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Safety Systems & Risk Management

Introduction

As industrial technology advances, the complexity of identifying and mitigating safety risks increases. Plant Managers and Engineers must understand that safety and risk management are integral to the daily operations of their plants and systems to meet ever-evolving international and national environmental and economic standards. Neglecting safety protocols can lead to financial losses from accidents, disruptions in production, legal actions, diminished market presence, and damage to both company assets and the environment.


Course Objectives

  • Implement hazard detection and risk evaluation for industrial processes and equipment.
  • Grasp the concept of system reliability and the application of fault tracking.
  • Gain hands-on experience with quantitative risk assessment methods and the necessary data documentation.
  • Provide strategic advice to leadership on optimal risk mitigation techniques.
  • Establish requirements for developing a secure operational framework.
  • Acknowledge and apply international standards for reliability and machine safety.


Target Audience

  • Plant Professionals
  • Engineers
  • Designers
  • All professionals committed to maintaining safety in high-risk environments


Course Outline

Day 1: Identifying Hazards

  • Course Introduction and Overview
  • The Importance of Safety Engineering
  • Case Studies of Major Industrial Accidents
  • Overview of Safety Systems
  • Techniques for Hazard Identification
  • Implementing Hazard Controls
  • Setting Risk Acceptance Criteria
  • Advanced Hazard Identification Methods
  • Eliminating Hazards Through Design
  • Review of Safety and Standards Codes, Both National and International
  • Application of Safety Analysis in Engineering, Chemical Processes, and Manufacturing


Day 2: Assessing Risks

  • Foundations of Safety Management
  • Lifecycle Safety Considerations
  • Comprehensive Hazard Identification Checklists
  • Risk Assessment in Processes, Workplaces, and Equipment
  • Task-Specific Risk Analysis
  • Introduction to Hazard and Operability Study (HAZOP)


Day 3: Ensuring Equipment Safety

  • Identifying Hazards in Machinery
  • Preventative Measures for Machinery Accidents
  • Practical HAZOP Insights
  • Analysis of Failure Modes, Human Factors, and Software Safety
  • Execution of Failure Mode and Effects Analysis
  • Exploring Human Performance and Error in Safety


Day 4: Technology of Reliability

  • Identifying and Preventing Failure Types
  • Preventative Strategies
  • Maintenance and Inspection Strategies
  • System and Component Reliability
  • Design Principles for Reliable Control and Protective Systems
  • High Integrity Protection Systems (HIPS) Concepts
  • Selection of Safety Integrity Levels (SIL)


Day 5: Analyzing Consequences

  • Dynamics of Fire, Explosions, and Toxic Releases
  • Use of Dispersion Modeling Software
  • Different Fire Types: Flash, Jet, Cascading, and Boiling Liquid Expanding Vapor Explosion (BLEVE)
  • Explosion Variants
  • Risk Quantification Techniques
  • Event Tree Analysis (ETA)
  • Course Closure and Review