Course Overview

Process Safety Management (PSM) Fundamentals introduces the core principles, regulatory framework, and practical application of process safety in high-hazard industrial environments such as refineries, petrochemical plants, and large-scale construction sites. Learners gain a working understanding of how PSM programs prevent catastrophic incidents — fires, explosions, toxic releases — by managing risk across equipment, procedures, and people. The course is designed for site-based personnel who must understand and support PSM elements in their daily work, even if they are not PSM specialists themselves.
Learning Outcomes

By the end of this course, learners will be able to:

1. Explain the purpose and history of Process Safety Management and distinguish it from occupational/personal safety.
2. Identify the 14 elements of PSM (e.g., OSHA 1910.119 / equivalent Gulf-region standards) and describe their role in preventing major incidents.
3. Recognize highly hazardous chemicals and processes covered under PSM at their site.
4. Describe the Management of Change (MOC) process and why uncontrolled changes are a leading cause of incidents.
5. Explain the purpose of Process Hazard Analysis (PHA) and how findings translate into corrective actions.
6. Identify roles and responsibilities for supervisors, engineers, and coordinators in supporting PSM compliance.
7. Apply basic incident investigation and near-miss reporting principles to strengthen a site's safety culture.

Course Outline

Part 1: Foundations of Process Safety Management
* What is PSM and why it exists (major incident case studies: Bhopal, Piper Alpha, Texas City)
* PSM vs. occupational safety — key differences
* Overview of the 14 PSM elements
* Regulatory landscape (OSHA PSM, Seveso, Gulf-region equivalents) and site-level applicability

Part 2: Core PSM Elements in Practice
* Process Hazard Analysis (PHA): purpose, methods (HAZOP, What-If), and follow-up
* Management of Change (MOC): why changes must be controlled, approval workflows
* Mechanical Integrity: inspection, testing, and maintenance of critical equipment
* Operating Procedures and Training: keeping documentation current and accessible

Part 3: Roles, Culture, and Continuous Improvement
* Roles and responsibilities across the workforce (supervisors, engineers, coordinators, operators)
* Incident investigation and near-miss/close-call reporting
* Emergency planning and response basics
* Building a strong process safety culture; auditing and continuous improvement