WHAT IS PROCESS SAFETY?
Process Safety is that part of overall safety that ensures that processes handling hazardous, toxic, flammable, explosive, pressurized materials work safely, without causing accidents and bad consequences to people, assets/equipment and the environment. This term is mainly used only in the "process industries", which are industries that handle and process bulk raw materials in relatively huge quantities (think chemicals manufacturing, oil and gas production, petroleum refining and similar). In these industry sectors, it is common to handle large quantities of flammable, explosive or toxic substances, often at high temperatures and pressure (or under vacuum).
What is Safety?
Safety is simply defined as “freedom from harm”. It is the expectation of every human being, to have a safe environment. In order to achieve this, different means are employed. So we need to have a safe home, a safe work environment, a safe means of transport and so on. Safety by itself is a vast subject and there are various sub disciplines within it.
For example, we may reduce the risk of overflow of a day tank, by having an overflow pipeline that will divert the excess flow to another tank, located at a lower level. In this case safety is achieved purely by the right piping and the use of gravity. This can be considered an example of achieving overfill protection by mechanical means and using Process Safety principles.
When operators of this unit shown above use Personal Protection Equipment such as helmets, gloves or safety shoes, they are following principles of Occupational Safety.
What kinds of safety are employed in manufacturing plants?
In a nutshell, in a manufacturing plant, especially in the process industries such as Oil & Gas, Chemicals, Pharmaceuticals, Power generation, Nuclear and similar we achieve safety via Process Safety, Functional Safety and Occupational Safety. In case the plant or facility has materials that are flammable or explosive, then we also use principles of Hazardous Area management to ensure safety. In case the facility uses computerized Automation systems such as DCS or PLC or SCADA or a SIS, then we also need to maintain cyber security of these systems in order to ensure overall safety.
In non-process industry sectors (such as automobile manufacturing or discrete parts manufacturing some widgets), the discipline of process safety is almost non-existent (except if the industry uses equipment such as steam boilers or oil or gas fired furnaces). In these sectors, machinery safety & occupational safety are dominant. Many of the machines that are on the shop floor are operated by workers, who work in close proximity to them. They are vulnerable to being hurt and hence modern machines have sophisticated protection mechanisms like hand protection interlocks, light curtains, high reliability emergency stop switches and so on. Machine safety using such devices is considered a part of Functional Safety.
Abhisam has online courses, workshops & consulting services on all the above areas. On this page, we will be only discussing Functional Safety, Safety Intergity Level (SIL) and and Safety Instrumented Systems. You can explore other pages of the Abhisam site to get more information on HAZOP, LOPA, Hazardous Area Classification, Industrial Cybersecurity, Personal Protective Equipment and similar related subjects.
Process Safety Courses Provided By Abhisam
We have the following Online Courses/E-learning courses related to Process Safety. Each of these courses consist of several modules that have text, animations & simulations, graphics, assessments, examples, real life case studies that help you become a professional. You can complete them from the comfort of your home or office or anywhere else. You can either take them online over the internet (Online version), or download it to your Windows PC (when you buy the Standard version). On passing the associated exam, you can get qualified as a professional, earn an electronic certificate with a unique ID number and a badge issued via Credly, that can be added to your Linked In Profile or other places online such as email signatures. This displays your qualifications and competencies to your colleagues, peers, bosses and potential employers and clients.
Hazard & Operability Study (HAZOP)The Hazard and Operability Study is a the predominant risk assessment technique used in the process industry. The Abhisam HAZOP course also includes CHAZOP (short for Control HAZOP or Computer HAZOP), which is used to analyze Automation and Control systems in the process industry that are DCS, PLC or SCADA or SIS. The course consists of the following modules:a) Basic Conceptsb) HAZOP Methodologyc) HAZOP Types, Standards & Legal Requirementsd) Managing HAZOPse) Case Studyf) Self Assessment TestClick for more details of the HAZOP course
Industrial Toxicology Training
Toxicology is known as the science of poison. The process industry is a very important part of the global economy. However many of the raw materials and products of this industry are toxic to humans, animals and the environment. The Industrial Toxicology course enables learners to understand all aspects of toxic materials used in industry. It covers the following topics:
a) Introduction to Toxicology
b) Basic Concepts of Industrial Toxicology
c) Toxicology Studies
d) Toxicity Measurements
e) Case Study
f) Self Assessment Test
Click here to learn more about Industrial Toxicology here
Safe Chemical Warehousing Courses
Warehouses are one of the most important parts of any supply chain. Chemical Warehouses are those that are used to store hazardous, flammable or toxic chemicals. Chemical warehouse safety goes beyond the ordinary steps that one takes to protect non toxic, non flammable or non hazardous material because a fire or explosion can result in not only damage of the stored goods, but also destroy the environment, cause injuries to people and give rise to consequential damages on a massive scale, which is disproportionately higher than the cost of goods stored. The course consists of the following modules:
a) Basic Concepts
c) Design and Product storage
d) Health Safety and Environment requirements
e) Operations & Management
f) Legal, Security & Emergency Requirements
g) Advanced Module (only in Enterprise version)
h) Self Assessment Test
Learn more about Chemical Warehouse Safety
Industrial Hygiene Process Safety
Industrial Hygiene deals with the anticipation, identification, evaluation and mitigation of hazards in the workplace. Industrial hygienists analyze, identify, and measure workplace hazards or stressors that can cause sickness, impaired health, or significant discomfort in workers through chemical, physical, ergonomic, or biological exposures. For most manufacturing plants or similar locations, maintaining Industrial Hygiene is essential part of compliance to legal requirements. This self learning software based training course is the easiest and fastest way to learn this subject at your own pace. This course consists of the following eight modules.
1.Introduction to Industrial Hygiene
2. Basic Concepts
3. Anticipation & Identification of Hazards
4. Evaluation of Hazards (including calculations)
5. Control of Hazards (including calculations)
6. Government Regulations
7. OSHA PSM Standard & Compliance
8. Case Study
9. Self Assessment Test
Learn more about Industrial Hygiene now
Understanding Fires & Explosions
Fires and Explosions are one of the biggest risks that face the process industry today. Understanding the mechanisms of these phenomena are essential to ensure safety. Although fires and explosions are treated as almost similar phenomena by many, the actual mechanism of each is different. We can also have events such as deflagration, detonations and BLEVE (Boling Liquid Expanding Vapor Explosion). This e-learning course helps you learn all about the causes and the mechanisms of fires and explosions in this sector.
a) Introduction to Fires & Explosions
b) Basic Concepts of Fires
e) Ignition Sources
f) Explosions Mechanism (including Detonation)
e) Self Assessment Test
After completing the above modules, the learner can take the associated exam and earn a Certificate of Completion and an electronic badge via Credly. Learn more about Fires and Explosions here
Preventing Fires & Explosions
Once the mechanism of how Fires and Explosions take place is understood, the next step is to understand how to prevent them from taking place. Since prevention is always better than cure, especially in the process industry where a single large fire or explosion can easily bankrupt a company, this course is essential for everybody who works in the process industries, not just safety managers or HSE personnel. This course has the following modules.
2. Use of flammability diagram
3. Controlling Static Electricity
4. Using Explosion protected equipment (electrical, electronic and mechanical) & instruments
6. Sprinkler Systems
7. Designing for Fire & Explosion prevention
Note that this course can be taken only after completing the Understanding Fires & Explosions course. Learners can complete this course, pass the associated exam and earn a Certificate of Completion, as well as an electronic badge from Credly. Learn all about Fire and Explosion Prevention here
LOPA (Layer of Protection Analysis) Training
Layer of Protection Analysis (LOPA) is a well known technique of Risk Assessment used mainly in the process industries. It can be used after HAZOP to determine the risk level of various protection layers and whether it is necessary to add any more independent layers to reduce the risk to an acceptable level. This self paced e-course has the following modules:
1.Hazards, Risks, Assessments
2. Types of Risk Assessments methods:
3. Probability Concepts
4. Introduction to Layer of Protection Analysis (LOPA)
5. LOPA methodology
6. Case Study 1: Tank Truck containing Toxic and Flammable Chemical: Unloading, Storage and Transfer to Plant
- Process Hazard Analysis
- Hazard and Operability Study (HAZOP)
- Estimating Consequences and Severity
- Identifying and developing scenario
- Identifying initiating Event and determining the frequency
- Identifying independent protection layers
- Estimating Risk of Scenario
- Evaluating the risk for decisions
- Implementation of LOPA
7. Self Assessment Test
The following modules will be only available in the Advanced Version:
8. Case Study 2: Polymerization Reaction LOPA
9. Case Study 3: Distillation operation LOPA
For more details please see here.
PHA (Process Hazard Analysis) Training
PHA stands for Process Hazard Analysis. A PHA study can use one or more risk assessment techniques to analyze the various possible hazards in a process, with a view to mitigating them via engineering or operational controls. This self paced e-course has the following modules:
1.Hazards, Risks & Risk Assessment
2. Types of Risk Assessments methods:
3. Probability Concepts
4. Basics of HAZID
5. Basics of HAZOP
6. Basics of QRA
7. Basics of LOPA
8. Basics of Bowtie Method
9. Selection Criteria for techniques
10. Self Assessment Test
This course is not yet available for sale. For more details please see here.
Offline Process Safety Training Courses and Workshops
In addition to the above online courses, we along with our associates, also conduct traditional classroom style Training Workshops from time to time in multiple cities around the world. These are offered as public courses but can also be offered as on site training at your location. Our trainers will travel to your location and deliver these programs. They can be customized as per your needs.
You can find more about all our workshops here.
Free White Papers By Abhisam
The following free white papers on Functional Safety, SIL and Safety Instrumented Systems are available on the Abhisam website and can be accessed from the links below.
You can also access informative white papers on other interesting topics here.
The following free videos are on topics related to Process Safety and provide useful information to learn the basics.Feel free to share, like them or embed them wherever you wish.
What is hazard and operability study (HAZOP)?
What Is Control Systems HAZOP (CHAZOP)?
Understanding Fires and Explosions
Process Safety Related Consulting
Abhisam provides some specialized Process Safety related consulting to select clients in the following areas, please follow the links to know more.
- Facilitate HAZOP Study Sessions or LOPA Study Sessions
- Conduct a rapid Process Safety Audit and Risk Assessment
- Conduct Technical Due Diligence before mergers and acquisitions in the process industry.
- Facilitate Decontamination and Decommissioning of process plants
Contact us for your requirements.
Process Safety Posts from the Abhisam Blog
- HAZOP Leader Certification Course is now online - July 16, 2020- The Abhisam HAZOP Leader certification course is now a completely online, e-learning course now. With the incidence of the pandemic and lockdowns in various places around the world, many learners demanded that the popular course be offered online. Abhisam is now pleased to inform participants that this HAZOP Leader certification course online ... Read more
- Learn HAZOP and CHAZOP. Get Certified. - Update: Please take the online self paced, HAZOP online course in e-learning format now, instead of the workshop, as we have suspended the physical presence workshops in view of the pandemic. If you have already completed the training, then you can upgrade yourself to the next level by qualifying as a HAZOP Leader here. Feb ... Read more
- New HAZOP Training Workshop in Thane (India) - Update: All in person workshops have been suspended and replaced by self paced, e-learning courses that do not require you to be present in person. They can be taken anywhere and most importantly, anytime. Please enroll now in the HAZOP online course now to earn a Certificate of Competency and an electronic badge. Original News: ... Read more