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Process Safety Management and Process Hazard Analysis


This 4-day course is offered in concert with TCI's risk management partner, Safety Management Services, Inc. (SMS).


This course is intended for managers, engineers, and safety professionals involved in PSM program implimentation. This course provides an understanding of the risk management sytems, protocols, and procedures necessary for safe explosive operations and compliance with OSHA 29 CFR 1910.119. Process hazards analysis and explosive classification are key to safe operations. Course emphasis includes the following :

  • Understanding the 14 elements of OSHA 29 CFR 1910.119 “Process Safety Management of Highly Hazardous Chemicals” and the unique aspects associated with propellant, explosives, and pyrotechnic materials

  • Insights to the importance of explosive classification and characterization testing and how test data are applied to ensure “safety by design” of explosive process equipment and facilities

  • Understanding the various PHA methodologies and the proper application to explosive operations to ensure systematic identification and elimination/mitigation of risk

Course Content:

Day 1 - PSM Principles for Explosive Operations

  • Explosives manufacturing heritage

  • PSM background

  • Fundamentals principles of explosives safety

  • OSHA PSM interpretations

Day 2 - Explosive Classification Testing for Process, Storage, and Facility Design

  • Classification testing heritage and current methods

  • In-process hazard classification of explosives

  • Explosives storage and staging principles

  • Risk reduction through "safety by design"

  • Code compliance

Day 3 & 4 - Process Hazards Analysis (PHA) Training for Team Leaders

  • Regulatory PHA Requirements

  • PHA methodologies

  • Workshops:  selecting and utilizing appropriate PHA methodology

  • Application of material characterization test data

  • Applying qualitative and quantitative PHA methodologies

  • How to document a PHA study

  • Managing the follow-up of PHA results

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