This course provides a practical foundation for engineers and safety professionals to integrate safety considerations into process design. Participants will explore key concepts such as inherent safety, electrostatic hazards, inerting, pressure relief systems, and basic PHA techniques like HAZOP, What-If, and SIL assessment.

Through case studies and real-world examples, the course emphasizes how early design decisions impact plant safety. It is ideal for those involved in design, operations, or safety review who seek hands-on tools to identify hazards and apply risk reduction strategies effectively.

Process Safety / Process engineer / Senior process engineers / Operation Engineers total max 20 (TBA)

Day 1:

8:00 AM – 9:00 AM      Register

9:00 AM – 12:00 PM

• Introduction to Process Safety
  • What is Process safety? / Process Safety vs Occupational Safety
  • PSM (Process Safety Management) Brief

• Accident and Failure in the Past
  • Nature of accidents
  • Process safety events and Swiss Chess model

• Concept of Safety in Design
  • Inherent / Passive / Active Procedural
  • Minimize / Substitute / Moderate / Simplify

• Fire and Toxic Release
  • The fire triangle
  • Flammability limit
  • Auto ignition temperature
  • Minimum ignition energy
  • Pool fire / Jet fire / flash fire / BLEVE / VCE
  • Combustion explosion
  • Toxic gas release
  • Nitrogen / Hydrogen hazards

12:00 PM – 13:00 PM Lunch Break

13:00 PM – 17:00 PM

• Static Electricity

• Inerting and Purging
  • Vacuum purging
  • Pressure purging
  • Vacuum – Pressure purging

• Layer of Protection Concepts
• Pressure Relieving System
  • Set pressure /Overpressure / Accumulation
  • Overpressure protection philosophy
  • Vapor depressurization
  • Relief load mitigation

Day 2:

8:00 AM – 9:00 AM      Register

9:00 AM – 12:00 PM

• Management of Change
  • Role and Responsibilities of person
• Risk Assessment Concepts
• PHA Techniques
  • Checklist
  • What IF and What IF exercise
  • HAZID
  • FMEA

12:00 PM – 13:00 PM Lunch Break

13:00 PM – 17:00 PM

• HAZOP (Hazard and Operability studies)
  • HAZOP introduction (What / How / When / Objective)
  • Terminology
  • Guidewords
  • Flowchart
  • Identifying nodes
  • Cause / Consequences / Safeguards / Risk Rank / Recommendation
  • HAZOP Exercise
• SIL Introduction
  • SIF / SIS /SIL
  • Method of SIL Assessment
    • Risk matrix
    • Risk graph
    • LOPA
    • Fault Tree and Event Tree Analysis