Process Safety Management (PSM)

Introduction

Process Safety Management (PSM) is a structured, engineering‑driven approach used to prevent catastrophic incidents such as explosions, fires, toxic releases, and major equipment failures. In high‑hazard industries—Oil & Gas, Petrochemical, Refining, LNG, Chemical Manufacturing, Fertilizers, Power Generation, and Industrial Plants—PSM is not optional; it is a regulatory and operational necessity.

This course provides participants with a deep understanding of PSM elements, hazard analysis methodologies, operating discipline, mechanical integrity, emergency planning, and leadership responsibilities. It aligns with OSHA 29 CFR 1910.119, CCPS guidelines, and API RP standards, ensuring global compliance and operational excellence.

The GTMCS Process Safety Management course delivers a technical, scenario‑based, and industry‑aligned learning experience designed to strengthen process safety culture and prevent major accidents.

This Training Course Will Highlight

PSM principles & regulatory frameworks

Process hazard analysis (PHA) tools (HAZOP, What‑If, FMEA)

Operating procedures & safe operating limits

Mechanical integrity & asset reliability

Management of Change (MOC) & operational discipline

Emergency planning & response for process facilities

Leadership roles in process safety

Course Benefits

Strengthen process safety awareness & engineering discipline

Improve capability to identify & control process hazards

Build confidence in applying PHA tools & methodologies

Enhance operational reliability & mechanical integrity

Increase compliance with OSHA, CCPS & API standards

Improve alignment between operations, engineering & HSE

Tools & Techniques Covered

HAZOP (Hazard & Operability Study)

What‑If Analysis

Failure Modes & Effects Analysis (FMEA)

Bow‑Tie Analysis

Mechanical integrity inspection tools

MOC workflows & documentation

Emergency planning & response frameworks

Practical Workshops

HAZOP node analysis simulation

Bow‑Tie development workshop

MOC case study & documentation practice

Mechanical integrity inspection planning

Process safety incident reconstruction

Real‑World Case Studies

Refinery explosion root cause analysis

Petrochemical toxic release investigation

LNG plant process safety management gaps

Chemical plant mechanical integrity failures

Oil & Gas shutdown process safety lessons

Industry Relevance

This course is essential for:

Process engineers & chemical engineers

HSE professionals & PSM specialists

Operations, maintenance & production teams

Shutdown, turnaround & reliability teams

Project managers & engineering managers

Anyone responsible for process safety or asset integrity

Future Skills Alignment

Process hazard analysis & risk engineering

Mechanical integrity & reliability management

Operational discipline & safe operating limits

Emergency planning & major accident prevention

Leadership in process safety culture

Objectives

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

Understand PSM principles & regulatory requirements

Conduct process hazard analysis using multiple tools

Apply safe operating limits & operating discipline

Manage changes effectively using MOC systems

Strengthen mechanical integrity & reliability programs

Support emergency planning & major accident prevention

Enhance process safety culture across operations

Training Methodology

Instructor‑led process safety workshops

Hands‑on PHA exercises & simulations

Case study analysis & group discussions

Scenario‑based process safety drills

Daily reflection & practical assignments

Organisational Impact

Stronger process safety culture & engineering discipline

Reduced major accident risks & catastrophic failures

Improved mechanical integrity & asset reliability

Enhanced compliance with global process safety standards

Better alignment between engineering, operations & HSE

Personal Impact

Strong process safety & hazard analysis skills

Improved engineering judgment & risk‑based thinking

Enhanced confidence in process safety leadership roles

Greater professional credibility in high‑risk industries

Career advancement in engineering, operations & HSE

Who Should Attend

Process engineers & chemical engineers

HSE officers & PSM specialists

Operations & maintenance teams

Shutdown & reliability engineers

Engineering managers & project managers

Anyone involved in process safety or asset integrity

Certificates

Upon successful completion of this training course, participants will receive a GTMCS Certificate of Completion.