Introduction

In today's high-risk industrial environments, Advanced Process Safety Management (PSM) has become essential for ensuring sustainable operations, regulatory compliance, and workforce safety. Advanced Process Safety Management (PSM) Training Course is meticulously designed to equip safety professionals, engineers, and operational leaders with the tools and expertise required to manage complex process systems, mitigate hazards, and implement world-class safety protocols.

Utilizing real-time case studies, cutting-edge industry practices, and interactive modules, this course blends theoretical foundations with practical insights. From advanced hazard identification techniques to quantitative risk assessments (QRAs), layer of protection analysis (LOPA), and emergency response planning, participants will gain an in-depth understanding of process safety standards such as OSHA 1910.119, API RP 754, and IEC 61511. This course is ideal for organizations looking to foster a proactive safety culture and meet global PSM expectations.

Programme Curriculum

Advanced Process Safety Management (PSM) Training Course

Introduction

Course Objectives

Understand the core principles of Advanced Process Safety Management (PSM)
Identify and assess critical process safety hazards using modern tools
Apply root cause analysis and failure investigation techniques
Design and implement effective risk control measures
Analyze process safety incidents to improve future performance
Understand compliance strategies for OSHA PSM standards
Evaluate safety integrity levels (SIL) and instrumentation requirements
Execute effective layer of protection analysis (LOPA)
Integrate human factors engineering in process safety design
Conduct HAZOP and What-If safety reviews
Develop and test emergency response and mitigation plans
Monitor performance using PSM metrics and leading indicators
Foster a process safety culture and leadership commitment

Target Audiences

Process Safety Engineers
HSE (Health, Safety & Environment) Managers
Operations and Plant Managers
Risk Management Professionals
Mechanical and Chemical Engineers
Compliance Officers
Emergency Response Planners
Industrial Safety Consultants

Course Duration: 5 days

Course Modules

Module 1: Foundations of Advanced PSM

Evolution of Process Safety Management
Key PSM elements and OSHA 1910.119
Role of safety culture in high-risk industries
Responsibilities and accountabilities in PSM
Introduction to key international standards (API, IEC, NFPA)
Case Study: Bhopal Disaster – A Turning Point in Process Safety

Module 2: Hazard Identification & Risk Analysis

Advanced HAZOP methodologies
Bow-tie analysis and fault tree analysis
What-If and Checklist reviews
Inherently safer design principles
Risk matrix applications
Case Study: Piper Alpha Explosion and Hazard Recognition Failures

Module 3: Process Safety Information & Technology Integration

Documentation and control of safety data
Use of P&IDs and process flow diagrams in safety planning
Integration of AI and digital twins in safety analytics
Chemical reactivity and thermal stability data
Technology management for process changes
Case Study: Texas City Refinery – Inadequate Safety Info

Module 4: Operating Procedures and Safe Work Practices

Development of standard operating procedures (SOPs)
Lockout/Tagout (LOTO) protocols
Permit-to-work systems
Managing shift handovers
Job safety analysis (JSA) and human error reduction
Case Study: Tesoro Anacortes – Operating Procedure Deviations

Module 5: Mechanical Integrity & Equipment Reliability

Preventive and predictive maintenance strategies
RAGAGEP (Recognized And Generally Accepted Good Engineering Practices)
Inspection and testing protocols
Asset integrity and corrosion management
Managing aging infrastructure
Case Study: BP Texas City – Equipment Integrity Breakdown

Module 6: Management of Change (MOC) and Pre-Startup Safety Reviews

MOC system design and implementation
Evaluating proposed changes for safety impact
Roles and responsibilities in MOC
Documentation and communication of changes
Conducting effective pre-startup reviews
Case Study: Valero McKee Explosion – MOC Failures

Module 7: Emergency Preparedness and Incident Investigation

Emergency response planning and drills
Incident investigation methods (TapRooT, RCA)
Developing and maintaining emergency action plans (EAP)
Communicating during a process emergency
Learning from near misses and process deviations
Case Study: Deepwater Horizon – Crisis Response Breakdown

Module 8: Safety Culture, Leadership & PSM Metrics

Building and sustaining a safety culture
Leadership roles in process safety
Using leading and lagging indicators effectively
Continuous improvement strategies in PSM
Engaging workforce in safety programs
Case Study: DuPont La Porte – Cultural Gaps and Leadership Failures

Training Methodology

Instructor-led interactive sessions
Real-world case studies and group discussions
Role-playing and scenario-based learning
Hands-on workshops with hazard simulation tools
Pre-and post-training assessments and feedback

Register as a group from 3 participants for a Discount

Send us an email: info@fineskilltrainingcenter.org or call +254769199797

Certification

Upon successful completion of this training, participants will be issued with a globally- recognized certificate.

Tailor-Made Course

We also offer tailor-made courses based on your needs.

Key Notes

a. The participant must be conversant with English.

b. Upon completion of training the participant will be issued with an Authorized Training Certificate

c. Course duration is flexible and the contents can be modified to fit any number of days.

d. The course fee includes facilitation training materials, 2 coffee breaks, buffet lunch and A Certificate upon successful completion of Training.

e. One-year post-training support Consultation and Coaching provided after the course.

f. Payment should be done at least a week before commence of the training, to Fineskill Training Center account, as indicated in the invoice so as to enable us prepare better for you.

Skills & Software Covered

Process Safety Risk Management HSE Industrial Engineering

Programme Fee

Duration: 5 Days

Method: Online or Physical

Online Price: $1,000

Physical Price: $1,500

Certification: Accredited Certificate

View Available Dates 📄 Download Course Outline (PDF)

Available Sessions

Location

Month

Year

Oct 19 2026

19 Oct — 23 Oct 2026

💻 Online / Virtual session

Online $1,000