As the technical complexity of designing and operating industrial facilities continues to increase, the role of the process safety engineer has become increasingly important in preventing major accidents. This role requires a combination of expertise in chemical, industrial, or mechanical engineering; a strong command of safety standards; familiarity with quantitative and qualitative risk analysis methods; and the ability to collaborate effectively within multidisciplinary teams.

The Comprehensive Process Safety Specialist Training Program is designed to develop highly skilled and capable professionals in this field. Drawing on international references and standards—including OSHA, CCPS, API, and IEC—as well as the practical experience of the domestic industry, the program delivers theoretical and hands-on training within a structured framework.
Participants will learn fundamental concepts such as inherently safer design principles, engineering document review, and process understanding, while also developing proficiency in professional risk-analysis tools and methodologies, including HAZOP, LOPA, QRA, and SIL.
The program also focuses on implementing safety management systems, designing audit programs, developing performance indicators, analyzing process incidents, and establishing training and management-of-change systems.

Accordingly, this comprehensive program is not merely a training course; it is a professional development pathway for cultivating key industry personnel who can not only analyze safety-related issues but also implement management systems, lead teams, and improve operational procedures across the organization.
The Comprehensive Process Safety Engineer Training Program is therefore designed to ensure that, upon completing this professional course, participants will have fully developed the following competencies:

• A Systematic Understanding of Industrial Processes, Engineering Documentation, and Process Equipment
• Accurate Hazard Identification and Assessment Using Risk Engineering Methods
• Design of Layered Safety Systems, Including SIS, Relief Devices, and Fire Protection Systems.
• Analysis of Safety Engineering Documentation, Including Cause-and-Effect Diagrams and Safety Integrity Philosophies.
• Ability to Manage Safety Projects, Prepare Technical Reports, and Advise Operations and HSE Managers.

A process safety engineer is not merely a safety analyst, but an active contributor to the design, implementation, and optimization of safety systems across the organization.

1) Introduction

Process industries such as oil, gas, petrochemicals, chemical manufacturing, pharmaceuticals, power generation, steel, and other related sectors routinely operate with hazardous chemicals, demanding operating conditions, and complex processes and equipment. If these hazards are not properly controlled, they can lead to catastrophic accidents. Documented historical events—such as the Bhopal disaster in India (1984), the Pasadena petrochemical complex explosion in the United States (1989), and the Texas City refinery explosions—have demonstrated that even a minor deficiency in design, operation, or maintenance can result in irreversible human, environmental, and economic consequences.

In response to these challenges, Process Safety Management (PSM) was developed globally as a structured, multidimensional approach. It focuses on anticipating and preventing process incidents rather than merely responding to them. Within this framework, key elements include the systematic identification of hazards—such as gas leaks, explosions, fires, and equipment failures—inherently safer process design, engineering risk analysis, management of change, personnel training, and continuous monitoring of operating conditions.

2) Program Objectives

Process safety is an interdisciplinary field at the intersection of chemical engineering, mechanical engineering, instrumentation, safety engineering, and risk management. Unlike occupational or general safety—which primarily focuses on individual behavior and personal protective measures—PSM addresses organizational systems, equipment, engineering documentation, systematic process analysis, and sound process design. This fundamental distinction necessitates more specialized and in-depth training.

Despite their extensive technical experience, many industry professionals lack sufficient knowledge or practical expertise in structuring process safety systems, conducting complex risk analyses such as HAZOP and SIL assessments, and designing and auditing safety management systems. This knowledge and skills gap is one of the principal reasons for the incomplete implementation of PSM across the country’s industries.
Developing an effective PSM system requires professionals who possess a strong technical understanding of processes and equipment, are proficient in risk-analysis methodologies, and can implement the necessary managerial and cultural structures throughout an organization. These professionals must be capable of working effectively with operations, maintenance, HSE, engineering design, and senior management teams to integrate process safety into the organization’s overall strategy.

Despite having access to modern equipment and advanced technologies, many industrial organizations in the country are unable to operate their facilities safely, sustainably, and with minimal risk due to a shortage of professionals specializing in PSM. Accordingly, developing and strengthening specialized human resources in this field is a strategic priority rather than merely an educational choice.

3) The Need for Training Process Safety Specialists

As the technical complexity of designing and operating industrial facilities continues to increase, the role of the process safety engineer has become increasingly important in preventing major accidents. This role requires a combination of expertise in chemical, industrial, or mechanical engineering; a strong command of safety standards; familiarity with quantitative and qualitative risk analysis methods; and the ability to collaborate effectively within multidisciplinary teams.

The Comprehensive Three-Level Process Safety Specialist Training Program is designed to develop competent and highly qualified professionals in this field. Drawing on international references and standards—including OSHA, CCPS, API, and IEC—as well as the practical experience of Iran’s industrial sector, the program delivers theoretical and practical training within a structured framework.
Participants will begin by learning foundational concepts such as inherently safer design principles, the analysis of engineering documents, and process fundamentals. They will then develop proficiency in professional risk assessment tools and techniques, including HAZOP, LOPA, QRA, and SIL. At the advanced level, the program focuses on implementing process safety management systems, designing audit programs, developing performance indicators, analyzing process incidents, and establishing training and management-of-change systems.

Therefore, this comprehensive program is not merely a training course; rather, it constitutes a professional development pathway for cultivating key industry personnel—professionals who not only analyze safety-related issues but also possess the ability to implement systems, lead teams, and improve operational procedures at the organizational level.
Accordingly, the Comprehensive Process Safety Engineer Training Program is designed to ensure that, upon completing all three training levels, participants will have fully developed the following competencies:

• A systematic understanding of industrial processes, engineering documentation, and process equipment.
• Accurate identification and assessment of hazards using risk engineering methods.
• Design of Layered Safety Systems, Including SIS, Relief Devices, and Fire Protection Systems.
• Analysis of Safety Engineering Documentation, Including Cause-and-Effect Diagrams and Safety Integrity Philosophies.
• Ability to Manage Safety Projects, Prepare Technical Reports, and Advise Operations and HSE Managers.

A process safety engineer is not merely a safety analyst, but an active contributor to the design, implementation, and optimization of safety systems across the organization.

4) Program Delivery Method

The Comprehensive Process Safety Engineer Training Program is designed to address both the professional needs of industry specialists and the training requirements established by international standards. The program is delivered through the following three consecutive, structured levels:

• Process Safety Engineering – Level 1
• Process Safety Engineering – Level 2
• Advanced Process Safety Management

Each level will take approximately four to five months to complete. The schedule and course content, presented in Appendices 1, 2, and 3, are structured to provide not only theoretical knowledge but also sufficient opportunities for practical exercises, analysis of real-world industry challenges, and the development of soft skills.

The program employs a blended learning approach. Approximately 80% of the training is delivered remotely through the university’s virtual learning platform. This component includes interactive online classes, question-and-answer sessions, analytical assignments, and multimedia learning resources.
The remaining 20% is delivered in person at the Petroleum University of Technology’s training center in Mahmoudabad, with an emphasis on practical workshops, specialized software training, industrial site visits where feasible, and group exercises. In-person attendance is considered essential for gaining practical experience and enhancing participants’ interdisciplinary capabilities.

Admission requirements for each level are defined progressively based on the relevant academic and professional prerequisites:

• Level 1 is intended for graduates of chemical engineering, safety engineering, industrial engineering, and other disciplines related to industrial processes. No entrance examination is required.
• Level 2 is open only to individuals who have either successfully completed Level 1 or demonstrated the required competency by passing a scientific pre-assessment covering the key concepts taught at Level 1.
• Level 3 is reserved exclusively for individuals who have qualified at Level 2 or applicants who demonstrate Level 2–equivalent competency through a scientific pre-assessment and a specialized interview.

The final assessment for each level will be conducted in multiple stages and will include:

• Online Written Examination: To assess participants’ understanding of theoretical concepts, standards, and safety engineering principles.
• Practical Project: Based on real-world case studies from the process industries, designed to challenge participants’ ability to analyze complex situations, develop safety solutions, and present their findings effectively.
• In-Person Interview and Assessment: To evaluate participants’ communication skills, ability to analyze interdisciplinary issues, and proficiency in presenting technical reports.

Upon completion of each level, participants will be awarded a recognized training certificate. Subject to the finalization of the relevant agreements, these certificates will be jointly issued by the Petroleum University of Technology, the Ministry of Petroleum’s Directorate General of HSE, and the Iranian Association of Chemical Engineering. They may be presented for employment purposes, organizational recruitment, and further professional development.

5) Target Groups

The Comprehensive Process Safety Engineer Training Program is designed to strengthen specialized capabilities in process safety and is intended for a broad range of professionals and individuals interested in this field. The program is particularly suitable for those who fall into one of the following categories:

• Engineers working in process industries—including oil and gas, petrochemicals, power generation, chemicals, pharmaceuticals, and steel—who are involved in operations, maintenance, HSE, engineering design, or performance monitoring and seek to enhance their capabilities in identifying and controlling process-related risks.
• HSE professionals and managers involved in designing, implementing, or auditing process safety management systems who require a deeper understanding of technical concepts and safety engineering principles.
• Graduates of chemical, industrial, mechanical, and industrial safety engineering, as well as related disciplines, who intend to pursue a career in process safety and acquire the practical knowledge and skills required to enter the job market or advance professionally.
• Consultants, auditors, and assessors of safety and risk management systems who are involved in evaluating and designing safety systems across various industries and require familiarity with current international standards, tools, and analytical techniques.

With its emphasis on competency development and the practical application of knowledge in real-world industrial settings, this program provides a valuable opportunity for individuals seeking to play an effective role in enhancing the safety, resilience, and sustainability of industrial facilities.

Appendix 1: Process Safety Engineering – Level 1

Process Safety Engineering – Level 1 Curriculum (232 Hours)

1. Introduction to Oil, Gas, and Petrochemical Processes (24 Hours)

1-1) Oil and Gas Upstream Value Chain

• Fundamentals of the Oil and Gas Industry;
  • Key Concepts and Terminology
  • History and Evolution of the Oil and Gas Industry
• Onshore and Offshore Oil and Gas Exploration and Well Drilling;
  • Seismic Survey Equipment and Operations
  • Exploratory Wells
  • Types and Components of Onshore and Offshore Drilling Rigs
  • Stages of Onshore and Offshore Oil and Gas Well Drilling
• Onshore Oil and Gas Production, Operations, and Processing;
  • Wellhead Equipment and Facilities
  • Wellhead Separator
  • Manifolds
  • Oil and Gas Separation
  • Production and Test Tanks
  • Desalting Unit
  • Desalting Unit
  • Gas Compression Stations
  • Gas and Natural Gas Liquids (NGL) Plant
• Block Flow Diagrams (BFDs) for Onshore and Offshore Oil and Gas Production, Operations, and Processing

1-2) Oil and Gas Refining Processes

• The Role, Feedstocks, and Products of Refineries in the Oil and Gas Industry
• Common Units and Processes in Crude Oil Refineries;
  • Crude Oil Distillation Unit (Desalting, Atmospheric Distillation, and Vacuum Distillation)
  • Gasoline Production Units (Isomerization, Catalytic Reforming, Alkylation, and Polymerization)
  • Hydrogen Processing Units (Hydrotreating and Hydrocracking)
  • Heavy Fraction Upgrading Units (FCC, Coking, Visbreaking, Solvent Deasphalting and Dewaxing, and Bitumen Blowing)
  • Product Blending Unit
  • Auxiliary Units (Vapor Recovery, Hydrogen Production, Demercaptanization, Sour Water Stripping, and Sulfur Recovery)
• Block Flow Diagrams (BFDs) for Oil Refinery Processes
• Common Units and Processes in Gas Processing Plants;
  • Receiving facilities Unit
  • Gas treatment Unit
  • MEG Regeneration and Injection Unit
  • Condensate stabilization Unit
  • Dehydration & Demercurysation Unit
  • C₁ & C₂ Recovery Unit
  • Export gas compression Unit
  • NGL Fractionation Unit
  • Sulphur recovery Unit
  • Sour water stripper Unit
  • Back-up Stabilisation Unit
  • Propane Refrigeration Unit
  • Condensate Demercaptanization Unit
  • Caustic regeneration Unit
  • C₂ Treatment & Drying Unit
  • C₃ Treatment & Drying Unit
  • C₄ Treatment & Drying Unit
• Block Flow Diagrams (BFDs) for Gas Processing Plants

1-3) Petrochemical Processes

• The Role, Feedstocks, and Products of the Petrochemical Industry within the Oil and Gas Sector
• Introduction to and Comparison of Different Types of Petrochemical Units
• Common Units and Processes in the Petrochemical Industry;
  • Natural Gas Fractionation (NF) Unit – Gas Separation
  • Olefin Production (OL) Unit
  • Methanol Production Unit
  • Ammonia Production Unit
  • Urea Production Unit
  • Aromatics Production (AR) Unit
  • Paraxylene Production (PX) Unit
  • Chlor-Alkali (CA) Unit
  • Ethylene Dichloride (EDC) Unit
  • Vinyl Chloride Monomer (VCM) Unit
  • Polyvinyl Chloride (PVC) Unit
  • Methyl Tert-Butyl Ether (MTBE) Unit
  • Low-Density Polyethylene (LDPE) Unit
  • High-Density Polyethylene (HDPE) Unit
  • Polypropylene (PP) Unit
  • ABS
  • Styrene-Butadiene Rubber (SBR) Unit
  • Polystyrene Production Unit
• Review of Process Block Flow Diagrams (BFDs), Final Products, and Their Industrial Applications

2) Introduction to Process Equipment (32 Hours)

• Process Equipment and Its Role in Industrial Facilities
• Types of Fluid-Handling Equipment (Compressors and Pumps) and Their Applicable Design Standards
• Mass-Transfer Equipment and Reactors (Reactors, Distillation and Absorption Equipment, Evaporators, Mixing and Crystallization Equipment, and Liquid–Liquid Extraction Units) and Applicable Design Standards
• Heat-Transfer Equipment (Cooling Towers, Heat Exchangers, Refrigeration Equipment, Air Coolers, etc.) and Applicable Design Standards
• Types of Storage Tanks in the Chemical Industry and Applicable Design Standards
• Types of Valves and Their Applications in Controlling Process Flows, and Applicable Design Standards
• API Standards 521, 520, and 526 for the Design of Pressure Relief Valves
• Utilities and Other Common Equipment (Including Ejectors, Filters, Mixers, etc.)

3) Introduction to Process Engineering Documents (32 Hours)

• Stages of Process Projects (Research and Development, Feasibility Studies and Conceptual Design, Pilot Testing, Detailed Engineering, Procurement and Supply, Construction, Commissioning, Operation, and Maintenance)
• The Master Document Register (MDR) and Engineering Disciplines (Process, Mechanical, Piping, Instrumentation, etc.)
• Engineering Document Development and Approval Process and Procedures for Revising Documents
• Engineering Drawing Interpretation and Introduction to PFDs, P&IDs, and Process Equipment Datasheets
• Symbols and Abbreviations Used in Process Documents
• The Cause-and-Effect Diagram and Its Application in Process Safety
• Control Loops and Emergency Shutdown (ESD) Systems
• Safety Philosophy Document, Safety Design Principles, and Applicable Requirements
• Plot Plan and Layout Drawings and Principles of Equipment Arrangement within Industrial Sites
• Material and Energy Balance Documents in Process Design

4) Major Process Hazards, Deviations, and Incidents in the Oil and Gas Industry (16 Hours)

• Introduction to Various Hazards in the Oil, Gas, and Petrochemical Industries and the Potential Consequences of Exposure to Them
• Introduction to Process Deviations in the Oil, Gas, and Petrochemical Industries, Including:
  • Normal and Emergency Conditions in Process Operations
  • Physical, Chemical, and Mechanical Factors Contributing to Process Deviations
  • Tools and Techniques for Detecting Process Deviations
  • The Role of Operators and Control Systems in Identifying Process Deviations
  • Consequences of Process Deviations
• Classification of Process Incidents by Event Type and Consequence (Types of Fires and Explosions, Chemical Releases, etc.)
• Analytical Review of Major Historical Incidents in the Oil, Gas, and Petrochemical Industries
• Root Cause Analysis of Incidents, with Emphasis on Technical, Organizational, and Human Factors
• Analysis of Recurring Patterns in Industrial Incidents
• Key Lessons Learned and Insights Gained from Real-World Incidents
• The Role of Safety Culture and Organizational Behavior in Incident Prevention
• Practical Recommendations for Reducing the Likelihood and Severity of Incidents in Operational Environments
• Discussion and Analysis of Case Studies of Major Domestic Incidents

5) Introduction to Process Safety Standards (16 Hours)

• Introduction to Different Types of Reference Documents, Including Standards, Codes, Guidelines, Databases, Instructions, and Regulations, and Their Practical Differences in Safety Engineering
• Introduction to Recognized National and International Process Safety Authorities and Standards Organizations, Including INSO, the Iranian Ministry of Petroleum, OSHA, NFPA, API, IEC, and Others
• Introduction to Management and Non-Management Safety Standards, Such as ISO 45001, ISO 14001, and ISO 31000, and Their Differences from Technical and Engineering Standards
• Introduction to Iranian Petroleum Standards (IPS), Including Their Structure, Classification, Coding System, and Application in Safe Process Design
• Introduction to American Petroleum Institute (API) Publications and an Overview of Key Standards Related to Safety and Technical Protection in the Oil, Gas, and Petrochemical Industries
• Introduction to National Fire Protection Association (NFPA) Publications and an Overview of Key Fire Safety Codes and Standards
• Introduction to Key American Society of Mechanical Engineers (ASME) Standards, with Emphasis on ASME BPVC Section VIII (Pressure Vessels), ASME B31.3 (Process Piping), and Other Relevant Safety Provisions
• Overview of Recognized European and International Standards, Including BS, IEC, ISO, and EN, and Their Applications, with Emphasis on IEC 61508 and IEC 61511 for Safety Instrumented Systems and ATEX Requirements for Explosive Atmospheres

6) Inherently Safer Design and the Application of Protection Layers in Process Industries (32 Hours)

• Principles and Fundamentals of Inherently Safer Design (ISD) in the Oil, Gas, and Petrochemical Industries
• Types of Protection Layers in the Oil, Gas, and Petrochemical Industries
• Basic Process Control Systems (BPCS)
• Safety Instrumented Systems (SIS) and Their Design Logic
• Emergency Shutdown Systems (ESD) and Their Design Logic
• Mechanical Protection Systems (Pressure Relief Devices, Depressurization Systems, etc.) and Their Types
• Physical Protection Systems in Process Units and Their Types

7) Fundamentals of Fire Protection Engineering (32 Hours)

• Fundamentals of Fire, Fire Types, and Explosions
• Introduction to Fire and Gas Detection Systems and Applicable Standards for Their Design and Layout in Process Industries
• Introduction to Active Fire Protection Systems and Applicable Standards for Their Design and Layout in Process Industries, Including Firewater Storage Tanks and Pumps, Firewater Distribution Networks, Deluge Systems, Fire Monitors and Hydrants, Hose Cabinets, Foam Systems, CO₂ Flooding Systems, Mobile Firefighting Equipment, etc.
• Passive Fire and Blast Protection Systems and Applicable Standards for Their Design and Layout in Process Industries
• General Principles and Fundamentals of Safety in the Design and Layout of Industrial Buildings (IBs) and Non-Industrial Buildings (NIBs)
  • Positive Pressurization and Ventilation in Buildings
  • Fire and Gas Detection Systems (F&G)
  • Types of Active Fire Protection Systems in Buildings
  • Blast-Resistant Design of Buildings
  • Passive Fire Protection Systems

8) Fundamentals of Process Safety Management (24 Hours)

• History, Origins, and Rationale for the Establishment of Process Safety Management (PSM)
• Process Safety Terminology and Definitions
• Review of Selected Historical Incidents in Iran and Worldwide from a Process Safety Management Perspective
• Economic and Operational Benefits of Implementing Process Safety Management (PSM)
• Similarities and Differences Between Process Safety Management and Other Management Systems, Particularly Integrated Management Systems (IMS)
• Introduction to Common Process Safety Management (PSM) Standards and Models and Analysis of Their Similarities and Differences
• Introduction to and Explanation of the 14 Elements of Process Safety Management (PSM) Based on the OSHA Model
• Introduction to Risk-Based Process Safety (RBPS) and Explanation of Its 20 Elements Based on the CCPS Model

9) Risk Management in Process Industries (24 Hours)

• Definition and Distinction of Key Concepts, Including Hazard, Risk, the ALARP Principle, Tolerable Risk, Residual Risk, and Uncertainty
• Structure and Key Components of a Risk Management System in Accordance with Established Frameworks such as ISO 31000 and CCPS Models
• Introduction to Recognized Standards and Authoritative References in Risk Management
• Comparative Analysis of Different Frameworks and Their Applications in the Oil, Gas, Petrochemical, and Chemical Industries
• Introduction to Quantitative, Qualitative, and Semi-Quantitative Hazard Identification and Risk Assessment Methods, Including HAZOP, HAZID, FMEA, FTA, ETA, and QRA; Their Advantages, Limitations, and Practical Applications Across Different Project Phases
• Definition of Severity, Likelihood, and Detectability Parameters; Risk Ranking; and the Use of Risk Matrix and Scoring Techniques
• Design and Development of Risk Matrices for Process Industries, Definition of Tolerable Risk Criteria and the ALARP Region, and Requirements for Documenting Related Decisions
• Review of the Design, Construction, Operation, Turnaround, and Decommissioning Stages of Process Facilities; Application of Process Hazard Analysis (PHA) Methods Across Different Project Phases; and Continuous Risk Assessment
• Risk Response Strategies and Policies in Process Industries, Including Various Control and Preventive Measures
• Cost–Benefit Analysis for Selecting Risk-Reduction Measures
• Approaches to Evaluating the Effectiveness of Control Measures and Assessing Residual Risk
• Key Performance Indicators (KPIs) in Risk Management and Corrective Feedback Mechanisms

Appendix 2: Process Safety Engineering – Level 2

Process Safety Engineering Training Curriculum – Level 2 (244 Hours)

1) Process Hazard Identification and Risk Assessment (HAZOP) (30 Hours)

• Introduction to the HAZOP Method, Its Applications, and Advantages
• Introduction to HAZOP Standards and Reference Resources
• Management of HAZOP Study Execution, Study Team Members and Their Responsibilities, and Study Requirements
• Methods for Dividing the P&IDs of the Unit under Study into HAZOP Nodes
• Selection of Guidewords and Process Parameters
• Identification of Process Deviations, Their Potential Causes, and Resulting Consequences
• Qualitative Risk Assessment Using a Risk Matrix and Determination of the Severity and Likelihood of Undesired Consequences
• Identification of Existing Control and Safety Safeguards and Assessment of the Need for Additional Safeguards
• PHA-Pro Software Training
• Practical Workshop Based on an Oil and Gas Industry Case Study
• Documentation and Analysis of HAZOP Study Findings
• Teamwork and HAZOP Meeting Facilitation Skills
• Implementation of HAZOP Study Findings in Process Design and Safe Operations

2) Functional Safety and Layer of Protection Analysis(SIL/LO PA) (16 Hours)

• Fundamentals of Functional Safety and the Safety Lifecycle
• Key Standards and Codes for Functional Safety
• Definition and Design of Safety Instrumented Functions (SIFs) within Safety Instrumented Systems (SIS)
• Qualitative and Quantitative Risk Analysis, SIL Target Setting, and Determination of the Required Risk Reduction Factor (RRF)
• Understanding Safety Integrity Levels (SIL) and the Requirements for Achieving the Target SIL (Systematic Capability and Random Hardware Integrity Requirements)
• Analysis of Component Reliability, Availability, and Failure Rates Using OREDA Data
• SIL Assessment Methods: Risk Matrix, Risk Graph, and Layer of Protection Analysis (LOPA)
• SIL Analysis and Verification Using Simplified Equations and 1oo2 and 2oo3 Voting Architectures
• Fault Tree Analysis (FTA) and Its Application in System Failure Analysis and Structured SIL Verification
• Identification and Classification of Failure Modes: Dangerous Detected (DD) and Dangerous Undetected (DU) Failures
• Hands-on Training in Specialized SIL Assessment Software, Such as PHA-Pro

3) Hazardous Area Classification (16 Hours)

• Definitions, Characteristics, and General Design Requirements
• Understanding the Key Principles and Requirements of NFPA 497, IP 15, and API RP 505
• Identification and Classification of Hazardous Areas in Accordance with Applicable Standards and Established Industry Practices
• Introduction to the Various Types of Explosion-Protected Equipment
• Selection and Application of Suitable Fixed and Portable Equipment for Hazardous Areas
• Fundamental Conditions Required for Ignition or Explosion
• Classification of Flammable and Combustible Liquids, Gases, and Vapors
• Fundamental Concepts and Classification Criteria
• Concepts and Principles for Determining the Extent of Classified Areas
• Determination of Hazardous Area Classification and Extent
• Selection of Suitable Electrical Equipment for Potentially Explosive Atmospheres
• Analysis and Development of Hazardous Area Classification Drawings

4) Consequence Modeling of Process Industry Accidents and Quantitative Risk Assessment (QRA) (40 Hours)

• Introduction to the Key Stages of Quantitative Risk Assessment (QRA)
• Common Methods for Identifying Hazard Sources and Selecting Accident Scenarios
• Theoretical and Software-Based Consequence Analysis of Process Incidents
• Definition of Consequence and Modeling of Gas Dispersion, Fire, and Explosion Scenarios Using PHAST
• Determination of Acceptable Separation Distances Between Process Units (Fire Zone Spacing) During the Design Phase
• Determination of Site Boundaries (Restricted Areas) and Impact Zones (Impacted Areas) Using Consequence Modeling
• Consequence Estimation (Number of Fatalities) and Statistical Methods for Estimating Incident Frequencies
• Quantitative Risk Calculation: Determination of Individual and Societal Risk and Pipeline Safety Corridors
• SAFETI Software Training for Quantitative Risk Assessment (QRA)
• Hands-on Workshop Using Industrial Case Studies in Consequence Modeling and Quantitative Risk Assessment (QRA)

5) Environmental Hazard Identification and Risk Assessment (HAZID) (16 Hours)

• Fundamentals and Principles of Hazard Identification Using the HAZID Method
• Comparison of HAZID with Other Hazard Identification Methods: Objectives, Advantages, and Limitations
• Introduction to Applicable Standards and Reference Frameworks, Including ISO 17776, and an Overview of Relevant National and International Legal and Regulatory Requirements
• Introduction to and Classification of More Than 30 Common Hazards in Process Facilities
• Review of the Potential Root Causes and Consequences Associated with Each Type of Hazard
• Evaluation of Existing Safeguards for Each Identified Risk
• Detailed Overview of the HAZID Study Procedure
• Defining the Scope of a HAZID Study
• Formation of the HAZID Team and the Technical Competency and Experience Requirements for Selecting Team Members
• Formation of the HAZID Team and the Technical Competency and Experience Requirements for Selecting Team Members
• Introduction to Standard Report Formats
• Analysis of Real-World Case Studies from the Oil, Gas, and Petrochemical Industries and Group Exercises for the Practical Application of HAZID Study Steps

6) Failure Modes and Effects Analysis (FMEA) for Process Equipment and Machinery (16 Hours)

• Introduction to FMEA and Its Application in Process Safety
• Overview of FMEA Approaches, Their Applications, and Key Differences (DFMEA, FMECA, and FMEA)
• Objectives, Applications, and Reference Standards for FMEA
• FMEA Study Process and Study Team
• Methods for Equipment Selection and Subsystem Analysis
• Identification of Fault and Failure Modes
• Analysis of the Causes and Consequences of Faults and Failures
• Methods for Determining Severity, Occurrence, and Detectability Factors
• Calculation of the Risk Priority Number (RPN) and Estimation of Action Priority (AP)
• Hands-on Workshop Using Industrial Case Studies on Conducting FMEA

7) Hazard Identification and Risk Assessment Using Bow-Tie Analysis, Event Tree Analysis (ETA), and Fault Tree Analysis (FTA) (30 Hours)

• Introduction to Bow-Tie Analysis, Event Tree Analysis (ETA), and Fault Tree Analysis (FTA)
• Principles, Applications, and Implementation Steps of Bow-Tie Analysis, Event Tree Analysis (ETA), and Fault Tree Analysis (FTA) in Process Safety
• Introduction to Bow-Tie Analysis in Risk Assessment
  • History, Objectives, and Applications of Bow-Tie Analysis
  • Reference Standards and Guidelines for Bow-Tie Analysis
  • The Bow-Tie Diagram and Its Components
  • Definition of Top Events, Hazards, Threats, Controls, Escalation Factors, and Barriers
  • Bow-Tie Study Process and Determination of Risk Levels for Threats and Consequences
  • Hands-on Workshop Using Industrial Case Studies on Conducting Bow-Tie Analysis
• Introduction to Event Tree Analysis (ETA) in Risk Assessment
  • History, Objectives, and Applications of Event Tree Analysis (ETA)
  • Reference Standards and Guidelines for Event Tree Analysis (ETA)
  • Event Tree Analysis (ETA) Study Process
  • Safety Functions in Event Tree Analysis and Event Tree Construction
  • Calculation of Event Failure Probabilities and Risk Values
  • Application of Event Tree Analysis (ETA) in Scenario Analysis
  • Hands-on Workshop Using Industrial Case Studies on Conductinggast Event Tree Analysis (ETA)
• Introduction to Fault Tree Analysis (FTA) in Risk Analysis
  • History, Objectives, and Applications of Fault Tree Analysis (FTA)
  • Reference Standards and Guidelines for Fault Tree Analysis (FTA)
  • Introduction to the Components of a Fault Tree (FTA)
  • Fault Tree Analysis (FTA) Study Process
  • Identification of Basic, Intermediate, and Top Events in FTA and the Logical Relationships Between Them
  • Hands-on Workshop Using Industrial Case Studies on Conducting Fault Tree Analysis (FTA)
• Integration of Bow-Tie Analysis, Event Tree Analysis (ETA), and Fault Tree Analysis (FTA) for Comprehensive Risk Assessment

8) Identification and Management of Safety-Critical Equipment (SCE) and Performance Standards (8 Hours)

• Conceptual Foundations and Practical Framework for Safety-Critical Equipment (SCE) within Process Safety Management Systems
• Definition of Safety-Critical Equipment (SCE) Based on International Standards and Guidelines
• Role and Position of Safety-Critical Equipment (SCE) within the Protection Layers of Process Systems
• Analytical Review of Standards and Technical Regulations Related to Safety-Critical Equipment
• Systematic Approaches to Identifying Safety-Critical Equipment (SCE Identification Methods)
  • Consequence-Based Identification
  • Risk-Based Identification
  • Prescriptive-Based Identification
• Application of HAZID, HAZOP, LOPA, Bow-Tie Analysis, and Other Risk Assessment Methods for SCE Identification
• Review of Practical Case Studies in the Oil, Gas, and Petrochemical Industries
• Development and Evaluation of Performance Standards
• Definition and Analysis of Key Performance Criteria: Functionality, Availability, Reliability, and Survivability
• Design of SCE Performance Monitoring and Reporting Systems (Assurance and Verification Plans)

9) Alarm Management and Rationalization (8 Hours)

• Fundamentals of Alarm Management and Its Role in Safety and Operations
• Causes of Alarm Floods and Their Impact on Operator Performance
• Standards-Based Alarm Management Philosophy
• Principles, Implementation Steps, and Methods for Alarm Rationalization
• Alarm Prioritization Based on Risk Severity and Response Time, and Structured Alarm Design and Prioritization
• Alarm Management under Different Operating Conditions
• Alarm System Performance Monitoring and Continuous Improvement (Software Tools for Alarm Analysis and Management Reporting)
• Review of Real-World Case Studies from Successful Alarm Rationalization Projects
• Group Exercise in Alarm Analysis, Classification, and Configuration
• Review of Common Errors, Challenges, and Practical Solutions in Operational Projects

10) Safety of Storage Tanks and Pressure Vessels (24 Hours)

• Definition and Importance of Storage Tanks and Pressure Vessels across Various Industries
• Classification of Storage Tanks by Application, Design, Pressure, Temperature, Stored Material, and Other Relevant Criteria
• Introduction to Applicable Standards, Including API 650, API 620, ASME BPVC Section VIII, and Others
• Introduction to Safety and Protection Systems for Storage Tanks, Including:
  • Pressure Control Systems
  • Explosion Prevention Systems
  • Earthing and Bonding Systems for Preventing Electrostatic Discharge
  • Fire Suppression Systems: Foam Systems, Deluge Valves, and Fire Monitors
• Identification of Hazards Associated with Storage Tanks and Pressure Vessels, Risk Assessment, and Determination of Control Measures
• Management of Change (MOC) and Its Impact on Storage Tank Safety
• Legal Requirements and National Regulations Related to Storage Tank Safety
• Review of Real-World Storage Tank Incidents and Analysis of Their Causes, Preventive Measures, and Lessons Learned

Asset Management in Process Safety (32 Hours)

• Fundamentals and Standards of Physical Asset Management in Process Industries
• Classification of Safety-Critical Equipment (SCE) and Asset Prioritization
• Preventive Maintenance Strategies
  • Risk-Based Maintenance (RBM)
  • Reliability-Centered Maintenance (RCM)
  • Development of Preventive Maintenance (PM) and Predictive Maintenance (PdM) Programs
  • Application of Condition Monitoring Techniques (Vibration Analysis, Thermography, etc.)
• Principles of Risk-Based Inspection (RBI) in Accordance with API RP 580 and API RP 581
• Determination of Inspection Intervals Based on Corrosion and Equipment Degradation Analysis
• Corrosion Management in Process Units and Control Methods (Coatings, Corrosion Inhibitors, and Cathodic Protection)
• Root Cause Analysis (RCA) Methods for Equipment Failures and Safety Incidents
• Supply Chain Management and Quality Control of Safety Equipment
  • Vendor Qualification and Evaluation
  • Equipment Inspection and Testing
  • Technical Documentation Management (Datasheets, Warranties, and Catalogs)
• Introduction to Data Management Systems, Documentation, and Technical Asset Databases (e.g., CMMS)
• Key Performance Indicators (KPIs) in Asset and Safety Management (MTBF, MTTR, Availability, etc.)
• Integration of Asset Management with the Process Safety Management System

Appendix 3: Advanced Process Safety Management

Advanced Process Safety Management Training Curriculum (300 Hours)

This program has been developed in accordance with internationally recognized standards and frameworks, including those established by OSHA, CCPS, and API, as well as proven national and international practices. Its curriculum is designed to address both the technical and engineering aspects and the human, organizational, and managerial dimensions of process safety.

The program begins with an overview of the evolution of Process Safety Management and an examination of major industrial incidents. Analyzing the lessons learned from these events provides a foundation for a deeper understanding of the importance and necessity of PSM. The program then explores the fundamental concepts of process safety culture and the role of employee participation in the success of safety management systems, recognizing that no system can be effective without the commitment and active involvement of its workforce.

A core component of the program is training in the principles of hazard identification and risk assessment. Participants become familiar with recognized risk analysis methods and learn how to lead multidisciplinary teams in conducting these studies. Key topics such as Management of Change (MOC), Pre-Startup Safety Review (PSSR), operating procedures, and Permit-to-Work (PTW) systems are also addressed within a structured framework as essential measures for preventing human and system failures.

Technical knowledge management and documentation are also key components of the program. Complete, accurate, and up-to-date information on system design and operation is essential for informed safety-related decision-making. Equipment reliability and asset integrity receive particular emphasis as critical contributors to process safety, with dedicated training provided in inspection, preventive maintenance, and asset lifecycle management.

Contractors and third-party personnel, who perform a substantial proportion of field operations, represent another key focus of the program. Contractor HSE management, training and competency assessment, and effective oversight are addressed as dedicated topics with a practical orientation. To strengthen organizational preparedness for critical situations, the program also provides detailed instruction on the design and implementation of emergency management plans, including scenario development, emergency preparedness drills, and coordination with emergency response organizations.

Process incident analysis and the application of root cause analysis tools constitute another key component of the program. This is complemented by training in the development of performance indicators for the continuous monitoring of process safety performance. These indicators enable organizations to adopt a proactive approach by using leading indicators to prevent process safety incidents, rather than merely responding after they occur.

The final modules of the program focus on the practical implementation of a Process Safety Management system. At this stage, participants learn how to conduct gap assessments, develop implementation roadmaps, plan system deployment, monitor performance, and carry out periodic audits. This process begins with evaluating the organization’s current state and continues toward achieving organizational maturity in process safety.

A distinguishing feature of this program is its coverage of Corporate Governance in Process Safety Management. This module examines the integration of PSM with other organizational management systems, including quality management, environmental management, and Integrated Management Systems (IMS), while introducing successful national and international models and practices.

Finally, modules covering Operating Management Systems, leadership, internal audits, and management reviews enable participants to institutionalize PSM not merely as a project, but as a permanent and dynamic component of organizational culture.

This program is designed to address the training needs of personnel at various organizational levels, from senior and middle managers to safety professionals and process, operations, and maintenance engineers. Through modern instructional approaches, case studies, practical exercises, specialized workshops, and staged assessments, the program aims to promote a deep and lasting understanding of process safety concepts.

Upon completion of the program, participants will not only have a thorough understanding of the theoretical and technical principles of Process Safety Management, but will also be capable of designing, implementing, monitoring, and continuously improving PSM systems within their organizations. This program represents an important step toward professional capacity building and the development of safer, more sustainable, and more resilient organizations capable of effectively responding to process hazards.