root Cause Analysis (11:30 – 01:00)
- Module 4: Simulation – MOC & Incident Scenario Drill (02:00 – 03:30)
Day 5: PSM Implementation & Performance Monitoring
- Module 1: Audits, Metrics, and Compliance Evaluation (07:30 – 09:30)
- Module 2: Building a PSM Roadmap and Safety Culture (09:45 – 11:15)
- Module 3: Final Group Project – PSM Framework Development (11:30 – 01:00)
- Module 4: Presentations, Q&A, and Certification Wrap-Up (02:00 – 03:30)
Certification
Participants will receive a Certificate of Completion in Process Safety Management (PSM), endorsed for Continuing Professional Development (CPD) and aligned with international safety and compliance standards.