IOSH Process Safety Course

This course is ideal for anyone involved in operations where process safety risks are present including:

• Operations and production managers
• Engineers and technical staff
• Health & safety professionals
• Supervisors and team leads
• Maintenance personnel
• Anyone responsible for managing or controlling process risks

No prior specialist knowledge of process safety is required.

This course delivers an in-depth, practical understanding of process safety through structured modules, real-world case studies, and interactive exercises.

• Understanding Hazards
• What factors affect risk
• Chemicals and hazardous materials
• Fire and explosion risks
• Corrosive substances
• Acute and chronic toxicity
• Environmental hazards

Case Studies & Practical Application:

• Williams Olefins incident
• Bayer Inherent Safety

Interactive Learning:

• Group Exercise: Applying inherent safety guidewords
• Understanding Processes
• Design intent
• Unit operations and utilities
• Chemical reactions and process behaviour
• Inherent safety in process design

Case Study:

T2 Laboratories runaway reaction

Worked Example:

Systematic assessment of inherent safety options for reactions

Key Focus:

• Best practice and lessons learned from past incidents
• Equipment & Processes Fit for Purpose
• Design intent and operational requirements
• Guidance, ACoPs and industry standards
• Asset integrity and maintenance

Case Study:

• Latent asset integrity failures
• Control Measures
• Critical safety systems
• Reliability and availability
• Instrumentation and control systems
• ATEX and hazardous area classification
• Ergonomics and human factors

Case Studies:

• Imperial Sugar dust explosion
• Formosa Plastics

Worked Examples:

• SIL determination using risk graph and fault tree analysis
• ATEX hazardous area classification (powder filling & tanker transfer)

Interactive Learning:

• Bow Tie analysis for control measures
• Human error in batch reactor operations

Key Focus:

• Inherent safety of control measures
• Learning from major incidents
• Identification of Hazards and Hazardous Materials
• HAZID
• HAZOP
• CHAZOP
• Task analysis

Case Study:

• DuPont Buffalo – hidden hazards during hot work
• Assessment of Risks
• Risk assessment methodologies
• Initiating causes of hazardous events
• Human error assessment
• Consequence and likelihood analysis
• Determining tolerability of risk
• Emergency response planning
• Escalation and domino effects
• Land use planning and environmental risk

Worked Example:

• New development near an existing hazardous site

Case Study:

• Emergency preparedness

Interactive Learning:

• Group Exercise: Developing a risk assessment checklist
• Management of Process Safety
• Safety management systems
• Process Safety Management (PSM) systems
• COMAH MAPP requirements
• Organisational roles and responsibilities
• Identification and evaluation of major accident hazards (MAHs)
• Operational control and procedures
• Management of Change (MoC)
• Performance monitoring and indicators
• Audit and review processes

Case Studies:

• Flixborough disaster
• DuPont Belle fatal exposure

Interactive Learning:

• Developing leading and lagging performance indicators
• Leadership in Process Safety
• The role of leadership in safety culture
• Embedding process safety into management systems
• Performance evaluation and corrective actions
• Corporate oversight and accountability

By the end of the IOSH Process Safety Course, participants will be able to:

1. Understand what process safety is and why it is critical
2. Identify major hazard risks in their workplace (inc Hazardous Materials and Substances)
3. Recognise the causes of major process safety incidents
4. Understand their role in preventing catastrophic events
5. Apply practical risk control measures
6. Contribute to a stronger process safety culture

• Participants complete a short assessment at the end of the course.
• On successful completion, learners receive an IOSH Process Safety Certificate.
• Certification demonstrates an understanding of key process safety principles.

Process safety incidents can have devastating consequences.

This IOSH Process Safety Course was developed to address the need for greater awareness and competence in managing major hazard risks, particularly in industries such as manufacturing, pharmaceuticals, chemicals, and energy.

Occupli is currently the only training provider accredited to deliver this IOSH Process Safety course, ensuring a level of expertise and quality not available elsewhere.

This course is delivered by Tracey Kelly, a highly experienced process safety specialist with extensive industry expertise.

Tracey brings:

• Deep knowledge of process safety management
• Real-world experience across high-risk industries
• A practical, engaging training style
• A strong focus on applying theory to real workplace scenarios
• A deep understand of hazardous materials and substances

Participants benefit from learning directly from a trainer who understands both the technical and operational realities of process safety.