Training on Risk Based Process Safety Management (RBPS)

Module 1: Overview of Risk-Based Process Safety (RBPS)

• Accident Prevention Background

• Swiss Cheese Model

• RBPS Concepts, Pillars, and Elements

• Process Safety Culture and Management Commitment

• Compliance with Standards (Legislation, International Industry Standards, Company Standards)

• Workforce Involvement, Safety Committees, Feedback, and Stakeholder Outreach

• Case Study: Major industrial accidents analyzed using Swiss Cheese Model

• Practical Exercise: Identify gaps in process safety culture in a sample scenario

Module 2: Understanding Hazards and Risk

• Process Safety Competency

• Process Knowledge Management: Availability, Maintenance, and Dissemination of Knowledge

• Hazard Identification and Risk Analysis

  • HAZID

  • HAZOP

  • Quantitative Risk Assessment (QRA)

• Case Study: Hazard identification in a chemical plant

• Practical Exercise: Conduct a mini-HAZOP session using a sample process diagram

Module 3: Operational Considerations

• Operating Procedures and Procedural Structure

• Safe Work Practices and Work Permits

• Asset Integrity and Reliability

• Contractor Management

• Training and Performance Assurance

• Case Study: Failure of asset integrity leading to operational incidents

• Practical Exercise: Review and improve a sample operating procedure

Module 4: Operational Readiness

• Management of Change (MOC)

• Operational Readiness and Pre-Start Up Safety Review (PSSR)

• Conduct of Operations: Safe Operating Limits

• Emergency Management and Response Planning

• Training and Recovery

• Case Study: PSSR evaluation of a new plant startup

• Practical Exercise: Develop an emergency response checklist for a sample process

Module 5: Learn from Experience

• Incident Investigation and Near Miss Reporting

• Root Cause Analysis (RCA)

• Measurement and Metrics, Key Performance Indicators (KPIs)

• Auditing: Internal and External

• Management Review and Continuous Improvement

• Case Study: Root cause analysis of a process safety incident

• Practical Exercise: Conduct a mock incident investigation

Module 6: Process Safety Leadership and Culture

• Leadership Roles in Process Safety

• Developing a Safety Culture

• Encouraging Open Communication and Reporting

• Case Study: Leadership impact on safety performance

• Practical Exercise: Assess safety culture in a hypothetical organization

Module 7: Risk Assessment and Quantitative Analysis

• Risk Assessment Techniques and Tools

• Probabilistic Risk Assessment

• Layers of Protection Analysis (LOPA)

• Case Study: Applying LOPA to a refinery process

• Practical Exercise: Perform a simplified risk assessment for a chemical process

Module 8: Emergency Preparedness and Crisis Management

• Emergency Planning and Response Teams

• Scenario-Based Drills and Exercises

• Business Continuity Considerations

• Case Study: Effective emergency response during a chemical leak

• Practical Exercise: Design a tabletop emergency drill

Module 9: Auditing and Performance Monitoring

• Safety Audits and Inspections

• Performance Metrics and Benchmarking

• Continuous Improvement Loops

• Case Study: Audit findings leading to process safety improvement

• Practical Exercise: Conduct a mini-audit of a sample process and identify gaps

Module 10: Integrated Case Study and Final Practical

• Review of all RBPS pillars and elements

• Case Study: Analyze a real or simulated industrial incident using all RBPS tools and concepts

• Practical Exercise: Prepare a full risk assessment, propose corrective actions, and present findings