IOSH Process Safety Course

This course is ideal for anyone working in the chemicals, pharma, food, beverage, utilities and other sectors who use hazardous chemicals for example:

• 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

Learners should have a basic understanding of process operations, hazard identification and risk assessment.

1. Understand the many aspects of Process Safety
2. Learn where to go to find guidance on hazards associated with substances and activities
3. Be aware of (and practice using) various tools for Hazard Identification & Risk Assessment
4. Understand the importance of understanding the Operating, Trip and Design parameters of processes and equipment
5. Understand the importance of identifying and managing the potential initiating events and control measures related to hazard scenarios
6. Understand the role of Hazard Analysis in Land Use Planning & risk reduction decisions
7. Understand the role of Human Factors and Competence in PSM
8. Understand the various aspects of a Safety Management System (& Major Accident Prevention Policy)
9. Understand the importance of Leadership, Safety Culture and ongoing evaluation of the Process Safety Management System

On completion of the course, participants will be able to:

• To give an awareness of and respect for Process Safety
• To give an understanding of where process safety hazards exist
• To give in understanding of the tools that can be used to properly assess and manage these risks
• To give an understanding of the various aspects of a Process Safety Management, Leadership and Culture
• To give an understanding of the role of Regulations in ensuring public, employee and environmental safety
• To help learners to appreciate that it is important to “know what they don’t know” about process safety

• Introduction
• Understanding Hazards
  • What factors affect risk?
  • Case study #1: Williams Olefins
  • Chemicals
  • Case Study #2: Bayer Inherent Safety
  • Group Exercise #1: Use of Inherent Safety guidewords
  • Fire
  • Explosion 
  • Corrosive substances
  • Acute toxicity
  • Chronic toxicity
  • Environmental
• Understanding Processes
  • Design intent
  • Unit Operations
  • Utilities
  • Chemical Reactions
  • Case Study #3: T2 runaway reaction
  • Inherent Safety of Processes
  • Worked Example #1:  using systematic process to assess IS options for reaction
  • Best Practice & Learning from Past Incidents
• Equipment and Processes fit for Purpose
  • Design Intent
  • Guidance, ACoPS and Standards
  • Asset Integrity
  • Case Study #4: latent Asset Integrity issues
• Control Measures
  • Safety Critical
  • Reliability & Availability
  • Control & Instrumentation
  • Worked Example #2: SIL determination using graph & FTA
  • ATEX
  • Case Study #5: Imperial Sugar dust explosion
  • Worked Example #3: ATEX HACs for powder filling and tanker transfer
  • Group Exercise #2: use Bow Tie to facilitate review of Control Measures
  • Ergonomics
  • Group Exercise #3: Human Error in adding ingredients to batch reactor
  • Inherent Safety of Control Measures
  • Best Practice & Learning from Past Incidents
  • Case Study #6: Formosa Plastics
• Identification of Hazards
  • HAZID
  • HAZOP
  • Case Study #7: DuPont Buffalo Hot Work: Hidden Hazards 
  • CHAZOP
  • Task Analysis
• Assessment of Risks
  • Risk Assessment
  • Group Exercise #4: Develop a checklist
  • Understanding Initiating Causes of Hazardous Events
  • Human Error Assessment
  • Consequence Assessment
  • Likelihood Assessment
  • Tolerability
  • Occupied Buildings
  • Emergency Response
  • Case Study #8: Emergency Preparedness
  • Escalation & Domino Effects
  • Land Use Planning
  • Environmental Risk Assessment
  • Risk Management Decisions
  • Basis of Safety
  • Worked Example #4: New development near existing site
• Management of Process Safety
  • Safety Management Systems
  • Process Safety Management Systems
  • CoMAH MAPP requirements
    • Organisation & Personnel
    • Identification & Evaluation of MAHs
    • Operational Control
    • Management of Change
    • Case Study #9: Flixborough
    • Planning for Emergencies
    • Monitoring Performance
    • Case Study #10: DuPont Belle Fatal Exposure
    • Process Safety Performance Indicators
    • Group Exercise #5: Developing Leading & Lagging Indicators
    • Audit & Review
• Leadership
  • Safety Culture
  • Process Safety Management Systems
  • Performance Evaluation, Corrective Action & Corporate Oversight
• Overview
  • Case Study #11: Texas City

• 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.