Select training course modules for the process industry available with us are:

1. Process hazard analysis
2. Applications of hazard and operability (HAZOP) methods
3. Quantitative process risk and loss assessment
4. Applications of quantitative process risk assessment
5. Decision making for process risk management
6. Loss prevention strategies for process industries
7. Learning from chemical process incident investigations
8. Designing for chemical process safety
9. Pipeline risk assessment
10. Safety management for offshore process facilities

These courses help introduce the relevant concepts and formulations for industry personnel, especially those managing process operations and safety. The approach adopted is a practice-oriented with an emphasis on quantitative techniques, wherever necessary. Each module is supplemented by detailed course material which features case studies illustrating the basic concepts.
The duration of each course module ranges from 2 – 5 days depending on the scope and rigour desired by the organization. Customized courses can also be made available as required.

PSM Training Modules
Course Module - 1
Title: Process Hazard Analysis

• Role of PHA in Process Safety Management
• The Organization and PHA Philosophy
• Overview pf PHA Methods: Applicability and Limitations
• Criteria for selecting an appropriate PHA technique
• Deciding on when and where to apply each PHA technique
• Necessary information, knowledge and skill requirements for PHA
• Illustration of Select PHA Techniques:
  • Relative Ranking
  • What-if/Checklist Analysis
  • Fault and Event Tree Analysis
  • Failure Modes and Effect Analysis
  • Human Reliability Analysis
  • Siting Analysis
• Hazard and Operability Study (HAZOP): Approach and Applications
• Introduction to Qualitative and Quantitative Risk Analysis
• Layer of Protection Analysis
• Principles of Inherently Safer Process Design

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Course Module - 2
Title: HAZOP Study and its Applications

• Using HAZOP for Process Safety Management
• Complementing HAZOP with other Hazard Identification Techniques
• Introduction to HAZOP Methodology
  • Preparing for and conducting a HAZOP study
  • Documenting and reporting the results of a HAZOP study
  • Implementing the recommendations of HAZOP
• HAZOP for Continuous and Batch Processes
• Specific Applications of HAZOP
  • Modification of existing operations
  • Repeat designs
  • Periodic hazard studies and the HAZOP of an existing plant
  • Computer-controlled processes
  • Operating procedures
  • Pilot plant and laboratory operations
  • Drains, vents and other interconnections between plants
  • Commissioning and decommissioning
  • Construction and demolition
  • Contract operations
• Case Studies on HAZOP for Select Applications and for Various Phases in Plant Lifecycle
• Prioritizing the Implementation of HAZOP Recommendations using Quantitative and Ranking Methods
• Using Software Aids for HAZOP Study
• Workshop on HAZOP using Dedicated Software
• Developing Company procedures for HAZOP study
• Preventing Process Accidents through HAZOP

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Course Module - 3
Title: Quantitative Process Risk and Loss Assessment

• Technical and Economic Issues in Chemical Process Safety Management; Benefits of Hazard and Risk Analysis; Current Regulatory Trends
• Overview of Hazard Identification Methodologies
• Methods for Assessing Consequences of Fires, Explosions, and Atmospheric Release of Toxic Substance; Estimation of Consequence Probability
• Estimation of Equipment and Process System Failures Probabilities: Quantitative Fault and Event Tree Analysis, Equipment Failure Data Sources
• Risk Management: Concepts and Methods; Identification of Individual and Societal Risk Contours around Chemical Process Facilities; Criteria for Risk Acceptance
• Using Risk Assessment for Emergency Planning / Incident Investigations
• Case Studies in Risk Analysis
• Demonstration of Software for Evaluating Hazard/Risk from Fires, Explosions, and Toxic Releases

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Course Module - 4
Title: Applications of Quantitative Processes Risk Assessment

• Using QRA as a basis for Risk Management
• Identification of Probable Sources of Accidents
• Evaluation of the Potential Consequences of Accidents
• Estimation of the Probable Scale of Equipment / Human Loss
• Case Studies in Risk Assessment for Toxic and Flammable Discharges
• Using Consequence Analysis for Investigation of Process Accidents
• Using Consequence Analysis for Equipment and Safeguard Design
• QRA as a Decision-tool for Process Modifications
• Using QRA for Process Layout / Siting / Land Use Planning
• Decision Making for Investments for Risk Management

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Course Module - 5
Title: Decision Making for Process Risk Management

• Elements of Chemical Process Safety Management, Concepts of Risk
• Methods for Assessing Consequences of and Likelihood of Major Process Accidents: Case Studies
• Risk Analysis: Qualitative and Quantitative Methodologies
• Case Studies in Risk Analysis of Process Plants
• Using Risk Estimates for Assessing Plant Layout Options
• Approving Process Modifications using Risk Analysis
• Using Risk Estimates for Determining the Effectiveness of Safeguards in Process Plants
• Using Risk Estimates for Optimization of Safeguards in Process Plants
• Using Process Risk Estimates for Emergency Planning
• Decision Making for Investments for Safety Instrumentation and Procedures
• Risk-based Preventive Maintenance Scheduling

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Course Module - 6
Title: Loss Prevention Strategies for Process Industries

• Review of Common Causes for Chemical Process Accidents; Various Modes of “Loss of Containment” of Hazardous Chemicals
• Using Hazard Evaluation Techniques Optimally for Loss Reduction
• Carrying out Safety Audits
• Concepts of Inherent Chemical Process Safety
• Chemical Plant Design Strategies for Safe Operation
• Techniques for Prevention of Chemical Process Accidents; Techniques for Detection of Leaks of Hazardous Substances
• Techniques for Mitigation of Consequences of Chemical Process Accidents
• Understanding Human Errors; Methodologies for Reduction of Human Errors
• Managing Changes in Process Design and Operation
• Emergency Planning: Identification of Credible Incidents for Emergency Planning; Overall Emergency Plan, Required Physical Facilities and Systems; Response Equipment and Supplies; Evaluating Process Risks for Emergency Planning
• Decontamination of Accident Site and Response Team
• Developing Process Safety Management Systems

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Course Module - 7
Title: Learning From Chemical Process Incident Investigation

• Case Histories of Select Major Accidents in the Process Industry
• Lessons from Analysis of Major Process Accidents
• Case Histories of Select Small-scale Accidents in the Process Industry
• Investigating Process Upsets and Accidents: Evolving a Structured Approach
• Predicting Consequence and Impacts of Accidents involving Hazardous Substances
• Selection of Realistic and Worst Case Accident Scenarios for Consequence Estimation
• Case Studies in Accident Consequence Analysis for Release of Toxic, Flammable and Explosive Substances
• Software for Prediction of Accident Consequences and Impacts
• Common Modes of Failures of Various Process Equipments
• Common Causes for Loss of Containment from Process Equipments
• Using Quantitative Techniques for Accident Investigation
• Case Studies in Process Accident Investigation
• Accident Consequence Analysis and Emergency Planning
• Estimating Process Accident Costs

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Course Module - 8
Title: Designing For Chemical Process Safety

• Design of Inerting / Purging of Process Vessels
• Fundamentals of Static Charge Generation
• Controlling Static Electricity
• Design Methods to Prevent Electrostatic Ignitions
• Workplace Ventilation Design
• Sprinkler Systems Design
• Relief Design Considerations
• Design of Rupture Disc Reliefs in Liquid / Vapour / Gas Service
• Deflagration Venting for Dust and Vapor Explosions
• Runaway Reaction Relief Design
• Venting for Fires External to Process Vessels
• Reliefs for Thermal Expansion of Process Fluids
• Design Principles of Inherent Process Safety
• Quantifying Inherent Process Safety

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Course Module - 9
Title: Pipeline Risk Assessment

• Assessment of requirements on safety management systems in international regulations for the control of major hazard pipelines
• International initiatives on the control of major accident hazards arising from pipelines
• Statistical analysis of world-wide accidents on gas pipelines
• Comparative study of onshore transmission accidents
• Reliability Assessment of Pipelines
• Generalized Risk assessment methodology for pipeline systems
• Critical aspects of risk assessment for hazardous pipelines containing flammable substances
• Risk-based inspection of underground and submarine pipelines
• Environmental Impact Assessment for Pipelines
• Calculating the consequences of a pipeline rupture
• Models for the release rate of hazardous gas from a hole on high-pressure pipelines
• Transient outflow models for pipeline puncture
• Thermal interaction analysis in pipeline systems
• Cost-Benefit analysis for pipeline safety
• Safety Audit of Pipelines