Process Safety Management

A holistic understanding of a PSM system.

Course Overview

  • The goal of this course is to shift participants from thinking of PSM elements as isolated parts and procedures to a system of interrelated mutually supportive actions and outcomes. This new perspective provides the foundation for incident and hazard reduction.


  • Participants will be divided into groups and asked to work collaboratively to analyze scenarios using incident videos and case studies and apply critical thinking skills to predict potential problems.

Learning Objectives:

By the end of the course you will be able to:

  • This course features a problem-based learning approach that provides a collaborative job-focused experience to accelerate skill development.


  • Participants will practice completing parts of the PSM analysis; identify and apply procedural requirements to manage the technology, facilities and personnel parts of PSM requirements; compare best-practice requirements to actual documented systems; collaboratively build a personal PSM on-the-job recommendation workbook; transfer in-class diagnostic strategies to job-related hazard and safety decisions; and demonstrate a holistic understanding of a PSM system.

Who Will Benefit

This course is ideally designed for:

  • managers, supervisors, engineers, safety personnel, and others involved in the design, operation, modification or maintenance of major hazard or other process plant graduates, chemical.


  • Other engineers en-route to achieving Chartered status anyone who would like to develop an understanding of process safety professionals who want to expand their knowledge of process safety.

Course Schedule

  • Ice Breaking


  • Expectation exercise.


  • Agenda Review.


  • PSM incident #1 Piper alpha.


  • Differences between PSM and Hard hat safety.


  • Incidents time line history.


  • PSM regulations and guidance.


  • CCPS and OSHA.


  • Egypt and PSM (Local regulations and initiatives).
  • Texas City case study.


  • CCPS Elements over view.


  • Management of change and project management.


  • Safe design and consequence analysis.


  • Consequence analysis and QRA.


  • Hazardous area classification and equipment.


  • Facility setting criteria.


  • Operating procedures and safe work practices.


  • Critical communications.
  • Chevron Refinery Case study.


  • Inherent safety.


  • Hazards and risk analysis.


  • Risk assessment and ALARP.


  • HAZOP.


  • SIL Review.


  • Human factors and Safety culture.
  • Document and knowledge management.


  • DuPont La Porte Case study.


  • Incident Investigation 5 Whys.




  • Fault tree.


  • HFAT.
  • Maintenance strategy and Risk based methodologies ,criticalities.


  • Safe operating limits and Safety critical elements.


  • Contractor management.


  • Case study.


  • Performance indicators.


  • PSM Standards.


  • Auditing and performance assurance.


  • Course test.

Course Deliverables

After completing this course, participants should compile a list of action items based on their learning to apply back on the job. This starts with writing new or upgrading existing PSM procedures. To build competency at the individual level, the participant should identify a coach, develop skills in applying PSM governance framework, develop a PSM dashboard, test the governance framework and dashboard in their department and then roll it out across the company.


Also, an overall road map for implementing PSM across the company should be established.

Five Days / Six Hours Per Day


(30 Hours of Instruction)