📘 Course Description:
This in-depth training course is designed to provide professionals with practical tools and techniques to identify, assess, control, and monitor risks in industrial processes, particularly in high-risk industries such as oil & gas, chemicals, power, and manufacturing.
Participants will explore key elements of Process Safety Management (PSM), learn to apply tools like HAZOP, LOPA, and Bow-Tie Analysis, and integrate risk-based thinking into operational and strategic decision-making. The course emphasizes proactive prevention of process-related incidents such as explosions, toxic releases, fires, and mechanical failures.
✅ By the end of this course, participants will:
-
Understand the principles of process risk and safety
-
Identify and evaluate process hazards
-
Apply leading risk assessment techniques (HAZID, HAZOP, LOPA)
-
Develop effective risk control and mitigation strategies
-
Integrate risk management into organizational systems
✅ Day 1: Introduction to Process Risk & Safety Management
| Time | Topic |
|---|---|
| 08:30 – 09:00 | Welcome & Registration |
| 09:00 – 10:30 | Overview of Process Safety & Risk Concepts |
| 10:30 – 10:45 | Coffee Break |
| 10:45 – 12:00 | Major Industrial Accidents & Root Causes (Case Studies) |
| 12:00 – 13:00 | Lunch Break |
| 13:00 – 14:30 | Risk Terminology: Hazard, Risk, Likelihood, Consequence, etc. |
| 14:30 – 14:45 | Break |
| 14:45 – 16:30 | Regulatory Framework (OSHA PSM, Seveso, API RP 750, etc.) |
✅ Day 2: Hazard Identification & Risk Assessment Tools
| Time | Topic |
|---|---|
| 08:30 – 10:30 | Hazard Identification Techniques: What-If, Checklist, HAZID |
| 10:30 – 10:45 | Coffee Break |
| 10:45 – 12:00 | Failure Modes and Effects Analysis (FMEA) |
| 12:00 – 13:00 | Lunch Break |
| 13:00 – 14:30 | Hazard and Operability Study (HAZOP): Principles & Examples |
| 14:30 – 14:45 | Break |
| 14:45 – 16:30 | HAZOP Workshop: Hands-on Case Study |
✅ Day 3: Risk Analysis and Evaluation Techniques
| Time | Topic |
|---|---|
| 08:30 – 10:30 | Introduction to Layers of Protection Analysis (LOPA) |
| 10:30 – 10:45 | Coffee Break |
| 10:45 – 12:00 | Bow-Tie Risk Assessment Method |
| 12:00 – 13:00 | Lunch Break |
| 13:00 – 14:30 | Quantitative vs Qualitative Risk Analysis |
| 14:30 – 14:45 | Break |
| 14:45 – 16:30 | Risk Matrices & Risk Tolerability Criteria |
✅ Day 4: Risk Mitigation & Barrier Management
| Time | Topic |
|---|---|
| 08:30 – 10:30 | Hierarchy of Controls: Elimination to PPE |
| 10:30 – 10:45 | Coffee Break |
| 10:45 – 12:00 | Safety Instrumented Systems (SIS) & Integrity Levels (SIL) |
| 12:00 – 13:00 | Lunch Break |
| 13:00 – 14:30 | Engineering and Administrative Controls |
| 14:30 – 14:45 | Break |
| 14:45 – 16:30 | Barrier Management & Bow-Tie Application Exercise |
✅ Day 5: Risk Communication, Monitoring & Continuous Improvement
| Time | Topic |
|---|---|
| 08:30 – 10:30 | Risk Communication & Decision-Making Under Uncertainty |
| 10:30 – 10:45 | Coffee Break |
| 10:45 – 12:00 | Performance Monitoring of Risk Controls (KPIs, audits) |
| 12:00 – 13:00 | Lunch Break |
| 13:00 – 14:30 | Integration with PSM and ISO 45001 / ISO 31000 |
| 14:30 – 14:45 | Break |
| 14:45 – 16:30 | Group Exercise, Course Review, Final Q&A, and Certificates |
📦 Course Materials:
-
HAZOP & LOPA templates
-
Bow-Tie diagrams & case studies
-
Risk assessment checklists
-
Regulatory compliance guide
🎯 Who Should Attend:
-
Process engineers & designers
-
Safety & HSE professionals
-
Plant and operations managers
-
Auditors and compliance officers
-
Risk & reliability engineers
