Mary Kay O’Connor PROCESS SAFETY CENTER

PROCESS SAFETY MANAGEMENTFUNDAMENTALSCourse Number: 2023QDuration: 3 daysDescriptionThis short course is designed to teach and apply the fundamentalsof chemical process safety; to provide a basic understanding ofprocess safety and the requirements of OSHA PSM Regulation 29CFR 1910.119 and EPA Risk Management Plan 40 CFR Part 68; tounderstand through case studies how the failure of process safetymanagement elements were found to be the root cause of majorincidents in the petroleum industry; to provide information on how toimplement, monitor and audit a process safety management program;and to illustrate through exercises the identification of hazards and theranking of risks.Who should attend?The course content is diverse enough for use by anyone involved inimproving process safety, including chemical engineers, mechanicalengineers, safety and health personnel, industrial hygiene personneland operators, and maintenance supervisors.16

Course instructorDr. Ray Mentzer (MKOPSC)AgendaModule 1: Introduction to Process Safety Management (PSM) Introduction. History of process safety legislation in the U.S. illustratedthrough past events. What is process safety? Process safety concepts and overview of the PSM elements.Module 2: Description of Each PSM Element and Case Studies Documentation. Employee participation. Accountability and leadership. Process safety information. Process hazard analysis. Mechanical integrity (case study: “Humber Refinery —Catastrophic Failure of De-ethanizer Overhead Pipe”. Safe work practices (hot work case study:“Piper Alpha Disaster”). Contractor management. Operating procedures (case study: “Feyzin LPG Disaster”). Training and competence. Management of change (case study: “FlixboroughDisaster”) Pre-startup safety review. Emergency planning and response (case study:“Major Tank Fire”). Incident investigation. Process safety audit. Trade secrets.17

INTRODUCTION TO HAZOP:BECOMING AN ACTIVE PARTICIPANTCourse Number: 2032QDuration: 2 daysDescriptionHazard and operability (HAZOP) studies can be one of the mostpowerful tools your facility has for identifying process hazards withinthe operating facility. Do you understand your role in the HAZOPprocess? Are you contributing to your fullest extent?This course will provide an understanding of why we do HAZOP, theobjectives of a HAZOP review, what is expected from a participant in aHAZOP and how to be an active participant in the HAZOP process. Inaddition, the course will also teach participants how to read a HAZOPreport and what the HAZOP report can teach us about the processhazards and safety systems in place to minimize the risk of catastrophicevents.The course will provide a brief overview of the role of HAZOP in processsafety management and risk assessment process and will go into detailon HAZOP terminology, guidewords and the HAZOP process.Who should attend?The class is intended to be an introductory course for technical andoperating staff who regularly attend HAZOP reviews or who expectto and/or plan to attend HAZOP reviews in the future. In addition,this class will also benefit operations staff as it will provide valuableinstruction on how to read HAZOP reports and use the informationwithin a HAZOP report to improve the safe operation of theirprocess plants.18

Course instructorMichael J. Snakard (Snakard Consulting Group LLC)AgendaDay 1: Fundamentals of HAZOP methodology Introduction. Hazards and risks. Elements of process safety management. Process hazard analysis. The HAZOP process. HAZOP worksheet. HAZOP terminology.Day 2: Toward an Active Participation in HAZOP What does “being an active participant” mean? Case studies: How could HAZOP have prevented accidents? Mock HAZOP on a compressor process facility. Participant will: Focus on the node and deviation under study. Identify credible causes and consequences Locate existing safeguards. Determine when recommendations are needed. What happens after HAZOP? Reading a HAZOP report. Conclusion.19

HAZOP LEADERSHIP:FROM GOOD TO GREATCourse Number: 3045QDuration: 5 daysDescriptionAre you looking to transform the quality of your hazard and operability(HAZOP) studies? Do you want to do more than just comply with thestandard or do more than just continually improve? Are you looking tomake a step function change in the analysis of process hazards withinyour plant?This five-day course will transform the way you lead HAZOP reviews. Theclass goes beyond traditional HAZOP courses and challenges facilitatorsto embrace their role in the future possibility of zero process safetyaccidents. In addition to providing attendees with detailed instructionon the need for HAZOPs, the objective of HAZOP, the HAZOP processand the application of guidewords to lead a HAZOP team through thesuccessful completion of a HAZOP review, the class will introduce theconcept of demanding more from the HAZOP team, leading them touncover “what they didn’t know they didn’t know.”The course will also provide a brief overview of the role of HAZOP inprocess safety management and risk assessment, and will discuss theuse of other hazard-identification processes, highlighting similarities anddifferences with the HAZOP process.Who should attend?The class is intended to be a HAZOP facilitation course for experiencedprofessionals who already have a good understanding of process safetymanagement, who have participated in HAZOP reviews, and who eitherwant to become a great facilitator or want to make a more meaningfulcontribution to the HAZOP reviews they attend. While not mandatory,it is recommended that attendees take the process safety managementcourse or HAZOP refresher course offered by the center prior to this class.20

Course instructorMichael J. Snakard (Snakard Consulting Group LLC)AgendaDay 1: Introduction to HAZOP The HAZOP technique: What? Why? When? and Where? The objectives of the HAZOP technique. HAZOP terminology and definitions. The HAZOP process (preparing, facilitating and reporting).Day 2: Transforming your HAZOPs Qualities of a great HAZOP facilitator. Bringing process safety culture to your HAZOP study. Uncovering what the team didn’t know they didn’t know. In-class practical exercise: HAZOP Documentation.Day 3: International Best Practices Special considerations (batch processes, global issues,revalidation). HAZOP LOPA, HAZOP SIL. Living into the future possibility of ZERO accidents. Group exercise: Participating in a Great HAZOP.Day 4: Practical Guide to Getting Started Process safety information. Estimating the duration of the HAZOP. In-class exercise: Identifying HAZOP Nodes. Starting a HAZOP review (scope methodology and process). Managing the flow of the HAZOP. HAZOP revalidations. RAGAGEP (recognized and generally accepted goodengineering practice). In-class exercise: Putting it all Together.Day 5: Group Exercise — Leading a Great HAZOP Break out into groups of 5-6 people per group. Alternate facilitating a great HAZOP. Constructive feedback from the group and instructor. Group discussion. Questions and answers.21

PRINCIPLES AND PRACTICESOF QUANTITATIVE RISK ASSESSMENTCourse Number: 3052QDuration: 2 daysDescriptionThis introductory course looks at the principles and practices ofquantitative risk assessment. Hazard identification and quantitative riskassessment (QRA) are key elements of a process safety managementsystem. This course, suited to those starting their careers in processsafety, will start with a review of the existing legal requirements for riskassessments in U.S. and EU countries, an overview of some of the mostcommon process hazards and hazards identification techniques, withparticular attention to the principle features of effective quantitative riskassessment. This includes an in-depth analysis of the risk estimation andevaluation techniques as well as the implementation of risk reductionmeasures.Who should attend?This course is introductory and intended for those who are starting acareer in process safety management. Delegates are likely to have adegree in engineering or science or equivalent industrial experience.Experience of working in the process industries will be an advantage.22

Course instructorsDr. Luc Véchot (MKOPSC-Qatar)Dr. Tomasz Olewski (MKOPSC-Qatar)AgendaDay 1: Methods and Techniques for the Evaluation of Risks Introduction. Regulatory framework. Definitions and concepts (hazards, risks). Main components of a quantitative risk assessment (QRA). Overview of the main process hazards. Hazards identification techniques. Consequence analysis (including software demo). Probabilistic calculations.Day 2: Practice of Risk Assessment Risk assessment principles. Risk tolerability criteria. Risk matrix. ALARP. Individual and societal risks. Individual risk calculation workshop. Societal risk calculation workshop. Risk reduction measures.23

AREA CLASSIFICATION AND MANAGEMENTCourse Number: 3061QDuration: 1 dayDescriptionArea classification is an important topic at this time because itis essential to meet OSHA Process Safety Management (PSM)requirements as indicated in 29 CFR 1910.119. It is more importantbecause of safety, National Electric Code (NEC) compliance, andeconomic reasons. The engineering spent on classification has a fastpayout. In this era of global competition, companies cannot financiallyor legally afford to shortchange classification. Recent additions to the1996 NEC emphasize the importance of area classification drawings.This course provides a comprehensive comparison of the types of areaclassification for chemical and petroleum processes and highlightsthe differences and, in particular, the application variations of NFPA497A and API RP500. The complexities in applying these standardswill be discussed. Finally, the course also presents a technique thatmeets OSHA process safety management requirements and has othersignificant advantages. In addition, in Europe the ATEX directivesrequire stringent attention to area classification. The purpose of thiscourse is to share ideas on classification and to present and discussexamples of classification drawings that will be useful to those involvedin this important task.24

Who should attend?This course is intended for those people who are involved indetermining and implementing area classification plans, operationsand maintenance personnel required to comply with area classificationpolicies and procedures, PSM coordinators, and PSM auditors.Course instructorJack Chosnek (consultant in process safety managementand knowledge management)25

COMBUSTIBLE DUST EXPLOSIONHAZARD AWARENESSCourse Number: 1071QDuration: 1 dayDescriptionThe emphasis of this course is the technical understanding ofcombustible dust phenomena. It enables attendees to betterunderstand dust hazards, to recognize potentially serious events, andto implement effective safeguards. The course will prove helpful toexperienced engineers, safety supervisors, and operating managers whoare committed to safe workplaces. The course will provide a uniqueopportunity to attend a dust explosion demonstration in MKOPSC-QatarProcess Safety Laboratory.Who should attend?PSM managers, HSE managers, engineers and operations personnelemployed by industries where the presence of hazard zones created bydust is very likely.26

Course instructorDr. Simon Waldram (Waldram Consultants Ltd)Agenda Understanding fundamental concepts.Learning from well-documented dust explosions.Recognizing factors that influence severity of an event.Surveying effective risk recognition and hazardmitigation techniques.Comprehensive overview of codes and standards,recognized and generally applied good engineeringpractices, OSHA regulations and OSHA’s NationalEmphasis Program.Visit to the MKOPSC Process Safety Laboratory for acombustible dust explosion demonstration.27

LAYER OF PROTECTION ANALYSIS (LOPA)Course Number: 3082QDuration: 2 daysDescriptionLayers of Protection Analysis (LOPA) is a popular risk analysis technique.It is conducted after a process hazards analysis has identified hazardousevents needing further analysis to better understand the functional andrisk reduction requirements for the safeguards. This course discussesthe quantitative assessment of initiating event frequencies and therobustness of safeguards.The course stresses understanding of event propagation, the attributesrequired for safeguards to be qualified as independent protection layers(IPL), and the proper determination of hazardous event frequencies.Evaluating enabling conditions and the appropriate use of frequencymodifiers in PHA and LOPA are discussed, as well as the interrelationshipof risk criteria and analysis boundaries. The course addresses howto document risk gaps in LOPA recommendations, including usingLOPA to assign the target safety integrity level (SIL) to identified safetyinstrumented systems (SIS). Workshop examples are used to illustrate themethodology and emphasize key learning points.Who should attend?Process safety managers, process safety specialists, process engineers,operations personnel, instrumentation and electrical personnel, LOPAfacilitation trainees, LOPA facilitators, and PHA facilitators.28

Course instructorBill Hearn (TÜV functional safety expert)AgendaDay 1: Risk management. Process risk measurements. PHA workshop.Risk criteria. Hazardous and harmful events. Enabling conditions and conditional modifiers. LOPA criteria. Frequency workshop.Independent protection layers (IPL). Types. Assessing independence. Independence workshop.Core attributes. Core attributes workshop.Day 2: LOPA methodology. Initiating cause frequency. IPL risk reduction. Independence of control and instrumented safety functions. LOPA IPL workshop.IPLs and side effects. Understanding secondary consequences. Multiple LOPA workshop examples.29

LABORATORY SAFETY COURSECourse Number: 2092QDuration: 2 daysDescriptionMKOPSC-Qatar presents a two-day course on laboratory safety. Thiscourse provides an overview of the fundamentals of safety managementin a laboratory.The first part of the course will raise awareness on the common chemicaland physical hazards associated with the work in chemical engineeringand chemistry laboratories. The attendees will learn about hazardcommunication, safe work practices, hierarchy of risk control strategiesfrom inherent safety to personal protective equipment and emergencypreparedness. The teaching will be supported by several historical casestudies, demonstrations and videos. The second part of the course willteach the attendees write an effective risk assessment for their workin the laboratory through a series of interactive in-class workshopswhere the students will have to identify the hazards associated to anexperimental setup, identify the protection and mitigation barriers, semiquantitatively evaluate the risks associated to the setup, and propose riskreduction measures.The course will help the attendees to affirm or reaffirm their commitmentto excellence in safety.A visit to a laboratory is scheduled at the end of the session.Who should attend?This course is intended for those who are involved in chemicalengineering and chemistry laboratories work, including laboratorytechnicians, laboratory managers, laboratory safety coordinatorsand researchers.30

Course instructorsDr. Luc Véchot and Dr. Tomasz Olewski (MKOPSC-Qatar)David Onchagwa and Khaled Elsaid (Texas A&M at Qatar)AgendaDay 1: Hazards and Risks in Laboratories Introduction. Incident case stories and safety culture. Hazard communication: hazard symbols (NFPA, EU, GHS). Workshop on how to read a safety data sheet. Laboratory hazard awareness: chemical and physical hazards. General laboratory safe practices. Chemical hygiene. Chemical management from cradle to grave. Safe use of electrical and mechanical equipment. Hierarchy of risk control strategies (from inherent safety to PPE). Emergency preparedness.Day 2: Risks Assessment in Laboratories. Fundamentals of laboratory safety management systems. Principles of semi-quantitative risk assessment. Elements of a semi-quantitative risk assessment. Hazard identification techniques. Determination of incident likelihood. Risk matrix and risk reduction measures. Practice: risk assessment workshops4: Workshop 1: laboratory gas blendingsetup experiment. Workshop 2: experimental study of chemicalreactivity using adiabatic calorimeter. Visit of the process safety laboratory.Note: The examples treated in class can be adapted to fit the needsof attendees.431

MANAGEMENT OF CHANGECourse Number: 2101QDuration: 1 dayDescriptionOSHA’s process safety management standard has identified managementof change (MOC) as a key element in controlling the potential hazards ina chemical processing facility. MOC policies and procedures are designedto insure that changes within chemical process plants do not result inoperations outside established safety parameters.The purpose of this course is to explain the concepts and currentpractice of MOC and to present a methodology designed to develop,implement and maintain an ongoing MOC program based on provenengineering management practices and regulatory requirements. Inaddition to examples of existing MOC policies and lessons learned fromrelated industries, the course will provide sample MOC program outlinesand checklists to assist participants in implementing an effective MOCprogram at their respective facilities.Upon completion of this course, participants should be able to develop acustomized version of the MOC policies and procedures provided herein.Furthermore, participants shall alsoWho should attend?This course is designed for corporate safety officers, chemical processdesign engineers, technical managers, and plant-level chemicalmanufacturing management.32

Course instructorJack Chosnek (consultant in process safety management andknowledge management)Agenda Concepts.Definitions.Principals and examples.Management of change practice.Interface to process safety management program.Auditing management of change.Risk management process requirements.Screening risk ranking techniques.Review example procedures.33

PROCESS SAFETY FOR MANAGERSAND EXECUTIVESCourse Number: 2111QDuration: 1 dayDescriptionThis course is designed to provide an overview of the process safetymanagement to managers. The content is comprehensive and providescase histori

The Mary Kay O’Connor Process Safety Center was established in 1995 as part of the Texas A&M Engineering Experiment Station (TEES) in memory of Mary Kay O’Connor, an operations superintendent who died in an explosion 23 October 1989 at a petrochemical complex in Pasadena, Texas, USA. Mary Kay O’Connor graduated from the