PROGRAM DETAILS

Introduction

Any industry must be committed to protecting the health, safety and the surrounding environment of all employees, facilities, members of the public and the environment. In addition, it seeks to prevent workplace related illness or injury to all employees and contractors and also promotes the importance of occupational health and safety in all aspects and operations of the refinery.

This commitment extends to implementing a system of monitoring potential hazards and their impacts in order to ensure that applicable laws, standards, regulations and industry codes of practice are not compromised.

Operating safely in any industry demands efficient control systems and constant vigilance at all stages of the processing and delivery operation. Highly trained Environment and Safety team observes strict adherence to safe practices, against criteria set internationally for the handling, storage and delivery of products.

Procedures for the receive of raw materials and finished products, as well as, the processing of final products and their delivery to the trade are monitored by state-of-the-art equipment on a twenty-four (24) hour basis.

In addition, an ongoing training programme must be implemented for staff as well as seminars for other stakeholders including contractors, marketing companies and government agencies.

In this short training programme you will get the benefit on how to link these three major issues (Health, Safety & Environment) at work and you will get the opportunity to learn and understand the importance of having a complete package in dealing with these issues.

Learning  Objectives

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

• Understand and implement global standards in health, safety, and environmental management.

• Apply advanced risk management methodologies to identify and control hazards.

• Integrate safety leadership with strategic planning, change management, and performance evaluation.

• Foster a proactive safety culture through employee involvement and behavioural safety techniques.

• Evaluate safety performance using key indicators and incident analysis.

• Recognize and control sources of ignition and explosion hazards in classified areas.

• Design and implement environmental protection and pollution control measures.

• Develop effective emergency response and environmental risk mitigation plans.

• Understand the legal and regulatory framework for workplace safety and environmental protection.

• Communicate and lead cross-functional safety programs with measurable results.

Target Audience

This program is ideal for:

• HSE Officers and Safety Managers

• Engineers and Technical Supervisors

• Maintenance and Plant Engineers

• Project Managers and Department Heads

• Operations and Facility Managers

• New Engineering Graduates aiming for HSE roles

• Government or regulatory personnel overseeing safety compliance

Training Methodology

The course will use a blend of instructional methods to ensure maximum understanding and practical learning. These include:

• Instructor-led lectures and expert presentations

• Real-world case studies and industry best practices

• Interactive workshops and group discussions

• Practical hands-on sessions using risk assessment tools and software

• Safety incident simulation and analysis

• Team exercises and role-based scenarios

Program Content

Module 1 Leadership Skill:

· Vision
· Mission
· Strategic Objectives/Goals
· Budgeting
· Strategic thinking on way forward
· Change Management/New Culture and commitment

Module 2 Performance Management:

· Balance Scored Cards
· Key Performance Indicators ( KPI)
· Bench Marking
· Performance Appraisal
· Communication Skill
· Decisions making & Problem Solving Skills
· Team work & work culture

Module 3  Managing Change:

· Communication Skill/Communication Channels
· Organization change
· Change Process ( Tool box talk, weekly meeting,..etc.)
· Reduce Resistance to change & best utility Practice to management changes.
· Motivation Skill

Module 4  Extra support

In addition to the above topics the candidate will gain knowledge and case studies in
Principles of Management

• Quality Management (TQM);
• Introduction to Management Information Systems
• Business and Technical Communication
• Supervision and management of Human Relations
• Managerial Decision Making and Economics
• International Business
• Management of Organisational Behaviour

Case studies and group discussion and Sharing views (trainees and instructors workshop)

Module 5 – Overview of Safety, Loss Prevention & Environment Protection

Modern day industrial and business practices require more than just defensive safety and security polices and traditional safeguards. An innovative, scientific and predictive approach to risk and safety must be developed & applied based on the requirements of the industry.

• Legislations and standards covering workplaces
• Introduction of Safety Culture in Industrial setting
• Risk Control & Safety
• Assessing Risk potential of a facility
• The Safety Case Approach
• Elements of environmental protection

Safety Culture at the Workplace

Building Good safety culture among the workforce is long-term defence against occurrence of hazards

• Motivation and employee involvement
• Development of proactive safety culture
• How to promote safety culture
• Behavioural Safety and employee’s involvement
• Selection of outcome indicators
• Attitudes in the workplace
• Manager operator relationships

Module 6 Safety Performance and Environment Monitoring

In any industry, the safety performance of the various functional areas and personnel needs to be measured to establish the safety standards of the company

• Measurement of Safety
• Near-miss Reporting/ Investigation of accidents
• Maintenance of Critical Equipment
• Safety Performance and Reliability – Terms & Concepts
• Matching environmental risk to safety performance

Safety Management Systems

A plant’s safety program should include aspects such as recognition and control of hazards, elimination of unsafe acts, avoidance of accidents, etc.

• The need for SMS
• Safety system standards & technologies
• Principles of environmental regulations
• Systems of implementation environmental protection
• Adoption of HASAWA principles
• Evaluating the Results with standards
• Development of Loss Prevention Policies and Procedures

Module 7 Hazard Identification & pollution Control

The goal of the hazard identification and control program is to make the workplace and its operations as safe as possible, to the extent feasible, and to keep employees from being harmed

• Hazard Identification & Control Program
• Modes & Classification of Hazards
• Principles & techniques of identifying chemical hazards
• Environmental hazards
• Health & safety at work rules

Techniques of Hazard Identification

Hazard identification/ classification is normally based on techniques and methodologies developed from basic understanding of material properties and experience in handling and storage

•  Strategy for Hazard Assessment
• Hazard Identification Process
• General Techniques of Hazard Identification
• Ranking Methods, Checklists, WHAT-IF….?, HAZOP, etc.
• Use of HAZOP Technique
• Human factors in HAZOP study
• Use of special features in computerized HAZOP techniques
• Analysis of information from P&I diagrams, PFD, etc
• Composition & Selection of the team
• Preparation of Reports
• Selection of Techniques

Module 8   Hazard Assessment of workplaces

Assessment of workplace must be accomplished to eliminate or reduce impact from hazards

• Hazards in the Workplace
• Problem Solving & Eliminating hazards
• Pollutants types and control
• Environmental impact of industry and how to reduce it

Module 9 Managing the Industrial Fires/ Explosions

Fires in oil & petrochemical installations pose a serious hazard to both life and property. It is essential, therefore, to understand the ways in which fire can occur and develop. The use of risk assessment should not be confined to major accident analysis, but be detectable throughout the normal operation of the facility

Case Studies of Industrial Fires & Explosions

Major Effects on environment caused by  Chemical Accidents

Consequences of accident on health 7 environment – use HAZAN technique

Consequence analysis considers the physical effects and the damages caused by workplace accidents. The basis of Cause Consequences Analysis (CCA) is the ability to estimate the most likely hazardous consequences of accidental releases of toxic and flammable gases or liquids under various conditions of release

• Components in Consequence Analysis
• Spill & Leaks related to environmental pollution
• Case Studies of Accident Scenarios
• Assessment of Consequences on environmental issues
• Identification of hazardous areas
• Results from Hazard Quantification procedures
• Short listing of Events and Follow up

Probabilistic Assessment of consequence due to mal-operation, loss of control & equipment failure

Using analytical tools such as “what If “, hazard and operability study (HAZOP), failure mode and effect analysis (FMEA), or “fault-tree” analysis, most of the possible process breakdowns can be determined. The likely cause of the unwanted events and its most probable failures sequence can be determined using these techniques

• Process control and safety control
• Construction of Fault Tree/ Event Tree
• Probability Analysis
• Evaluation of HAZOP results through Quantification techniques
• Examples & case studies

Module 10 Control of Ignition using Hazardous Area Classification

Identifying the sources of ignition & estimating the probability of ignition and of explosion if a leak occurs is an important element in reducing the risk of its occurrence

 Sources of Ignition & Fire spread possibilities

• Control of Ignition Sources
• Features of an effective model for ignition probability
• Description & Definitions of Zoning

Selection & Safeguarding of Equipment in Hazardous Locations

Electrical and non-electrical equipment located in hazardous areas need to protected against causing accidental ignition

•  Safety of Hazardous Equipment
• Basic Principles in the various types of protection
• Methods of Protection
• Classification & Selection of Electrical Apparatus
• Safeguarding of Electrical/ Non-electrical equipment
• Marking & Certification of Equipment

Management of environmental issues

An emergency in a plant is one that has the potential to cause serious injury or loss of life. It may cause extensive damage to property and serious disruption both inside and outside the plant

•  Prevention of pollution and environment damage
• Pollution Control Measures
• Detection of leaks to stop pollution
• Environmental Emergency Response Plan
• Basic environmental Plan Requirements
• Detailed Emergency Response Plan for pollution
• Maintaining the Plan of pollution control
• Learning from Incidents/ Near-misses

Application of Risk Assessment to industrial operations

Workshop/ discussion on applying hazard identification techniques

Case Studies, examples & application