Training on Process Safety Management (PSM) & Chemical Hazards

Module 1: Fundamentals of Process Safety Management

• Process safety vs occupational safety

• Major accident hazards and risk concepts

• International PSM frameworks and standards

• Case Study:Overview of major industrial process disasters

Module 2: Chemical Hazards Identification & Classification

• Toxic, flammable, reactive, and corrosive chemicals

• GHS, SDS interpretation, and chemical labeling

• Exposure routes and health impacts

• Case Study:Chemical exposure incidents in industrial facilities

Module 3: Process Hazard Analysis (PHA) Techniques

• HAZID, HAZOP, What-If, FMEA

• Risk ranking and prioritization

• Documentation and follow-up actions

• Case Study:Conducting a HAZOP for a chemical process unit

Module 4: Operating Procedures & Safe Work Practices

• Standard operating procedures (SOPs)

• Permit-to-work systems

• Contractor and workforce safety integration

• Case Study:Failures in operating procedures and lessons learned

Module 5: Asset Integrity & Mechanical Integrity

• Equipment design, inspection, and maintenance

• Corrosion management and integrity monitoring

• Managing aging assets

• Case Study:Equipment failure leading to chemical release

Module 6: Management of Change (MoC)

• Technical, organizational, and procedural change

• Risk assessment before implementation

• MoC governance and approval workflows

• Case Study:Uncontrolled change causing process instability

Module 7: Incident Investigation & Learning Systems

• Root cause analysis methods

• Near-miss reporting and learning culture

• Corrective and preventive actions

• Case Study:Analysis of a major process safety incident

Module 8: Emergency Planning & Chemical Incident Response

• Emergency response planning and coordination

• Chemical spill, fire, and explosion response

• Community and stakeholder communication

• Case Study:Emergency response to a large-scale chemical release

Module 9: Process Safety Leadership & Culture

• Safety leadership roles and accountability

• Human factors and organizational behavior

• Process safety performance indicators

• Case Study:Leadership failures and safety culture breakdowns

Module 10: Integrated PSM Systems & Capstone Application

• Auditing and continuous improvement

• Integration of PSM into business operations

• Development of a facility-level PSM action plan

• Case Study:Building an end-to-end PSM system for a high-hazard plant