The Process Safety and Operational Readiness Training Course by Arab British Fellowship Training Academy provides a structured approach to preparing industrial facilities, processes, systems, personnel, and procedures for safe and reliable operations. The course develops practical knowledge of Process Safety Readiness, covering risk identification, process safety management, operational controls, safety-critical systems, emergency preparedness, and readiness verification before startup and normal operations.

As part of the Operations Readiness and Assurance Training courses specialisation within the Engineering maintenance and operation category, the programme focuses on integrating process safety requirements into operational readiness activities. Participants will explore PSM, HAZOP, HAZID, LOPA, startup safety, risk assessment, operating procedures, competency assurance, pre-startup safety reviews, and readiness assurance techniques to support safe commissioning, startup, and ongoing plant operations.

By the end of this course, participants will be able to:

• Understand the principles and framework of Process Safety Readiness.
• Apply process safety management principles throughout operational readiness activities.
• Identify process hazards using HAZID and HAZOP techniques.
• Evaluate risk controls using LOPA and related risk assessment methods.
• Develop effective startup safety and pre-startup readiness practices.
• Assess the readiness of safety-critical systems, equipment, procedures, and personnel.
• Establish operational readiness requirements for commissioning and startup.
• Identify gaps that could affect safe and reliable plant operations.
• Strengthen emergency preparedness and operational control measures.
• Integrate process safety requirements into maintenance and operations planning.
• Support pre-startup safety reviews and readiness verification.
• Improve coordination between engineering, maintenance, operations, and process safety teams.

Target Audience

• Process Safety Engineers
• Operations Engineers and Managers
• Maintenance Engineers and Managers
• Operations Readiness Professionals
• HSE and Process Safety Professionals
• Commissioning and Startup Teams
• Project Engineers and Managers
• Plant and Facility Managers
• Reliability and Asset Integrity Professionals
• Engineering and Maintenance Supervisors
• Operations Readiness and Assurance Specialists
• Professionals involved in industrial facility commissioning and startup

Module 1: Fundamentals of Process Safety and Operational Readiness

• Process safety principles and objectives
• Operational readiness concepts
• Process safety versus occupational safety
• Readiness assurance throughout the asset lifecycle
• Process safety roles and responsibilities
• Safety-critical elements and performance requirements

Module 2: Process Safety Management (PSM)

• Core elements of PSM
• Process safety leadership and accountability
• Management of change
• Operating procedures and safe work practices
• Mechanical integrity and asset reliability
• Contractor and competency management
• Process safety performance monitoring

Module 3: Hazard Identification and Risk Assessment

• Principles of hazard identification
• HAZID methodology and applications
• HAZOP study principles
• Risk identification during project and operational phases
• Safeguards and preventive controls
• Risk ranking and prioritisation
• Managing actions from hazard studies

Module 4: Layer of Protection Analysis (LOPA)

• Fundamentals of LOPA
• Initiating events and consequences
• Independent protection layers
• Risk reduction requirements
• Evaluating safeguards and protection systems
• LOPA documentation and action management
• Integrating LOPA into process safety readiness

Module 5: Operational Readiness Planning

• Developing an operational readiness strategy
• Readiness requirements and assurance plans
• Operations and maintenance readiness
• Procedures, documentation, and systems readiness
• Staffing and competency requirements
• Spare parts, tools, and maintenance readiness
• Readiness tracking and gap management

Module 6: Startup Safety and Pre-Startup Safety Review

• Principles of startup safety
• Commissioning and startup risk management
• Pre-Startup Safety Review (PSSR)
• Verification of equipment and safety systems
• Operating procedure verification
• Personnel competency and training verification
• Managing outstanding items before startup

Module 7: Safety-Critical Systems and Equipment Readiness

• Identification of safety-critical equipment
• Mechanical integrity considerations
• Inspection and testing requirements
• Instrumentation and control system readiness
• Emergency shutdown and protection systems
• Alarm and interlock verification
• Maintenance and reliability readiness

Module 8: Emergency Preparedness and Operational Controls

• Emergency response readiness
• Emergency procedures and drills
• Incident response responsibilities
• Permit-to-work and isolation systems
• Operating envelope and process controls
• Loss prevention and escalation control
• Emergency equipment and resource readiness

Module 9: Readiness Assurance, Verification and Gap Closure

• Readiness assessment methodologies
• Readiness checklists and verification
• Assurance reviews and audits
• Identifying and classifying readiness gaps
• Action tracking and close-out
• Evidence-based readiness assurance
• Management of residual risks

Module 10: Integrating Process Safety into Sustainable Operations

• Process safety performance indicators
• Continuous improvement
• Lessons learned and incident learning
• Operational discipline
• Process safety culture
• Maintaining readiness after startup
• Integrating process safety with maintenance and operational excellence