Introduction
The production of the process industry often involves hazards. Their nature can be both physical and chemical. Physical hazards derive from operating conditions that may be extreme, such as very low or very high temperatures and pressures. Chemical hazards are those associated with the materials present in the process, which can be toxic, flammable, exposable, or release energy due to spontaneous reactions. Indeed, it is necessary to put the substances into a reactive state in order to enable one to produce the desired products that may lead to hazards.
This comprehensive training course will provide an overview of each of the process safety management elements in the plant. Facilitators will also share best practices for implementing and managing each of these elements. The course is organized into 5 modules, each module will shed the light on the safety process that will be involved in the design of plants.
Program objectives
In this training program, you will:
- Learn how to identify process safety and major accident hazards in your facilities, and how to assess their risks and define critical controls (barriers)
- Understand the concepts of static and dynamic barrier management, and how barrier management can be used to analyze process safety and root cause incident investigation.
- Get hands-on experience with the development of bowtie diagrams
- Learn the characteristics of different types of barriers: hardware (plant), human (people), and organizational (process)
- Understand how a PSM system can help manage process safety risks, by providing governance and structure in terms of:
- Showing commitment of the organization to process safety
- Understanding hazards and their associated risk
- Managing risk in operations, maintenance, and when new projects are initiated, and
- Learning from incidents.
- Get a detailed overview of the expectations and good-industry practices.
Target Audience
The course is designed for those responsible for developing and implementing process safety management in their organization and plant design, but that does not yet have a solid understanding of process safety and good industry practices of PSM.
This could include:
- Plant or unit managers
- Head of sections or departments:
- Operations.
- Maintenance inspection.
- Engineering
- Senior engineers :
Course contents
Module 1:
Commit to process safety
- Process safety culture
- Compliance with standards
- Process safety competency
- Hazardous Properties of Materials
Exothermic and Pressure-Generating Reactions
- Formal Kinetics Description of Chemical Reactions
- Reactor Models
- Autocatalytic Reactions
- Polymerization
- Extreme Process Conditions
- Endothermic Processes
Module 2:
Understand Hazards and Risk
- Process knowledge management
- Hazard identification and risk analysis
Manage Risk
- Operating procedures
- Safe work practices
- Asset integrity and reliability
- Contractor management
- Training and performance assurance
- Management of change
- Operational readiness
- Conduct operations
- Emergency management
Module 3:
Safe Design and Operation of Plants
- Procedure for Ensuring Safety in Planning, Building, and Operating Plants
- Principles of Plant Safety and Fundamental Concepts
- External Events
- Plant Layout and Spacing
- Fire and Explosion Protection
Personal Safety and Personal Protective Equipment
- Safe Design and the Procurement of Safe Apparatuses and Work Equipment
- Apparatuses, Machinery, and Tools
- Hazard Assessment
- Personal Protective Equipment
- Safe Handling of Chemical Substances
- Work with Special Hazards: Permit-to-work System
Safety of Process Plants by Process Control
- Control System Characteristics and P&I Diagrams
- Programmable Electronic Systems
- Integration of PCE in the Safety Concept
- Case Study: Iron-Catalyzed Oxidation of Ethanol with Hydrogen Peroxide
Protection of Equipment (End-of-pipe Technology)
- Safety Valves
- Bursting Disc Protection Device
- Combination of Safety Valve and Bursting Disc Protection Device
- Dimensioning of Relief Devices
- Constructive Measures of Explosion Protection
Module 4:
Risk
- Overview of Risk and Safety Analyses
- Risk Limits
- Representation of Risks
Investigation of Engineered Plant Systems
- Fundamentals
- Mathematical Description of the Components of Engineered Systems
- Determination of Reliability Data for Engineered Components
- Boolean Variables and Their Application in Fault Tree Analysis
- Methods for Increasing the Survival Probability and Availability
- Dependent Failures
- Human Error
- Examples and Case Studies for the Application of Fault Tree Analysis
Module 5:
Consequences of Accidents
- Failure of Containment
- Emission from Leaks
- Pool Formation and Pool Vaporization
- Atmospheric Dispersion
- Fires and Explosions
- BLEVE
- Dust Explosion
- Flight of Missiles
- Scenarios and Probability Assignments
- Case Study: Risk Assessment for the Failure of a Natural Gas High-Pressure Pipeline
Functional Safety (Safety Integrity Levels)
Determination of Appropriate Distances Between Industry and Residential Areas
- Risk-Based Approach
- Processing of Random Variables
- Risk Limits and Distances on the Basis of Risk Considerations
- Deterministic Procedure in Germany Based on the Guidelines of the Commission of Plant Safety (KAS)
Things to do and places to visit in London
With so many attractions in London, anyone can find something to delight them. Art lovers will enjoy the world-renowned museums and galleries, most of which are free. Sports fans are spoilt for choice by the city's array of football clubs. Theatre and music fans have a vast list of venues to visit, whilst shopaholics have Harrods, Oxford Street, Camden and much more to look forward to after arranging flights to London.
Some unmissable London attractions include:
- Seeing priceless masterpieces in the Tate Britain or the National Gallery.
- Watching the changing of the guard at Buckingham Palace.
- Visiting Trafalgar Square's famous monument.
- Marveling at the Crown Jewels in the Tower of London.
- Getting a bird's eye view of the city from the London Eye.
- Tasting one of Brick Lane's famous curries.
- Browsing the exclusive shops of Knightsbridge.
- Visiting a market – Spitalfields for antiques, Camden for clothes or Borough Market for street food.
- Admiring design from around the world in the Victoria and Albert Museum.
- Looking for clues at the home of fiction's most famous detective, Sherlock Holmes.
- Strolling through one of the lovely parks, including Hyde Park, St James' Park or Kew Gardens.
- Eating Britain's most famous dish, fish and chips.
- Watching the street performers in Covent Garden.
- Enjoying the views at a South Bank cafe.