Process Safety Management

Programme Summary

Develop a structured understanding of how organisations prevent major process incidents and maintain effective barriers throughout plant operation and change. Participants connect process knowledge, hazard evaluation, asset integrity and operational discipline with leadership and learning. Case-based activities focus on identifying weaknesses, coordinating responsibilities and selecting practical actions and indicators without overstating specialist engineering or analysis competence.

Training Objectives

1 Clarify process safety leadership and system responsibilities; 2 Strengthen understanding of major hazard control barriers; 3 Connect operational disciplines with asset integrity requirements; 4 Improve management of change and readiness decisions; 5 Support learning through incidents indicators and review.

Learning Outcomes

1 Map process safety responsibilities to operating activities; 2 Identify barrier weaknesses in a supplied scenario; 3 Review proposed changes for safety review requirements; 4 Recommend actions for operational readiness deficiencies; 5 Select indicators linked to specified critical controls.

Target Audience

Process engineers; Operations managers; Process safety coordinators; Maintenance managers; HSE managers; Plant supervisors.

Target Industries

Chemical manufacturing; Oil and gas processing; Petrochemical production; Fuel storage terminals; Pharmaceutical manufacturing; Industrial gas production.

Course Contents

• Module 1 Process Safety Framework and Leadership: Major accident hazards and process safety distinctions; Leadership culture workforce involvement and accountability; Regulatory scope and framework selection.
• Module 2 Process Knowledge and Hazard Information: Chemical properties and reaction hazards; Process diagrams inventories and operating limits; Accessible current and controlled technical information.
• Module 3 Hazard Identification and Risk Evaluation: Structured hazard studies and team competence; HAZOP and protection layer analysis awareness; Risk decisions assumptions and action tracking.
• Module 4 Barrier Management and Inherent Safety: Prevention mitigation and escalation barriers; Inherently safer design and practical limitations; Critical controls performance standards and dependencies.
• Module 5 Operating Procedures and Conduct: Safe operating limits and abnormal conditions; Startup shutdown and temporary operating modes; Shift handover discipline and human factors.
• Module 6 Competence and Contractor Management: Role knowledge skills and performance assurance; Contractor selection briefing and interface controls; Workforce involvement and stakeholder communication.
• Module 7 Safe Work and Operational Control: Permit systems and hazardous maintenance interfaces; Isolation hot work and simultaneous operations; Authorisation supervision and changing work conditions.
• Module 8 Asset Integrity and Reliability: Safety critical equipment and inspection priorities; Defect escalation maintenance and repair assurance; Backlogs impairment controls and records.
• Module 9 Management of Change: Technical organisational and temporary changes; Risk review approval and document updates; Training communication and change closeout.
• Module 10 Operational Readiness and Emergency Management: Prestartup checks and unresolved safety actions; Emergency scenarios resources and coordinated response; Testing plans and maintaining response readiness.
• Module 11 Incident Learning and Corrective Action: Process incidents near misses and weak signals; Investigation of barrier and system weaknesses; Actions learning transfer and effectiveness checks.
• Module 12 Indicators Review and Improvement: Leading and lagging process safety indicators; Assurance activities and management review inputs; Prioritised improvement plans and sustained accountability.

Assessment

• 60 single best answer questions, including applied scenarios; one mark per question.
• 90 minute invigilated digital examination with identity verification. Approved accessibility adjustments preserve the assessed competence.
• Supplied process diagrams and framework extracts allowed; internet, AI and personal notes prohibited.
• Individual applied assessment (45 minutes): Review a fictional plant-change case and its barrier records. Identify material system gaps, specify management-of-change and prestartup actions, prioritise responsibilities, and propose leading and lagging indicators that test whether the selected critical controls remain effective.
• Assessment criteria: Correct linkage of hazards barriers and system gaps; Proportionate change and operational readiness actions; Relevant control indicators with clear accountability.
• Pass each component separately: 45/60 written marks (75%) and at least 70% on the applied task.
• All mandatory criteria must pass: Do not recommend startup with unresolved essential safety barriers; Do not bypass required change review or safety-critical approval.
• Individual results and feedback are provided. One reassessment may follow coaching under the published enrolment terms.

Certification

• Successful learners receive a TQCSI Arabia digital Certificate of Successful Completion.
• The certificate records the learner name, exact programme title, teaching hours, completion date and unique verification reference.
• Verified identity, full attendance and separate written and applied passes are required; all mandatory critical criteria must be met.
• Proposed issue target: within 30 calendar days of approved results and settlement of applicable fees.
• Records assessed process-safety management fundamentals; it does not qualify HAZOP facilitators, functional-safety specialists or independent process-safety assessors.
• Attendance confirmation may record completed hours for unsuccessful learners; it does not certify successful completion.

Programme Profile

Number of daysNumber of daysNumber of days

333

Total teaching hoursTotal teaching hoursTotal teaching hours

18 hours; breaks, pre course work and formal final assessments excluded.18 hours; breaks, pre course work and formal final assessments excluded.18 hours; breaks, pre course work and formal final assessments excluded.

Delegates allowedDelegates allowedDelegates allowed

Maximum 20 delegates.Maximum 20 delegates.Maximum 20 delegates.

Training prerequisitesTraining prerequisitesTraining prerequisites

Industrial process and basic risk-management knowledge is required. Engineering, operations, maintenance or HSE experience is recommended; specialist hazard-analysis qualifications are not required.Industrial process and basic risk-management knowledge is required. Engineering, operations, maintenance or HSE experience is recommended; specialist hazard-analysis qualifications are not required.Industrial process and basic risk-management knowledge is required. Engineering, operations, maintenance or HSE experience is recommended; specialist hazard-analysis qualifications are not required.

Pre course assignment and assessmentPre course assignment and assessmentPre course assignment and assessment

Review a fictional process description and incident summary for 30 minutes; identify major hazards, protective barriers and missing operating information.Review a fictional process description and incident summary for 30 minutes; identify major hazards, protective barriers and missing operating information.Review a fictional process description and incident summary for 30 minutes; identify major hazards, protective barriers and missing operating information.

End of course assessmentEnd of course assessmentEnd of course assessment

60 question written exam (90 minutes) and individual applied task (45 minutes).60 question written exam (90 minutes) and individual applied task (45 minutes).60 question written exam (90 minutes) and individual applied task (45 minutes).

Passing criteriaPassing criteriaPassing criteria

75% written and 70% applied, passed separately; full attendance. All mandatory criteria must pass.75% written and 70% applied, passed separately; full attendance. All mandatory criteria must pass.75% written and 70% applied, passed separately; full attendance. All mandatory criteria must pass.