Process Safety Management Masterclass

Mastering Principles, Compliance, and Best Practices for Safer Industrial Operations

What you'll learn

Explain the principles, scope, and regulatory requirements of Process Safety Management in line with global best practices.

Conduct effective Process Hazard Analyses (PHA) using methods such as HAZOP, What-If, and LOPA to identify and control potential risks.

Develop, implement, and maintain comprehensive operating procedures and safe work practices for high-hazard operations.

Apply Mechanical Integrity (MI) and Management of Change (MOC) principles to ensure equipment reliability and safe process modifications.

Plan and execute incident investigations, emergency response strategies, and pre-startup safety reviews (PSSR) to prevent recurrence of failures.

Foster a strong safety culture through employee participation, contractor management, and leadership engagement.

Integrate PSM elements with Enterprise Risk Management (ERM) and adopt emerging digital technologies to enhance safety performance.

Requirements

Knowledge of safety is an advantage but not mandatory.

Description

This Process Safety Management Masterclass is a comprehensive online training course designed to equip professionals with the knowledge, skills, and tools to effectively manage hazards in high-risk industrial environments. Drawing on international standards, regulatory requirements, and proven industry practices, this course covers every critical element of a robust PSM framework—from hazard analysis and mechanical integrity to incident investigation and emergency planning. Participants will gain a deep understanding of how to systematically prevent catastrophic chemical releases, fires, and explosions while fostering a proactive safety culture.In today’s complex industrial landscape, PSM is not just a legal requirement but a business imperative. Through engaging lectures, real-world case studies, and interactive exercises, this course bridges the gap between theory and application. Learners will explore OSHA’s 14 PSM elements, global regulations like the EU Seveso III Directive, and best-practice guidelines from the Center for Chemical Process Safety (CCPS). Special emphasis is placed on integrating PSM with enterprise risk management and leveraging digital tools such as digital twins, IoT sensors, and predictive analytics to enhance safety performance.The masterclass goes beyond compliance to focus on operational excellence. Learners will learn how to identify process hazards, evaluate and control risks, develop safe operating procedures, and implement effective management of change systems. Critical skills in incident investigation, employee engagement, contractor management, and performance auditing will be developed, ensuring that graduates can lead PSM initiatives that protect people, assets, and the environment.Whether you are a plant manager, safety professional, engineer, or consultant, this course offers a complete roadmap for implementing, auditing, and continuously improving PSM systems. By the end of the program, participants will be equipped not only to meet regulatory demands but also to drive a culture of safety leadership, operational reliability, and sustainable industrial performance.

Overview

Section 1: Introduction

Lecture 1 Introduction

Lecture 2 Introduction to Process Safety Management I

Lecture 3 Introduction to Process Safety Management II

Lecture 4 Lesson Notes: Introduction to PSM

Section 2: Regulatory Frameworks and Standards

Lecture 5 Regulatory Frameworks and Standards I

Lecture 6 Regulatory Frameworks and Standards I

Lecture 7 Regulatory Frameworks and Standards III

Lecture 8 Lesson Note: Regulatory Frameworks and Standards

Section 3: Process Hazard Analysis (PHA)

Lecture 9 Process Hazard Analysis (PHA) I

Lecture 10 Process Hazard Analysis (PHA) II

Lecture 11 Lesson Note: Process Hazards Analysis (PHA)

Section 4: Operating Procedures and Safe Work Practices

Lecture 12 Operating Procedures and Safe Work Practices I

Lecture 13 Operating Procedures and Safe Work Practices II

Lecture 14 Operating Procedures and Safe Work Practices III

Lecture 15 Lesson Note: Operating Procedures and Safe Work Practices

Section 5: Mechanical Integrity (MI)

Lecture 16 Mechanical Integrity (MI) I

Lecture 17 Mechanical Integrity (MI) II

Lecture 18 Mechanical Integrity (MI) III

Lecture 19 Lesson Note: Mechanical Integrity

Section 6: Management of Change (MOC)

Lecture 20 Management of Change (MOC) I

Lecture 21 Management of Change (MOC) II

Lecture 22 Management of Change (MOC) III

Lecture 23 Lesson Note: Management of Change (MOC)

Section 7: Incident Investigation

Lecture 24 Incident Investigation I

Lecture 25 Incident Investigation II

Lecture 26 Incident Investigation III

Lecture 27 Lesson Note: Incident Investigation

Section 8: Employee Participation and Safety Culture

Lecture 28 Employee Participation and Safety Culture I

Lecture 29 Employee Participation and Safety Culture II

Lecture 30 Employee Participation and Safety Culture III

Lecture 31 Lesson Note: Employee Participation and Safety Culture

Section 9: Training and Competency Development

Lecture 32 Training and Competency Development I

Lecture 33 Training and Competency Development II

Lecture 34 Training and Competency Development III

Lecture 35 Lesson Note: Training and Competency Development

Section 10: Pre-Startup Safety Review (PSSR)

Lecture 36 Pre-Startup Safety Review (PSSR) I

Lecture 37 Pre-Startup Safety Review (PSSR) II

Lecture 38 Pre-Startup Safety Review (PSSR) III

Lecture 39 Lesson Note: Pre-Startup Safety Review (PSSR)

Section 11: Emergency Planning and Response

Lecture 40 Emergency Planning and Response I

Lecture 41 Emergency Planning and Response II

Lecture 42 Emergency Planning and Response III

Lecture 43 Emergency Planning and Response IV

Lecture 44 Lesson Note: Emergency Planning and Response

Section 12: Process Safety Information (PSI)

Lecture 45 Process Safety Information (PSI) I

Lecture 46 Process Safety Information (PSI) II

Lecture 47 Process Safety Information (PSI) III

Lecture 48 Process Safety Information (PSI)

Section 13: Contractors and Third-Party Management

Lecture 49 Contractors and Third-Party Management I

Lecture 50 Contractors and Third-Party Management II

Lecture 51 Contractors and Third-Party Management III

Lecture 52 Lesson Note: Contractors and Third-Party Management

Section 14: Compliance Audits and Performance Metrics

Lecture 53 Compliance Audits and Performance Metrics I

Lecture 54 Compliance Audits and Performance Metrics II

Lecture 55 Compliance Audits and Performance Metrics III

Lecture 56 Lesson Note: Compliance Audits and Performance Metrics

Section 15: Integrating PSM with Enterprise Risk Management (ERM)

Lecture 57 Integrating PSM with Enterprise Risk Management (ERM) I

Lecture 58 Integrating PSM with Enterprise Risk Management (ERM) II

Lecture 59 Integrating PSM with Enterprise Risk Management (ERM) III

Lecture 60 Lesson Note: Integrating PSM with Enterprise Risk Management (ERM)

Section 16: Digitalization and Future of PSM

Lecture 61 Digitalization and Future of PSM I

Lecture 62 Digitalization and Future of PSM II

Lecture 63 Digitalization and Future of PSM III

Lecture 64 Lesson Note: Digitalization and Future of PSM

Process, chemical, and mechanical engineers working in high-hazard industries.,Health, Safety, and Environment (HSE) professionals responsible for compliance and risk management.,Plant managers and supervisors overseeing operations involving hazardous substances.,Maintenance and reliability engineers involved in equipment inspection and integrity programs.,Regulatory compliance officers and internal auditors in manufacturing and process industries.,Consultants and trainers providing safety and risk management services.,Graduate students or early-career professionals aspiring to specialize in industrial process safety.