Process Safety Management Course

Lesson 1 • Process Hazard Fundamentals

Covers chemical and physical hazards inherent to covered processes. Grounds learners in hazard recognition before risk analysis methods.

Lesson 2 • PSM Program Structure and Governance

Explains how organizations structure PSM programs, assign ownership, and integrate them into management systems.

Lesson 3 • What Is Process Safety Management

Defines PSM, its scope, and its distinction from personal safety. Provides the conceptual baseline for all subsequent chapters.

Lesson 4 • Core PSM Elements Overview

Introduces the 14 PSM elements as an integrated system. Shows how each element supports the others to prevent catastrophic releases.

Lesson 1 • PSI Auditing and Gap Closure

Provides methods for auditing PSI completeness and correcting deficiencies. Systematic gap closure reduces risk from missing or inaccurate information.

Lesson 2 • Chemical Hazard Information

Covers required chemical data including toxicity, reactivity, and flammability. Accurate chemical data underpins hazard analysis and emergency response.

Lesson 3 • Equipment and Mechanical Design Data

Covers piping and instrumentation diagrams, equipment specifications, and design codes. Accurate equipment data supports mechanical integrity programs.

Lesson 4 • Process Technology Documentation

Defines required process technology records including chemistry, limits, and consequences of deviation. These records anchor PHA and operating procedures.

Lesson 1 • HAZOP Study Methodology

Provides step-by-step HAZOP execution using guide words and deviations. HAZOP is the industry-standard method for complex continuous processes.

Lesson 2 • PHA Revalidation and Quality Assurance

Addresses PHA update triggers, revalidation cycles, and quality review processes. Ensures PHAs remain accurate as processes and knowledge evolve.

Lesson 3 • What-If and Checklist Analysis

Teaches structured brainstorming and checklist-based hazard identification. These methods suit simpler processes and serve as PHA entry points.

Lesson 4 • Failure Mode and Effects Analysis

Applies FMEA to equipment and instrumentation within process systems. Connects component-level failures to system-level consequences.

Lesson 1 • Safe Work Practices and Permit Systems

Covers hot work, confined space, lockout/tagout, and line-breaking permits. Permit systems control non-routine work that introduces ignition or exposure risk.

Lesson 2 • Startup, Shutdown, and Emergency Procedures

Addresses the unique hazards and complexity of non-routine operations. These procedures carry the highest consequence of error in process environments.

Lesson 3 • Writing Clear and Accurate Procedures

Teaches human-factors-based writing techniques for step-by-step procedures. Clear procedures reduce reliance on memory and minimize execution errors.

Lesson 4 • Procedure Review and Continuous Improvement

Establishes cycles for procedure validation, worker feedback, and revision. Continuous improvement keeps procedures aligned with actual process conditions.

Lesson 1 • Quality Assurance in Maintenance

Establishes quality controls for materials, fabrication, and maintenance activities. Poor quality in repairs introduces new failure modes into critical equipment.

Lesson 2 • Corrosion and Degradation Management

Addresses corrosion mechanisms, monitoring strategies, and corrosion allowance calculations. Degradation management extends equipment life and prevents unexpected failures.

Lesson 3 • Fitness for Service and Defect Assessment

Applies fitness-for-service assessment to evaluate equipment with known defects. Enables risk-informed decisions on repair, replacement, or continued operation.

Lesson 4 • Inspection and Testing Methods

Covers non-destructive examination, pressure testing, and functional testing techniques. Method selection depends on equipment type, material, and failure mode.

Lesson 1 • MOC Review and Authorization Process

Covers hazard review, technical approval, and authorization steps within MOC. A rigorous review process prevents unreviewed hazards from entering the process.

Lesson 2 • Pre-Startup Safety Review Execution

Provides a structured PSSR checklist and sign-off process for new and modified equipment. PSSR is the final safety gate before introducing hazardous materials.

Lesson 3 • Organizational and Personnel Change Management

Extends MOC principles to staffing, organizational structure, and contractor changes. Personnel changes can erode process safety knowledge if unmanaged.

Lesson 4 • Updating PSI and Procedures After Changes

Ensures process safety information and procedures reflect implemented changes. Outdated documentation after a change is a leading cause of incidents.

Lesson 1 • Evidence Preservation and Scene Management

Covers immediate post-incident actions to preserve physical and documentary evidence. Evidence integrity is essential for accurate root cause determination.

Lesson 2 • Lessons Learned and Knowledge Sharing

Establishes processes for sharing investigation findings across the organization and industry. Lessons learned programs multiply the value of each investigation.

Lesson 3 • Root Cause Analysis Techniques

Applies causal tree, barrier analysis, and bow-tie methods to identify systemic causes. Moving beyond direct causes reveals management system failures driving incidents.

Lesson 4 • Corrective Action Development and Tracking

Translates root causes into effective, verifiable corrective actions with owners and deadlines. Poorly designed actions fail to prevent recurrence despite investigation effort.

Lesson 1 • Audit Finding Resolution and Program Improvement

Manages audit finding prioritization, corrective action assignment, and program-level trend analysis. Closing findings systematically strengthens the overall PSM program.

Lesson 2 • Conducting and Reporting PSM Audits

Covers field observation, interview techniques, and finding documentation during audits. Skilled audit execution produces actionable findings rather than superficial observations.

Lesson 3 • Emergency Response Training and Drills

Designs tabletop, functional, and full-scale exercises to validate emergency plans. Regular drills expose gaps before real emergencies reveal them.

Lesson 4 • PSM Compliance Audit Planning

Establishes audit scope, team composition, and protocol development for PSM audits. Thorough planning determines whether audits find real deficiencies or miss them.