Process Safety Readiness: PSM, HAZOP and Startup Safety Training Course
1Summary
Most major process safety incidents don't happen because a hazard was unknown — they happen because a known gap was never closed before startup. The Process Safety Readiness Training Course gives participants the tools to prevent that: identifying process hazards, applying Process Safety Management, and verifying that safety-critical systems, procedures, and people are genuinely ready before commissioning and normal operations begin.
As part of Arab British Fellowship Training Academy's Operations Readiness and Assurance Training courses specialisation within the Engineering maintenance and operation category, the programme covers PSM, HAZID, HAZOP, LOPA, startup safety, pre-startup safety reviews, and readiness verification techniques to support safe commissioning and ongoing plant operations.
2Objectives and target group
This course develops the capability to:
- Apply process safety management principles throughout readiness activities.
- Identify process hazards using HAZID and HAZOP techniques.
- Evaluate risk controls using LOPA and related risk assessment methods.
- Conduct effective startup safety reviews and pre-startup readiness checks.
- Assess the readiness of safety-critical systems, equipment, procedures, and personnel.
- 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.
Target Audience
- Process safety, operations, and maintenance engineers/managers.
- Operations readiness, assurance, and reliability specialists.
- HSE and process safety professionals.
- Commissioning and startup teams.
- Project engineers and managers.
- Plant and facility managers.
- Asset integrity professionals.
- Engineering and maintenance supervisors involved in industrial commissioning and startup.
3Course Content
Module 1: Process Safety and Readiness — the Fundamentals
- Process safety principles versus occupational safety.
- Operational readiness concepts and lifecycle.
- Safety-critical elements, roles, and performance requirements.
Module 2: Hazard Identification and Risk Assessment
- Principles of hazard identification; HAZID and HAZOP methodologies.
- Risk identification during project and operational phases.
- Safeguards, risk ranking, and managing actions from hazard studies.
Module 3: Layer of Protection Analysis (LOPA)
- Fundamentals of LOPA: initiating events and consequences.
- Independent protection layers and risk reduction requirements.
- LOPA documentation and integrating it into readiness assurance.
Module 4: Process Safety Management (PSM)
- Core elements, leadership, and accountability in PSM.
- Management of change and operating/safe work procedures.
- Mechanical integrity, contractor management, and performance monitoring.
Module 5: Safety-Critical Systems and Equipment Readiness
- Identifying safety-critical equipment and mechanical integrity.
- Inspection, testing, and instrumentation/control system readiness.
- Emergency shutdown systems and alarm/interlock verification.
Module 6: Operational Readiness Planning
- Developing an operational readiness strategy and assurance plans.
- Procedures, documentation, and staffing/competency requirements.
- Readiness tracking and gap management.
Module 7: Startup Safety and Pre-Startup Safety Review
- Principles of startup safety and commissioning risk management.
- Pre-Startup Safety Review (PSSR) and equipment/procedure verification.
- Personnel competency verification and managing outstanding items.
Module 8: Emergency Preparedness and Operational Controls
- Emergency response readiness, procedures, and drills.
- Permit-to-work, isolation, and operating envelope controls.
- Loss prevention, escalation control, and emergency resource readiness.
Module 9: Sustaining Readiness After Startup
- Readiness assurance, verification, and gap closure methodologies.
- Process safety performance indicators and incident learning.
- Operational discipline, safety culture, and continuous improvement.