🏭 Process Safety Management (PSM)
Control the Process. Manage the Risk. Prevent Major Incidents.
The Process Safety Management (PSM) Course is designed to provide engineers, managers, supervisors, safety professionals, operations personnel, and maintenance teams with practical knowledge of managing hazards associated with industrial processes involving hazardous chemicals, energy, pressure, temperature, and complex equipment.
Participants learn how to identify process hazards, understand operating limits, manage changes safely, control critical equipment, investigate incidents, prepare for emergencies, and strengthen process safety systems. Through practical scenarios, case studies, risk-assessment exercises, and interactive discussions, the course promotes a proactive approach to preventing fires, explosions, toxic releases, equipment failures, and other major process incidents.
🏭 What You’ll Learn
⚠️ Process Hazard Awareness
Understand how hazardous energy, chemicals, pressure, temperature, and process conditions can contribute to major incidents.
🔍 Process Hazard Identification
Learn how to systematically identify hazards associated with processes, equipment, materials, and operating conditions.
📊 Risk Assessment
Understand how process risks can be evaluated and controlled before they result in serious incidents.
🔄 Management of Change
Learn why changes to equipment, chemicals, processes, technology, procedures, or personnel need structured review.
🛡️ Safety-Critical Controls
Understand the importance of protective systems, alarms, interlocks, emergency shutdowns, relief systems, and other critical safeguards.
🚨 Emergency Preparedness
Develop awareness of emergency planning and response for fires, explosions, toxic releases, spills, and process upsets.
🛡️ Key Training Areas
Participants are introduced to:
🏭 Process Safety Management fundamentals
🔍 Process Hazard Analysis
📊 Risk assessment
🧪 Hazardous chemical management
⚙️ Process equipment safety
🌡️ Pressure and temperature hazards
🔥 Fire and explosion prevention
💨 Toxic and hazardous releases
🔄 Management of Change (MOC)
🛠️ Mechanical integrity
🚨 Emergency preparedness
📝 Incident investigation
📋 Operating procedures
👷 Training and competency
🔒 Permit-to-work awareness
⚡ Energy isolation
🔥 Hot-work safety
🏗️ Contractor safety
📑 Safety documentation
📈 Process safety performance
🔄 Continuous improvement
🔧 Practical Process Safety Training
Understand the Process. Identify the Hazard. Protect the System.
Participants can gain practical exposure to:
01 — UNDERSTAND THE PROCESS
Review the process, materials, equipment, operating conditions, and potential sources of hazardous energy.
02 — IDENTIFY HAZARDS
Recognise conditions that could lead to fire, explosion, toxic release, overpressure, loss of containment, or other major incidents.
03 — ASSESS THE RISK
Evaluate potential consequences and likelihood using the organisation’s established risk-assessment methodology.
04 — IDENTIFY SAFEGUARDS
Understand the role of engineering and administrative safeguards in preventing or limiting major incidents.
05 — CONTROL OPERATIONS
Ensure work is performed within established operating procedures and safe operating limits.
06 — MANAGE CHANGES
Evaluate proposed changes before implementation.
07 — MAINTAIN CRITICAL EQUIPMENT
Support the reliability and integrity of equipment that prevents or mitigates major incidents.
08 — LEARN FROM EVENTS
Use incidents, near misses, audits, and process deviations to improve safety.
🔍 Process Hazard Analysis
Find the Failure Before the Process Finds It for You
Participants develop awareness of how process hazards can be identified by examining:
Hazardous chemicals
Process conditions
Pressure systems
Temperature extremes
Flow conditions
Equipment failures
Human factors
Utility failures
Loss of containment
Ignition sources
Control-system failures
Emergency scenarios
What Can Go Wrong? Why Can It Go Wrong? What Prevents It?
🧪 Hazardous Chemical & Process Control
Control the Substance. Control the Process.
Participants learn the importance of understanding:
🧪 MATERIAL
Properties and hazards of chemicals and process materials.
🌡️ CONDITIONS
Temperature, pressure, flow, concentration, and other relevant process conditions.
⚙️ EQUIPMENT
Vessels, pipelines, pumps, valves, reactors, tanks, and other process equipment.
🛡️ SAFEGUARDS
Alarms, interlocks, relief systems, containment, shutdown systems, and procedures.
🚨 CONSEQUENCES
Potential effects of fire, explosion, toxic exposure, or environmental release.
🔄 Management of Change (MOC)
A Small Change Can Create a New Hazard
Participants learn why changes should be systematically reviewed before implementation.
Changes may involve:
Equipment
Process parameters
Chemicals or raw materials
Technology
Control systems
Procedures
Layout
Utilities
Software or instrumentation
Operating conditions
Organisational responsibilities
CHANGE → REVIEW → ASSESS → APPROVE → IMPLEMENT → VERIFY
A structured change-management process helps ensure that new hazards are identified before the change becomes operational.
⚙️ Mechanical Integrity
Safety-Critical Equipment Must Remain Reliable
Participants develop awareness of maintaining the integrity of equipment such as:
Pressure vessels
Storage tanks
Pipelines
Pumps
Valves
Relief devices
Safety systems
Instrumentation
Emergency shutdown systems
Fire-protection systems
Critical machinery
The course highlights the importance of inspection, testing, maintenance, documentation, defect management, and timely corrective action.
🚨 Safety-Critical Systems
Your Last Line of Defence Should Always Be Ready
Participants learn the role of safeguards such as:
🔔 ALARMS
Warn operators when process conditions move outside acceptable limits.
🔒 INTERLOCKS
Help prevent unsafe process conditions from developing.
🛑 EMERGENCY SHUTDOWN
Support rapid control of dangerous process conditions.
💨 RELIEF SYSTEMS
Help protect equipment from excessive pressure where applicable.
🧯 FIRE PROTECTION
Help control and respond to fire hazards.
🚧 CONTAINMENT
Helps prevent or limit hazardous releases.
🔥 Fire & Explosion Prevention
Control Fuel. Control Ignition. Control the Process.
Participants develop awareness of:
Flammable materials
Ignition sources
Static electricity
Hot surfaces
Hot work
Electrical hazards
Process deviations
Ventilation
Gas and vapour releases
Fire detection
Emergency shutdown
Fire protection
Major Fires and Explosions Are Often Preventable Through Strong Process Controls.
💨 Loss of Containment
Prevent the Release Before It Becomes an Emergency
Participants learn to consider potential causes such as:
Equipment failure
Corrosion
Overpressure
Incorrect operation
Valve failure
Pipeline damage
Poor maintenance
Incorrect connections
Process deviation
Human error
The course emphasises early identification, effective maintenance, operating discipline, inspection, and appropriate emergency controls.
📝 Operating Procedures
Safe Processes Require Clear Procedures
Participants develop awareness of procedures covering:
Normal operations
Start-up
Shutdown
Emergency shutdown
Temporary operations
Process deviations
Maintenance
Inspection
Safe operating limits
Emergency response
Know the Safe Operating Limits Before the Process Reaches Them.
👷 Training & Competency
Competent People Are a Critical Process Safeguard
Participants learn why personnel involved in process operations should understand:
Process hazards
Operating procedures
Emergency procedures
Equipment limitations
Safety-critical controls
Alarm response
Permit requirements
Energy isolation
Incident reporting
Changes to the process
Competency Must Match the Risk of the Job.
🔒 Permit-to-Work & Energy Isolation
Process environments often involve multiple hazardous energy sources.
Participants develop awareness of:
🔥 Hot Work
Control ignition sources and fire hazards.
🔒 Isolation
Control electrical, mechanical, hydraulic, pneumatic, pressure, thermal, and other hazardous energy.
🕳️ Confined Spaces
Recognise atmospheric and access hazards where applicable.
🏗️ Work at Height
Control fall and dropped-object risks.
🛠️ Maintenance
Coordinate safe maintenance activities with process operations.
🚨 Emergency Preparedness
Prepare for the Event You Hope Never Happens
Participants develop awareness of emergency planning for:
🔥 FIRE
Alarm, isolation, evacuation, and emergency response.
💥 EXPLOSION
Immediate emergency actions, area control, and communication.
💨 TOXIC RELEASE
Control exposure, follow emergency procedures, and use appropriate response resources.
🧪 CHEMICAL SPILL
Isolate the area and follow approved spill-response procedures.
⚙️ PROCESS UPSET
Recognise abnormal conditions and follow established response procedures.
🚨 EVACUATION
Understand alarms, emergency routes, assembly areas, and accountability procedures.
📝 Incident & Near-Miss Investigation
Learn From What Happened — And What Almost Happened
Participants learn how process-safety investigations can examine:
What happened?
What process conditions existed?
What equipment was involved?
Which safeguards were available?
Which safeguards failed?
Were procedures followed?
Were there organisational or human factors?
What corrective actions are required?
How can recurrence be prevented?
Focus on Root Causes and System Improvements — Not Just Immediate Causes.
📊 Process Safety Performance
Measure What Prevents Major Incidents
Participants develop awareness of proactive and reactive indicators such as:
🔍 Safety-Critical Inspections
Are critical safeguards being inspected and maintained?
⚙️ Equipment Integrity
Are critical defects being identified and corrected?
🚨 Alarm & Shutdown Systems
Are critical protective systems available and functional?
📋 Management of Change
Are changes being properly reviewed?
📝 Near Misses
Are process deviations and near misses being captured?
🔄 Corrective Actions
Are identified risks being closed effectively?
🎯 Learning Outcomes
After completing the course, participants will be able to:
Understand the fundamentals of Process Safety Management.
Recognise the difference between personal safety and process safety risks.
Identify common process hazards.
Understand basic Process Hazard Analysis principles.
Recognise hazardous process conditions and potential loss-of-containment scenarios.
Understand the importance of safety-critical controls.
Recognise the role of Management of Change.
Understand basic mechanical-integrity principles.
Appreciate the importance of operating procedures and competency.
Understand permit-to-work and energy-isolation awareness.
Recognise fire, explosion, toxic-release, and process-upset hazards.
Support emergency preparedness and response.
Understand the importance of incident and near-miss investigation.
Use process-safety information to support continuous improvement.
Contribute to preventing major process incidents.
👷 Who Can Attend?
This course is suitable for:
Process Engineers • Production Managers • Operations Personnel • Maintenance Teams • HSE Professionals • Safety Officers • Plant Managers • Engineering Managers • Supervisors • Process Technicians • Project Engineers • Contractors • Safety Committee Members
🧠 Training Approach
Understand → Identify → Assess → Control → Monitor → Improve
The course combines:
📚 Classroom Learning
Fundamental Process Safety Management concepts.
🔍 Hazard Identification
Practical process-hazard identification exercises.
📊 Risk Assessment
Scenario-based assessment of process risks and safeguards.
🔄 MOC Case Studies
Examples of how changes can introduce new process hazards.
⚙️ Safety-Critical Equipment Scenarios
Understanding safeguards, equipment integrity, and failure prevention.
🚨 Emergency Scenarios
Interactive process-emergency decision-making exercises.
📝 Incident Case Studies
Learning from major incidents and near misses.
🔄 Process Safety Management Cycle
Prevent the Release. Prevent the Incident. Protect the Process.
🏭 01 — UNDERSTAND
Understand the process, materials, equipment, and operating conditions.
↓
🔍 02 — IDENTIFY
Identify hazards and potential major-incident scenarios.
↓
📊 03 — ASSESS
Evaluate risks and potential consequences.
↓
🛡️ 04 — CONTROL
Establish effective engineering and administrative safeguards.
↓
⚙️ 05 — MAINTAIN
Protect the integrity and reliability of safety-critical systems.
↓
🔄 06 — MANAGE CHANGE
Identify and control hazards introduced by changes.
↓
👀 07 — MONITOR
Track process conditions, safeguards, deviations, and safety performance.
↓
🚨 08 — RESPOND
Prepare for and respond to abnormal and emergency conditions.
↓
📝 09 — LEARN
Investigate incidents, near misses, and process deviations.
↓
🔄 10 — IMPROVE
Strengthen the process safety system continuously.
🏆 Key Benefits
For Operations Teams
Improve awareness of process hazards, safe operating limits, abnormal conditions, and emergency response.
For Engineers & Maintenance Teams
Strengthen understanding of equipment integrity, process changes, safeguards, and maintenance-related risks.
For Safety Professionals
Develop stronger process-risk awareness and support systematic process safety improvement.
For Managers
Improve process safety leadership, decision-making, risk management, and accountability.
For Organisations
Support prevention of major incidents, strengthen safety-critical controls, improve process reliability, and build a proactive process safety culture.
⭐ Why Process Safety Management Matters
A process-safety incident can have consequences far beyond an individual injury. Fires, explosions, toxic releases, overpressure events, and major loss of containment can affect employees, contractors, communities, assets, production, and the environment.
Process Safety Management provides a structured approach to understanding and controlling these risks before they become major incidents.
Control the Process. Protect the People. Prevent the Major Incident.
🏭 Process Safety Management (PSM)
Understand the Hazard. Strengthen the Safeguards. Prevent Major Incidents.
Develop the knowledge and practical awareness required to identify process hazards, manage safety-critical systems, control changes, and strengthen the overall process safety culture.
