Safety in Process Equipment Design and Operation: A Complete Guide
Course Overview
This comprehensive 5-day program is designed for engineers, safety professionals, and technical managers involved in **designing, operating, and maintaining process equipment** in industries such as oil & gas, petrochemical, manufacturing, and power generation.
The course provides a deep understanding of the **principles of process safety**, with emphasis on **equipment design integrity, hazard identification, risk assessment, and operational safety controls**. Participants will explore international standards, accident case studies, and best practices to ensure that safety is embedded in every stage of process design and plant operation.
By combining technical knowledge with practical applications, the course ensures that participants can confidently develop and manage systems that minimize risk, protect personnel, and ensure plant reliability.
Course Objectives
By the end of the course, participants will be able to:
* Understand key principles of process safety management (PSM).
* Identify and control hazards associated with process equipment.
* Apply engineering safety standards in design, selection, and operation.
* Conduct risk assessments (HAZOP, HAZID, SIL, LOPA).
* Analyze incident case studies to prevent recurrence.
* Integrate safety culture and compliance into daily operations.
Learning Outcomes
Upon successful completion, participants will be able to:
* Design process systems with safety and reliability as core priorities.
* Apply risk-based decision-making in equipment design and modification.
* Interpret and apply international safety standards such as **API, ASME, OSHA, and IEC 61511**.
* Evaluate safety integrity levels (SIL) and safeguard performance.
* Manage inspection, maintenance, and emergency procedures effectively.
* Promote proactive safety culture across teams and departments.
Course Duration
**5 Days (35 Guided Learning Hours)**
Delivery Mode: **In-Person / Virtual (Instructor-Led)**
Target Audience
This course is ideal for professionals working in process industries, including:
* Process Engineers and Plant Designers
* Operations and Maintenance Engineers
* Health, Safety & Environment (HSE) Officers
* Risk and Reliability Engineers
* Production Supervisors and Shift Leaders
* Engineering Consultants and Project Managers
Who Should Attend
* Individuals responsible for ensuring process safety and integrity.
* Engineers involved in equipment design, installation, or modification.
* HSE professionals seeking a deeper understanding of process risks.
* Technical managers and supervisors overseeing operational safety.
Certification
Participants who complete the program will be awarded a
🎓 **Professional Certificate in Safety in Process Equipment Design and Operation**
by **KeLeaders Institute of Engineering, Safety & Technology**.
This certification demonstrates competence in process safety management and engineering design in accordance with international best practices.
5-Day Course Outline
Day 1: Fundamentals of Process Safety and Equipment Design
* Introduction to process safety management (PSM)
* The hierarchy of controls and risk reduction
* Overview of process equipment and safety-critical systems
* Design safety principles and hazard containment
* Case study: Learning from historical process incidents
Day 2: Engineering Standards and Equipment Design Integrity
* International codes and standards (API, ASME, ISO, IEC)
* Material selection and compatibility
* Pressure vessels, piping, valves, and safety relief systems
* Design verification and integrity management
* Workshop: Identifying design-related safety flaws
Day 3: Risk Assessment and Hazard Analysis Techniques
* Hazard Identification (HAZID) and Hazard & Operability Study (HAZOP)
* Layer of Protection Analysis (LOPA)
* Safety Integrity Level (SIL) assessment
* Quantitative Risk Assessment (QRA)
* Group Exercise: Conducting a sample HAZOP session
Day 4: Operational Safety and Maintenance Controls
* Safe startup, operation, and shutdown procedures
* Permit-to-Work (PTW) systems and isolation procedures
* Preventive and predictive maintenance for safety-critical equipment
* Emergency response planning and control of abnormal situations
* Case Study: Analysis of process plant failure and lessons learned
Day 5: Safety Culture, Auditing, and Continuous Improvement
* Building a proactive safety culture and leadership commitment
* Incident investigation and root cause analysis (RCA)
* Safety audits, performance metrics, and continuous monitoring
* Integrating safety with process optimization and efficiency
* Final group project: Designing a safety improvement plan for a process system
Methodology
* Expert-led technical lectures
* Case studies of real industrial accidents
* Group-based problem-solving workshops
* Practical exercises on HAZOP and SIL
* Interactive discussions and simulations
Learning Benefits
* Gain advanced insight into safe equipment design and operation.
* Improve process reliability and reduce risk of incidents.
* Apply global engineering standards to enhance safety compliance.
* Strengthen coordination between design, operations, and HSE teams.
* Receive international recognition as a process safety professional.
Contact Info:
Enquiry at : admin@keleaders.com
Whatsapp: 0044 790 125 9494
For more details visit our website : www.keleaders.com
