Process Safety

Course Description

In this three-day hands-on course students learn how create and implement a process safety management program that: complies with government regulations, creates a culture of safety, avoids injury, improves quality, protects the environment, and saves lives.

Course Objectives

Upon successful completion of this course, students will be able to:

• Understand why process safety is necessary.
• Enumerate the elements of a properly designed process safety program.
• Develop and implement a process safety management program.
• Indentify hazards and mitigate their effects.
• Comply with government regulations.
• Establish a criteria and methods for selecting contractors and equipment in the process.
• Work with others to protect the workforce and the environment.
• Think in terms of an inherently safer design.
• Create a safer work environment.

Course Benefits

By learning how to develop and implement a process safety management program, students will increase their productivity by learning how to work safely, avoid injury, protect the environment, and save lives.

Who Should Attend

In order to demonstrate a commitment to safety and to reinforce a culture of safety within the organization, managers and executives responsible for operations and safety should attend along with their team members, compliance auditors, engineers and others responsible for process, operations, maintenance, production, health, safety and the environment.

Prerequisite

None.

Method Of Instruction

Lecture, short interactive quizzes, questions and answers, and workshop tasks.

Course Outline

Chapter 1: Process Safety

• Types Of Hazards
• Incident
• Risk
• What Is Process Safety
• Process Safety Is Prevention
• Equipment Malfunction
• Personal Safety
• Why Have Process Safety
• Process Safety Management
• Process Safety Management Parts
• Performance-Based Standard
• Chapter 1 Review Questions
• Chapter 1 Review

Chapter 2 Employee Participation

• Why Employee Participation Is Necessary
• Section 304
• Paragraph (c)
• Interpretation
• Contractors
• Employer Obligation
• Team Participants
• Chapter 2 Review Questions
• Chapter 2 Review

Chapter 3 Process Safety Information

• Paragraph (d) Requirements
• Hazards Of Highly Hazardous Chemicals
• Identifying Hazardous Chemicals
• Threshold Limit Value
• Threshold Limit
• Material Safety Data Sheets
• Technology Of The Process
• Block Flow Diagram Example
• Part Of Automated Control Systems
• Equipment In The Process
• Codes And Standards
• Equipment Information
• Equipment Numbering
• Chapter 3 Review Questions
• Chapter 3 Review

Chapter 4 Process Hazard Analysis

• What Is Process Hazard Analysis
• Facility Siting
• Getting Started With Process Hazard Analysis
• The Process Of Process Hazard Analysis
• Methodologies
• Which Methodology To Use
• What-If
• What-If Process
• What-If Steps
• What-If Example Questions
• Checklist
• What-If/Checklist
• What-If/Checklist Team
• What-If/Checklist Information
• What-If/Checklist Procedure
• What-If/Checklist Limitations
• Hazard And Operability Study
• When To Conduct A HAZOP Study
• HAZOP Team
• The HAZOP Team Leader
• HAZOP Procedure
• HAZOP Procedure Flow Chart
• Modes Of Operation
• Design Intent
• Deviation
• Guide Words
• Process Parameters
• Process Parameters With Guide Words
• HAZOP Example
• HAZOP Advantages
• HAZOP Success Factors
• HAZOP Disadvantages
• Failure Mode And Effects Analysis
  • FMEA Worksheet
• Fault Tree Analysis
• Why Have Fault Tree Analysis
• Fault Tree Analysis Steps
• Fault Tree
• Constructing A Fault Tree
• Benefits Of Constructing A Fault Tree
• Fault Tree Analysis Symbols
• Failure Mode And Failure Mechanism
• Failure Mode Versus Failure Mechanism
• Fault Tree Example Problem
• Fault Tree Exercise
• Chapter 4 Review Questions
• Chapter 4 Review

Chapter 5 Operating Procedures And Training

• Getting Started With Operating Procedures
• Paragraph (f)(1)
• Paragraph (f)(3)
• Standard Operating Procedures
• Benefits Of Standard Operating Procedures
• Writing Operating Procedures
• Writing Style
• Content Of Operating Procedures
• Periodic Review Of Operating Procedures
• Training
• Training Subjects
• Refresher Training
• Training Documentation
• Chapter 5 Review Questions
• Chapter 5 Review

Chapter 6 Contractors

• Who Is A Contractor
• Contract Employer Responsibilities
• Paragraph (f)(4)
• Employer Responsibilities
• Controlling Access
• Injury And Illness Log
• Preparing Bid Solicitations
• Evaluating Contractors
• DART Rate
• Incidence Rate
• Chapter 6 Review Questions
• Chapter 6 Review

Chapter 7 Pre-Startup Safety Review

• What Is A Pre-Startup Safety Review
• When To Conduct A Pre-Startup Safety Review
• Benefits Of A Pre-Startup Safety Review
• Purpose Of A Pre-Startup Safety Review
• Who Can Conduct A Pre-Startup Safety Review
• Pre-Startup Safety Review Steps
• Owner And Contractors
• Chapter 7 Review Questions
• Chapter 7 Review

Chapter 8 Mechanical Integrity

• Benefits Of Mechanical Integrity
• Preventive Maintenance
• Corrective Maintenance
• Maintenance Failure
• Mechanical Integrity Is More Than Maintenance
• Management Responsibility
• Equipment
• Inspection
• Chapter 8 Review Questions
• Chapter 8 Review

Chapter 9 Working Safely

• Management Responsibility
• Safe Work Practices
• Hot Work
• Hot Work Permit
• Fire Prevention
• Flammables
• Confined Space
• Confined Space Hazards
• Confined Space Incidents
• Confined Space Entry Program
• Working At Height
• What To Do When Working At Height
• What Not To Do When Working At Height
• Lockout Tagout
• Planning An Excavation
• Chapter 9 Review Questions
• Chapter 9 Review

Chapter 10 Management Of Change

• Why Have Management Of Change
• Management Of Change Program
• What Is A Change
• "Replacement In Kind"
• Is It Change?
• Change Control Mechanism
• Before Changes
• Questions To Ask
• After Changes
• Emergencies And Management Of Change
• Chapter 10 Review Questions
• Chapter 10 Review

Chapter 11 Incident Investigation

• Definitions
• When To Investigate
• Who Should Investigate
• Employee Involvement
• Purpose Of Incident Investigation
• Employer Obligations
• Content Of An Incident Investigation Report
• Six Key Questions
• More On Incident Investigation
• Chapter 11 Review Questions
• Chapter 11 Review

Chapter 12 Emergency Planning And Response

• Emergency Action Plan
• When To Review The Emergency Action Plan
• Emergency Procedures
• Emergency Shutdown
• Building Escape Route
• Assembly Point
• Alarm Systems
• Consequences Of Not Following Emergency Procedures
• Chapter 12 Review Questions
• Chapter 12 Review

Chapter 13 Compliance Audits And Trade Secrets

• Paragraph (o)
• Purpose Of A Compliance Audit
• Audit Process
• Documents To Examine
• Questions Auditors Should Ask
• Trade Secrets
• Protecting Trade Secrets
• Chapter 13 Review Questions
• Chapter 13 Review

Chapter 14 Making Plants Safer

• Process Intensification
• Minimization
• Substitution
• Substitution Examples
• Attenuation
• Limiting The Effects Of Failure
• Safer Ways To Limit The Effects Of Failure
• Simplicity
• The Domino Effect
• Avoiding The Domino Effect
• Making Incorrect Assembly Impossible
• Making Status Clear
• Reliability
• Easier To Control
• Passive Safety
• Chapter 14 Review Questions
• Chapter 14 Review