IOSH Process Safety Training Course

Course aims

• Understand the many aspects of Process Safety
• Learn where to go to find guidance on hazards associated with substances and activities
• Be aware of (and practice using) various tools for Hazard Identification & Risk Assessment
• Understand the importance of understanding the Operating, Trip and Design parameters of processes and equipment
• Understand the importance of identifying and managing the potential initiating events and control measures related to hazard scenarios
• Understand the role of Hazard Analysis in Land Use Planning & risk reduction decisions
• Understand the role of Human Factors and Competence in PSM
• Understand the various aspects of a Safety Management System (& Major Accident Prevention Policy)
• Understand the importance of Leadership, Safety Culture and ongoing evaluation of the Process Safety Management System

Who should attend this course?

EHS professionals, engineers and senior management looking to develop a comprehensive understanding of process safety, working in industries involving hazardous materials/processes, the risk of explosion or catastrophic failure. The course content and case studies were selected to represent the broad array of hazardous challenges seen across the spectrum of Irish Industry.

Course Pre-requisites.

Learners should have a basic understanding of process operations, hazard identification and risk assessment.

Course Objectives

On completion of the course, participants will be able to give:
• an awareness of and respect for Process Safety
• understanding of where process safety hazards exist
• understanding of the tools that can be used to properly assess and manage these risks
• an understanding of the various aspects of a Process Safety Management, Leadership and Culture
• an understanding of the role of Regulations in ensuring public, employee and environmental safety
• To help learners to appreciate that it is important to “know what they don’t know” about process safety.

Understanding Hazards

o What factors affect risk?
o 1# Case study : Williams Olefins
o Chemicals
o 2# Case Study : Bayer Inherent Safety
o Group Exercise #1: Use of Inherent Safety guidewords
o Fire
o Explosion
o Corrosive substances
o Acute toxicity
o Chronic toxicity
o Environmental

Understanding Processes

o For Design intent
o Unit Operations
o Utilities
o Chemical Reactions
o 3# Case Study : T2 runaway reaction
o Inherent Safety of Processes
o Worked Example #1: using systematic process to assess IS options for reaction
o Best Practice & Learning from Past Incidents

Equipment and Processes fit for Purpose

o Design Intent
o Guidance, ACoPS and Standards
o Asset Integrity
o 4# Case Study : latent Asset Integrity issues

Control Measures

o Critical Safety
o Reliability & Availability
o Instrumentation & Control
o Worked Example #2: SIL determination using graph & FTA
o ATEX
o 5# Case Study : Imperial Sugar dust explosion
o Worked Example #3: ATEX HACs for powder filling and tanker transfer
o Group Exercise #2: use Bow Tie to facilitate review of Control Measures
o Ergonomics
o Group Exercise #3: Human Error in adding ingredients to batch reactor
o Inherent Safety of Control Measures
o Best Practice & Learning from Past Incidents
o 6# Case Study : Formosa Plastics

Identification of Hazards

o HAZID
o HAZOP
o 7# Case Study : DuPont Buffalo Hot Work: Hidden Hazards
o CHAZOP
o Task Analysis

Assessment of Risks

o Risk Assessment
o Group Exercise #4: Develop a checklist
o Understanding Initiating Causes of Hazardous Events
o Human Error Assessment
o Consequence Assessment
o Likelihood Assessment
o How Tolerable
o Occupied Buildings
o Emergency Response
o 8# Case Study : Emergency Preparedness
o Escalation & Domino Effects
o Land Use Planning
o Environmental Risk Assessment
o Risk Management Decisions
o Basis of Safety
o Worked Example #4: New development near existing site

Management of Process Safety

o Safety Management Systems
o Process Safety Management Systems
o CoMAH MAPP requirements
o Organisation & Personnel
o Identifing & Evaluating of MAHs
o Operational Control
o Importance of Management of Change
o 9# Case Study 9: Flixborough
o Planning for Emergencies
o Monitoring Performance
o 10# Case Study : DuPont Belle Fatal Exposure
o Knowledge of Process Safety Performance Indicators
o Group Exercise #5: Developing Leading & Lagging Indicators
o Audit & Review

Leadership

o Relating to Safety Culture
o In Process Safety Management Systems
o Performance Evaluation, Corrective Action & Corporate Oversight

 Overview

o 11# Case Study : Texas City