PROCESS SAFETY CENTER

Transcription

1 CONTINUING EDUCATION COURSE GUIDE Mary Kay O Connor PROCESS SAFETY CENTER MAKING SAFETY SECOND NATURE

2 MARY KAY O CONNOR PROCESS SAFETY CENTER Mission Lead the integration of process safety through education, research, and service into learning and practice of all individuals and organizations. Vision Serve as the Process Safety Center of Excellence that promotes: Process safety as a personal value that is second nature for all stakeholders Continuous progress toward zero injuries and elimination of adverse impacts on the community. Values Health and safety of the community and the workforce Sharing of knowledge and information Sound scholarship and academic freedom Diversity of thought and viewpoint Independence to practice sound science Integrity of science validated by peer review Freedom to evaluate and comment on public policy Progress without undue influence by special interests Individual and group achievement 2

3 TABLE OF CONTENTS Course Number Title Page Number Continuing Education Program. Continuing Education (CE) Course Descriptions Process Safety Management Fundamentals. What Went Wrong? Learning from Chemical Plant Incidents (one-day)..... Alarm Management... Layer of Protection Analysis (LOPA). Process Hazard Analysis Leadership Training... Safety Instrumented Systems (SIS) Implementation... Safety Integrity Level (SIL) Verification.. Pressure Relief Systems Best Practices... Reactive Chemical Hazards Assessment (one-day). Reducing Human Error in Process Safety (one-day).... Disposal Systems Analysis Best Practices Engineering Decision Making (one-day).... Gas Explosion Hazards on Offshore Facilities.. Hazard Analysis for LNG Facilities. Blast & Fire Response of Structures in Oil & Gas Facilities and Mitigations Dust Explosion Hazards... Courses Offered via Distance Learning Courses Available Upon Request (Course descriptions in Cumulative Course Guide) Registration. 33 3

4 CONTINUING EDUACTION PROGRAM Expertise Instructors include leaders in the fields of process safety management, liquefied gas safety, ammonia and fertilizer plant safety, refinery and chemical plant safety engineering, and risk assessment for the process industries. Customized Courses The Mary Kay O Connor Process Safety Center also provides structured training programs aimed at specific company objectives. Any of our short courses can be tailored to the specific needs of the facility if desired. Having the instructor travel to your facility eliminates travel time and costs for the facility employees. This option presents a win-win for you and your employees no travel, tailored course, and a focused group of colleagues with similar experience and objectives. These courses can accommodate audiences as small as 8 or up to 20, in general. For more information and contract arrangements for a customized course, please contact Valerie Green at or by at [email protected]. Symposia Each year the Center hosts a Fall Symposium and a Spring Symposium. Both events are eligible for continuing education credit and offer a variety of training and educational opportunities. Please visit our website at: for event information. Safety Practice Certificate The Safety Practice Certificate is a program which allows engineers currently in industry to gain a greater knowledge of process safety. This program was created for those industry engineers who want a more in-depth study of process safety in chemical engineering. The certificate requires 125 for completion within a three year timeframe. The certificate has 84 of required courses. The remaining hours may be obtained through courses offered at training facilities in Houston, TX, other distance learning course offerings, and through the Center s International Annual Symposium in College Station, Texas. There is some flexibility in topic choice with the CE classes, so that applicants can focus their studies in a specific topic area. The application for this certificate is always open. A worksheet to help you keep track of your credits earned and the application for the program are available at education/safety-practice-certificate. Upon completion of the program requirements, participants will be issued a certificate of completion. 4

5 Continuing Education Units ()/ Professional Development Hours () The CEU is a nationally recognized unit designed to provide a record of an individual s continuing education achievements. The Engineering Program Office of Continuing Education, in cooperation with the Texas Engineering Experiment Station, has approved the Mary Kay O Connor Process Safety Center short courses for. Per the Texas Board of Professional Engineers: Each license holder shall meet the Continuing Education Program (CEP) requirements for professional development as a condition for license renewal. Every license holder is required to obtain 15 PDH units (1.5 ) during the renewal period year. A minimum of 1 PDH (0.1 CEU) per renewal period must be in the area of professional ethics, roles and responsibilities of professional engineering, or review of the Texas Engineering Practice Act and Board Rules. The complete rule can be found on the Texas Board of Professional Engineers website at RULE Continuing Education Programs. A CEU certificate will be issued by the Engineering Program Office of Continuing Education upon the successful completion of each course. PARTICIPANT COMMENTS The SIS class tied the code back to practical application. Mason D. Martin, ConocoPhillips Reviewed the actual step-by-step process for LOPA. Stephen Greco, Lubrizol-Deer Park I enjoyed the methodology for evaluating chemical hazards.. Ronnie Hampton, Eastman Chemical I enjoyed the identification of terms and conditions of PSM/RMP.. William (Bill) Worley, El Paso Pressure relief design from the equipment perspective. Charles Chan, Sempra Utilities The instructor had the ability to present the SIS material in an understandable manner with real-world examples. Tom Rutherford, Pegasus Intl. All PSM points were very helpful and I look forward to taking the advanced class. John Jewett, El Paso Presentation of Inherent Design was excellent. Delivery and slides were informative, yet not too detailed... Brad Cozart, DNV Thanks again for a well-presented and informative course. This was the second course I ve taken at MKOPSC and both have been top notch...jesse L. Roberts, BHP Petroleum 5

6 Process Safety Management Fundamentals 2-Day Course 1082 Program Content: This short course is designed to teach and apply the fundamentals of chemical process safety. Objectives: To provide a basic understanding of Process Safety and the requirements of OSHA PSM Regulation 29 CFR and EPA Risk Management Plan 40 CFR Part 68. To understand through case studies how the failure of Process Safety management elements were found to be the root cause of major incidents in the petroleum industry. To provide information on how to implement, monitor, and audit a Process Safety Management program. To illustrate through exercises the identification of hazards and the ranking of risks. Day 1: Module 1: Introduction Course administration Course participants Objectives of the course History of Process Safety legislation in the USA illustrated through past events What is Process Safety? Process Safety concepts and overview of the PSM elements Module 2: Process Safety Management Elements (Description of Each Element) Documentation Employee Participation Accountability and Leadership Process Safety Information Process Hazard Analysis Mechanical Integrity; Case Study: Humber Refinery Catastrophic Failure of De- Ethanizer Overhead Pipe Safe Work Practices (Hot Work); Case Study: Piper Alpha Disaster Contractor Management Operating Procedures; Case Study: Feyzin LPG Disaster Training and Competence Management of Change; Case Study: Flixborough Disaster Pre-Startup Safety Review Emergency Planning and Response; Case Study: Major Tank Fire Incident Investigation Process Safety Audit Trade Secrets 6

7 Process Safety Management Fundamentals (cont.) 2-Day Course 1082 Day 2: Module 3: Life Cycle Model Holistic Approach Inherent Safety Project Management and Process Safety Getting it Right Module 4: Hazards and Consequences Types of Failures releasing hazardous materials Video Session documenting vapor cloud, flash fire, explosion (deflagration and detonation), pool fire, BLEVE, Boil-over Toxic Releases Facility Siting Module 5: Risk and Risk Analysis Methodologies Hazard and Risk Types of Risk HAZOPS Study Task Risk Assessment Exercise Module 6: Human Factors A Just Safety Culture Ergonomics, fundamental behavior, human error Module 7: Texas City Disaster Presentation/Video Exercise: Draw out the holes in the protective barriers using the Swiss Cheese Model Module 8: PSM and Other Management Systems Using Synergy from Other Management Systems (ISO 9001, & OSHA 18001) TQM (Total Quality Management) Gap Analysis Key Process Safety Indicators Audits Module 9: Course Summary Followed by an Open Quiz Who Should Attend? Anyone involved in improving process safety; including chemical engineers, mechanical engineers, safety and health personnel, industrial hygiene personnel, and operators, and maintenance supervisors

8 1141 What Went Wrong? Learning from Chemical Plant Incidents 1-Day Course Program Content: Awareness of chemical and petroleum process safety fundamentals is vital to the success of all that work in chemical plants and refineries. Get a real life look at case histories of process accidents in the chemical industry. Heighten your awareness, understanding, and appreciation of the fundamentals which create chemical plant accidents. Participate in an interactive review and exchange covering numerous actual process incidents reinforced by hundreds of vivid images of plant sites in peril, fires, or damaged equipment. These exercises examine the management system needs for safe operations. Enjoy a practical, fast-paced, interactive exchange on process safety details between you, other attendees, and the presenter. Improve safety awareness within facilities when employees have failed to notice the high potential for safety related incidents. Increase awareness level of proper Management of Change policies. Understand the basics of fires and explosions and understand Tales Tanks Tell about process safety (Tanks are often the victims of chemical process and reveal mistakes), as illustrated through case histories. Understand the fundamentals of process safety to protect people, ensure the integrity of the equipment, and preserve the viability of the organization. Gain an appreciation of a situation response teaching technique that the attendee can use in their own companies to spread knowledge and understand some of the basics of human error. Learn of resources to use at your workplace while witnessing fires, explosions, or damaged equipment, and determine the approach to shape your process safety programs. Course Outline: Introductions & expectations Risk & Perceptions of Risk Risks are not always as they appear. This introductory module examines risks of industry and ordinary life factors. Accidental Fires & Explosions This module looks at the fundamentals of fires and explosions. It also reviews cases of incomplete hot work permits and process maintenance flaws which lead to massive leaks. Plant Modifications: Troubles & Treatment This portion of the program looks at how many small, seemingly helpful, well-intentioned changes can lead to unintended troublesome consequences. This reinforces the need for effective Management of Change programs. 8

9 1141 What Went Wrong? Learning from Chemical Plant Incidents (Cont.) 1-Day Course Incident Investigations How Far Should We Go? This is a classic look at accident investigations developed by Dr. Trevor A. Kletz, in which five different investigators reviewed the same case and came up with five drastically different causes. Pump Explosions Dangers of dead heading pumps. Tales Tanks Tell A look at a wide array of process safety incidents in which various elements of process safety were not considered and tanks suffered. Human Error Why some people act as they do within chemical plants. Layers of Protection A look at many of the within-the-fence training, hardware, and procedures with enhanced process safety Wrap Up, Evaluations, and Quiz The majority of incidents discussed are well-documented in Roy Sander s Book (2005) Chemical Process Safety Learning from Case Histories. Third Edition (ISBN X). Who Should Attend? Chemical Process Safety must be second nature to all who design, operate, and maintain refineries and chemical plants. The material is best suited to operations supervisors, lead operators of chemical manufacturing units or petroleum refining units, maintenance foremen, plant related managers, process engineers, design engineers, plant safety engineers, property insurance professionals, and other professionals interested in Chemical Process Safety awareness. Note: This class is also available as a two-day class

10 Alarm Management 2-Day Course 1162 Program Content: This course provides an introduction to industry standard alarm management practices, with primary focus on the lifecycle steps in the ISA18.2 standard Management of Alarm Systems for the Process Industries. The major lifecycle steps will be explained, and exercises will illustrate alarm philosophy development, rationalization, and bad actor resolution. Day 1: Alarm Management Overview History and Purpose Regulatory Requirements Timeline Standards / Guidelines ISA 18.2 Others ISA 18.2 Lifecycle Philosophy and Identification Rationalization Detailed Design and HMI Design Enhanced and Advanced Alarming Implementation Operation and Maintenance Monitoring and Assessment Management of Change Lifecycle Entry Points Day 2: Safety Alarms ISA 18.2 references/requirements ISA84 references/requirements Alarm Management Steps Examples Wrap-up Philosophy Rationalization Bad Actor Resolution Continuous Improvement

11 2042 Layer of Protection Analysis (LOPA) 2-Day Course Program Content: Layers of Protection Analysis (LOPA) is a popular risk analysis technique. It is conducted after a process hazards analysis has identified hazardous events needing further analysis to better understand the functional and risk reduction requirements for the safeguards. This course discusses the quantitative assessment of initiating event frequencies and the robustness of safeguards. The course stresses understanding of event propagation, the attributes required for safeguards to be qualified as Independent Protection Layers (IPL), and the proper determination of hazardous event frequencies. Evaluating enabling conditions and the appropriate use of frequency modifiers in PHA and LOPA are discussed, as well as the interrelationship of risk criteria and analysis boundaries. The course addresses how to document risk gaps in LOPA recommendations, including using LOPA to assign the target Safety Integrity Level (SIL) to identified Safety Instrumented Systems (SIS). Workshop examples are used to illustrate the methodology and emphasize key learning points. Risk management Risk criteria Independent Protection Layers (IPL) Core attributes LOPA methodology IPLs and side effects Day 1: Risk management Process risk measurements PHA workshop Risk criteria Hazardous and harmful events Enabling conditions and conditional modifiers LOPA criteria Frequency workshop Independent Protection Layers (IPL) Types Assessing independence Independence workshop Core attributes Core attributes workshop 11

12 2042 Layer of Protection Analysis (LOPA) (Cont.) 2-Day Course Day 2: LOPA methodology Initiating cause frequency IPL risk reduction Independence of control and instrumented safety functions LOPA IPL workshop IPLs and side effects Understanding secondary Consequences Multiple LOPA workshop examples Who Should Attend? Process safety managers, process safety specialists, process engineers, operations personnel, instrumentation and electrical personnel, LOPA facilitation trainees, LOPA facilitators, and PHA facilitators

13 Process Hazard Analysis Leadership Training 2-Day Course 2052 Program Content: This course is intended to prepare PHA team members for team leadership. It introduces techniques commonly utilized in the petrochemical, chemical, and oil and gas industries. It also includes hands-on example problems from industry. Many engineers or operating company professionals have attended PHAs, but have not been prepared for the unique requirements of team leadership. This course, while providing an introduction to PHA methodologies, is intended to augment the skill sets of those persons. Each class offering is adjusted to meet the specific needs of the current class members, with class interaction encouraged. Following introductions of class members, the course starts with a simple presentation on hazard and operability studies (HAZOP 101), and a hands-on example problem. Next, the team discusses the evolution of PSM in the United States so that team leaders understand how PSM came about. Regulatory requirements for PHAs are then discussed, including Process Safety Management (PSM) programs, Risk Management Programs (RMP), and Safety and Environmental Management Systems (SEMS). Discussion includes when studies are required, and assists the PHA leader in identifying and managing compliance issues. Along with discussion of the PHA methodologies, attendees discuss how to prepare for a PHA, and then how to manage the team during the project implementation. Preparation of reports is another topic, presented with visual examples. Additionally, checklists of general safety issues, facility siting issues, and human factor issues are included in the class notes. Day 1: Introductions HAZOP 101 with workshop Evolution of PSM Regulatory requirements for PHAs Preparation for PHAs Leadership skills for managing teams HAZOPs in detail HAZOP workshop Who Should Attend? Process Hazard Analysis participants Day 2: What-If? And What-If? / checklist What-If? workshop FMEA and fault tree analysis PHA reports and documentation Facility siting, human factors LOPAs in PHAs PHA software PHAs for batch processes PHAs for process modifications Final workshop

14 2073 Safety Instrumented Systems (SIS) Implementation 3-Day Course Program Content: This course reviews the various good engineering practices that apply to Safety Instrumented Systems (SIS) implemented in process industry facilities. It presents the requirements of IEC using a lifecycle framework that is supplemented with several industrial guidance documents. It explains how risk analysis techniques, such as Layer of Protection Analysis (LOPA), are used to identify the need for administrative and engineered safeguards. IEC establishes requirements for designing and managing SISs to achieve specified Safety Integrity Levels (SIL), which are related to order of magnitude ranges of risk reduction. When LOPA determines that an SIS is required, the required risk reduction becomes the target SIL for the SIS. The course is designed to provide the student with an understanding of the required safety management system, how to perform LOPA to identify the need for an SIS and to assign the SIL, how to design the SIS to meet the specified SIL, how to verify that the SIL can be achieved, and how to develop an operating plan to maintain the SIL throughout the SIS life. SIS standards overview Planning Process risk and protection layers Establishing risk evaluation criteria Layer of Protection Analysis (LOPA) Selection of devices Data estimation Design decisions Verification example Operating basis Day 1: Getting Started Module 1 SIS Standards Overview This course begins with a brief introduction to the various good engineering practices that apply to Safety Instrumented Systems (SISs) implemented in process industry facilities. Special focus is given to international standards, such as IEC and 61508, and recognized guidance documents, such as the CCPS Guidelines books and several ISA technical reports. Module 2 Planning An overview of IEC is presented followed by detailed requirements for the safety management system contained in clauses 5 through 7. Key elements are competence, independent review, verification, functional assessment, management of change, and auditing. 14

15 2073 Safety Instrumented Systems (SIS) Implementation 3-Day Course Module 3 Process Risk and Protection Layers Process risk derives from process miss-operation and is an inherent part of process design. This inherent risk must be reduced below internationally accepted risk criteria using Independent Protection Layers (IPLs) that are designed and managed to meet seven (7) core attributes. Module 4 Establishing Risk Evaluation Criteria The risk assessment phase is addressed in IEC Clauses 8 and 9. The initiating events for process hazards are identified, and the frequency and consequence severity of each potential event is estimated. Depending on the type of risk analysis, various conditional modifiers may also be considered when assessing the risk. Once the risk is understood, a risk reduction strategy can be developed. Day 2: Risk Analysis to Design Module 5 Layer of Protection Analysis Layer of protection analysis (LOPA) is covered in the CCPS book, Layer of Protection Analysis: Simplified Process Risk Assessment. LOPA identifies the initiating events and their frequency, the consequences and their severity, the required risk reduction, and the protective functions implemented in each protection layer to achieve the required risk reduction. Module 6 Safety Requirements Specification (SRS) Part 1 The SRS in IEC Clause 10 is a collection of information that specifies the SIS design basis required to ensure process safety during all operating modes. The SRS defines the functionality, integrity, reliability, operability, and maintainability requirements based on operational goals, intended operating modes and process safety time limitations. Module 7 Safety Requirements Specification Part 2 IEC Clause 11 provides many specific design requirements including the need for fault tolerance and separation of the SIS from the BPCS. Module 8 Selection of Devices SIS device selection is addressed in IEC Clause ISA TR guidance is presented related to field devices and logic solvers. Emphasis is placed on demonstrating that the device is user-approved for safety based on a review of manufacturer information and actual field experience. 15

16 2073 Safety Instrumented Systems (SIS) Implementation 3-Day Course Day 3: Verification and Operating Basis Module 9 Data Estimation IEC Clause 11.9 requires verification of the SIS performance through calculation of the probability of failure on demand (PFD) and the spurious trip rate of the SIS as specified and maintained. Various types of data estimates are discussed with an emphasis on collecting internal and industrial data. Module 10 Design Decisions The voting architecture, diagnostic coverage, proof test interval, and common cause failure potential affects the achievable PFD, and the spurious trip rate. The impact of each design decision is discussed and typical examples are presented. Module 11 Example Verification An example of Safety Instrumented Functions (SIF) will be assessed to illustrate how choices in field device architecture, test interval, and logic solver technology affect the achievable PFD and spurious trip rate. Module 12 Operating Basis There are many day-to-day operational and maintenance activities that must take place for the SIS to sustain its expected performance throughout its installed life. Operation and maintenance procedures must be developed and verified prior to the introduction of hazards into the process unit. These procedures support the detection and response to faults and process alarms, the initiation of manual shutdown, reset after shutdown, and proof tests. Who Should Attend? Control systems, instrument, electrical, and process safety specialists, PSM managers, and PSM compliance auditors

17 Safety Integrity Level (SIL) Verification 2-Day Course 2082 Program Content: This course covers the performance verification of Safety Instrumented Functions (SIF), including calculation of the Probability of Failure on Demand (PFD) and Spurious Trip Rate (STR). These calculations must take into account the device failure rates, system architecture, subsystem voting configuration, specified diagnostics and testing, and repair times. The PFD calculation must also take into account the susceptibility of the SIF to common mode and common cause failure. IEC requires that the PFD be verified by calculation to prove that each SIF meets its target Safety Integrity Level (SIL). This course provides students with an understanding of the fundamentals needed to address this requirement in their workplace. It familiarizes students with Failure Modes and Effects Analysis (FMEA), the identification of safe, dangerous, detected, and undetected device failures, the selection of failure rate data, understanding key design parameters, and applying the calculation methodology. The two approaches for approving a device for use in an SIS - certification and prior use - are also explained. The course presents a series of examples as workshops to illustrate the important concepts and assumptions implicit in the calculations. The student must bring a scientific calculator and notepad to the course. Overview of the requirements of SIS standards Failure analysis fundamentals Failure Modes and Effects Analysis (FMEA) Introduction to the math for probability of failure on demand and spurious trip rate Key elements affecting performance Workshops -- problems worked by students. Various cases will be modeled showing how changes to design and maintenance strategy affect results. Day 1: Overview of SIS standards Failure fundamentals Failure Modes and Effects Analysis (FMEA) Introduction to the math for probability of failure on demand and spurious trip rate Key Elements Integrity Where do you get data from? What does it mean? Voting/Fault Tolerance why do you need redundancy? How does it help? Test Interval How does the test interval affect the integrity? Diagnostic Coverage What effect does diagnostics have? Common Cause How is this modeled? 17

18 Safety Integrity Level (SIL) Verification 2-Day Course 2082 Periodic workshops throughout the day How to read manufacturer certification reports How to model SIF based on LOPA recommendations Understanding mean time to failure and useful life Partial stroke testing and proof test coverage Day 2: Example System Impact of diagnostics and need for compensation measures Calculation demonstration showing the impact of redundancy Workshops problems worked by students. Various cases will be modeled showing how changes to design and maintenance strategy affect results. Who Should Attend? Control systems engineers, instrument engineers, and process safety specialists

19 3102 Pressure Relief Systems Best Practices 2-Day Course Program Content: The OSHA Process Safety Management (PSM) mandate of 1993 brought safety to the forefront of our businesses. Along with many other pieces of critical process safety information, it demanded adequate verification and documentation of the design basis for all new and existing pressure relief and disposal systems. However, it did not outline how to do this nor what constitute adequate documentation. Due to imposed deadlines that quickly approached, companies rushed to be in compliance. In the mid 1990 s, most would argue that there was not enough time nor money budgeted to carry out the huge scope of work that OSHA called for. Consider for a moment the operations of one of the larger refineries (~300,000 BPD) in the United States and read the following questions: How does this refinery identify, analyze, and maintain all of the equipment, relief device and process information associated with 5,000 pieces of equipment, 20,000 overpressure scenarios, and millions of flare venting combinations? How does this refinery ensure that all pressure relief and disposal system information is accurate, accessible, and maintainable? How does this refinery do all of the above without incurring astronomical costs? Approximately twenty years after the initial push for compliance and the implementation of the OSHA National Emphasis Program (NEP), companies have some breathing room to re ask themselves the above questions. The answers are the best practices covered in this course. The ultimate goal is a corporate wide standardization of philosophy, engineering analysis, software, and information management that guarantees an accurately designed, electronically documented, and easily maintained pressure relief and disposal system for an acceptable dollar investment. These best practices outline how to achieve this goal: Adoption of a sensible approach to risk management Commitment to best practices Standardization of equipment based engineering analysis Identifying and implementing appropriate Recognized and Generally Accepted Good Engineering Practices (RAGAGEPs) Standardization of relational database and integrated information management architecture Coupling of pressure relief and disposal system documentation to Management of Change processes Relief device inspection program Relief device removal procedures 19

20 3102 Pressure Relief Systems Best Practices (Cont.) 2-Day Course Who Should Attend? This course outlines the best practices of pressure relief design so it is primarily intended for personnel who have the responsibility of maintaining and auditing the pressure relief system design basis documentation for OSHA compliance. The intended audience includes auditors, process engineers, technical managers, and project managers

21 Reactive Chemical Hazards Assessment 1-Day Course 3111 Program Content: As an introduction to reactivity of industrial chemicals and the evaluation of potential hazards due to their reactive nature, this course discusses identification and characterization of chemical hazards. Also discussed is the use of a hierarchical evaluation and management approach for safer and more economical chemical processes. Why a systematic approach to chemical reactivity is important Why reactive hazard management should include management of risk Definition of a potentially hazardous reactivity Types of chemicals and chemical reactions Chemical incompatibility Chemical energy of formation and potential release of energy Effects of catalysis, inhibitors, contaminants, and corrosion products Reaction conditions, including temperature, pressure, concentration, and time Equipment reliability and availability including failure, testing, and repair Systematic prediction of potential chemical hazards using literature information, computation methods, screen testing, and detailed experimental analysis Industrial case studies illustrating effects of energy, reaction pathways, unexpected reactions, kinetics, and aging Who Should Attend? Reactive hazards analysts, process safety managers and coordinators, and operation managers and superintendents. Note: This class is also available as a two-day class

22 3121 Reducing Human Error in Process Safety 1-Day Course Program Content: Human error is a significant source of risk within any organization. Management uses a variety of operational controls and barriers, including policies, procedures, work instructions, employee selection and training, auditing, etc., to reduce the likelihood of human error. Accidents occur when there is a failure in one or more of these controls and/or barriers. Many companies are working to reduce their incident rates by integrating a more detailed analysis of human factors into their incident investigation procedures. In doing so, companies can identify weaknesses in their operational controls at a specific job site, within an operating region, and across the organization. Subsequent improvements to these controls will then help to reduce the on. The following course will outline a process that companies can use to integrate human factor data into incident investigations and identify operational controls that need improvement. The course is being offered as either 1-day or 2-day training. The 1-day training will be open to representatives from different companies and will be more general in nature. The 2-day training will be provided to a single company and will be tailored to their specific operations. Who Should Attend? Process safety management coordinators, risk management planning coordinators, and new health, safety, and environment auditors

23 Disposal Systems Analysis Best Practices 1-Day Course 3151 Program Content: The OSHA Process Safety Management (PSM) mandate of 1993 brought safety to the forefront of our businesses. Along with many other pieces of critical process safety information, it demanded adequate verification and documentation of the design basis for all safety disposal system components. However, it did not outline how to do this nor what constitute adequate documentation. Due to imposed deadlines that quickly approached, companies rushed to be in compliance. The primary goal of a disposal system, such as flare, analysis is to ensure that all processes are adequately protected against potential global overpressure contingencies. The design basis of flare relief header system components such as pressure relief devices, piping network, knockout drums, flare seals, and flare tip should always be available and this data should reflect the current operating condition of the process. In recent years, refining and petrochemical facilities have experienced tremendous growth in response to increasing demand for fuels and chemical precursors. At the same time higher expectations were established to be incompliance with corporate, local, and federal regulations. Under these circumstances it has become more challenging to keep an eye on the update and maintenance of the flare header adequacy analysis during fast paced engineering design and debottlenecking projects. The challenge stems from the time and cost requirements that are associated with such an effort. This course describes a best practice to analyze disposal systems that will provides refining, petrochemical and chemical facilities operators and managers with comprehensive plan to efficiently maintain and reflect the adequacy status of the flare system components. The course outlines the following components: Commitment to best practices and adoption of a sensible approach to risk management Standardization of disposal systems analysis Identifying and implementing appropriate Recognized and Generally Accepted Good Engineering Practices (RAGAGEPs) Standardization of relational database and integrated information management architecture Disposal system components engineering analysis Flare quantitative risk analysis (QRA) and flare consolidation Who Should Attend? This course outlines the best practices of pressure relief design so it is primarily intended for personnel who have the responsibility of maintaining and auditing the pressure relief system design basis documentation for OSHA compliance. The intended audience includes auditors, process engineers, technical manages, and project managers

24 4061 Engineering Decision Making 1-Day Course Program Content: This course will discuss and exercise decision making examples using decision tree figures and other tools to analyze decision alternative outcomes and probabilities including the likelihood of observing particular outcomes in tests to lower uncertainty for more accurate decision making. Course topics include: Method and components of an engineering decision Flaw of averages and the importance of working with variability of critical parameters Use of probability to model uncertain events and guide uncertainty reduction Expected likelihood and expected utility of alternative outcomes Value of information and method to determine how much additional information, if any, is needed prior to making an engineering decision, and the value of perfect information to find the value limit of additional information to make a given decision Bayes Model to update probability estimates using new information How to calibrate engineering decisions based on tolerable risk ranges Information gathering, analysis, and decision making are vital components of engineering responsibility. This responsibility includes the value of information to decrease uncertainty for cost effective decrease of outcome risk. Such decisions employ information to estimate values and outcome probabilities of decision alternatives. Therefore, the pillars of engineering decision making are the values and probabilities of alternative outcomes. Exercises and case studies drawn from life and from engineering applications will illustrate the tools needed for professional decision making applications. Case studies include natural gas or oil drilling, building extension and rebuilding, toxic exposures, dikes to avoid flooding, replacement of leaking pipeline, and offshore platforms. Who Should Attend? All engineering personnel (design, operations, maintenance) who are involved in day-to-day operations and decision making in the plants. In addition, all project managers should attend this course. Note: This class is also available as a two-day class

25 Gas Explosion Hazards in Petrochemical Facilities: Onshore/ Offshore 2-Day Course 4072 Program Content: An advanced course looking into explosion hazards on offshore facilities. The course addresses all aspects of explosion hazards: ignition processes, release and dispersion, explosion mechanisms, blast loads and modeling of all these aspects. On the second day, a tour of the TEEX Brayton Fire Training Field and Disaster City. Course attendants will experience at least one large-scale fire demonstration. Day 1: Day 2: Gas Explosion Basics Explosion Accidents: Statistics and Examples Rough Offshore Explosion and Investigation Release and Dispersion in Offshore Facilities Ignition Sources Fundamentals Preventative Measures Mitigation and Control North Sea Lessons Learned Advanced Explosion Modeling Explosion Analyses Part 1: Objective and Motivation Part 2: Explosion Risk Analyses Simple Approach Part 3: Explosion Risk Analyses Advanced Approach Part 4: Selected Examples of Safety Case Analyses Who Should Attend? Safety engineers, safety consultants, structural & design engineers, oil & gas HSE, investigation team leaders, and process safety management coordinators

26 4132 Hazard Analysis for LNG Facilities 2-Day Course Program Content: GexCon is presenting an advanced course on the analysis of explosion and other hazards for Liquefied Natural Gas (LNG) facilities. The 2-day course will address multiple hazards associated with onshore and offshore LNG facilities including: LNG release and dispersion, explosion modeling, cryogenic spills, prevention and mitigation, probabilistic risk assessments, legislation, accidents, selected case studies. The course will prove helpful to experienced engineers, safety supervisors, and operating managers who are committed to safe workplaces. Who Should Attend? Safety engineers, managers, supervisors, and other personnel involved in the design, operation, or modification of onshore and offshore LNG facilities as well as onshore processing facilities

27 Blast & Fire Response of Structures in Oil & Gas Facilities and Mitigations 2-Day Course 4182 Program Content: The primary objective of this course is to offer fundamental understanding on blast and fire engineering that can be applied for both onshore and offshore oil and gas structures. The course content encompasses the state-of-the-art methods developed for analyzing blast and fire events and their influence on human and infrastructures. This course will not only enhance the capacity of participants on basic principles applied to blast and fire engineering, but also will provide them with numerous practical applications by pulling in real-world problems accomplished in each area. The course content is summarized in below: Different methods for computing the blast load on structures will be discussed. The semiempirical and computational fluid dynamics (CFD) approaches for simulating blast phenomenon and blast-structure interaction effects will be outlined. The methodologies for determining the blast loads on structures by taking into account the interaction between structure and blast wave, i.e. the effect of wave reflection from surface of structure and clearing effects, will be explained. A quantitative risk assessment procedures will be outlined to identify blast exceedance curves. The method for interpretation of pressure/impulse exceedance curves in order to determine the blast loads will also be described. Further, a riskbased approach to design and assess onshore and offshore structures for blast loading will be presented. The performance criteria and its different categories under blast loading will be presented. The performance criteria will include various structural components and their detailing in different types of structures. In addition, the performance criteria will encompasses nonstructural items in different types of buildings, i.e. doors, windows, openings, and interior details. Subsequently, the building occupant vulnerability to blast load will be explained. The fatality/lethality curves and the methods for estimating maximum individual risks will be presented. A methodology for computing structural response of piping and pressure vessels to blast loading in offshore structures and petrochemical facilities will be presented. The criteria for using drag force or overpressure to represent the blast load on pipes and pressure vessels will be detailed

28 Blast & Fire Response of Structures in Oil & Gas Facilities and Mitigations 2-Day Course 4182 Innovative methods for retrofitting the existing structures, which are vulnerable to blast loading, will be described. The strengthening approaches at both foundation level and structure level will be explained. Fire analysis procedures for determining characteristics of different types of fire, such as pool fire, jet fire, and flash fire will be discussed. Subsequently, the methods for predicting the reduction in structural capacity of steel structures exposed to fire will be explained. Also, the approaches for protecting the steel structural members against fire such as utilizing passive fire protection and its optimization will be outlined. Numerical simulation of heat transfer by convection, conduction and radiation will be explained in conjunction with its application in predicting the temperature rise inside a shelter building engulfed by an external fire. Further, the impact of radiation on human body and human response criteria to temperature rise inside the building will be presented. Who Should Attend? All practicing structural engineers, technical safety engineers involved in design and assessment of onshore and offshore oil & gas structures and similar. Date: March 22-23, 2016 Location: Phoenix Contact Customer Technology (PCCT) Center; Houston, TX

29 4232 Dust Explosion Hazards 2-Day Course Program Content: GexCon is presenting an advanced course on dust explosion hazards. The 2-day course will address multiple hazards associated with dust explosions including: dust properties, explosion modeling, preventive measures, ignition sources, protective measures, process hazard analysis, legislation, accidents, and selected case studies. The course will prove helpful to experienced engineers, safety supervisors, and operating managers who are committed to safe workplaces. Who Should Attend? PSM manager, HSE managers, engineers and operations personnel employed by industries where the presence of hazard zones created by dust is very likely

30 COURSES OFFERED VIA DISTANCE LEARNING Our Distance Learning Program allows individuals in a university academic program to participate in university courses. These courses follow the syllabus outline with all other students, completing homework, taking quizzes and exams, and projects as applicable. In order to receive a certificate for these courses, participants must complete all work and receive a C or better on graded work. These courses follow the academic calendar and are offered on a semester basis (Fall: August December; Spring: January May). SENG 422: Fire Protection Engineering Fire protection design concepts and considerations for chemical, petrochemical, and hydrocarbon processing facilities. Special attention is given to fire hazard analysis, fire risk assessment, fire protection features, and emergency response. Specific fire protection design considerations are studied for the various types of facilities and processes. Prerequisite: Instructor approval SENG 310: Industrial Hygiene Engineering Application of scientific and engineering principles in the selection and design of control systems related to chemical, physical, and ergonomic exposures in the process and manufacturing industries, relationships of criteria, analysis and specifications for the assessment and control of occupational related illnesses SENG 321: Industrial Safety Engineering Concepts of designing, operating, and maintaining optimally safe systems, risk management, economic impact, legislation, performance measurement, and accident investigation and analysis, principles and practices in Industrial Hygiene Engineering, Fire Protection Engineering, and Introduction to Systems Safety Engineering

31 CHEN 455/655 SENG 455/655: Process Safety Engineering Applications of engineering principles to process safety and hazards analysis, mitigation, and prevention, with special emphasis on the chemical process industries, including source modeling for leakage rates, dispersion analysis, relief valve sizing, fire and explosion damage analysis, hazards identification, risk analysis, and accident investigations CHEN 460/660: Quantitative Risk Analysis in Safety Engineering Following the growth in complexity of engineering systems, demands are increasing for health, safety, and environmental quality with more stringent requirements for reliability and increased engineering performance. This course presents the fundamentals of quantitative risk analysis for cost-effective engineering applications, risk criteria, and risk decisions CHEN 430 SENG 430: Risk Analysis Safety Engineering Concepts of risk and risk assessment, which uses all available information to provide a foundation for risk-informed and cost-effective engineering practices. Examples and exercises are drawn from a variety of engineering areas SENG 312: System Safety Engineering Application of system safety analytical techniques to the design process, emphasis on the management of a system safety or product safety program, relationship with other disciplines, such as reliability, maintainability, human factors, and product liability applications

32 Register Online: REGISTRATION To register online go to: When on the Schedule of Classes and Registration page, select from the list of courses offered and choose Register for this course. You will be linked to a secure site allowing you to register and pay for the course online. You will receive a confirmation upon completing your registration. Register by Phone: Call and we will take your registration over the phone. Hours are 8 am to 5 pm, CST, Monday through Friday. Register by Fax: Fax your registration to , 24 hours a day, 7 days a week. Register by Mail: Mary Kay O Connor Process Safety Center Attention: Valerie Green Texas A&M University 3122 TAMU College Station, TX Make checks payable to: Mary Kay O Connor Process Safety Center For all other questions contact: Valerie Green Associate Director [email protected] 32

33 Mary Kay O Connor Process Safety Center Continuing Education Registration Form Last Name First Name MI Company Name Mailing Address City State Zip Code Telephone Fax Address* COURSE TITLE COURSE DATE FEE CANCELLATION & REFUND POLICY 1) If the course is cancelled for any reason, we will provide a 100% refund or the student can transfer their registration fee to the next offering of the same course, or to a different course. 2) If the student cannot attend the course, they may have a substitute attend. 3) Cancellations must be received ten working days prior to the start of the course to receive a refund. After that time, there will be a 30% penalty. All refunds will incur a $25 service charge. 4) The Center will not be responsible for any costs and/or expenses incurred by the registrant when a class is cancelled. * addresses received via this registration form will be added to our distribution list unless otherwise noted. REGISTRATION & FEES To register online go to and select courses offered under the Standard Courses section and then you will be linked to the website listing all of our courses. Follow the instructions and be sure to wait for confirmation that your registration was received before exiting the site. Early registration is 4 weeks prior to the course date. See individual classes for fee (based on course duration). Circle one: Total $ Credit Card #: Card Holder: Exp. Date: Security Code: Please send registration form and check (made payable to the Mary Kay O Connor Process Safety Center) or fax registration if paying by credit card (American Express, Diners Club, MasterCard, or Visa) to: Mary Kay O Connor Process Safety Center Attention: Valerie Green Texas A&M University College Station, TX Phone: (979) Fax:

34 Mary Kay O Connor Process Safety Center 34