Introduction to Process Safety Engineering


Who should attend?

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

Level :Knowledge

Prerequisite :
  • Provide evidence of a basic technical knowledge in process, instrumentation, static and dynamic equipment.

Course Content

  • RISK IDENTIFICATION - Duration : 1.25 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.

      • 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 - Duration : 0.25 Day

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

      • Fire and 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, location, 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.

      • 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.

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,
  • Strengthen the integration of the human factor from the design stage.

Ways & Means

  • The pedagogy is active and builds on the experience of the participants and the knowledge of the site:
  • several exercises and applications (50% case studies or tutorial exercises), with a ‘’rolling case’’ on a typical processing unit
  • safety impact of a simple modification,
  • identification of safety barriers with the impact of their maintenance on their effectiveness.
  • a number of visual aids: videos, learning from incidents (Texas City, Buncefield, Achinsk…).

Learning assessment

  • Quiz.


Coordinator :IFP Training trainer (permanent or contracted) having a good expertise and/or experience of the related topics, trained to adult teaching methods, and whose competencies are kept up-to-date.

To French entities : IFP Training is referenced to DataDock ; you may contact your OPCO about potential funding. Please contact our disabled persons referent to check the accessibility of this training program :