Health, Safety & Security

Training Course: Process and Plant Safety


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HE234796

30 Mar - 3 Apr 2025

Istanbul (Turkey)

Hotel : DoubleTree by Hilton Istanbul Esentepe

Cost : 5775 € Euro

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 :
    • Reliability.
    • Inspection.

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)

Health, Safety & Security

Training Course: Process and Plant Safety


Register Now
Quick Inquiry
Discount Group Download Brochure (38)

HE234796

30 Mar - 3 Apr 2025

Istanbul (Turkey) - DoubleTree by Hilton Istanbul Esentepe

Hotel : DoubleTree by Hilton Istanbul Esentepe

Cost: 5775 € Euro


  About Istanbul

Few places compare to the vibrant, cosmopolitan city of Istanbul, whose enormous size straddles both Europe and Asia, forming a bridge between western and eastern cultures. Resting upon the natural harbor of the Golden Horn, the skyline of the once-Constantinople is pierced with minarets and ancient monuments that embody centuries of history. While it is brimming with historical landmarks and colorful markets, modern Istanbul is also well represented through its contemporary art scene, European-style café culture, world-class dining venues.


  Things to do and places to visit in Istanbul

Istanbul is teeming with attractions and landmarks from historic sights and unique cuisine to lively markets and unmistakable culture. It is a thriving city, with a myriad of things to do that skillfully manage to blend every aspect of both the contemporary and the historical world.

On a city break in Istanbul be sure to:

  • Visit a hammam, a traditional Turkish bath, whose origins date back to Roman times.
  • Marvel at the Hagia Sophia, Süleymaniye Mosque and Blue Mosque, Istanbul's most spectacular monuments that dominate the skyline.
  • Explore the Topkapi Palace Museum, one of Istanbul's most visited museums, home to over 80,000 artifacts.
  • Walk through the Basilica Cistern, an underground marvel built in the 4th century.
  • Be dazzled by the Grand Bazaar, one of the world's oldest and largest covered markets.
  • Go shopping for exotic products and Turkish delights in the Spice Bazaar.
  • Cross the bridge connecting Europe and Asia against the backdrop of the Bosphorus, or take a Bosphorus cruise.
  • Taste the diversity and flavor of Turkish cuisine.
  • Admire panoramas of the city from the Galata Tower.
  • Walk through Taksim Square, the city's dynamic square that never sleeps.
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