Protecting Assets & Lives: Process Safety in Refining Training Course

Introduction

In the highly hazardous environment of an oil refinery, where flammable and toxic materials are processed under extreme conditions, upholding rigorous process safety standards is not just a regulatory requirement but a fundamental imperative. Catastrophic incidents, such as fires, explosions, or toxic releases, can lead to severe injuries or fatalities, extensive property damage, significant environmental contamination, and profound reputational and financial repercussions. A robust understanding and proactive application of process safety management principles are essential for preventing such events and ensuring the long-term sustainability of refining operations.

This intensive training course is meticulously designed to equip participants with a comprehensive and practical understanding of process safety in refining. From exploring the fundamental principles of hazard identification and risk assessment to mastering various layers of protection, incident investigation techniques, and the elements of a robust Process Safety Management (PSM) system, you will gain the expertise to identify, evaluate, and mitigate risks effectively. This empowers you to enhance operational safety, prevent major accidents, ensure regulatory compliance, and strategically contribute to a culture of safety excellence within refinery operations.

Target Audience

  • Process Engineers and Chemical Engineers.
  • Operations Managers and Supervisors in Refineries.
  • HSE (Health, Safety, and Environment) Professionals.
  • Maintenance and Reliability Engineers.
  • Project Engineers involved in Refinery Design/Modifications.
  • Technical Staff and Operators in Refinery Units.
  • Risk Management and Loss Prevention Specialists.
  • Regulatory Compliance Officers.

Duration: 10 days

Course Objectives

Upon completion of this training course, participants will be able to:

  • Understand the fundamental principles and importance of process safety in refining.
  • Grasp the concept of major accident hazards and their potential consequences.
  • Analyze various techniques for hazard identification and risk assessment.
  • Comprehend the elements of a comprehensive Process Safety Management (PSM) system.
  • Evaluate different layers of protection and their role in preventing incidents.
  • Develop practical skills in conducting incident investigations and root cause analysis.
  • Navigate regulatory requirements and industry standards for process safety.
  • Formulate robust strategies for designing, implementing, and auditing effective process safety programs.

Course Content

  1. Introduction to Process Safety Management (PSM)
  • Definition of process safety vs. personal safety.
  • Historical context and major industrial accidents (e.g., Flixborough, Bhopal, Texas City).
  • Consequences of process safety incidents.
  • The 14 elements of OSHA PSM standard and other international frameworks (e.g., API RP 75, IEC 61511).
  • Benefits of a robust PSM system.
  1. Major Accident Hazards in Refining
  • Characteristics of hazardous materials (flammability, toxicity, reactivity).
  • Types of major accident hazards: fires, explosions (flash fire, vapor cloud explosion, BLEVE), toxic releases.
  • Risk concepts: hazard, risk, consequence, likelihood.
  • Identifying potential major accident scenarios in refinery units.
  • Understanding domino effects and cascading failures.
  1. Hazard Identification Techniques
  • Process Hazard Analysis (PHA) methodologies overview.
  • Hazard and Operability (HAZOP) studies: methodology, guide words, team roles.
  • What-If analysis.
  • Checklists and Safety Reviews.
  • Fault Tree Analysis (FTA) and Event Tree Analysis (ETA) introduction.
  1. Risk Assessment and Management
  • Qualitative, quantitative, and semi-quantitative risk assessment.
  • Risk matrix and ALARP (As Low As Reasonably Practicable) principle.
  • Establishing risk tolerance criteria.
  • Risk reduction strategies: elimination, substitution, engineering controls, administrative controls, PPE.
  • Residual risk management.
  1. Process Safety Information (PSI) and Documentation
  • Importance of accurate and up-to-date PSI.
  • Types of PSI: P&IDs, PFDs, material safety data sheets (MSDS/SDS), electrical area classifications.
  • Management of PSI throughout the facility lifecycle.
  • Roles and responsibilities for maintaining PSI.
  • Utilizing PSI for hazard analysis and training.
  1. Management of Change (MOC)
  • Principles of MOC: ensuring changes do not introduce new hazards or increase existing risks.
  • Scope of MOC: process, equipment, procedures, personnel.
  • MOC workflow: initiation, review, approval, implementation, close-out.
  • Temporary vs. permanent changes.
  • Importance of pre-startup safety reviews (PSSR).
  1. Mechanical Integrity and Assurance
  • Importance of equipment integrity for preventing failures.
  • Inspection, testing, and preventive maintenance programs.
  • Codes and standards for mechanical integrity (e.g., API 510, 570, 653).
  • Fitness-for-Service assessments.
  • Managing aging infrastructure and integrity threats.
  1. Emergency Preparedness and Response
  • Developing a comprehensive emergency response plan (ERP).
  • Incident command system (ICS).
  • Emergency equipment: fire fighting, gas detection, spill containment.
  • Emergency drills and exercises.
  • Communication protocols during emergencies.
  1. Incident Investigation and Root Cause Analysis
  • Importance of thorough incident investigation (not just accidents).
  • Methodology for incident investigation: data gathering, analysis, conclusions, recommendations.
  • Root cause analysis (RCA) techniques: 5 Whys, Fishbone Diagram, Barrier Analysis.
  • Implementing recommendations and tracking closure.
  • Learning from incidents and sharing lessons learned.
  1. Safety Culture and Auditing
  • Elements of a strong safety culture: leadership commitment, employee involvement, accountability.
  • Human factors in process safety.
  • Process safety training and competency.
  • PSM auditing: internal and external audits, audit findings and corrective actions.
  • Continuous improvement in process safety performance.

CERTIFICATION

  • Upon successful completion of this training, participants will be issued with Macskills Training and Development Institute Certificate

TRAINING VENUE

  • Training will be held at Macskills Training Centre. We also tailor make the training upon request at different locations across the world.

AIRPORT PICK UP AND ACCOMMODATION

  • Airport pick up and accommodation is arranged upon request

TERMS OF PAYMENT

Payment should be made to Macskills Development Institute bank account before the start of the training and receipts sent to info@macskillsdevelopment.com

For More Details call: +254-114-087-180

 

 

 protecting Assets & Lives: Process Safety In Refining Training Course in Bosnia and Herzegovina
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