Process Safety Management (PSM): Comprehensive 5-Day Training Course

Course Overview

This essential Process Safety Management (PSM) training program delivers critical expertise for HSE and operations professionals across the Kingdom of Saudi Arabia (KSA), Oman, GCC countries (UAE, Qatar, Kuwait, Bahrain), and Africa. The course covers PSM elements, hazard analysis, safety systems, management of change, emergency planning, and performance measurement essential for preventing catastrophic incidents in refineries, petrochemical plants, gas processing facilities, chemical manufacturing, and offshore operations.

With the Middle East operating over $800 billion in process facilities and major incidents costing $500 million to $10 billion in losses, this training addresses critical competencies for professionals at Saudi Aramco, SABIC, PDO, ADNOC, Ma’aden, Qatar Energy, Dangote, complying with Saudi Aramco SAEP, OSHAD, OSHA PSM 1910.119, Seveso III, supporting Saudi Vision 2030 industrial safety excellence.

Target Audience

• Process Safety Engineers in refineries, petrochemicals across Saudi Arabia, Oman, GCC, Africa

• HSE Managers implementing PSM programs

• Operations Managers ensuring process safety integrity

• Maintenance Engineers supporting safety-critical systems

• Project Engineers integrating PSM in facility design

• Plant Managers accountable for process safety performance

• Technical Managers overseeing PSM compliance and improvement

Day 1: PSM Fundamentals & Regulations

Morning Session: Process Safety Principles

• Process safety definition: preventing uncontrolled releases of hazardous materials/energy

• Major incidents: Bhopal (1984), Piper Alpha (1988), Texas City (2005), Deepwater Horizon (2010)

• Lessons learned: management system failures, multiple barrier failures, organizational factors

• Process hazards: flammable materials, toxic substances, reactive chemicals, high pressure/temperature

• Consequences: fires, explosions, toxic releases, environmental damage, fatalities, business disruption

• Risk management: identifying hazards, assessing risks, implementing controls, monitoring performance

• Layers of protection: inherent safety, engineering controls, administrative controls, emergency response

• Process safety vs. occupational safety: low-frequency/high-consequence vs. high-frequency/low-consequence

• Business case: regulatory compliance, asset protection, reputation, operational continuity

• Regional context: GCC high-value facilities (Saudi Aramco, SABIC), African expanding downstream

Afternoon Session: PSM Regulations & Standards

• OSHA PSM 1910.119: 14 elements, applicability, covered processes

• Saudi Arabia: Saudi Aramco SAEP (Safety and Engineering Practices), RCJY (Royal Commission Jubail Yanbu) standards

• UAE OSHAD: Process Safety Management requirements, Occupational Safety and Health System Framework

• Oman: Ministry of Labour regulations, PDO process safety standards

• International standards: API RP 750, API RP 754, CCPS guidelines, Seveso III (European), IEC 61511

• ISO 45001: integration with occupational health and safety management

• PSM elements: employee participation, process safety information, hazard analysis, operating procedures

• Management of change, mechanical integrity, hot work permits, contractor management

• Pre-startup safety review, emergency planning, incident investigation, compliance audits, trade secrets

• Regulatory enforcement: inspections, citations, penalties across GCC and Africa

• Workshop: PSM compliance gap analysis for your facility

Day 2: Process Safety Information & Hazard Analysis

Morning Session: Process Safety Information (PSI)

• PSI definition: comprehensive documentation of process design, operation, hazards

• Chemical information: physical properties, reactivity, toxicity, flammability, SDS

• Corrosivity, thermal/chemical stability, hazardous effects of mixing incompatible materials

• Process technology: block flow diagrams, process flow diagrams (PFD), chemistry, maximum intended inventory

• Design basis: temperature, pressure, composition ranges, reaction rates

• Equipment information: P&IDs, materials of construction, design codes (ASME, API)

• Electrical classification, relief system design, ventilation, safety systems

• Documentation requirements: maintaining current, accessible, complete information

• PSI in FEED, detailed engineering, as-built documentation, updates through MOC

• Regional considerations: Saudi Aramco specifications, vendor documentation, multi-lingual workforces

• Case studies: PSI gaps contributing to incidents, documentation excellence at SABIC facilities

Afternoon Session: Process Hazard Analysis (PHA)

• PHA definition: systematic evaluation identifying and controlling hazards

• PHA methodologies: What-If, Checklist, HAZOP, FMEA, Fault Tree Analysis (FTA)

• HAZOP (Hazard and Operability Study): most common in oil & gas, systematic node-by-node review

• HAZOP guide words: no, more, less, reverse, as well as, part of, other than

• HAZOP team: leader, scribe, process engineer, operations, maintenance, instrumentation

• Node selection: equipment groupings, logical boundaries, manageable scope

• Deviations: applying guide words to parameters (flow, temperature, pressure, composition, level)

• Causes and consequences: brainstorming potential scenarios

• Safeguards: existing protection layers preventing/mitigating consequences

• Recommendations: additional safeguards, procedure improvements, design changes

• Risk ranking: likelihood and severity matrices, prioritizing actions

• PHA revalidation: every 5 years per OSHA, more frequent for modifications

• Documentation: detailed reports, action tracking, resolution verification

• Workshop: Conducting mini-HAZOP on process unit (distillation, reactor, compression)

Day 3: Operating Procedures & Management of Change

Morning Session: Operating Procedures & Training

• Operating procedures: comprehensive written instructions for safe operations

• Procedure content: startup, normal operations, temporary operations, emergency shutdown, normal shutdown

• Emergency operations, consequences of deviations, safety systems, operating limits

• Procedure development: operator involvement, technical accuracy, readability, accessibility

• Format: step-by-step, checklists, flowcharts, graphics for multi-lingual workforce

• Procedure updates: through MOC, incident learnings, continuous improvement

• Training requirements: initial training, refresher, verification of understanding

• Training documentation: records, competency assessment, knowledge testing

• Safe work practices: hot work permits, confined space entry, lockout/tagout (LOTO), line breaking

• Contractor management: informing of hazards, evaluating safety performance, contractor training

• Regional practices: Saudi Aramco contractor management, ADNOC permit systems

• Workshop: Developing operating procedure section for process unit

Afternoon Session: Management of Change (MOC)

• MOC definition: managing modifications to process chemistry, technology, equipment, procedures, organization

• MOC triggers: permanent changes, temporary changes (time-limited), replacements in kind exceptions

• Organizational changes: personnel changes affecting PSM, reorganizations, workload

• MOC process: request submission, technical review, hazard assessment, authorization

• Pre-startup safety review (PSSR), training, updating documentation, tracking

• Technical review: process safety impact, engineering analysis, PHA review/update

• Authorization: appropriate management level based on risk and cost

• PSSR: confirming construction/modifications per specifications, safety systems functional, training completed

• Common failures: bypassing MOC, inadequate hazard review, poor documentation

• Temporary changes becoming permanent without proper review

• Examples: equipment modifications, procedure changes, catalyst changes, control system upgrades

• Organizational MOC: key personnel changes, restructuring, contractor transitions

• MOC in projects: integrating with FEED, detailed engineering, construction, commissioning

• Workshop: MOC case study review and approval/rejection decisions

Day 4: Mechanical Integrity & Safety Systems

Morning Session: Mechanical Integrity (MI)

• MI definition: ensuring equipment designed, installed, maintained to prevent releases

• Covered equipment: pressure vessels, piping, relief/vent systems, emergency shutdown systems

• Controls, pumps, compressors, heat exchangers critical to process safety

• Written procedures: inspection, testing, maintenance aligned with manufacturer recommendations

• Inspection and testing: frequencies, methods, acceptance criteria, qualified inspectors

• API 510 (pressure vessels), API 570 (piping), API 653 (tanks), API 580 (risk-based inspection)

• Preventive maintenance: scheduled tasks, condition monitoring, predictive maintenance

• Quality assurance: fabrication, installation, testing following codes/standards

• Equipment deficiency correction: timely repairs, safe operating limits pending repair

• Pressure relief systems: sizing per API 520/521, testing, preventing blockage

• Safety instrumented systems (SIS): maintaining SIL (Safety Integrity Level) performance

• Corrosion management: monitoring, materials selection, corrosion inhibitors

• Regional challenges: high temperatures in GCC, corrosive crudes, H2S environments

• Asset integrity programs: Saudi Aramco IDMS (Integrity Data Management System), digital systems

• Workshop: Developing mechanical integrity testing schedule

Afternoon Session: Safety Instrumented Systems (SIS)

• SIS definition: independent protection layers preventing/mitigating hazardous events

• Functional safety standards: IEC 61508, IEC 61511 lifecycle requirements

• Safety Instrumented Functions (SIF): automated responses to hazardous conditions

• SIL determination: tolerable risk, risk reduction required, SIL 1/2/3 assignment

• LOPA (Layer of Protection Analysis): quantitative method for SIL selection

• SIS architecture: sensors, logic solver, final elements, redundancy (1oo1, 1oo2, 2oo3)

• Independence: SIS separate from BPCS (Basic Process Control System), common cause failures

• SIS lifecycle: design, installation, commissioning, operation, testing, maintenance, modification

• Proof testing: periodic functional testing verifying SIF performance, frequencies based on SIL

• Management: bypasses (temporary, documented, authorized), documentation, modifications through MOC

• Common SIS: emergency shutdown valves, high integrity pressure protection systems (HIPPS), burner management

• Regional applications: Saudi Aramco SIS standards, ADNOC IEC 61511 compliance

• Workshop: SIL determination using LOPA for process scenario

Day 5: Audits, Metrics & Continuous Improvement

Morning Session: PSM Audits & Compliance

• PSM audits: comprehensive evaluation of PSM system effectiveness

• Audit frequency: at least every 3 years per OSHA, more frequent for complex facilities

• Audit protocol: 14 PSM elements, detailed questions, verification methods

• Audit team: competence, independence, using knowledgeable personnel

• Audit process: planning, opening meeting, document review, interviews, field verification, findings

• Audit findings: observations, non-conformances, opportunities for improvement

• Corrective actions: timely response, root cause determination, verification of effectiveness

• Management review: audit results, corrective action status, program improvements

• Regulatory inspections: Saudi Civil Defense, MOMRA, OSHA-equivalent authorities

• Inspection preparedness: document availability, escort protocols, response procedures

• Self-assessments: annual reviews, maintaining awareness between formal audits

• Regional best practices: Saudi Aramco PSM compliance excellence, SABIC audit programs

Afternoon Session: PSM Metrics & Performance

• Process safety metrics: API RP 754 Tier 1, Tier 2, Tier 3, Tier 4 indicators

• Tier 1: loss of primary containment (LOPC) with significant consequences

• Tier 2: LOPC of lesser consequence, challenges to safety systems

• Tier 3: near-misses, demand on safety systems, process deviations

• Tier 4: operating discipline, management system health (audits, training, MOC)

• Leading indicators: predictive of future performance (inspections, PHAs, training completion)

• Lagging indicators: historical outcomes (incidents, regulatory citations)

• Benchmarking: comparing performance against industry (CCPS, API databases)

• KPI dashboards: real-time visibility, trend analysis, management review

• Safety culture: relationship between culture and PSM performance

• Continuous improvement: lessons learned, incident analysis trends, emerging best practices

• Technology: digital PSM platforms, AI/analytics, mobile applications

• Regional trends: Saudi Aramco PSM maturity, GCC advancing process safety culture

• PSM program sustainability: leadership commitment, resources, organizational learning

• Final workshop: PSM program assessment and improvement roadmap for your organization

Learning Outcomes

Upon completion, participants will be able to:

• Understand PSM regulatory requirements across Saudi Arabia, Oman, GCC, international standards

• Implement 14 PSM elements systematically in refining, petrochemical, gas processing facilities

• Conduct Process Hazard Analysis using HAZOP and other methodologies effectively

• Manage process changes through robust MOC systems preventing incidents

• Establish mechanical integrity programs ensuring equipment reliability and safety

• Design and maintain SIS meeting IEC 61511 functional safety requirements

• Conduct PSM audits evaluating compliance and effectiveness comprehensively

• Measure PSM performance using API RP 754 metrics and leading indicators

• Drive continuous improvement building resilient process safety culture

Course Delivery & Certification

• Format: Technical lectures, HAZOP workshop, case studies, audit exercises, group discussions

• Materials: Comprehensive manual, PSM templates, HAZOP worksheets, audit protocols, regulatory standards

• Certification: Professional certificate recognized across KSA, Oman, UAE, Qatar, Kuwait, Bahrain, Africa

• Language: English (Arabic support available)

• CPD Credits: Continuing professional development for HSE and process engineers

• Locations: Riyadh, Dhahran, Jubail, Yanbu (KSA), Muscat, Sohar (Oman), Dubai, Abu Dhabi, Doha, Lagos, Cairo

Why This Course is Mission-Critical

Process safety incidents cost $500M-$10B per major event (Deepwater Horizon $65B total). GCC facilities handle massive quantities of hydrocarbons at high pressures/temperatures. Regulatory compliance mandatory (OSHA PSM, OSHAD, Saudi standards). Mature PSM programs reduce incident likelihood by 80-95%. Leading operators (Saudi Aramco, Shell, ExxonMobil) attribute low Tier 1 rates to rigorous PSM. Vision 2030 demands world-class safety protecting investments, communities, environment.

This training delivers proven methodologies from CCPS guidelines, API standards, Saudi Aramco PSM excellence, addressing regional challenges: high-consequence facilities, complex operations, diverse workforces, supporting systematic hazard management and zero major incident goals.

Prevent catastrophic incidents. Protect people and assets. Achieve PSM excellence.