Training on Risk Based Process Safety Management (RBPS)

Industrial operations involving hazardous processes require robust safety systems to prevent accidents, protect workers, and maintain operational reliability. Risk-Based Process Safety Management (RBPS) provides a structured framework for identifying hazards, managing risks, and strengthening safety culture across organizations.

This 10-day training course equips participants with the knowledge and practical skills needed to design, implement, and improve effective process safety management systems based on the Center for Chemical Process Safety (CCPS) RBPS framework. The course focuses on proactive risk identification, systematic hazard analysis, and the integration of safety practices into operational processes.

Participants will explore the four pillars of RBPS—commitment to process safety, understanding hazards and risks, managing risk, and learning from experience. The program also covers techniques for process hazard analysis, incident investigation, safety performance monitoring, and continuous improvement in high-risk industrial environments.

Through real-world case studies, simulations, and practical exercises, participants gain hands-on experience applying RBPS principles to operational scenarios. By the end of the course, learners will be able to strengthen process safety management systems, reduce operational risks, and improve overall safety performance within industrial operations.

Duration

 10 Days

Who Should Attend

• Process Safety Managers and Engineers
• Health, Safety, and Environment (HSE) Professionals
• Risk Management Professionals
• Operations Managers
• Maintenance Personnel
• Quality Assurance Managers
• Regulatory Compliance Officers
• Professionals involved in managing safety in industrial operations

Organizational Impact

• The organization can significantly reduce the likelihood of catastrophic incidents, which protects human life and prevents massive financial losses, legal fees, and reputational damage.

• By demonstrating a strong commitment to process safety, the organization builds trust and credibility with regulators, investors, and the public.

• A safer operational environment leads to less downtime and improved productivity by minimizing disruptions caused by accidents and near misses.

• The training ensures the organization meets and exceeds stringent global safety standards, which is essential for business continuity and global market access.

Personal Impact

• The participant will gain a highly valuable and specialized skill set in a critical area of industrial safety and risk management.

• This expertise is a crucial skill for career progression into senior safety, operations, or leadership roles in high-hazard industries.

• The individual will be able to contribute directly to the organization's viability and reputation by protecting its people, assets, and processes.

• The training provides the confidence and authority to lead safety initiatives and manage complex, high-stakes safety challenges.

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

• Understand the principles of Risk Based Process Safety utilizing the CCPS model
• Recognize the importance of the necessary commitment to ensure the implementation RBPS management system through an understanding of safety culture
• Describe the primary international standards related to process safety and the importance of compliance
• Understand the importance competency maintenance including the principles of continuous improvement involving both the workforce   and other stakeholders
• Understand and practice a structured approach to hazard assessment
• Understand the principles of managing risk
• Understand and employ the principles of continuous improvement through a structured learning and review process including audits

Module 1: Overview of Risk-Based Process Safety (RBPS)

• Accident Prevention Background

• Swiss Cheese Model

• RBPS Concepts, Pillars, and Elements

• Process Safety Culture and Management Commitment

• Compliance with Standards (Legislation, International Industry Standards, Company Standards)

• Workforce Involvement, Safety Committees, Feedback, and Stakeholder Outreach

• Case Study: Major industrial accidents analyzed using Swiss Cheese Model

• Practical Exercise: Identify gaps in process safety culture in a sample scenario

Module 2: Understanding Hazards and Risk

• Process Safety Competency

• Process Knowledge Management: Availability, Maintenance, and Dissemination of Knowledge

• Hazard Identification and Risk Analysis

  • HAZID

  • HAZOP

  • Quantitative Risk Assessment (QRA)

• Case Study: Hazard identification in a chemical plant

• Practical Exercise: Conduct a mini-HAZOP session using a sample process diagram

Module 3: Operational Considerations

• Operating Procedures and Procedural Structure

• Safe Work Practices and Work Permits

• Asset Integrity and Reliability

• Contractor Management

• Training and Performance Assurance

• Case Study: Failure of asset integrity leading to operational incidents

• Practical Exercise: Review and improve a sample operating procedure

Module 4: Operational Readiness

• Management of Change (MOC)

• Operational Readiness and Pre-Start Up Safety Review (PSSR)

• Conduct of Operations: Safe Operating Limits

• Emergency Management and Response Planning

• Training and Recovery

• Case Study: PSSR evaluation of a new plant startup

• Practical Exercise: Develop an emergency response checklist for a sample process

Module 5: Learn from Experience

• Incident Investigation and Near Miss Reporting

• Root Cause Analysis (RCA)

• Measurement and Metrics, Key Performance Indicators (KPIs)

• Auditing: Internal and External

• Management Review and Continuous Improvement

• Case Study: Root cause analysis of a process safety incident

• Practical Exercise: Conduct a mock incident investigation

Module 6: Process Safety Leadership and Culture

• Leadership Roles in Process Safety

• Developing a Safety Culture

• Encouraging Open Communication and Reporting

• Case Study: Leadership impact on safety performance

• Practical Exercise: Assess safety culture in a hypothetical organization

Module 7: Risk Assessment and Quantitative Analysis

• Risk Assessment Techniques and Tools

• Probabilistic Risk Assessment

• Layers of Protection Analysis (LOPA)

• Case Study: Applying LOPA to a refinery process

• Practical Exercise: Perform a simplified risk assessment for a chemical process

Module 8: Emergency Preparedness and Crisis Management

• Emergency Planning and Response Teams

• Scenario-Based Drills and Exercises

• Business Continuity Considerations

• Case Study: Effective emergency response during a chemical leak

• Practical Exercise: Design a tabletop emergency drill

Module 9: Auditing and Performance Monitoring

• Safety Audits and Inspections

• Performance Metrics and Benchmarking

• Continuous Improvement Loops

• Case Study: Audit findings leading to process safety improvement

• Practical Exercise: Conduct a mini-audit of a sample process and identify gaps

Module 10: Integrated Case Study and Final Practical

• Review of all RBPS pillars and elements

• Case Study: Analyze a real or simulated industrial incident using all RBPS tools and concepts

• Practical Exercise: Prepare a full risk assessment, propose corrective actions, and present findings