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Introduction to Process Safety Engineering

Introduction to Process Safety Engineering

5 days
SEC/SAFENGRC-E
Sessions
This course is not scheduled.
Who should attend?

Audience

    • Managers, engineers, technicians in charge of the design, the modification, the maintenance or the operation of industrial facilities.

Level

  • Foundation
  • This course provides an overview of safety reviews in a project and highlights the main principles to design and maintain the prevention, mitigation and protection barriers.
Learning Objectives
  • Upon course completion, the participants are able to:
  • be instrumental in the safety reviews done during a project or plant modification,
  • improve process safety practices and reinforce the integration of the human factor from the design stage.
Course Content

RISK IDENTIFICATION

1.5 days

  • Risk identification and acceptability with respect to people, environment and assets - Hazard and risk - Residual risk - Risk assessment matrix.
  • Review of hazardous phenomena: gas dispersion, toxic release, thermal radiation, overpressure blast.
  • Preliminary risk quantification: evaluation of risk consequences (grass root project or revamping) based on HAZID/HAZOP reviews.

INHERENT SAFETY DESIGN & LAYOUT OPTIMIZATION

0.25 day

  • Layout optimization based on safety reviews: Safety distances - Fire zones - Deluge zones.
  • Reducing hazardous inventories, leak control systems, disposal system (flare, diked area…) and drainage systems, equipment sealing.

TYPE OF SAFETY BARRIERS

0.25 day

  • Safety barriers: technical, organizational, human; prevention, mitigation, protection, active/passive. Criteria of safety barriers’ efficiency.

PREVENTION BARRIERS

1.5 days

  • Pressure equipment and atmospheric storage tanks: selection of material of construction, corrosion, pressure resistance - Piping classes.
  • Overpressure and negative pressure protection: pressure safety valves, rupture discs: selection criteria, design, implementation, inspection.
  • Safety Instrumented Systems (SIS) and Safety Integrity Level (SIL) - Typical architecture of Safety Instrumented Systems: hierarchy, interaction with process control system and Fire & Gas system.
  • Flammability control: minimizing ignition sources, hazardous area classification, equipment selection and location in hazardous areas.

DETECTION, MITIGATION & PROTECTION SYSTEMS

0.5 day

  • Fire & gas detection system: technology of sensors, selection and location - Cause and Effect Matrix, Voting - Relationship with mitigation systems.
  • Passive fire and blast protection: description of material, utilization, monitoring and inspection - Identification of surface/elements to be protected.
  • Active firefighting systems: extinguishing agents (water, foam, dry chemicals, inert/inhibition gas).
  • Fixed systems with water or foam: elements of the fire main system (main ring, fire water pumps, consumers, water tank, foam solution), application rate.

DAY-TO-DAY INDUSTRIAL RISK MANAGEMENT

1 day

  • Human factors: functioning of the human being - examples of systems embedding human behavior or human error: equipment accessibility, plant ergonomics, graphic display design, alarm management…
  • Management of Change (MOC): technical, organizational and human expertise (reliability of documentation, suitability/application of the procedures, corporate’s specifications...).
  • Maintaining the efficiency of the barriers - Example of a risk management tool: the bow tie.
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Ways & Means
  • The pedagogy is active and builds on the experience of the participants and the knowledge of the site:
  • Interactive lecturing, by experienced instructor(s),
  • Several exercises and applications (50% case studies or tutorial exercises),
  • A number of visual aids (Videos, Learning from Incidents (Texas City, Buncefield, Achinsk…)).