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Safety in Plant Operation

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E-learning This course offers a combination of online and face-to-face training sequences

Who should attend?

  • This course provides trainees with a better understanding of product and equipment risks in order to ensure safe operation.
Public :
  • Operating personnel (operators, panel operators, shift leaders, engineers) in refineries and petrochemical/chemical plants; any staff involved in operations (maintenance, SHE department).

Level : Foundation

Course Content

  • E-learning: PRODUCTS HAZARDS – PREVENTION & OPERATING PRECAUTIONS

    Module 1 - OCCUPATIONAL HEALTH & SAFETY

      • Vocabulary and safety indicators.
      • Potential hazards in facilities.
      • Hazardous products classification.

  • Module 2 - FLAMMABILITY

      • Combustion phenomenon.
      • Ignition sources and consequences of a combustion.
      • Preventive measures against ignition risks.

  • Module 3 - OCCUPATIONAL HEALTH

      • Products toxicity.
      • Specific risks from most common products used in plants.
      • Chemical risk prevention.

  • Module 4 - FLUIDS BEHAVIOR

      • Pressure in a vessel.
      • Heat addition consequences.
      • Heat removal consequences.
  • TRAINING SESSION (4 days)

    PRODUCTS RISKS: PREVENTION & OPERATING PRECAUTIONS

      • Case studies involving products risks analyzed in subgroups, in order to strengthen information from the e-learning. Share ideas with the entire group. Lessons learned.

  • SAFETY IN PROCESS OPERATIONS

      • Precautions and risks related to the use of utilities: inert gases, liquid water, steam, air, gas oil, fuel gas.
      • Safety related to blowdown and drainage toward: flare, slops, tanks, oily water…
      • Blinding (lockout/tag-out) procedures: conditions for installing blinds or spades.
      • Degassing-inerting: steam, nitrogen, water, vacuum …
      • Works permits: different types and use.
      • Entry into vessels. Atmosphere analysis: oxygen content, explosivity, toxicity.
      • Start-up: checks, accessibility and cleanliness, line up, nitrogen, water, steam or vacuum deaeration.
      • Tightness testing; commissioning and start-up.

  • HANDS-ON ACTIVITIES ON A TYPICAL UNIT DECOMMISSIONING

      • Case study, common thread of this training, used as a workshop with different groups of trainees in order to apply the different topics for decommissioning and commissioning & Start Up. Procedure writing with instructions for each step. Presentation to the group, sharing & discussions. Lessons learned.

  • IMPLEMENTATION OF THE PRINCIPLES & GUIDELINES

      • Preparation of shutdown, decommissioning or/and commissioning, start-up procedure for a typical unit. Common thread throughout the training, carried out sequentially during the session, in order to increase mutual understanding of decommissioning principles. Lessons learned.

  • HUMAN BEHAVIOR & SAFETY MANAGEMENT

      • Human factors. Safety barriers, compliance with procedures, risk of routine.
      • Employees' involvement: commitment and responsibility.
      • Available tools to improve safety: procedures, risk assessment, safety meetings, accident investigation and reporting, audits, field observations, emergency drills.

Learning Objectives

  • Upon completion of the course, participants will be able to:
  • identify and assess the risks inherent to product handling, equipment use and operations,
  • measure the possible consequences on safety, health and the environment,
  • apply recommended preventive measures,
  • adopt the most appropriate behavior to counter risks.

Ways & Means

  • E-learning modules before the training to learn & refresh knowledge about risks.
  • Workshop: preparation of shutdown, decommissioning or/and commissioning, start-up procedure for a typical unit.
  • Case studies and analysis of incidents and accidents.