FM-HRC/Revision0Page1CourseOverviewThiscourseteacheshowgoodhazardrecognitioncanpreventorinfluenceanincident.Thecourseaddressesthedifferencebetweenpersonalsafetyhazardsandprocesssafetyhazards,howincidentsoccurthroughabreakdownofprocesssafetyhazardcontrols.Studentswillexploreanindustrycasestudyandtheimpactofhazardrecognitionontheincident.Studentswillalsoanalyzetypicalprocessscenariosandmakedeterminationsonhazardrecognitionandpreventativemeasures.I.CurriculumCriteria:ProcessSafetyHazardRecognitionTopicsCourseContent/CriteriaTargetAudience–ProcessOperatorsandMaintenanceCrafts,andFrontLineSupervisionEvaluationCriteriaTopic1:Importanceofhazardrecognitionandhowprocesssafetyincidentsoccur.Estimatedlengthofthistopic:60minutesLearningObjectives:1.Understandthedifferencebetweenpersonalsafetyhazardsandprocesshazards.2.Recognizehowprocessincidentsoccurwhenlayersofprotection/hazardbarriersbreakdown.3.Understandthatgoodhazardrecognitioncanpreventorinfluenceanincident.Content:1.Reviewthedifferencebetweenprocesshazardsandpersonalsafetyhazards.Conveythefollowinginformation.a.Processsafetyhazardsarethosethatmayresultfromarefineryorchemicalfacilityprocess.Typicalprocesssafetyincidentsinvolvetheescapeoftoxicsubstancesorthe1.Studentsshallbeabletorecallanexampleofatleastoneprocesssafetyincidentandhowhazardrecognitionaffectedtheoutcome.FM-HRC/Revision0Page2releaseofflammablematerialwhichmayormaynotresultinfiresorexplosions.Processsafetyincidentsmaydamagetheplant,causeinjuriesorfatalities,orhavethepotentialtoimpactthelocalcommunity.b.Personalsafetyhazardsarethosethataffectindividualsbuthavelittletodowiththeprocessingactivityoftheplant.Typicallytheyrefertoincidentssuchasslips,trips,falls,electrocutions,orvehicleaccidents.2.ExplainhowprocessincidentsoccurusingasimplifiedversionofJamesReason’sSwissCheesemodel:a.Hazardsarecontainedbymultiplelayersofprotection.b.Eachlayerofprotectionmayhaveweaknessesor“Holes.”c.Whenholesalign,thepotentialforprocesssafetyincidentsincreases(referto1aforexamples).d.Layersofprotectionmaybephysical,engineered,containment,proceduralorbehavioralcontrolsdependantonpeople.e.Holescanbeexisting,developovertime,orbeactivelyopenedbypeople.f.GiveexampleswhatoperatorsandcraftsmencandotoplugtheholesintheSwisscheese.FM-HRC/Revision0Page33.Exploreanindustrycasestudy.Showanexampleofamajorindustryincident(e.g.Bhopal,BPTexasCity;Tesoro,etc).a.Discusscausalfactorsandlessonslearned.b.Discusshowprocesssafetyhazardrecognition(orlackthereof)influencedtheincident.c.DrawrelationshipsbetweentheSwissCheeseModelandtheincidentsexampledabove.4.OPTIONAL:Showanexampleofacompanyrelatedincident.a.Discusscausalfactorsandlessonslearned.b.Discusshowprocesssafetyhazardrecognition(orlackthereof)influencedtheincident.c.DrawrelationshipsbetweentheSwissCheeseModelandtheincidentsexampledabove.Topic2:ImportanceofProcessSafetyControlsinpreventingprocesssafetyincidents.Estimatedlengthofthistopic:90minutesLearningObjectives:1.Knowtheimportanceofprocesssafetycontrolsinpreventingincidentsandtheinteractionbetweenoperatorsandcraftsmentosustainsuchcontrols.2.Understandthatprocesssafetyincidentsoccurwhenmultipleprocesssafetycontrolsbreakdownandthoseeffectivecontrolscanprotectpeoplefromprocesssafetyhazards.1.Studentsshallbeabletoexplainthepurposeofprocesssafetycontrols.2.Studentsshallbeabletorecognizetheirrolesinmaint...
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