Fundamentals of Process Safety & Loss Prevention Course

Introduction

This course is designed to provide participants with a detailed and up-to-date overview of safety and loss, major incidents have been occurring around the world for as long as hazardous materials have been processed. Loss prevention is not only concerned with incidents that cause injury to people. It covers all forms of loss, including damage to the environment and property and interruption to production caused by major failures of a plant, even when there is no injury to people or damage to the surroundings. The escape of toxic methyl isocyanate vapor from the Union Carbide India Limited plant at Bhopal in India on December 1984 was the most serious chemical plant incident in history, causing thousands of deaths and many tens of thousands of severe injuries, many of them causing permanent incapacity. This and the explosion at the Phillips Petroleum polyethylene plant at Pasadena on 23 October 1989, which killed 23 people and injured hundreds more, alerted management and governments to the need for much more than traditional occupational safety and health programs to provide safety for those working in, or living around, process plants. However, this was not new knowledge. Major incidents have been occurring around the world for as long as hazardous materials have been processed.

Objectives

Upon the successful completion of this course, each participant will be able to:

• Apply and gain an in-depth knowledge on safety and loss prevention
• Define what risk assessments are used for and how to prepare them
• Identify frequency of risk assessments and schedule them as well as identify who should conduct risk assessments and management
• Conduct a risk assessment and management and identify risks, evaluate levels of risk and use a standardized rating process
• Use forms provided, record and report risk assessment findings
• Identify the consequences of major accidents in terms of fire, explosion, toxic releases and their costs
• Discuss and implement risk assessment techniques in oil and gas industry and explain root cause analysis and provision of examples of actual accidents
• Utilize quantified risk assessment “QRA”, risk and cost-benefit analysis resource allocation for production, maintenance and safety
• Employ practical application of advanced risk management techniques to new projects and current activities
• Recognize the difference between hazard, risk and risk management
• Develop the skills of applying advanced risk assessment techniques and determine how to evaluate different types of risk
• Develop a strategy for planning and implementing risk reduction action plans
• Create a plan of action of implementation

Training Methodology

This is an interactive course. There will be open question and answer sessions, regular group exercises and activities, videos, case studies, and presentations on best practice. Participants will have the opportunity to share with the facilitator and other participants on what works well and not so well for them, as well as work on issues from their own organizations. The online course is conducted online using MS-Teams/ClickMeeting.

Who Should Attend?

This course provides a complete and up-to-date overview of loss prevention and safe working procedures for all safety management specialist, engineer and technical personnel who are responsible for the safety of their work force. Their responsibilities include design, training, maintenance, production and safety for production support equipment.

Course Outline

Introduction The Situation

• Handling the Situation
• Management of the Hazards, or the Potential for Mishap
• Why Bother with Risk Management, Anyway?
• The Benefits of Risk Management
• Scope of Process Risk & Reliability Management
• The Risk Spectrum
• Steps in Risk Management of a Process Plant
• Risk Management Without Numbers
• Some Illustrations of the Approach
• Define the Context

Hazard Identification Introduction

• Types of Impact
• Typical Types of Incident Leading to the Impact
• Types of Process Plant Incidents
• Approaches to Systematic Identification of Hazards & Risks

Ranking & Short-Listing of Risks Introduction

• The Pareto Principle
• Two Classes of Risks for Attention
• Ranking the Hazards & the Associated Risk Scenarios
• Examples of Scoring Systems for Use in Rapid Ranking
• Estimation of the Magnitude of the Consequences or the Frequency, of Operational Losses
• Case Studies
• Risk Management Without Numbers
• Identifying the Questions to be Answered in the Risk Assessment

Risk & Reliability Criteria Introduction

• The Problem with “Acceptable Risk”
• Some Everyday Risks
• Risks to Members of the Public from New Plant
• Risks to Employees
• Economic Factors in Risk Criteria
• Regulatory Approaches to Setting Risk Criteria
• The Meaning & Uses of “As Low as Reasonably Practicable”
• Calculating & Displaying the Risks of Potential Losses

Assessment of the Severity of the Consequences of Hazardous Incidents

• Introduction: Calculation Versus Estimation
• Fires
• BLEVEs
• Vapor Cloud Explosions
• Other Explosions
• Toxic Gas Escapes
• Environmentally Damaging Escapes
• Assessment of Probability of Fatality Using Probity Mathematics

Quantitative Risk Assessment: Computer Modeling, uses in Setting Buffer Zones, Strengths & Limitations, Uses & Abuses

• Modeling the Risk
• Separation Distances (or Buffer Zones)
• Some Experiences with Quantitative Risk Assessment
• Summary of the Strengths & Limitations of Quantitative Risk Assessment
• Applications of Hazard Analysis & Risk Assessment
• Faults in the Application of Hazard Analysis & Risk Assessment

A Systematic Approach to Risk Reduction

• Principles
• Transferring the Risk
• Reducing Fire Risks in Process Plants
• Steps in Design of a New Plant to Maximize Fire Safety
• Case Study: Upgrading a Firefighting Water System
• Principles of Firefighting
• Reducing the Risks in Warehouse Operations

Management of Risk & Reliability of Existing Plants & Operations

• Some Principles for Good Management of Process Safety & Reliability
• Ongoing Monitoring & Auditing of Process Safety & Reliability
• Some Approaches to Assurance of Effective Process Risk Management
• Design of a Program for Routine Monitoring of Process Risk & Reliability

Introduction to “Software” or the “Human Factor”: Including Safety Culture, Safety Climate, & Human Error

Introduction to “Software” or the “Human Factor”: Including Safety Culture, Safety Climate, & Human Error

Role of the Risk & Reliability Manager