Course outline
Module 1
Chapter 1: Process safety and the Process Safety Engineer (PSE)
Process Safety Basics Training Course 001 Distinguish process safety from occupational (personal) safety Define MAH, LOPC, hazard, risk, and barriers (prevention vs mitigation) Explain the scenario chain from hazard to harm and where controls act Describe what “good” looks like for a PSE in an operating business Ide...
$495.00
Module 2
Chapter 2: How major accidents happen: learning from history
By the end of this session, you should be able to describe major accidents as outcomes of systems that drift, not isolated errors. We’ll use five recurring patterns—degraded controls, weak change management, poor operating discipline, latent design vulnerabilities, and failures to learn—as a diagnostic checklist. Yo...
$495.00
Module 3
Chapter 3: Hazards in process plants: materials, energy, and escalation
Welcome to Chapter 3. This chapter builds hazard intuition without heavy math. We’ll cover the core hazard families you’ll see in process plants—flammability and explosion, toxicity/corrosives, reactivity, overpressure, and stored energy. A key theme is that hazards are not only “chemicals”; energy states like press...
$495.00
Module 4
Chapter 4: Risk concepts and ALARP/SFAIRP decision making
Risk language: why discipline matters Decisions involve operators, maintenance, engineers, leaders—shared language prevents confusion Loose language → inconsistent decisions and weak audit trails Risk language links physical reality to engineered and organizational action Documented assumptions enable revalidation a...
$495.00
Module 5
Chapter 5: Barrier-based thinking (Bowtie as the “map”)
Welcome. Chapter 5 introduces bowtie logic as the ‘single-page architecture’ that connects hazards to the controls that prevent and mitigate harm. In process safety, we often talk about ‘safeguards,’ but bowtie forces us to be explicit: what is the top event, what prevents it, what mitigates outcomes, and what condi...
$495.00
Module 6
Chapter 6: Hazard identification toolkit (hands-on, beginner-friendly)
Welcome to the hazard identification toolkit chapter. The goal is practical participation: you should be able to join a HAZID, What‑If, HAZOP, or FMEA session and contribute in a disciplined, scenario-based way. A key message is that hazard identification is a quality gate. If scenarios are vague or safeguards are a...
$495.00
Module 7
Chapter 7: Layers of Protection Analysis (LOPA) and IPL credibility
Explain what LOPA is and where it fits between PHA, bowtie, and SIL/QRA decisions. Distinguish a protection layer from an independent protection layer (IPL). Build a single cause–consequence pair with traceable initiating event frequency assumptions. Assess IPL credibility using independence, effectiveness, and audi...
$495.00
Module 8
Chapter 8: Engineering controls and safeguards (the engineered barrier set)
Explain the hierarchy of controls as used in process safety and why engineered safeguards dominate MAH risk control. Define engineered safeguards and distinguish preventive vs mitigative engineered barriers. Describe what “healthy” looks like for engineered safeguards (availability, effectiveness, and evidence). Ide...
$495.00
Module 9
Chapter 9: SIS and functional safety (layered depth)
Define functional safety, SIS, and SIF, and explain how they fit in the barrier stack. Explain how LOPA outputs can lead to a SIF requirement and a SIL target. Describe the functional safety lifecycle and why front-end specification matters. Explain proof testing concepts (interval, coverage, hidden failures) and wh...
$495.00
Module 10
Chapter 10: Relief and disposal systems (conceptual + optional sizing logic)
Explain why overpressure protection exists and why rupture is a major accident escalation mechanism. Define PRD, relief system, disposal system, and design basis using the chapter’s terminology. Recognize the common overpressure scenario families (blocked outlet, fire exposure, control failure/runaway). Describe the...
$495.00
Module 11
Chapter 11: Human factors integrated into barrier performance
Explain why human factors belongs inside barrier performance (not as an afterthought). Define human factors, human reliability, workload, fatigue, alarm response, shift handover, and procedures (chapter terminology). Identify common human-related failure pathways in major accidents (alarm overload, procedure depende...
$495.00
Module 12
Chapter 12: Operational control: procedures, PTW, SIMOPS, and operating limits
Define operational control and how it sustains barrier performance. Explain safe operating limits and how to make limits actionable in operations. Describe permit-to-work (PTW) as a coordination and hazard-control system. Recognize SIMOPS interaction hazards and apply matrix + authority + communication controls. App...
$495.00
Module 13
Chapter 13: Mechanical integrity and asset integrity as a barrier assurance system
Mechanical integrity and asset integrity as a barrier assurance system Audience: Intermediate Today’s chapter is about integrity as a major-accident barrier, not just a maintenance activity. Mechanical integrity (MI) keeps process equipment fit for service, while asset integrity management (AIM) expands that idea to...
$495.00
Module 14
Chapter 14: Management of Change (MOC) and readiness (PSSR)
This chapter is about one of the most common ways major accident risk is accidentally created: change. Plants usually operate safely because key assumptions hold—design intent, operating limits, equipment integrity, and safeguard performance. Change is dangerous because it can break those assumptions in ways that ar...
$495.00
Module 15
Chapter 15: Incident investigation and organisational learning (barrier lens)
This chapter uses a barrier lens and bowtie language to keep investigations anchored to how the system is supposed to control hazards: what threats challenged the system, what barriers were supposed to stop escalation, and what was impaired, missing, or inadequate. You’ll also see a strong emphasis on verification:...
$495.00
Module 16
Chapter 16: Leading indicators and barrier health monitoring
The chapter’s central idea is barrier health monitoring: use leading indicators to detect deterioration and precursor signals while you still have time to restore barrier effectiveness. That means your indicators must attach to barriers and their assurance activities, not to vague aspirations like “improve culture.”...
$495.00
Module 17
Chapter 17: Regulatory frameworks and standards (global map)
In this chapter we build a practical “global map” of how process safety is regulated and evidenced. The goal is not to turn you into a lawyer, but to help you translate what a regulator expects into the barrier outcomes you actually have to design, operate, and assure. We contrast goal-setting safety case regimes wi...
$495.00
Module 18
Chapter 18: Safety in design and lifecycle management
Audience: Intermediate (operators, engineers, and project staff in major-hazard industries) Explain what “safety in design” means and why early decisions have high leverage. Describe how hazard studies should change by lifecycle phase and remain traceable. Identify what “operational readiness / PSSR” must verify bef...
$495.00
Module 19
Chapter 19: Digital transformation and the future of process safety
Audience level: Intermediate Explain how digital twins, predictive analytics, remote monitoring, and AI support barrier assurance (not replace safeguards). Define key terms: digital transformation, digital twin, predictive analytics/AI, model risk, data drift, validation, verification, OT cybersecurity. Identify dig...
$495.00
Module 20
Chapter 20: Case studies (barrier failure narratives)
Use the chapter’s consistent learning method: scenario → barrier model → degradation → missed warnings → requirements and assurance tasks. Define and apply key terms (barrier types, bowtie/top event, escalation, impairment, SCE, performance standard, assurance, proof test). Identify cross-cutting weaknesses revealed...
$495.00
Module 21
Chapter 21: Building a career in process safety engineering
1. Define “process safety competency” and how it is demonstrated in practice. 2. Describe competency pathways for key roles (engineers, operators, maintenance, HSE/PSM, leaders). 3. Use the chapter’s four credibility behaviors to strengthen decision quality. 4. Explain why field verification and documentation discip...
$495.00
Module 22
Chapter 22: Conclusion: the evolving mission of process safety
Welcome to the conclusion chapter. This session is aimed at engineers and practitioners who already recognize the basics of hazards, scenarios, and barriers, and now need a durable mental model for how process safety stays relevant as technology and context change. We’ll use the chapter’s core message: the hazard la...
$495.00