TC-102: OSHA General Industry 10 Hour Training
This 10 hour course was designed by OSHA for managers, engineers, technicians, mechanics, operators, and other personnel that work in any manufacturing facility. It includes required core topics, elective topics, and additional topics you can choose that are especially suited to your organization. It can be scheduled to be completed in one very long day, or more typically, over two days, or even in a series of one-hour sessions scheduled over the course of time (up to six months).
This course establishes a familiarity with the OSHA standards that are most commonly cited and covers the key requirements of OSHA compliance.
Students receive a manual for reference. OSHA provides certification in the form of wallet cards that Bluefield Process Safety will mail to each participant who successfully completes the course.
Core Topics (seven hours total)
Introduction to the OSH Act and OSHA (2 hours)
Walking and Working Surfaces
Exit Routes, Emergency Action Plans, Fire Prevention Plans
Personal Protective Equipment
Elective Topics (at least two topics for an hour each)
Hazardous Materials (PSM and HazWOpER)
Additional Topics (these or elective topics to complete 10 hours)
Permit Required Confined Space Entry
Hazard Identification and Risk Assessment
Safety Culture and Ethics
Product Liability and Safety
TC-107.8: Investigating Incidents
This is a one day course intended for process safety personnel who participate in or lead incident investigation teams. This course goes more in depth than the incident investigation awareness training that may be included as part of OHSA 10 Hour Training.
This one-day, instructor-led course uses a combination of lecture, discussion, and hands-on exercises to teach the skills necessary to effectively function as the leader of an incident investigation committee, and to analyze incidents in a systematic manner that assures improvement of the process that generated the incident. Students will leave the course ready and able to complete and lead incident investigations and improve overall safety.
ESH Management Theory
The Incident Analysis Process
Activators, Behaviors, and Consequences
TC-201: The Safety Lifecycle
This course is for professionals responsible for implementing process safety in a technical or industrial environment, including those for responsible for specifying and implementing Safety Instrumented Systems (SIS). It is also an excellent introduction for anyone seeking a better understanding of the safety lifecycle.
This half-day instructor led course covers the complete Safety Lifecycle. The IEC 61511 standard will be referenced and used as a guide through the analysis, realization, and operation of an SIS. Exercises will include process hazard analysis, SIL determination, SRS definition, and SIF design.
Introduction to the Safety Lifecycle
Regulations and Standards
Process Safety Information
Safety Integrity Levels
Safety Instrumented Systems
Safety Requirements Specifications
Pre Startup Safety Review
Operations and Maintenance
Proof Testing and Inspections
Functional Safety Management
Quality Systems and Documentation
TC-204: Process Safety Management
This is a one to two hour class. It is general awareness training intended for personnel that work in a facility with processes covered by OSHA's Process Safety Management standard: managers, engineers, technicians, mechanics, operators, and others.
The course introduces workers to the OSHA PSM standard and its 14 elements with special emphasis on employer and employee responsibilities under the standard. Each participant receives copies of the presentation material and accompanying notes.
Contents of the Standard
Comparison with RMP
Risk Management Planning
Traps and Pitfalls
Elements of PSM
Review and Analysis
O & M
Focus on Selected PSM Topics
Process Hazard Analysis
Pre-Startup Safety Reviews
Management of Change
Help and Information
TC-205: PSM Compliance Auditor Training
This is a half day course. It is intended for personnel that are responsible for ensuring OSHA's Process Safety Management standard is being effectively and fully enforced at their facility.
The course refreshes workers to the OSHA PSM standard and its 14 elements before applying the standard hands-on to practical application scenarios and instructor-lead review of company safety procedures. Each participant receives copies of the presentation material, example scenarios, and accompanying notes. With sufficient time to prepare, the example scenarios will be adapted to incorporate the facilities own PSM-covered process and documentation
Basic awareness of the OSHA PSM standard (TC-204 or equivalent)
29 CFR 1910.119 Process Safety Management
Process Hazards Analysis
Management of Change
Pre-Startup Safety Reviews
TC-221: Preparing PFDs and P&IDs
This is a very full one day course for process design engineers responsible for preparing piping and instrument diagrams as part of front-end engineering design packages.
This is not a course on drafting standards. Instead, it is intended for process engineers who must start with a clean sheet of paper and prepare P&IDs, but who do not have a mentor in their organization to guide their efforts. The course includes examples and exercises that are completed individually and in groups.
Experience or training reading P&IDs (BC-222 or equivalent).
Introduction to Flow Diagrams
Electrical and Instrument Symbols
Process Equipment Symbols
Drawing Interpretation Exercise
Reviewing, Revising, and Issuing Flow Diagrams
Electrical and Instrument Review of P&IDs
Reviewing Equipment and Lines on P&IDs
Overall P&ID Reviews
Making Revisions and Management of Change
Cost of Revisions
P&ID Review Exercise
Preparing Process Flow Diagrams
Laying Out PFDs
Material and Heat Balance Exercise
Preparing Piping and Instrument Diagrams
Laying Out P&IDs
Piping and Equipment
Electrical and Instrumentation
Operating and Safety Considerations
P&ID Preparation Exercise
TC-222: Reading P&IDs
This is a half-day course intended primarily for inexperienced engineers and technicians with little or no experience with process flow diagrams and piping and instrument diagrams. It helps organizations avoid the costs and delays that result from misunderstanding drawings. It exposes students to all of the elements of PFDs and P&IDs and teaches students how to read and interpret these fundamental drawings.
Students receive copies of the presentation.
Introduction to Flow Diagrams--BFDs, PFDs, EFDs
Process Equipment Symbols
TC-232: Process Hazards Analysis Facilitator Training
This course is for process safety personnel who have participated in Process Hazards Analysis and want to learn how to facilitate a PHA.
This one day course is a hands-on, instructor-led course. The course includes a review of several PHA techniques (including HazOp, WhatIf, Checklist), and gives guidance on when each of those techniques may be preferred over others. It then focuses on the PHA technique most widely used in the chemical process industries, the HazOp. The course addresses how to prepare for a PHA, how to identify PHA nodes on a P&ID, how to conduct a PHA (including tips on keeping the team moving and dealing with disruptive team members), and the format for compiling and reporting the results of the PHA. The course concludes with a discussion of how to estimate the time and cost of a HazOp and other PHAs.
Recommended to have experience participating in at least one PHA
Techniques for Conducting a PHA
Preparing for a PHA
Conducting a PHA
Working with a Scribe
Compiling a PHA
TC-235: Establishing Risk Tolerance Criteria
Students will gain understanding of what elements make up risk, the amount of risk tolerated in society, and the amount of risk tolerated in organizations and industry (specifically the process industry). Students will also engage in practical exercises to allow them to set risk tolerance criteria that are useful as a design basis.
Hazards vs. Consequences vs. Risk
Likelihood and Consequence Analysis
Quantification of Risk
Prevention vs. mitigation
TC-236: Assessing Risk—Off-site Consequence Analysis
This course is for process safety personnel who quantify the consequences of safety incidents for the purposes of quantifying risk off the plant site.
The US EPA's guidance documents on off-site consequence analysis (OCA) describe how the consequence component of risk should be determined for both worst cases and alternative cases. While other tools are available, the EPA OCA guidance is widely used, and the basis of comparison for most discussions with the public. This one day course explains the theory behind these EPA-approved techniques, and trains students in their use through a combination of lecture, discussion, and hands-on exercises. The course wraps up with an exercise in the use of the EPA software, RMP*Comp, and a review of the requirements for an EPA Risk Management Plan.
Experience assessing consequence (i.e. Bluefield Course 236)
Toxic Gas Releases
Liquid Spill and Vaporization
Vapor Cloud Explosions
BLEVE (Boiling Liquid Expanding Vapor Explosions)
EPA Risk Management Plans
TC-237: Assessing Risk—Layers of Protection Analysis (LOPA)
This is a half day course to train process safety personnel to participate in and facilitate LOPA teams for the purposes of estimating the likelihood component of risk.
This LOPA technique is endorsed by the Center for Chemical Process Safety and widely accepted in the process industries. This course prepares students to develop scenarios, evaluate safeguards as potential layers of protection, and use appropriate probabilities to calculate frequency, or likelihood, of safety critical scenarios.
Students receive a copy of the Bluefield Process Safety LOPA tool, and training to calibrate it to their organizations own risk tolerance criteria.
Understanding Layers of Protection Analysis
Layers of Protection
Overview of LOPA
Event Tree Analysis
Elements of LOPA
Limitations of LOPA
Using Layers of Protection Analysis
Plant Operations as Tests
TC-238: Assigning SILs
This one hour course applies to anyone within the process industry that is involved in establishing or assigning Safety Integrity Levels. Students need not be the engineers or supervisors responsible for verifying SIL effectiveness.
Course material will review the risk and tolerable risk, discuss and evaluate tools to compare risk with risk tolerance criteria, practice calibration of tools to applicable criteria and process variables at the client company, and discuss how to evaluate results from the tools to achieve SIL values
Competent understanding of components of risk and tolerable risk criteria
Review of Assessing Risk
Likelihood and Consequence Components
Tolerable Risk Criteria
Tools for Calculating and Comparing Risk
Calibrating Tools to Established Tolerable Risk Criteria
TC-245: Designing Safety Instrument Functions
This four hour course introduces students to the Safety Instrumented Functions and helps them to understand different considerations and techniques required to effectively design SIFs.
This is a hands-on, instructor-led course that uses a combination of lecture, class discussion, and exercises to teach the material. Students will work individually and in groups to develop and evaluate different functions. Students will receive copies of presentation and supplemental notes.
Basic knowledge of safety instrumented systems (BC-201 or equivalent)
Safety Instrumented Functions
General Design Issues
Basic SIF Design
Specific Design Issues
Pump and Discharge
Double Block and Bleed
Unit Isolate and Bypass
Valve Position Switches
TC-260: SIL Verification Calculations
This half day course is open to all process industry professionals who are asked to verify or modify Safety Integrity Levels or who audit Safety Instrumented Systems. Students review math and theory involved in SIL establishment, then learn to use industry software to validate and audit established SILs.
Experience with Safety Instrumented Systems and knowledge about SILs
PFD and PFDAVG Equations