COURSE OVERVIEW:

Process Safety Management (PSM) is a systematic framework designed to prevent high-consequence, low-frequency incidents such as fires, explosions, and toxic releases in industrial facilities. This course provides a comprehensive introduction to the 14 elements of the OSHA PSM standard and the Risk-Based Process Safety (RBPS) guidelines developed by the Center for Chemical Process Safety (CCPS). Participants will examine the fundamental difference between personal safety (occupational health) and process safety (asset integrity and containment).

The scope of this training involves a detailed analysis of how to manage the technical, organizational, and human factors that contribute to process safety. Attendees will explore the critical importance of Process Safety Information (PSI), including P&IDs and chemical reactivity data, as the foundation for all safety assessments. The course emphasizes the proactive identification of hazards through methodologies such as HAZOP and What-If analysis, ensuring that the "layers of protection" are robust and functional.

Coverage includes the lifecycle of process safety, from initial design and Management of Change (MOC) to Pre-Startup Safety Reviews (PSSR) and Incident Investigation. Participants will examine the role of mechanical integrity in ensuring that critical equipment like relief valves and sensors perform as intended. By integrating leadership commitment with rigorous operational discipline, this course equips professionals with the knowledge to build a resilient process safety culture that protects personnel, the environment, and business continuity.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

1.  Define the core philosophy of Process Safety vs. Occupational Safety.

2.  Identify the 14 mandatory elements of the OSHA PSM Standard (29 CFR 1910.119).

3.  Evaluate the quality of Process Safety Information (PSI) for a facility.

4.  Participate effectively in a Process Hazard Analysis (PHA) team.

5.  Explain the importance of Operating Procedures in preventing human error.

6.  Implement a rigorous Management of Change (MOC) workflow.

7.  Conduct a Pre-Startup Safety Review (PSSR) for new or modified equipment.

8.  Identify critical equipment for a Mechanical Integrity (MI) program.

9.  Execute a thorough Hot Work Permit and Safe Work Practice system.

10.  Analyze the root causes of process incidents using systematic techniques.

11.  Develop and test Emergency Planning and Response protocols.

12.  Facilitate effective Process Safety Audits and compliance reviews.

13.  Foster a "Chronic Unease" and high-reliability organizational culture.

TARGET AUDIENCE:

Safety Officers, Operations Personnel, Maintenance Supervisors, Engineering Managers, and Corporate Compliance Auditors.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.