Process Safety Management Compliance Training Course

Participants can determine whether a process falls within OSHA PSM coverage and document the basis.

• Threshold quantities for listed highly hazardous chemicals under 1910.119
• Flammable liquid and gas thresholds, exemptions and aggregation rules
• Covered process boundaries defined using interconnected vessel and piping logic
• Documenting coverage determinations, exclusions and assumptions for audit evidence
• EPA Risk Management Program interfaces with OSHA PSM obligations
• Process inventory calculations using maximum intended inventory and mixture data

Participants can establish roles, consultation routes and records that support PSM accountability.

• Written employee participation plans meeting OSHA PSM requirements
• Worker access to process hazard analyses and operating procedures
• RACI matrices assigning ownership across PSM element activities
• Management review agendas addressing risk, actions, resources and performance
• Escalation criteria for unresolved process safety concerns and deviations
• Document retention schedules aligned with PHA, MOC and audit records

Participants can compile and assess process safety information required before hazard analysis.

• Chemical hazard information including toxicity, reactivity and thermal stability
• Process technology data covering chemistry, inventories, limits and consequences
• Safe operating limits established for pressure, temperature, flow and level
• Piping and instrumentation diagrams controlled through document revision systems
• Equipment design data including materials, relief basis and electrical classification
• Codes and standards used to assess equipment design compliance

Participants can select and prepare an appropriate process hazard analysis method.

• PHA revalidation intervals, team composition and action tracking requirements
• HAZOP guidewords applied to nodes, parameters and design intent
• What-If analysis structured around credible deviations and consequences
• Failure Mode and Effects Analysis for equipment-level failure mechanisms
• Checklist analysis using recognised codes, standards and operating experience
• PHA scope statements defining process boundaries, assumptions and deliverables

Participants can document HAZOP deviations, causes, consequences, safeguards and recommendations.

• Node selection based on P&IDs, operating modes and hazard potential
• Guideword combinations generating deviations from intended operating conditions
• Cause identification separating initiating events from enabling conditions
• Existing safeguards tested for independence, functionality and human reliability
• Recommendations written with accountable owners, deadlines and closure evidence
• HAZOP worksheets recording assumptions, discussions and residual risk decisions

Participants can evaluate process risk and determine whether additional safeguards are justified.

• Risk matrices calibrated with defined likelihood and consequence criteria
• Hierarchy of controls applied to process hazard risk reduction
• Layers of Protection Analysis using initiating event frequencies
• Independent protection layer criteria for alarms, trips and relief devices
• Safety Integrity Level concepts and limits of simplified assessments
• Residual risk acceptance documented through authorised decision-making processes

Participants can assess operating procedures and safe work practices against PSM requirements.

• Startup, normal operation, emergency shutdown and temporary operation procedures
• Operating limits linked to consequences of deviation and corrective actions
• Procedure format supporting field use, revision control and accessibility
• Lockout-tagout controls for hazardous energy during process equipment maintenance
• Hot work permit requirements within or near covered processes
• Line breaking, confined space and opening equipment safe work controls

Participants can plan operator training and verify competence for process safety-critical tasks.

• Initial training content covering process hazards and operating procedures
• Refresher training intervals based on performance, change and risk
• Competence assessment using observation, questioning and task demonstration
• Shift handover standards covering plant status, hazards and outstanding work
• Operating discipline indicators for procedure use, deviations and interventions
• Training records demonstrating completion, understanding and employee identification

Participants can establish contractor controls for work affecting covered process hazards.

• Contractor prequalification criteria covering skills, incidents and safety performance
• Host employer responsibilities for hazard communication and site rules
• Contractor employer duties for training, procedures and employee instruction
• Pre-job meetings addressing simultaneous operations and interface hazards
• Performance monitoring through field observations, permit reviews and audits
• Contractor injury and illness logs maintained for covered process work

Participants can plan and document a pre-startup safety review before introducing hazardous chemicals.

• PSSR triggers following new facilities or significant process modifications
• Construction verification against design specifications and approved engineering documents
• Operating procedures, PHA actions and training completed before startup
• Mechanical integrity checks confirming critical equipment readiness for service
• Walkdown methods identifying incomplete work, temporary conditions and deviations
• PSSR sign-off records defining exceptions, controls and accountable authorities

Participants can assess mechanical integrity programmes for process safety-critical equipment.

• Critical equipment registers covering vessels, piping, relief devices and controls
• Inspection and test plans based on degradation mechanisms and codes
• API 510, API 570 and API 653 inspection programme interfaces
• Preventive maintenance tasks for pumps, compressors, alarms and interlocks
• Deficiency management using risk ranking, interim controls and repair deadlines
• Quality assurance for spare parts, fabrication, installation and maintenance work

Participants can manage technical, procedural and organisational changes before implementation.

• MOC screening criteria distinguishing replacement in kind from change
• Technical basis statements describing purpose, hazards and design implications
• Risk reviews covering process safety information, PHA and operating procedures
• Authorisation workflows assigning engineering, operations and HSE approvals
• Temporary change controls with expiry dates, reviews and restoration actions
• Post-implementation verification confirming documents, training and field readiness

Participants can investigate process safety incidents and convert findings into effective corrective actions.

• Incident triggers including releases, fires, explosions and near misses
• Evidence preservation using scene control, photographs, records and interviews
• Barrier analysis identifying failed, missing and degraded controls
• Five Whys and causal factor charting for systemic cause analysis
• Corrective actions written with verification criteria, owners and due dates
• Learning reviews connecting incident findings to PHA, procedures and training

Participants can evaluate emergency planning arrangements for credible process loss scenarios.

• Release scenarios informing emergency action plans and response procedures
• Incident command roles, communications and decision escalation arrangements
• Shelter-in-place, evacuation and muster controls for toxic releases
• Firewater, detection, isolation and emergency shutdown system interfaces
• Mutual aid agreements and emergency services information requirements
• Drill evaluation methods capturing response gaps and improvement actions

Participants can conduct a PSM audit and report evidence-based findings.

• PSM audit frequency requirements and independent auditor selection criteria
• Audit protocols mapped to each OSHA PSM element requirement
• Evidence sampling across documents, interviews, observations and system records
• Finding statements distinguishing nonconformance, observation and improvement opportunity
• Root cause review for recurring audit findings and overdue actions
• Audit reports presenting risk, evidence, ownership and closure expectations

Participants can develop indicators that reveal process safety control performance and deterioration.

• API RP 754 Tier 1 and Tier 2 indicators
• Leading indicators for PHA actions, inspections, MOCs and training
• Barrier health measures for alarms, relief devices and safety instrumented systems
• KPI definitions specifying numerator, denominator, source and reporting frequency
• Trend analysis separating normal variation from deteriorating control performance
• Management dashboards linking indicators to decisions, actions and verification

Participants can build an assurance cycle that prioritises and tracks PSM improvement work.

• Gap assessments comparing current controls against OSHA PSM requirements
• Risk-based action prioritisation using severity, exposure and control weakness
• Action registers linking findings, owners, resources, milestones and evidence
• Three-lines assurance roles for operational, specialist and independent review
• Periodic management reviews testing action closure and control effectiveness
• Improvement roadmaps sequencing quick fixes, engineering work and capability development

Participants can design a controlled PSM documentation structure that supports retrieval and assurance.

• Document hierarchies connecting policies, standards, procedures and field instructions
• Revision control preventing obsolete P&IDs and procedures remaining available
• Record retention requirements for PHAs, incidents, training and audits
• Evidence indexes linking PSM requirements to supporting controlled records
• Digital workflow controls for approvals, notifications and action closure
• Data quality checks identifying missing dates, signatures and technical approvals

Participants can build, review and present a complete PSM compliance improvement package for a selected covered process.

• Covered process profile defining inventories, boundaries, hazards and accountable roles
• PSM gap assessment mapped against 1910.119 element requirements
• Selected PHA findings analysed for safeguard and action adequacy
• Mechanical integrity, MOC and procedure evidence tested for control gaps
• Prioritised improvement plan assigning risk ratings, owners and completion milestones
• Management review presentation defending findings, resources, indicators and assurance checks