Course Details

This course is appropriate for a wide range of professionals but not limited to:

• Safety Managers and HSE Professionals
• Instrumentation and Control Engineers
• Process and Chemical Engineers
• Plant Operations Supervisors
• Maintenance and Reliability Technicians

• Expert-led sessions with dynamic visual aids
• Comprehensive course manual to support practical application and reinforcement
• Interactive discussions addressing participants’ real-world projects and challenges
• Insightful case studies and proven best practices to enhance learning

By the end of this course, participants should be able to:

• Identify and classify common industrial hazards using systematic methods.
• Apply major international safety regulations and management systems.
• Understand the lifecycle and requirements of Safety Instrumented Systems (SIS).
• Design and validate Safety Instrumented Functions (SIF) based on required risk reduction.
• Implement robust isolation methods like Lock-Out/Tag-Out and Permit-to-Work systems.
• Develop effective emergency response plans and incident investigation protocols.

DAY 1

Safety Management and Hazard Analysis

• Welcome and Introduction
• Pre-test
• Overview of international safety regulations (OSHA, HSE, local codes)
• Introduction to Process Safety Management (PSM) and Safety Culture
• Fundamentals of hazard identification and risk assessment
• Techniques for Hazard and Operability studies (HAZOP)
• Introduction to Layers of Protection Analysis (LOPA)

DAY 2

Operational Safety and Isolation Procedures

• Principles of safe work practices and regulatory compliance
• Implementing the Permit-to-Work system for high-risk activities
• Procedures for Lock-Out/Tag-Out (LOTO) and stored energy isolation
• Safety procedures for confined space entry and hot work
• Electrical safety, arc flash hazards, and personal protective equipment (PPE)
• Fire protection systems and emergency response planning

DAY 3

Safety Instrumented Systems (SIS) Fundamentals

• Introduction to Safety Integrity Level (SIL) concepts
• Understanding the IEC 61508 and IEC 61511 functional safety standards
• Defining Safety Instrumented Functions (SIF) and their performance requirements
• SIS architecture, components, and the importance of separation from control systems
• Calculating probability of failure on demand (PFD) for SIFs
• Specifying safety requirements specifications (SRS) for ESD systems

DAY 4

ESD System Design and Components

• Architecture and design of Emergency Shutdown (ESD) systems
• Review of safety PLC (logic solver) technology and reliability
• Selection and validation of safety-rated sensors and transmitters
• Selection and sizing of final elements (e.g., safety shutoff valves)
• ESD system testing, bypassing, and maintenance procedures
• High-reliability communications in safety systems

DAY 5

System Verification and Review

• Verification and validation of the completed Safety Instrumented System
• Procedures for functional safety assessments and audits
• Developing effective inspection and proof testing schedules for SIFs
• Methodology for incident investigation and root cause analysis
• Review of human factors in safety system operation
• Post-test
• Certificate ceremony