Petrosync - Enhanced Process Safety Management Training Course

Enhanced Process Safety Management

Type
Training
Training Code
PST0186

Course Overview

Oil and gas companies handle the most dangerous chemicals and processes across all industries. Catastrophic incidents and casualties are products of the failure to manage process safety. The danger present in everyday operations is evolving thus it is essential to always improve in handling risk and hazard. Most companies already have established safety guidelines to follow. However, there is a constant need to continuously improve implementation and existing methodologies in order to gain better efficiency and attain optimal operations in a safe work environment.

This course addresses the above needs in process safety management. Aside from learning the methodologies and techniques in reducing risks and hazards, it will also integrate the concept of business continuity improvement to address how to further develop existing methodologies that companies have. The course will start with tackling the technical elements on risk & hazard identification (HAZOP, HAZID, SIL, LPA, etc.). It would then move on to the procedures in risk and hazard reduction and their application in having an inherently safer system design. The topic on contractor management shall also tackle how to manage safety between end-users and engineering contractors. Lastly, to culminate the course, guidelines on how to improve productivity and profitability through continuous improvement in safety management will also be provided. Extensive case studies will be discussed in order to learn from past industry accidents and catastrophes. Moreover, in-depth class discussion will be facilitated in order to promote a good exchange of industry knowledge amongst delegates.

Course Objectives:

IMPROVE safety skills through techniques in process safety management
INTEGRATE risk & hazard reduction methods across the full spectrum of process safety elements
UNDERSTAND the critical elements necessary for safety design
GAIN practical risk reduction methods ready for implementation
APPLY techniques in process safety management through practical exercises and industry case studies
MANAGE high-risked working environment
OVERCOME the limitations and blocks to acheiving a optimal process safety
PROMOTE business continuity improvement through understanding of safer systems design

Specially Designed For:

PSM Managers/Engineers
Process Managers/Engineers
HSE Managers/Engineers
Operations Managers/Engineers
Maintenance Managers/Engineers
Control, Monitoring, Emergency Response

Course Outlines

DAY 1

Overview of the Course

Introduction to Process Safety Management

Identification of Hazards in all Asset Phases

Conceptual
Design
Construction
Operations and Maintenance
Dismantlement

Understanding Hazards and Risks

What is a Hazard? What is a Risk?
Group Discussion: Why do people miss Hazards?
How do we look completely on Hazards?
Process Hazards (Instructor-led Class Discussion)
Company HSE Procedures (Instructor-led Class Discussion)
Process Risk & Hazard Analysis Methods

Process Design Stages
Parallels of General HSE & Process Safety System

HW Prep: Piper Alpha Case Study

Research for additional information on Piper Alpha Case
Review the video at the end of the class
Learning Focus: The Many Hazards, How the Hazards were
Addressed, Role of Culture, Interface of the Safety Systems,
Control of Work, Work Permitting Processes, Shift
Handovers, Emphasizing the Criticality of Doing Simple
Things Well

DAY 2

Review of Day 1 Case Study

Multiple Blocks to Safety
Review Piper Alpha Case Study (Focus: Safety System)
Review of PSM Elements
The ultimate business outcome
Class Discussion

Risk Reduction Methods & Systems by PSM Element

General Safety Systems
Role of Audit and Assessment
Training and Development
Incident Investigation and Reporting
Employee Participation and All Other Elements

PSM Elements

Emergency Shutdown Systems
Fire and Gas Systems
Safety Instrumented Systems & Functions
Designing SIF and SIS
Integrity Specification of a SIF
Read the Texas City Refinery Report
Learning Focus

Case Study

DAY 3

Review of Day 2 Case Study: Texas City Refinery Systemic Failures
Class Discussion Based on HW Prep

Instructor-led Overview: Inherently Safer Design & Strategies

ISD Strategies
Application of ISD to Oil & Gas Facilities

Process Monitoring & Control

Calculations for Reliabitliy

Failure Types and Modes
Failure and Reliability
Demand Modes
Probability of Failure on Demand
SIF Implementation for Low Demand Modes

Safety Critical Equipment

Overview of what it is
Where you may want to look for it

Fire Zoning, Electrical Hazardous Area Classification

Hazards Associated with Specific-Plant Systems & Equipment
Plant Layout & Equipment Spacing
Pressure Relief and Flare Systems
Fire and Explosion Protection Principles

HW Prep: Cross- Industries Safety (Bhopal & Bayer Crop Science Incident)

Research for more info on Bhopal Case
Research for more info on Bayer Crop Science Incident in West Virginia
Instructor will review DuPont’s response to the Bhopal incident as an example of how ISD is used
Study of inherently safer design and its role in business success: Bhopal, DuPont response to Bhopal and ISD example, Bayer response to Bhopal, Business outcomes of these decisions almost 30 years later

Case Study

DAY 4

Advanced Investigation