Process Safety Management and Major Hazard Control Training Course

Course Introduction

Process Safety Management (PSM) is a systematic and disciplined approach to preventing catastrophic incidents involving hazardous chemicals, flammable materials, toxic substances, and high-energy industrial processes. The Process Safety Management and Major Hazard Control Training Course provides participants with comprehensive knowledge of internationally recognized process safety principles, regulatory requirements, engineering controls, and management systems that minimize operational risks while protecting people, assets, the environment, and business continuity. The course emphasizes practical implementation strategies that strengthen organizational resilience and sustainable operational excellence across high-risk industries.

The course explores every element of an effective Process Safety Management system, including process safety information, hazard identification, process hazard analysis, operating procedures, mechanical integrity, management of change, contractor safety, emergency preparedness, incident investigation, compliance auditing, and continuous improvement. Participants will develop the competencies required to establish, evaluate, and continuously enhance process safety programs that meet international standards and industry best practices while improving operational reliability and regulatory compliance.

Participants will gain practical expertise in identifying major accident hazards, conducting risk assessments, implementing multiple layers of protection, and developing effective prevention and mitigation strategies. The training examines internationally recognized methodologies such as HAZOP, LOPA, Bowtie Analysis, Fault Tree Analysis (FTA), Event Tree Analysis (ETA), Quantitative Risk Assessment (QRA), and Safety Integrity Level (SIL) determination. These methodologies enable organizations to proactively identify hazards, evaluate risks, and implement robust controls that significantly reduce the likelihood and consequences of major industrial accidents.

The course also addresses emerging technologies and modern approaches that are reshaping process safety management, including digital twins, Industrial Internet of Things (IIoT), artificial intelligence, predictive analytics, machine learning, remote monitoring, industrial cybersecurity, and advanced asset integrity management. Participants will understand how digital transformation enhances real-time risk monitoring, predictive maintenance, operational decision-making, and process safety performance while addressing new technological and cyber-related risks affecting industrial operations.

Practical workshops, industrial case studies, simulation exercises, and lessons learned from major process safety incidents provide participants with valuable opportunities to apply theoretical knowledge to real operational challenges. Participants will strengthen their ability to investigate incidents, identify root causes, improve safety culture, evaluate barrier effectiveness, and implement corrective actions that enhance organizational learning while preventing future accidents across complex industrial facilities.

Upon successful completion of this course, participants will possess the technical knowledge, leadership capabilities, and practical skills required to develop, implement, audit, and continuously improve Process Safety Management systems and major hazard control programs. They will be equipped to support regulatory compliance, strengthen organizational safety culture, improve operational resilience, optimize asset integrity, and reduce business risks while contributing to safe, reliable, and sustainable industrial operations.

Duration

10 days

Who Should Attend

• Process Safety Engineers

• Chemical Engineers

• Process Engineers

• Plant Managers

• Operations Managers

• Production Managers

• HSE Professionals

• Safety Engineers

• Mechanical Engineers

• Instrumentation and Control Engineers

• Reliability Engineers

• Maintenance Engineers

• Asset Integrity Engineers

• Project Engineers

• Risk Assessment Specialists

• Operations Supervisors

• Engineering Consultants

• Compliance and Regulatory Officers

• Emergency Response Coordinators

• Professionals responsible for process safety, operational risk, and major hazard management

Course Objectives

• Develop a comprehensive understanding of Process Safety Management principles, regulatory frameworks, and management systems required to prevent catastrophic industrial incidents and improve operational resilience.

• Master internationally recognized Process Safety Management elements including hazard identification, process safety information, operating procedures, mechanical integrity, and management of change implementation.

• Strengthen the ability to identify major accident hazards, evaluate process risks, and implement effective prevention and mitigation measures using structured engineering and management methodologies.

• Learn to conduct advanced Process Hazard Analyses utilizing HAZOP, LOPA, Bowtie Analysis, Fault Tree Analysis, Event Tree Analysis, and Quantitative Risk Assessment techniques.

• Acquire practical knowledge for developing effective major hazard control strategies that integrate engineering safeguards, administrative controls, emergency preparedness, and organizational learning initiatives.

• Understand international standards including OSHA Process Safety Management, CCPS guidelines, IEC functional safety requirements, and relevant regulatory compliance obligations for high-hazard industries.

• Develop expertise in incident investigation, root cause analysis, barrier failure evaluation, and corrective action management that strengthens organizational process safety performance and continuous improvement.

• Apply risk-based inspection, mechanical integrity management, reliability engineering, and asset integrity strategies that improve equipment performance and reduce operational risk exposure.

• Evaluate the impact of human factors, safety culture, leadership practices, organizational behavior, and competency management on sustainable process safety performance and operational excellence.

• Examine emerging technologies including digital twins, Industrial Internet of Things, artificial intelligence, predictive analytics, and industrial cybersecurity for enhancing process safety management.

• Strengthen capabilities in emergency response planning, crisis management, business continuity planning, and resilience strategies that minimize the consequences of major industrial accidents.

• Build the confidence and technical competence required to lead multidisciplinary Process Safety Management initiatives that improve regulatory compliance, operational reliability, environmental protection, and organizational sustainability.

Comprehensive Course Outline

Module 1: Fundamentals of Process Safety Management

• Principles and objectives of Process Safety Management systems

• Understanding major accident hazards in process industries

• Regulatory requirements and international safety frameworks

• Process safety leadership and organizational accountability

Module 2: Process Safety Information

• Developing comprehensive process safety information systems

• Documentation of hazardous chemicals and process technologies

• Equipment design basis and engineering documentation management

• Maintaining accurate technical information throughout facility lifecycle

Module 3: Process Hazard Identification and Risk Assessment

• Hazard identification methodologies for complex industrial processes

• HAZOP, What-If, Checklist, and Preliminary Hazard Analysis techniques

• Risk ranking methodologies and consequence evaluation approaches

• Practical workshops using real industrial process scenarios

Module 4: Advanced Process Hazard Analysis

• Layers of Protection Analysis for risk reduction evaluation

• Bowtie Analysis linking threats, barriers, and consequences effectively

• Fault Tree Analysis and Event Tree Analysis methodologies

• Quantitative Risk Assessment supporting strategic decision-making

Module 5: Major Hazard Control Strategies

• Engineering controls preventing catastrophic process failures

• Administrative controls supporting operational risk management

• Independent Protection Layers improving facility safety performance

• Barrier management for sustained risk reduction effectiveness

Module 6: Mechanical Integrity Management

• Equipment inspection strategies supporting process safety objectives

• Reliability-centered maintenance for critical safety equipment

• Corrosion management and asset integrity improvement programs

• Fitness-for-service evaluation and lifecycle management techniques

Module 7: Management of Change

• Managing engineering, operational, and organizational modifications safely

• Risk assessment during process and equipment changes

• Documentation, approval, and implementation of change management

• Verification activities before startup following modifications

Module 8: Operating Procedures and Safe Work Practices

• Developing clear operating procedures for normal and emergency conditions

• Permit-to-work systems supporting hazardous maintenance activities

• Isolation procedures and energy control best practices

• Human performance improvement within operational environments

Module 9: Incident Investigation and Organizational Learning

• Root cause analysis methodologies for process safety incidents

• Barrier failure analysis and corrective action development

• Learning from historical industrial accident case studies

• Knowledge management supporting continuous safety improvement

Module 10: Emergency Preparedness and Crisis Management

• Emergency response planning for major hazard facilities

• Incident command systems and coordinated emergency management

• Business continuity planning during major industrial disruptions

• Practical emergency response exercises and scenario evaluations

Module 11: Functional Safety and Critical Protection Systems

• Functional safety principles supporting process hazard reduction

• Safety Instrumented Systems and Safety Integrity Level concepts

• Emergency shutdown systems and protective instrumentation design

• Integration of functional safety within Process Safety Management

Module 12: Digital Process Safety and Emerging Technologies

• Digital twins supporting predictive process safety management

• Artificial intelligence applications in operational risk assessment

• Industrial Internet of Things for real-time safety monitoring

• Cybersecurity considerations for critical industrial control systems

Module 13: Human Factors and Safety Culture

• Human reliability and performance influencing process safety outcomes

• Leadership behaviors strengthening organizational safety culture

• Competency management and workforce capability development

• Behavioral safety strategies supporting operational excellence

Module 14: Compliance Auditing and Performance Measurement

• Conducting effective Process Safety Management compliance audits

• Performance indicators measuring process safety effectiveness

• Regulatory inspection preparation and continuous compliance improvement

• Benchmarking against international industry best practices

Module 15: Industry Applications and Advanced Case Studies

• Oil and gas Process Safety Management implementation practices

• Petrochemical and refinery major hazard management examples

• Chemical manufacturing and pharmaceutical safety applications

• Lessons learned from internationally recognized major accident investigations

Module 16: Future Trends and Integrated Process Safety Project

• Sustainability and climate resilience within process safety management

• Advanced predictive analytics supporting proactive risk management

• Integrated Process Safety Management implementation project workshop

• Strategic roadmap for achieving long-term operational safety excellence

Training Approach

This course will be delivered by our skilled trainers who have vast knowledge and experience as expert professionals in the fields. The course is taught in English and through a mix of theory, practical activities, group discussion and case studies. Course manuals and additional training materials will be provided to the participants upon completion of the training.

Tailor-Made Course

This course can also be tailor-made to meet organization requirement. For further inquiries, please contact us on: Email: training@upskilldevelopment.com Tel: +254 721 331 808

Training Venue 

The training will be held at our Upskill Training Centre. We also offer training for a group (at a discount of 10% to 50%) at requested location all over the world. The Onsite course fee covers the course tuition, training materials, two break refreshments, buffet lunch, airport transfers, Upskill gift package, and guided tour.

Visa application, travel expenses, dinners, accommodation, insurance, and other personal expenses are catered by the participant

Certification

Participants will be issued with Upskill certificate upon completion of this course.

Airport Pickup and Accommodation

Airport pickup and accommodation is arranged upon request. For booking contact our Training Coordinator through Email: training@upskilldevelopment.com, +254 721 331 808

Terms of Payment:

Unless otherwise agreed between the two parties’ payment of the course fee should be done 3 working days before commencement of the training so as to enable us to prepare better.