Process Safety and Operational Readiness Training Course

Module 1: Fundamentals of Process Safety and Operational Readiness

• Process safety principles and objectives
• Operational readiness concepts
• Process safety versus occupational safety
• Readiness assurance throughout the asset lifecycle
• Process safety roles and responsibilities
• Safety-critical elements and performance requirements

Module 2: Process Safety Management (PSM)

• Core elements of PSM
• Process safety leadership and accountability
• Management of change
• Operating procedures and safe work practices
• Mechanical integrity and asset reliability
• Contractor and competency management
• Process safety performance monitoring

Module 3: Hazard Identification and Risk Assessment

• Principles of hazard identification
• HAZID methodology and applications
• HAZOP study principles
• Risk identification during project and operational phases
• Safeguards and preventive controls
• Risk ranking and prioritisation
• Managing actions from hazard studies

Module 4: Layer of Protection Analysis (LOPA)

• Fundamentals of LOPA
• Initiating events and consequences
• Independent protection layers
• Risk reduction requirements
• Evaluating safeguards and protection systems
• LOPA documentation and action management
• Integrating LOPA into process safety readiness

Module 5: Operational Readiness Planning

• Developing an operational readiness strategy
• Readiness requirements and assurance plans
• Operations and maintenance readiness
• Procedures, documentation, and systems readiness
• Staffing and competency requirements
• Spare parts, tools, and maintenance readiness
• Readiness tracking and gap management

Module 6: Startup Safety and Pre-Startup Safety Review

• Principles of startup safety
• Commissioning and startup risk management
• Pre-Startup Safety Review (PSSR)
• Verification of equipment and safety systems
• Operating procedure verification
• Personnel competency and training verification
• Managing outstanding items before startup

Module 7: Safety-Critical Systems and Equipment Readiness

• Identification of safety-critical equipment
• Mechanical integrity considerations
• Inspection and testing requirements
• Instrumentation and control system readiness
• Emergency shutdown and protection systems
• Alarm and interlock verification
• Maintenance and reliability readiness

Module 8: Emergency Preparedness and Operational Controls

• Emergency response readiness
• Emergency procedures and drills
• Incident response responsibilities
• Permit-to-work and isolation systems
• Operating envelope and process controls
• Loss prevention and escalation control
• Emergency equipment and resource readiness

Module 9: Readiness Assurance, Verification and Gap Closure

• Readiness assessment methodologies
• Readiness checklists and verification
• Assurance reviews and audits
• Identifying and classifying readiness gaps
• Action tracking and close-out
• Evidence-based readiness assurance
• Management of residual risks

Module 10: Integrating Process Safety into Sustainable Operations

• Process safety performance indicators
• Continuous improvement
• Lessons learned and incident learning
• Operational discipline
• Process safety culture
• Maintaining readiness after startup
• Integrating process safety with maintenance and operational excellence