Foundations of Process Safety | AIChE

Foundations of Process Safety

Interested in training a group of 10 or more? Bulk discounts start with 10+ users. Request a quote here.

CCPS’ Foundations of Process Safety was developed especially for companies looking to train their staff in the fundamental concepts of Process Safety. It is widely used by corporate training departments across different sectors of industry. Companies large, small and in-between use CCPS’ Process Safety Boot Camp to ramp-up staff knowledge to a common level quickly and easily.

This intensive 4-day course is taught by two seasoned instructors, each with a minimum of 25 years of experience in process safety. The agenda covers key process safety areas including Risk Based Process Safety, Process Hazard Analysis, Regulatory Compliance and Process Safety in Plant and Design Operations.

Who Should Attend:

Technical staff in the process industries, pipeline industries, utility companies, and engineering service companies who need to move beyond an understanding of personal safety and learn the basics of Process Safety and Process Safety Management, including:

  • Chemical Engineers
  • Process Design Engineers
  • Manufacturing Engineers
  • Chemists
  • Mechanical and Reliability Engineers
  • Instrumentation/Automation Engineers
  • Shift Supervisors
  • Lead Operators
  • EHS Specialists
  • Managers who wish to gain a more comprehensive understanding of best risk based management system practices

Interested in taking this course in North America ?

Please register for the Process Safety Boot Camp course.

Learning Outcomes:

  • List the four pillars and 20 different elements of risk based process safety.

  • Compare the different types of process hazard analysis techniques including an introduction to HAZOP.

  • Describe how process safety management should be used in coordination with process design and plant operations.

  • Explain the importance of inherently safer processes during plant design along with risk analysis and management.

  • Analyze the concept of layers of protection to prevent and/or mitigate loss of containment events.

  • Discuss the principles of Risk Analysis and Risk Management.

Who Should Attend:

Technical staff in the process industries, pipeline industries, utility companies, and engineering service companies who need to move beyond an understanding of personal safety and learn the basics of Process Safety and Process Safety Management, including:

  • Chemical Engineers
  • Process Design Engineers
  • Manufacturing Engineers
  • Chemists
  • Mechanical and Reliability Engineers
  • Instrumentation/Automation Engineers
  • Shift Supervisors
  • Lead Operators
  • EHS Specialists
  • Managers who wish to gain a more comprehensive understanding of best risk based management system practices

DAY 1

  • Introduction
    • Occupational safety vs. process safety 
    • Business case for process safety 
    • Key principles of process safety 
  • Anatomy of an Incident 
  • Loss of Containment
    • Containment and control 
    • Prevention 
    • Mitigation

DAY 2

  • Introduction to Management Systems and Risk Based Process Safety 
  • Process Safety Culture Compliance with Standards 
  • Inherently Safer Concepts
    • Process Design 
  • Process Safety Competency
    • Workforce Involvement
    • Human Factors 
  • Stakeholder Outreach 
  • Process Knowledge Management
  • Understanding Material Hazards

DAY 3

  • Specific Hazards
    • Chemical hazards 
    • Reactivity 
    • Toxicity 
    • Corrosivity 
    • Inherent Safety 
  • Hazard Identification and Risk Analysis
    • Hazard evaluation techniques 
    • Consequence and Impact Frequency 
    • Risk Analysis 
    • Risk criteria 
    • Risk acceptance 
  • Operating Procedures 
  • Safe Work Practices

DAY 4

  • Hot Work Permits, etc. 
  • Asset Integrity and Reliability 
  • Contractor Management 
  • Training and Performance Assurance 
  • Management of Change (MOC) 
  • Operational Readiness & PSSR 
  • Conduct of Operations 
  • Emergency Management 
  • Incident Investigation 
  • Measures and Metrics 
  • Auditing Compliance 
  • Management Review and Continuous Improvement 
  • Additional EPA RMP regulations 

Day One

7:30 – 8:00

Registration

8:00 – 8:15

Welcoming Remarks

8:15 – 11:30

  • Introduction to Process Safety
  • Key Concepts and Anatomy of an Incident
  • Loss of Containment (and Prevention/Mitigation)

11:30 – 12:30

Lunch Break

12:30 – 5:00

  • Management Systems for Process Safety – a Risk-Based Approach

FI​RST FOUNDATION BLOCK – COMMIT TO PROCESS SAFETY

  • Element 1: Process Safety Culture
  • Element 2: Compliance with Standards
  • Element 3: Process Safety Competency
  • Element 4: Workforce Involvement
  • Element 5: Stakeholder Outreach

Day Two

8:00 – 11:30

FIRST FOUNDATION BLOCK--COMMIT TO PROCESS SAFETY (continued) 

  • Human Factors 
  • Element 6: Process Safety Knowledge Management
    • Inherent Hazards of Chemicals
    • Flammability & Combustibility
    • Chemical Reactivity Hazards
    • Toxicity
    • Corrosivity

11:30 – 12:30

Lunch Break

12:30 – 5:00

  • Element 6: Process Safety Knowledge Management (continued)
    • Process Plant Design Considerations
    • Inherently Safer Design Concepts
    • Layout & Spacing
    • Overpressure & Vacuum
    • Fire Prevention & Mitigation
    • Hazardous Area Classification
    • Static Electricity, Grounding, Bonding, and Inerting
    • Flame & Detonation Arrest
    • Fireproofing, Firewalls, and Emergency Isolation

SECOND FOUNDATION BLOCK – UNDERSTANDING HAZARDS & RISKS 

  • Element 7: Hazard Identification and Risk Analysis (HIRA) 
    • Hazard Identification

Day Three

8:00 – 11:30

  • Element 7: Hazard Identification and Risk Analysis (HIRA) (continued)
    • Analyzing Potential Consequences & Impacts
    • Estimating Probability
    • Risk Analysis, Risk Assessment, and Risk Tolerance

THIRD FOUNDATION BLOCK – MANAGE RISK

  • Element 8: Operating Procedures

11:30 – 12:30

Lunch Break

12:30 – 5:00

  • Element 9: Safe Work Practices
  • Element 10: Asset Integrity and Reliability
  • Element 11: Contractor Management
  • Element 12. Training and Performance Assurance

Day Four

8:00 – 11:30

THIRD FOUNDATION BLOCK—MANAGE RISK (continued)

  • Element 13: Management of Change
  • Element 14 Operational Readiness
  • Element 15: Conduct of Operations
  • Element 16: Emergency Management

11:30 – 12:30

Lunch Break

12:30 – 5:00

FOURTH FOUNDATION BLOCK—LEARN FROM EXPERIENCE

  • Element 17: Incident Investigation
  • Element 18: Measures and Metrics
  • Element 19: Auditing
  • Element 20: Management Reviews and Continuous Improvement

This course is approved by RCEP (Registered Continuing Education Program).

Find answers to questions about registration and refunds, tuition and fees, travel and lodging (for location-based courses), how eLearning courses work, how credits work, and more. 

Go to FAQs Page

No public sessions of this course are scheduled at this time. If you are interested in receiving updates related to this course please fill out the Course Inquiry Form.

Request Group Training
  • Course ID:
    CH910
  • Source:
    CCPS - Center for Chemical Process Safety
  • Language:
    English
  • Skill Level:
    Basic
  • Duration:
    4 days
  • CEUs:
    3.20
  • PDHs:
    32.00
  • Accrediting Agencies:
    Florida
    New Jersey
    New York
    RCEP