Course Overview
This one‑day course provides a structured introduction to developing and implementing a Process
Safety Management (PSM) program. Participants learn how to apply recognized PSM frameworks—
including OSHA PSM, US EPA RMP, CSA Z767, and the CSChE/CIC PSM Standard—to industrial operations
such as process plants, tank farms, and hazardous materials facilities. The course emphasizes practical
steps for building a compliant, effective, and sustainable process safety management program.
Learning Objectives
Participants will be able to:
- Understand the purpose and structure of a process safety management program.
- Compare major PSM frameworks and identify common elements.
- Develop core components of a PSM program, including hazard analysis, procedures, training,
and mechanical integrity. - Apply risk‑management principles to hazardous operations.
- Evaluate existing facility practices and identify gaps.
- Build an implementation roadmap for their organization.
Hourly Course Delivery Schedule
08:30 – 09:00
Registration and Introductions
Course overview, participant backgrounds, expectations.
09:00 – 10:00
Module 1: Introduction to Process Safety Management
Purpose, history, regulatory drivers, major incidents.
10:00 – 11:00
Module 2: PSM Frameworks and Standards
OSHA PSM, US EPA RMP, CSA Z767, CSChE/CIC PSM Standard.
11:00 – 11:15
Break
11:15 – 12:15
Module 3: Core Elements of a PSM Program
Hazard analysis, operating procedures, training, mechanical integrity.
12:15 – 13:00
Lunch
13:00 – 14:00
Module 4: Hazard Identification and Risk Analysis
PHA methods, LOPA, risk ranking, documentation.
14:00 – 15:00
Module 5: Implementing and Managing a PSM Program
Governance, roles, audits, management of change.
15:00 – 15:15
Break
15:15 – 16:15
Module 6: Case Studies and Practical Exercises
Incident reviews, PHA exercises, gap analysis.
16:15 – 16:30
Wrap‑Up and Q&A
Instructor Script and Course Content
Module 1 – Introduction to Process Safety Management (09:00–10:00)
Purpose of Process Safety Management
Process safety management focuses on preventing fires, explosions, toxic releases, and other
catastrophic events involving hazardous materials. It addresses low‑frequency, high‑consequence
events that can impact workers, the public, and the environment.
Historical Drivers
- Major industrial incidents (Bhopal, Texas City, Buncefield).
- Regulatory responses in the US and Canada.
- Increasing expectations from regulators, insurers, and communities.
Key Concepts
- Process safety lifecycle.
- Risk tolerance and ALARP principles.
- Human factors and organizational culture.
Module 2 – PSM Frameworks and Standards (10:00–11:00)
OSHA Process Safety Management (29 CFR 1910.119)
Covers 14 elements including process safety information, process hazard analysis, operating procedures,
training, mechanical integrity, and emergency planning.
US EPA Risk Management Program (40 CFR Part 68)
Focuses on off‑site consequence analysis, accident history, prevention programs, and emergency
response coordination.
CSA Z767 – Process Safety Management
Canadian standard emphasizing leadership, risk assessment, asset integrity, competency, and continuous
improvement.
CSChE/CIC PSM Standard
A Canadian framework aligned with industry best practices, emphasizing risk‑based decision‑making
and lifecycle management.
Common Themes Across Frameworks
- Hazard identification and analysis.
- Competency and training.
- Mechanical integrity.
- Management of change.
- Incident investigation.
- Emergency preparedness.
- Auditing and continuous improvement
Module 3 – Core Elements of a PSM Program (11:15–12:15)
Process Safety Information
- Chemical hazards.
- Process technology.
- Equipment design information.
Process Hazard Analysis (PHA)
- HAZOP, What‑If, Checklist, FMEA.
- Identifying causes, consequences, safeguards, and recommendations.
Operating Procedures
- Normal operations.
- Startup and shutdown.
- Emergency operations.
- Safe work practices (LOTO, hot work, confined space).
Training and Competency
- Operator training requirements.
- Refresher training.
- Documentation and verification
Mechanical Integrity
- Inspection and testing programs.
- Equipment criticality.
- Maintenance procedures and records.
Module 4 – Hazard Identification and Risk Analysis (13:00–14:00)
Hazard Identification Tools
- HAZID workshops.
- Bow‑tie analysis.
- Failure mode identification.
Risk Analysis Methods
- Qualitative and semi‑quantitative methods.
- Layer of Protection Analysis (LOPA).
- Risk matrices and ranking
Documentation and Communication
- Recording PHA findings.
- Tracking recommendations.
- Communicating risk to operators and management.
Module 5 – Implementing and Managing a PSM Program (14:00–15:00)
Governance and Leadership
- Roles of management, supervisors, and operators.
- Establishing accountability.
- Building a safety culture.
Management of Change (MOC)
- When MOC is required.
- Reviewing technical, safety, and environmental impacts.
- Approval and documentation.
Incident Investigation
- Root cause analysis.
- Corrective actions and follow‑up.
- Learning from near misses.
Audits and Continuous Improvement
- Internal and external audits.
- Performance indicators.
- Program maturity assessments.
Module 6 – Case Studies and Practical Exercises (15:15–16:15)
Case Studies
- Tank farm overfill incident.
- Reactor runaway scenario.
- Pump seal failure leading to toxic release.
Group Exercise
Participants complete a simplified PHA using a What‑If or HAZOP worksheet:
- Identify hazards.
- Evaluate consequences and safeguards.
- Recommend improvements.
Lessons Learned
- Importance of documentation.
- Common gaps in PSM programs.
- Sustaining long‑term program performance.
References
- OSHA 29 CFR 1910.119 – Process Safety Management of Highly Hazardous Chemicals.
- US EPA Risk Management Program (40 CFR Part 68).
- CSA Z767 – Process Safety Management.
- CSChE/CIC Process Safety Management Standard.
- Industry best practices and guidance documents.