Course Objectives:

By the end of this training, participants will be able to:

1. Fundamentals of Critical Equipment and System Overrides

• Understand the role of overrides in industrial processes, including oil & gas, power plants, and chemical industries.
• Define the different types of overrides:
• Manual Overrides (Bypassing automated controls).
• Emergency Overrides (Shutdown and safety system interventions).
• Software/System Overrides (Temporary control system bypass).
• Identify risks associated with overriding safety and operational systems.

2. Critical Equipment and Safety Systems

• Recognize critical equipment that may require system overrides:
• Pressure Safety Valves (PSV).
• Emergency Shutdown (ESD) Systems.
• Fire and Gas Detection Systems.
• Control Valves and Actuators.
• Compressors, Pumps, and Turbines.
• Understand when and why overrides are needed, such as during maintenance, startup, or troubleshooting.

3. Procedures and Authorization for Overrides

• Develop proper authorization protocols for implementing overrides.
• Understand industry best practices for managing overrides, including:
• Temporary vs. Permanent Overrides.
• Approval and Documentation Requirements.
• Audit Trails and Override Tracking.
• Learn override permit systems and compliance with industry standards (API, OSHA, IEC 61511).

4. Risk Assessment and Hazard Management

• Perform risk assessments before applying overrides.
• Identify potential consequences of bypassing safety systems.
• Apply risk mitigation strategies to minimize hazards associated with overrides.
• Conduct Failure Mode and Effects Analysis (FMEA) for override scenarios.

5. Emergency Response and Override Recovery

• Establish emergency procedures in case of override system failure.
• Learn best practices for returning systems to normal operation after an override.
• Implement alarm management strategies to minimize human error during overrides.

6. Troubleshooting and Case Studies

• Study real-world incidents related to system overrides and their impact on safety and operations.
• Develop systematic problem-solving approaches for override-related failures.
• Apply reliability-centered maintenance strategies to prevent unnecessary overrides.

Target Audience

This course is designed for professionals involved in industrial operations, process safety, and control system management, including:

1. Engineers & Technical Personnel

• Process Engineers
• Control System Engineers
• Instrumentation & Automation Engineers
• Mechanical Engineers

2. Operations & Maintenance Teams

• Field Operators
• Maintenance Engineers
• Reliability Engineers
• Emergency Response Teams

3. Health, Safety, and Environmental (HSE) Professionals

• HSE Officers
• Process Safety Management (PSM) Teams
• Compliance and Regulatory Personnel

4. Management & Decision-Makers

• Operations Managers
• Safety and Risk Managers
• Plant Supervisors