Safety In Process Design

As a participant, you will gain essential skills to design safer, more reliable processes and reduce risk. You’ll learn to apply inherent safety principles, conduct risk assessments using methods like HAZOP and LOPA, and understand safety systems such as alarms, interlocks, and SIS. Through real-world case studies, you’ll identify common design flaws and learn best practices to prevent incidents. The course also covers regulatory compliance, safety standards, and hands-on applications to ensure you can proactively design for safety, improve operational reliability, and foster a strong safety culture in your organization.

Day 1

• Kick off, introductions, course objectives and expectations
• Process Safety versus personal safety; history of process safety developments and industry major incidents
• Process safety Management Processes including risk management
• Hazard identification, Bowtie, LOPA, ALARP, Hierarchy of Controls, process safety Critical Elements, Activities, Positions
• Group Exercise

Day 2
Codes and standards for Safe Design, active protection

• Safe Design: pressure and temperature
• Overpressure protection, flare systems
• Overtemperature protection: emergency depressuring
• Material selection and degradation

Day 3
Continue active protection, Passive protection / escalation control

• Safeguarding Instrumented Functions
• Release Detection Systems, ROV, TSO
• Fire protection
• Area Classification/ATEX/Site Lay out
• Exercise (optional)
• Safeguarding Memorandum

Day 4
Static electricity, reactive hazards, fire and explosions

• Static electricity
• Reactive hazards
• Flammability, Ternary Diagrams
• Exercise(s)
• Types of fires/explosions (VCE, BLEVE, Flash, Pool), dispersion, toxicity
• Process and Operational Safety/MOC/Transient conditions

Day 5
Management of Change, Process safety culture

• MOC exercise(s) – Risk Screening Form
• Getting the right Process Safety Culture
• Process Safety Fundamentals
• Measuring the health process safety: leading, lagging indicators (pyramid)
• Process Safety Reviews
• Discussion of client specific subject(s)