Safety in Plant Operation


Who should attend?

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

Level : Foundation

Course Content


      • Hazard and risk identification.
      • Safety, health, environmental consequences.
      • Risk management: technical, organizational and human aspects.

      • Flammability:
      • Explosive atmosphere: combustible products (gaseous, liquid and solid). Oxidizers. Ignition sources; flames, self-ignition temperature, sparks and static electricity, pyrophoric products, etc.
      • Preventive measures and precautions: during normal conditions, during draining and sampling; in the event of leaks; with regard to storage tanks; during loading and unloading; during repair work.
      • Risks and precautions related to BLEVE.
      • Chemical and physical hazards involving personnel:
      • Poisoning: ingestion, metabolism and elimination. Prevention.
      • Burns caused by heat sources and chemical products.
      • Fluid behavior and related risks:
      • Pressure in a vessel and consequences of an increase or decrease in temperature: thermal expansion, vaporization, collapsing due to vacuum, freezing due to pressure drop, etc.
      • Risk assessment and preventive measures.
      • Pressure equipment related risks.
      • Main risks.
      • Preventing of risks through the correct use of safety equipment and devices.
      • Corrosion hazards and monitoring.

      • Preparation of shutdown, decommissioning or/and commissioning, start-up procedure for a typical unit.
      • 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/tagout) procedures: conditions for installing blinds or spades.
      • Degassing-inerting: steam, nitrogen, water, vacuum, work permits…
      • 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.

      • Human factors. Safety barriers, compliance with procedure, 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

  • Workshop: preparation of shutdown, decommissioning or/and commissioning, start-up procedure for a typical unit.
  • Case studies and analysis of incidents and accidents.